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RU2019118468A - Многослойные композитные изделия и способы их изготовления - Google Patents

Многослойные композитные изделия и способы их изготовления Download PDF

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Publication number
RU2019118468A
RU2019118468A RU2019118468A RU2019118468A RU2019118468A RU 2019118468 A RU2019118468 A RU 2019118468A RU 2019118468 A RU2019118468 A RU 2019118468A RU 2019118468 A RU2019118468 A RU 2019118468A RU 2019118468 A RU2019118468 A RU 2019118468A
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RU
Russia
Prior art keywords
multilayer composite
composite product
paragraphs
product according
fibers
Prior art date
Application number
RU2019118468A
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English (en)
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RU2752490C2 (ru
RU2019118468A3 (ru
Inventor
Джеймс БЁРНС
Том ОДУМ
Джей ВЕКСИ
Джин БРАЙЕР
Дерек БАСС
Original Assignee
Шо Индестриз Груп, Инк.
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Publication of RU2019118468A publication Critical patent/RU2019118468A/ru
Publication of RU2019118468A3 publication Critical patent/RU2019118468A3/ru
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Publication of RU2752490C2 publication Critical patent/RU2752490C2/ru

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Claims (83)

1. Многослойное композитное изделие, содержащее:
а) жесткую подложку, содержащую жесткую внутреннюю часть, имеющую первую поверхность и противоположную вторую поверхность, при этом жесткая внутренняя часть содержит по меньшей мере одну смесь из уплотненного волокна, и при этом по меньшей мере одна смесь из уплотненного волокна состоит из первого множества ориентированных волокон, имеющих первую температуру плавления, и второго множества ориентированных волокон, имеющих вторую температуру плавления, отличную от первой температуры плавления; и
б) декоративную часть, имеющую первую поверхность и противоположную вторую поверхность, при этом вторая поверхность декоративной части прикреплена к первой поверхности жесткой внутренней части.
2. Многослойное композитное изделие по п. 1, отличающееся тем, что смесь из уплотненного волокна имеет плотность по меньшей мере около 160 кг/м3 (10 фунтов/фут3).
3. Многослойное композитное изделие по п. 1, отличающееся тем, что жесткая внутренняя часть содержит первую часть, имеющую первую плотность, и вторую часть, имеющую вторую плотность, отличную от первой плотности.
4. Многослойное композитное изделие по п. 1, отличающееся тем, что жесткая внутренняя часть содержит по меньшей мере две смеси из уплотненного волокна.
5. Многослойное композитное изделие по любому из пп. 1–4, отличающееся тем, что композит дополнительно содержит уплотненный слой, содержащий неволокнистую композицию.
6. Многослойное композитное изделие по п. 5, отличающееся тем, что уплотненный слой расположен между правой внутренней частью и декоративной частью.
7. Многослойное композитное изделие по любому из пп. 1–6, отличающееся тем, что первое множество ориентированных волокон ориентировано, по существу, произвольным образом.
8. Многослойное композитное изделие по любому из пп. 1–7, отличающееся тем, что второе множество ориентированных волокон ориентировано, по существу, произвольным образом.
9. Многослойное композитное изделие по п. 1–6, отличающееся тем, что первое множество ориентированных волокон ориентировано, по существу, однородно.
10. Многослойное композитное изделие по любому из пп. 1–6 или п. 9, отличающееся тем, что второе множество ориентированных волокон ориентировано, по существу, однородно.
11. Многослойное композитное изделие по любому из пп. 1–10, отличающееся тем, что первое множество ориентированных волокон содержит штапельное волокно, объемно–жгутовое волокно или их комбинацию.
12. Многослойное композитное изделие по любому из пп. 1–10, отличающееся тем, что второе множество ориентированных волокон содержит штапельное волокно, объемно–жгутовое волокно или их комбинацию.
13. Многослойное композитное изделие по любому из пп. 1–12, отличающееся тем, что первое множество ориентированных волокон и второе множество ориентированных волокон, каждое независимо, содержит сложный полиэфир, полипропилен, полиэтилен, полиамиды, полиуретан, полимолочную кислоту, ацеталь, сополиэфир, сополиамид, полистирол или их комбинацию.
14. Многослойное композитное изделие по любому из пп. 1–13, отличающееся тем, что смесь из уплотненного волокна дополнительно содержит третье множество ориентированных волокон.
15. Многослойное композитное изделие по п. 14, отличающееся тем, что третье множество ориентированных волокон имеет третью температуру плавления, отличную от первой температуры плавления или второй температуры плавления.
16. Многослойное композитное изделие по любому из п. 14 или 15, отличающееся тем, что третье множество ориентированных волокон содержит натуральное волокно.
