Base interlining, methods for their manufacture and application thereof

Abstract

The invention relates to a novel binder system and its use for bonding textile fabrics as well as products containing such bonded textile fabrics. The materials according to the invention are suitable for manufacturing base interlinings which may be used for manufacturing base interlinings for sarking, roofing and sealing membranes, particularly for manufacturing coated sarking, roofing and sealing membranes.

Claims

1. A method of making an article, the method comprising: melting at least one polymer to form a melted polymer; passing the melted polymer through spinneret rows to form spun polymer streams; stretching the spun polymer streams to form a plurality of fibers; forming the plurality of fibers into a spunbond textile fabric; applying a binder system to the spunbond textile fabric, wherein the binder system comprises an aqueous dispersion comprising: at least one emulsion polymer and at least one starch; wherein the binder system has a viscosity of between 10 and 2200 mPa*s in accordance with DIN EN ISO 3219 at 23° C.; and solidifying the binder system into a binder that is incorporated into the spunbond textile fabric.

2. The method of claim 1, wherein the article has a heat dimensional stability of at most 1.6% in a longitudinal direction and at most 1.7% in a cross direction.

3. The method of claim 1, wherein the solidifying of the binder system comprises drying the binder system.

4. The method of claim 1, wherein the article is selected from the group consisting of a sarking membrane, a roofing membrane, and a sealing membrane.

5. The method of claim 1, wherein the binder system further comprises one or more additives selected from the group consisting of a preservative, a stabilizer, an antioxidant, an antifoaming agent, a waterproofing agent, a UV stabilizer, a filler, and a pigment.

6. The method of claim 1, wherein the plurality of fibers comprise polyester fibers.

7. The method of claim 1, wherein the plurality of fibers comprise melt-spinnable polyesters.

8. The method of claim 6, wherein the polyester fibers comprise polyethylene terephthalate (PET).

9. The method of claim 8, wherein the polyester fibers comprise at least 85 mol % of polyethylene terephthalate (PET).

10. The method of claim 8, wherein the polyester fibers comprise at least 95 mol % of polyethylene terephthalate (PET).

11. The method of claim 8, wherein the plurality of fibers further comprise polybutylene terephthalate fibers.

12. The method of claim 6, wherein the polyester fibers comprise flame retardantly modified polyesters.

13. The method of claim 1, wherein the at least one starch has a molecular weight M.sub.w between 5×10.sup.2 and 1×10.sup.8.

14. The method of claim 1, wherein the at least one starch is a natural starch.

15. The method of claim 1, wherein the at least one starch comprises at least one vegetable starch selected from the group consisting of potatoes, manioc, arrowroot, batata, wheat, maize, rye, rice, barley, millet, oat, sorghum, chestnuts, acorns, beans, peas, and bananas.

16. The method of claim 1, wherein the at least one emulsion polymer of the binder system comprises 20 to 80 parts by weight of vinyl aromatic compounds.

17. The method of claim 16, wherein the vinyl aromatic compounds comprise styrene.

18. The method of claim 1, wherein the binder system further comprises one or more emulgators.

19. The method of claim 18, wherein the emulgators are selected from the group consisting of polyalkylene glycol, sulfonated parafinic hydrocarbons, alkyl sulphates, and alkaline metallic salts of fatty acids.

20. The method of claim 1, wherein the textile fibers comprise one or more type of reinforcing fibers selected from the group consisting of aramid fibers, carbon fibers, glass fibers, mineral fibers, high-strength polyester fibers, high-strength polyamide fibers, and metal fibers.

21. The method of claim 1, wherein the textile fabric has a weight per unit area of 20 g/m.sup.2 to 500 g/m.sup.2.

22. The method of claim 1, wherein the spinneret rows are arranged behind one another.

23. The method of claim 1, wherein the spinneret rows are grouped together in rows.

24. The method of claim 1, further comprising a step of laying the plurality of fibers on a conveyor belt after stretching the spun polymer streams.

25. The method of claim 24, wherein the step of laying the plurality of fibers on a conveyor belt, comprises using a rotating baffle plate in dispersion texture or by forming a curtain.

26. A method of making a reinforced sarking, roofing, or coated sealing membrane, comprising forming a plurality of fibers into a spunbond textile fabric; applying a binder system to the spunbond textile fabric, wherein the binder system comprises an aqueous comprising: at least one emulsion polymer and at least one starch, wherein the binder system has a viscosity of between 10 and 2200 mPa*s in accordance with DIN EN ISO 3219 at 23° C., solidifying the binder system into a binder that is incorporated into the spunbond textile fabric to form a base interlining, and reinforcing a sarking, roofing, or coated sealing membrane with said base interlining.

27. The method of claim 26, wherein the step of forming a plurality of fibers into a spunbond textile fabric comprises: melting at least one polymer to form a melted polymer; passing the melted polymer through spinneret rows to form spun polymer streams; stretching the spun polymer streams to form a plurality of fibers; forming the plurality of fibers into a spunbond textile fabric.

Description

EXAMPLES

(1) The following table 1 shows a comparison of the textile fabrics bonded with the binder system according to the invention against the respective single components of the binders.

(2) A spunbonded non-woven based on polyethylene terephthalate (PET-spunbond) with a weight per area unit of 180 g/m.sup.2 (Type JM33/180) is examined.

(3) Example 1 shows a standard binder system based on SBR and urea binder, example 2 shows a binder system based on urea and acrylate, example 3 shows a binder system according to the invention, example 4 shows a binder system based on starch and acrylate, example 5 shows a binder system based on starch. Typically, the liquor concentration is 15-40% (i.e. solid matter in liquor)

(4) TABLE-US-00001 Test no. 1 2 3 4 5 SBR- 90 40 dispersion urea resin 10 10 acrylate- 90 40 dispersion starch 60 60 100 Set application [%] 20 20 20 20 20 (% weight of raw non- woven) Maximum [daN/5 cm] 56 59 57 51 46 longitudinal tensile force Maximum longitudinal [daN/5 cm] 25 19 27 n.t. 31 tensile force, hot Maximum cross tensile [daN/5 cm] 47 48 45 36 36 force Longitudinal TDS [%] 1.8 1.9 1.3 1.6 0.8 Cross TDS [%] −1.6 −1.8 −1.4 −1.7 −1.3 VW - Test [mg/kg FA] ~400 ~400 ~30 ~30 <10 Water suction [mm] 80 72 72 59 66