Method for manufacturing breathable waterproof membrane

Abstract

The invention discloses a method for manufacturing a breathable waterproof membrane. The method comprises the steps of a) providing a material web comprising at least one stabilizing layer and a film material holding a template and combined with the at least one stabilizing layer, b) bringing the material web into a washing machine, and c) washing the template out of the film, thereby bringing the porous structure into the film material. The method is industrially applicable to the manufacture of breathable waterproof films with minimal crease marks and weak spots.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a breathable, waterproof membrane and the membrane produced according to the method. The membrane can be associated with a fabric. Background Technology

[0002] Breathable waterproof membranes are well-known. They prevent water penetration while allowing moisture to pass through. Their primary applications are in clothing, apparel, and footwear. However, breathable waterproof membranes are also used in other areas.

[0003] Such membranes are typically produced through stretching or phase inversion. However, these processes and membranes use permanent chemicals, such as PFCs (fluorinated compounds), or toxic solvents, such as DMF (dimethylformamide).

[0004] An improved method uses template removal technology, also known as the template removal method. Particles are mixed with molten polymer. This mixture is extruded into a film, and then the particles are removed to create pores. The particles are typically removed by dissolution or dispersion. The particles serve as a template. Typically, the particles are immiscible polymers or fillers, such as calcium carbonate.

[0005] This works well for small membranes. However, industrial applicability requires an effective particle removal method. Because the membrane is very thin, the risk of developing crease marks and weak points during this removal process is very high.

[0006] EP 3 178 873 A1 discloses a method for manufacturing a waterproof and breathable porous polymer membrane by coating a matrix with a dispersion comprising a polymer, coating particles, and a diluent / solvent. The particles are removed by dissolution. These steps are suitable for roll-to-roll processes. When using roll-to-roll coating, 100 m³ membranes can be prepared in a single piece. 2 Polymer film.

[0007] EP 3 936 658 A1 describes a seamless manufacturing process for a 3D waterproof and breathable porous polymer membrane by spraying, dipping, or coating a matrix comprising a dispersion of polymer, coated or uncoated particles, and a diluent. The particles are removed by dissolution. The membrane is then processed sheet by sheet. Porosity is thus created after 3D coating and shaping. After complete removal of the template, the 3D object is washed again and then dried at room temperature or using a drying / heating device. Summary of the Invention

[0008] The purpose of this invention is to provide a method for manufacturing a breathable waterproof membrane that can be used industrially.

[0009] In one aspect of the present invention, a method for manufacturing a breathable waterproof membrane is provided, the method comprising the following steps:

[0010] - Provide a material web comprising at least one stabilizing layer and a retaining template combined with a membrane material in conjunction with the at least one stabilizing layer.

[0011] - The material web is brought into, preferably forward-carried into, the washing machine, and

[0012] - The template is washed out of the membrane, thereby introducing the porous structure into the membrane material.

[0013] The material provided in the first step is extended in an elongated shape, thus forming a material web. The membrane material holding the template is stabilized by a stabilizing layer.

[0014] The membrane material of the template is kept bonded to the stabilizing layer. Preferably, the membrane material is attached to the stabilizing layer.

[0015] Preferably, the membrane material that holds the template is prepared by mixing molten membrane material with a template. A material web is prepared by combining the membrane material with a stabilizing layer, thereby providing some kind of connector. The connector can be spread over the entire area of ​​the material web (e.g., co-extruded with a filled membrane), or the connector can be distributed in a dotted manner over the entire area of ​​the material web (e.g., dot-laminated after the extrusion of a filled membrane).

[0016] In some variations of this method, the entire material web is fed into a washing machine and washed simultaneously. In some variations, the material web is provided in a loose sheet shape within the machine. In other variations, the material web is provided as a wound and the entire wound is washed simultaneously.

[0017] In a preferred variation of this method, the material web is fed through a washing machine, whereby the template is washed out of the membrane and the porous structure is introduced into the membrane material. Preferably, the material web is configured in the shape of a wound, and this wound is unwound when the material web is fed into the washing machine. Therefore, the material web is not washed all at once. Preferably, the material web unwound for washing is wound into a second wound after washing, i.e., the material web is processed in a roll-to-roll washing process.