17. Многослойное композитное изделие по п. 16, отличающееся тем, что натуральное волокно содержит лубяные волокна, хлопок, целлюлозу, шерсть, шелк, лен, минерал, кокос, стекло или любую их комбинацию.
18. Многослойное композитное изделие по любому из пп. 1–17, отличающееся тем, что жесткая внутренняя часть, по существу, не содержит материала ПВХ.
19. Многослойное композитное изделие по любому из пп. 1–13 или 18, отличающееся тем, что жесткая внутренняя часть, по существу, не содержит материала на основе древесины.
20. Многослойное композитное изделие по любому из пп. 1–19, отличающееся тем, что жесткая внутренняя часть дополнительно содержит наполнитель.
21. Многослойное композитное изделие по п. 20, отличающееся тем, что наполнитель содержит одно или более из карбоната кальция, тригидрата алюминия, барита, полевого шпата, стеклобоя, летучей золы, каолиновой глины, известняка, пенополиуретана, каучука, термопластичного порошка, термопластичного полиуретана (ТПУ), волластонита или любой их комбинации.
22. Многослойное композитное изделие по любому из пп. 1–21, отличающееся тем, что по меньшей мере одно из первого и второго множеств волокон содержит многокомпонентное волокно.
23. Многослойное композитное изделие по п. 22, отличающееся тем, что многокомпонентные волокна имеют конфигурацию нити «ядро–оболочка».
24. Многослойное композитное изделие по п. 23, отличающееся тем, что внутренняя часть многокомпонентных волокон содержит сложный полиэфир.
25. Многослойное композитное изделие по любому из пп. 22–24, отличающееся тем, что многокомпонентное волокно содержит по меньшей мере первый компонент, имеющий первую температуру плавления, и по меньшей мере второй компонент, имеющий вторую температуру плавления, отличную от первой температуры плавления.
26. Многослойное композитное изделие по любому из пп. 1–25, отличающееся тем, что по меньшей мере одно из первого и второго множеств ориентированных волокон содержит регенерированные волокна.
27. Многослойное композитное изделие по п. 26, отличающееся тем, что регенерированные волокна содержат бывшее в употреблении волокно.
28. Многослойное композитное изделие по п. 26, отличающееся тем, что регенерированные волокна содержат постиндустриальное волокно.
29. Многослойное композитное изделие по любому из пп. 1–28, отличающееся тем, что жесткая внутренняя часть имеет толщину в диапазоне от около 0,5 мм до около 12 мм.
30. Многослойное композитное изделие по любому из пп. 1–29, отличающееся тем, что жесткая внутренняя часть проницаема для влаги.
31. Многослойное композитное изделие по п. 30, отличающееся тем, что скорость проницаемости водяных паров составляет более чем около 1,36 кг (3 фунтов) на 93 м2 (1000 футов2) за 24 часа.
32. Многослойное композитное изделие по любому из пп. 1–31, отличающееся тем, что результаты испытаний многослойного композита на лучистый поток подпадают под класс I в соответствии с ASTM E–648.
33. Многослойное композитное изделие по любому из пп. 1–32, отличающееся тем, что многослойное композитное изделие проявляет остаточное вдавливание, составляющее менее 8% от общей толщины изделия при измерении в соответствии с ASTM F1914–07(2011).
34. Многослойное композитное изделие по любому из пп. 1–32, отличающееся тем, что вдавливание многослойного композитного изделия из–за статической нагрузки меньше или равно 0,005 дюйма при измерении в соответствии с ASTM F970.
35. Многослойное композитное изделие по любому из пп. 1–34, отличающееся тем, что многослойное композитное изделие проходит испытание на радиус изгиба оправки менее 2,54 см (1 дюйма), измеренное в соответствии с ASTM F137 (2013).
36. Многослойное композитное изделие по любому из пп. 1–35, отличающееся тем, что модуль упругости при изгибе многослойного композитного изделия составляет от около 0,1 ГПа до 15,0 ГПа, измеренный в соответствии с ASTM D790.
37. Многослойное композитное изделие по любому из пп. 1–36, отличающееся тем, что прочность на изгиб многослойного композитного изделия составляет от около 20 МПа до 400 МПа, измеренная в соответствии с ASTM D790.
38. Многослойное композитное изделие по любому из пп. 1–37, отличающееся тем, что многослойное композитное изделие демонстрирует, по существу, выровненное напряжение компонента, характеризующееся максимальной разницей в размерах не более 0,17% при нагреве при 80°С (180°F) и охлаждении до температуры окружающей среды.
39. Многослойное композитное изделие по любому из пп. 1–38, отличающееся тем, что для многослойного композитного изделия не требуется период акклиматизации для выравнивания напряжения компонента.
