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    • 6. 发明申请
    • Method of Forming a Consolidated Fibrous Structure
    • 形成合并纤维结构的方法
    • US20100186880A1
    • 2010-07-29
    • US12360542
    • 2009-01-27
    • Sujith NairSasha StankovichYunzhang WangVenkatkrishna RaghavendranHowell B. Eleazer
    • Sujith NairSasha StankovichYunzhang WangVenkatkrishna RaghavendranHowell B. Eleazer
    • B29C70/52
    • B29C70/10B29C70/46B29K2223/00
    • A method of consolidating thermoplastic fibrous layers. The method begins with providing a plurality of fibers, where the fibers have a core with an exterior surface portion comprising polypropylene and a first layer disposed on at least a portion of the core. The first layer contains a first polymer, where the first polymer contains at least 70% α-olefin units and is characterized by a melting temperature less than the melting temperature of the exterior surface of the core. These fibers are formed into a fibrous layer. Next, a second layer is applied to the fibrous layer such that the second layer covers at least a portion of the first layers of the fibers. The second layer contains a second polymer being a co-polymer having at least 50% α-olefin units which is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C., and a melting temperature lower than the melting temperature of the exterior surface of the core. The viscosity of the second polymer is less than a tenth of the viscosity of the first polymer measured at 170° C. Next, heat and optionally pressure are applied to the fibrous layer causing at least a portion of the second layers of the fibers in each fibrous layer to fuse to other first or second layers of the fibers within the same fibrous layer, at least a portion of the second layers of the fibers of each fibrous layer fuse with at least a portion of the first or second layers of the fibers in an adjacent fibrous layer, and at least a portion of the interstices to be filled with a blend of the first and second polymers, where the blend filling the interstices comprises at least 80% wt the second polymer.
    • 一种固结热塑性纤维层的方法。 该方法开始于提供多个纤维,其中纤维具有芯,其具有包括聚丙烯的外表面部分和设置在芯的至少一部分上的第一层。 第一层包含第一聚合物,其中第一聚合物含有至少70%的α-烯烃单元,其特征在于熔融温度低于芯的外表面的熔融温度。 这些纤维形成纤维层。 接下来,将第二层施加到纤维层,使得第二层覆盖纤维的第一层的至少一部分。 第二层包含第二聚合物,其是具有至少50%的α-烯烃单元的共聚物,其特征在于数均分子量为约7,000g / mol至50,000g / mol,粘度为约2,500和 在170℃下测量150,000cP,并且熔融温度低于芯的外表面的熔融温度。 第二聚合物的粘度小于在170℃下测量的第一聚合物的粘度的十分之一。接下来,将热量和任选压力施加到纤维层,使纤维层中的每个纤维的至少一部分第二层纤维 纤维层,以在相同的纤维层内融合到纤维的其它第一或第二层,每个纤维层的纤维的第二层的至少一部分与纤维的第一或第二层的至少一部分融合 相邻的纤维层,以及要填充第一和第二聚合物的共混物的空隙的至少一部分,其中填充空隙的共混物包含至少80重量%的第二聚合物。