[0018] In some preferred variations of this method, the material web is wound into the shape of a roll, and the wound material web is carried into or forward into the washing machine. The roll is also referred to as a bundle or bundle. This roll washing method, for example, when a stabilizing layer or another layer is used as a spacer between film layers within the roll, enables the template to be washed out of the film even in the wound state, thus providing a channel for removing the medium while the material web is still in the shape of the roll, to wash out the template.

[0019] This method enables the use of environmentally friendly template removal technology for the production of long and wide membrane sheets. The fragile and brittle membrane material is supported and protected by a stabilizing layer, preventing damage during the washing process. However, the washing process can be carried out very efficiently because the membrane material, in the form of a web, can preferably be washed either by conveying the web through the washing machine or by providing the web to the washing machine in the form of a wound piece.

[0020] In some variations of the method of the present invention, the material web is conveyed and / or washed in a continuous process; in other variations, the material web is conveyed and / or washed in batches. Preferably, the material web is conveyed sequentially, i.e., in batches or continuously.

[0021] The tension typically required in washing machines can be applied to the stabilizing layer. Therefore, the membrane material must be handled with care. This minimizes damage to the membrane and improves quality. For example, it avoids or at least minimizes breakage, tearing, and crease marks or folds or weak points that could lead to undesirable pores in the membrane. Furthermore, it allows for clean cuts on the sides of the membrane.

[0022] In a preferred embodiment, at least one stabilizing layer is also present in combination with the film material when the material web is dried after washing. This is advantageous because the tension typically required during the drying process can also be applied to the stabilizing layer.

[0023] In some methods, the template is washed out without any stabilizing layer, and at least one stabilizing layer is subsequently used in the drying step. The combination of the stabilizing layer and the film material can be achieved by fixing, such as lamination, or by rolling, or by other means mentioned herein. This is a separate invention also claimed in the patent application.

[0024] In some preferred variations of this method, the washing machine includes a water bath through which the material web is conveyed. The liquid is preferably water, an acid, or a mixture of water and an acid. It is preferably acetic acid, formic acid, or citric acid, and most preferably water and / or sulfonic acid. The washing medium can also be an alkaline environment or water mixed with a solvent, such as ethanol or isopropanol.

[0025] Preferably, the membrane is a polymer membrane, and the template is a mineral or salt. Other materials and templates known in the prior art may also be used.

[0026] The combination of the stabilizing layer and the membrane material can be washed immediately after assembly, for example, immediately after leaving the co-extrusion unit. The combination of the stabilizing layer and the membrane material can also be rolled into a coil.

[0027] Typical dimensions of the rolled-up material web are 150 cm to 160 cm wide and several hundred meters long, preferably 800 m to 1000 m long. Other sizes are also possible. The membrane material, i.e., the membrane-like film, is very thin. Typical thickness is between 25 μm and 60 μm or 30 μm and 50 μm before washing, and between 15 μm and 35 μm after washing, more preferably between 30 μm and 35 μm before washing, and between 15 μm and 25 μm after washing.

[0028] Preferably, the washing machine is a known machine capable of processing the material web. Preferably, the washing machine can unwind and rewind the material web, or the washing machine is a washing machine capable of processing the wound material. The material web is preferably washed between the unwinding and rewinding processes. Preferably, the composite material is washed in a tensioned state, at least when washed in the unwinding state. When the composite material is washed in a rolled state, the stabilizing layer forming the intermediate layer, i.e., the spacer, absorbs tension from the film and provides support during washing and drying.

[0029] Preferably, the washing machine is a dyeing machine, that is, a machine primarily developed and used for dyeing materials.

[0030] Preferably, the washing machine is a roll dyeing machine or jet overflow machine, skein dyeing machine (Haspelkufe, also known as a winch-reel machine), or flat-width washing machine or warp beam dyeing machine, wherein the aforementioned machines are suitable for washing in place of dyeing and / or other than dyeing. Other types of machines may also be used. The washing machine is an industrially applicable machine capable of handling large webs of material, preferably several hundred meters long.

[0031] In a skein dyeing machine, the fabric web moves continuously on a skein and is immersed in a liquid bath below. The fabric web is guided through the machine without tension, preventing deformation.