40. Многослойное композитное изделие по любому из пп. 1–39, отличающееся тем, что декоративная часть содержит декоративный поверхностный слой, содержащий поливинилхлорид (ПВХ), отбеленный ПВХ, непрозрачный ПВХ, ориентированный полипропилен (ОПП), полиолефин (ПO), тканый полиэтилен (ПЭ), нетканый ПЭ, тканый полипропилен (ПП), нетканый ПП, тканый ПЭТ, ПЭТ из отбеленного волокна, нетканый ПЭТ, тканый нейлон, нетканый нейлон, обычную бумагу, обычную фольгу или фольгированный ориентированный полипропилен.
41. Многослойное композитное изделие по любому из пп. 1–40, отличающееся тем, что декоративная часть содержит слой изображения.
42. Многослойное композитное изделие по п. 41, отличающееся тем, что изображение напечатано или иным образом перенесено на поверхность декоративного поверхностного слоя.
43. Многослойное композитное изделие по п. 41, отличающееся тем, что изображение напечатано или иным образом перенесено на поверхность любого видимого слоя.
44. Многослойное композитное изделие по любому из пп. 1–43, отличающееся тем, что декоративная часть прикреплена к первой поверхности жесткой внутренней части с помощью адгезива.
45. Многослойное композитное изделие по любому из пп. 1–43, отличающееся тем, что декоративная часть прикреплена к первой поверхности жесткой внутренней части иглопрокалыванием.
46. Многослойное композитное изделие по п. 45, отличающееся тем, что декоративная часть, прикрепленная иглопрокалыванием, дополнительно спрессовывается горячим прессованием с первой поверхностью жесткой внутренней части.
47. Многослойное композитное изделие по любому из пп. 1–43, отличающееся тем, что декоративная часть прикреплена посредством порошкового рассеяния.
48. Многослойное композитное изделие по п. 47, отличающееся тем, что рассеянный порошок содержит полимер, включающий полипропилен, сложный полиэфир, полиэтилен или их комбинацию.
49. Многослойное композитное изделие по любому из пп. 45–48, отличающееся тем, что слой изображения образуется путем прямой печати после того, как декоративная часть будет прикреплена к первой поверхности жесткой внутренней части.
50. Многослойное композитное изделие по любому из пп. 1–49, отличающееся тем, что декоративная часть дополнительно содержит износостойкий слой, приклеенный к слою изображения.
51. Многослойное композитное изделие по любому из пп. 40–50, отличающееся тем, что декоративная часть дополнительно содержит тканые волокна, камень, керамику, стекло, иглопробивной материал, кожу, шкуры животных, шпон или любую их комбинацию.
52. Многослойное композитное изделие по любому из пп. 50–51, отличающееся тем, что износостойкий слой является, по существу, прозрачным слоем.
53. Многослойное композитное изделие по любому из пп. 50–52, отличающееся тем, что износостойкий слой содержит по меньшей мере одно из: полиэтилентерефталата (ПЭТ), модифицированного гликолем полиэтилентерефталата (ПЭТГ), полиуретана, полиуретанового реакционноспособного термоплавкого клея (ПУР), полипропилена, политриметилентерефталата (ПТТ), поливинилхлорида (ПВХ), полиамида.
54. Многослойное композитное изделие по любому из пп. 50–53, отличающееся тем, что износостойкий слой содержит по меньшей мере одно из: термостабилизированного двуосноориентированного ПЭТ (ДоПЭТ), аморфного ПЭТ (aПЭТ), регенерированного ПЭТ (рПЭТ), модифицированного гликолем полиэтилентерефталата (ПЭТГ), полиолефина, циклического олефинового сополимера (ЦOC), циклического олефинового полимера (ЦОП), поливинилиденфторида (ПВДФ), сополимеров полимолочной кислоты (PLA), нейлона, ацетата целлюлозы, поли(метилметакрилата) (ПММА), термопластичного полиуретана (ТПУ), термопластичных эластомеров (ТПЭ), поликарбоната, полиэтилена (ПЭ), полиэтилена высокой плотности (HDPE), полиэтилена низкой плотности (LDPE) или их сополимера.
55. Многослойное композитное изделие по любому из пп. 50–54, отличающееся тем, что износостойкий слой имеет толщину вплоть до около 30 мил.
56. Многослойное композитное изделие по любому из пп. 1–55, отличающееся тем, что верхняя поверхность декоративной части тиснена или тиснена в регистр.
57. Многослойное композитное изделие по любому из пп. 1–56, отличающееся тем, что многослойное композитное изделие является композитным напольным изделием.