[0032] In jet overflow machines, the material web moves in the same manner as in skein dyeing machines, where the liquid also moves. Additionally, the material web typically moves faster than in skein dyeing machines.

[0033] Skein dyeing machines (winch-reel machines) and jet overflow machines offer the advantage of minimizing costs when used for washing fabric webs. These machines are cheaper than the other machines mentioned above. Furthermore, the washing process is faster and therefore more cost-effective compared to the washing processes in the other machines mentioned above. These machines also require less water than flat-web washing machines, which further reduces costs.

[0034] In yarn dyeing machines and jet overflow machines, the material web may shrink or wrinkle.

[0035] In a flat-web washing machine, the material web is kept under tension to prevent wrinkling and maintain a constant width throughout the process. The material web is fed via a roll-to-roll process, entering different baths at a speed that allows for the correct residence time. Several windings, located both inside and outside the baths, ensure complete dissolution of the template and subsequent rinsing. In the same continuous production, drying and rewinding steps are placed last. The final product is a material web comprising the membrane material in a porous state, in the form of a winding.

[0036] A web-flattening machine applies tension to a web of material and maintains its width. However, web-flattening machines require a considerable amount of water.

[0037] The dyeing machine comprises a large, enclosed cylinder with two main rollers located in the upper part of the machine. A web of material is wound onto one roller and fed onto the other. Liquid is located at the bottom of the cylinder below the two rollers. Typically, many smaller rollers are submerged in the liquid, serving as guide rollers. The liquid intended for use with such a machine is a dyeing liquid. However, in the claims of this invention, the liquid is a washing liquid, such as water, and the machine is used for washing, not for dyeing. The machine requires only a minimal amount of liquid.

[0038] Most preferably, skein dyeing (winch-reel) machines and jet overflow machines are used. These machines are particularly suitable for washing fabrics or webs of materials with films without a co-extruded stabilizing layer. In addition, these machines are particularly suitable for washing webs of materials with layers laminated to a film, such as fabrics.

[0039] All the machines mentioned above can be used for lamination. However, when the material web includes a co-extruded stabilizing layer, a roll-dyeing machine and a flat-web machine are preferred.

[0040] In particular, material webs with a co-extruded stabilizing layer washed with the film, and material webs with a co-extruded polymer stabilizing layer but without a layer laminated to the film, are preferably washed using an open-web washing machine or a roll-dyeing machine, wherein the open-web washing machine is preferred because it minimizes costs by repeating short residence times at high speeds in acid.

[0041] The following table shows which machine is preferred for which type of web material:

[0042] *Shore D, the raw material polymer used to produce membrane materials.

[0043] **Elongation at break of washed membrane material.

[0044] In particular, when using a co-extruded stabilizing layer, the following are preferably applicable:

[0045] To select one machine over another, the elongation at break of the template-filled membrane material is compared with the elongation at break of the stabilizing layer. Preferably, the elongation at break of the template-filled membrane material should be higher. In this way, tension can be maintained in the stabilizing layer without damaging the membrane material.

[0046] The membrane material holding the template is bonded to at least one stabilizing layer. Different ways of combining the materials are possible. In some preferred variations of the method, the membrane material is fixed to at least one stabilizing layer. For example, the layer can be laminated to the membrane material, for instance, using dotted adhesive points, or the layer can be co-extruded together with the membrane material holding the template. In other variations of the method, the membrane material and at least one stabilizing layer are wound together, wherein the stabilizing material forms an intermediate layer between the windings of the wound membrane material. This also stabilizes the membrane material. This intermediate layer method is particularly advantageous when using a warp dyeing machine for washing the template out of the membrane. Other methods of stabilizing the membrane material by using a stabilizing material can also be used.

[0047] Preferably, at least one first stabilizing layer is present in the stabilizing layer, which is co-extruded together with the membrane material holding the template. This is a fairly effective way to attach the membrane to the stabilizing layer, minimizing stress on the membrane and therefore minimizing the risk of membrane damage. The material used for the first stabilizing layer is preferably selected by the opposite polarity of the material of the membrane used to hold the template, so as to facilitate separation when needed. Typical materials used in the first stabilizing layer are polyethylene (PE, LDPE), polyamide (PA), polypropylene (PP), polymethyl methacrylate (PMMA), polyester (PES, including PLA, PET, PCL, PBAT, PHB, PHA), polyurethane (TPU, polyester-based or polyether-based), preferably having a thickness of 10 micrometers to 50 micrometers.