58. Многослойное композитное изделие по п. 56, отличающееся тем, что напольное изделие выполнено в виде панели, планки, листа, доски или плитки.
59. Многослойное композитное изделие по любому из пп. 1–58, дополнительно содержащее множество боковых краев.
60. Многослойное композитное изделие по п. 59, отличающееся тем, что множество боковых краев не определяет какую–либо форму механизма взаимозамкнутости.
61. Многослойное композитное изделие по п. 59, отличающееся тем, что множество боковых краев образует механизм взаимозамкнутости.
62. Многослойное композитное изделие по любому из пп. 1–61, отличающееся тем, что многослойное композитное изделие непосредственно приклеено к подповерхностному слою.
63. Многослойное композитное изделие по любому из пп. 1–61, отличающееся тем, что многослойное композитное изделие свободно лежит на подповерхностном слое.
64. Многослойное композитное изделие, содержащее:
а) жесткую подложку, содержащую жесткую внутреннюю часть, имеющую первую поверхность и противоположную вторую поверхность, при этом жесткая внутренняя часть содержит по меньшей мере одну смесь из уплотненного волокна, и при этом по меньшей мере одна смесь из уплотненного волокна состоит из первого множества ориентированных волокон, содержащих натуральное волокно, имеющего определенную температуру разложения, и второго множества ориентированных волокон, имеющего температуру плавления ниже, чем температура разложения первого множества ориентированных волокон; и
б) декоративную часть, имеющую первую поверхность и противоположную вторую поверхность, при этом вторая поверхность декоративной части прикреплена к первой поверхности жесткой внутренней части.
65. Многослойное композитное изделие, содержащее:
а) жесткую подложку, содержащую жесткую внутреннюю часть, имеющую первую поверхность и противоположную вторую поверхность, при этом жесткая внутренняя часть содержит по меньшей мере одну смесь из уплотненного волокна и при этом по меньшей мере одна смесь из уплотненного волокна состоит из множества ориентированных многокомпонентных волокон, при этом каждое из множества ориентированных многокомпонентных волокон содержит по меньшей мере первый компонент, имеющий первую температуру плавления, и по меньшей мере второй компонент, имеющий вторую температуру плавления, отличную от первой температуры плавления; и
б) декоративную часть, имеющую первую поверхность и противоположную вторую поверхность, при этом вторая поверхность декоративной части прикреплена к первой поверхности жесткой внутренней части.
66. Способ изготовления многослойного композитного изделия, включающий:
а) образование жесткой подложки, содержащей жесткую внутреннюю часть, имеющую первую поверхность и противоположную вторую поверхность, при этом жесткая внутренняя часть содержит по меньшей мере одну смесь из уплотненного волокна и при этом по меньшей мере одна смесь из уплотненного волокна состоит из первого множества ориентированных волокон, имеющего первую температуру плавления, и второго множества ориентированных волокон, имеющего вторую температуру плавления, отличную от первой температуры плавления;
б) образование декоративной части, имеющей первую поверхность и противоположную вторую поверхность; и
в) прикрепление второй поверхности декоративной части к первой поверхности жесткой внутренней части.
67. Способ изготовления многослойного композитного изделия, включающий:
а) образование жесткой подложки, содержащей жесткую внутреннюю часть, имеющую первую поверхность и противоположную вторую поверхность, при этом жесткая внутренняя часть содержит по меньшей мере одну смесь из уплотненного волокна и при этом по меньшей мере одна смесь из уплотненного волокна состоит из множества ориентированных многокомпонентных волокон, при этом каждое из множества многокомпонентных волокон содержит по меньшей мере первый компонент, имеющий первую температуру плавления, и по меньшей мере второй компонент, имеющий вторую температуру плавления, отличную от первой температуры плавления;
б) образование декоративной части, имеющей первую поверхность и противоположную вторую поверхность; и
в) прикрепление второй поверхности декоративной части к первой поверхности жесткой внутренней части.
68. Способ изготовления многослойного композитного изделия, включающий:
a) образование жесткой подложки, содержащей жесткую внутреннюю часть, имеющую первую поверхность и противоположную вторую поверхность, при этом жесткая внутренняя часть содержит по меньшей мере одну смесь из уплотненного волокна и при этом по меньшей мере одна смесь из уплотненного волокна состоит из первого множества ориентированных волокон, содержащих натуральное волокно, имеющего определенную температуру разложения, и второго множества ориентированных волокон, имеющего температуру плавления ниже, чем температура разложения первого множества ориентированных волокон;
б) образование декоративной части, имеющей первую поверхность и противоположную вторую поверхность; и
в) прикрепление второй поверхности декоративной части к первой поверхности жесткой внутренней части.
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