[0048] In some variations of this method, the membrane and at least one stabilizing layer have approximately the same width.

[0049] In some variations of this method, a membrane holding the template is extruded without a first stabilizing layer, and then the membrane is thermo-calendered into a knitted, woven, or nonwoven fabric without adhesive points to provide stability during washing.

[0050] In some variations of this method, the membrane holding the template is separated from the first stabilizing layer and reattached to the knitted fabric, woven fabric, nonwoven fabric, or wash-stabilizing paper without adhesive points by means of side seams on each side or removable glue or by means of other side-attachment methods to provide stability during washing.

[0051] In some variations of this method, the support membrane holding the template into the washing step can be clamped or attached to both sides to provide greater tension and stability during washing and drying. This is preferred when using a flat-web washing machine.

[0052] In some variations of this method, at least one of the stabilizing layers, preferably a first stabilizing layer, has a first width, and the membrane material holding the template has a second width, wherein the second width is smaller than the first width. In other variations, the stabilizing layer has the same width as the membrane material. This is especially true when the stabilizing layer and the membrane material are co-extruded.

[0053] When the stabilizing layer has a width larger than the membrane material, the internal and / or external conveying devices of the washing machine enable the material web to be conveyed primarily through these membrane-free areas in contact with the stabilizing layer. This applies to the washing step and preferably also to the drying step. This further minimizes the risk of membrane damage. Preferably, at least one of the at least stabilizing layers, preferably the first stabilizing layer, forms two boundaries along the elongated edge of the membrane material holding the template. This facilitates the transfer of the membrane to, through, and further out of the washing machine.

[0054] In some preferred variations of the method, the first stabilizing layer mentioned above is conveyed together with the membrane material holding the template through a washing machine, wherein the membrane is fixed to the first stabilizing layer. Therefore, an additional fixing step is unnecessary. However, fixing with clamps or mechanical fixation can still be used as an additional fixing step.

[0055] Preferably, after the template has been removed, the first stabilizing layer is separated from the membrane material and preferably removed from the membrane material. This means that the first stabilizing layer is removed from the membrane material after the washing step, and preferably after the drying step.

[0056] In some variations of this method, a second stabilizing layer in at least one stabilizing layer is connected to the membrane material holding the template, wherein the second stabilizing layer is arranged on the side opposite to the first stabilizing layer, and wherein the membrane material forms an intermediate layer. The first stabilizing layer is preferably co-extruded with the membrane material holding the template. However, the first stabilizing layer can also be fixed to the membrane material by other fixing methods or means. The connection between the second stabilizing layer and the membrane material is preferably achieved by lamination using point-like adhesive points. Fixation can also be achieved using alternative means or methods.

[0057] In some variations of this method, at least the second stabilizing layer forms two boundaries along the elongated edge of the membrane material holding the template, and thus has a width different from that of the membrane material. In some embodiments, the first stabilizing layer also forms such boundaries on the two elongated sides of the membrane material. In other embodiments, particularly when the first stabilizing layer is co-extruded with the membrane material, the first stabilizing layer does not form boundaries, but the material has approximately the same width.

[0058] Preferably, the first stabilizing layer is removed before the second stabilizing layer and the membrane material holding the template are brought into, preferably forward through, the washing machine. This means that the first layer primarily helps to attach the second stabilizing layer to the membrane, and the newly combined material web is brought into, preferably forward through, the washing machine. For example, the newly combined material web can be conveyed through the washing machine, or the newly combined material web can be supplied to the machine and washed in the washing machine as a wound piece, for example, when using a warp dyeing machine.

[0059] In some variations of this method, the first stabilizing layer is removed after the second stabilizing layer is fixed to the membrane material. In other variations, the first stabilizing layer is removed before the second stabilizing layer is fixed to or combined with the membrane material.

[0060] Preferably, the second stabilizing layer remains on the membrane material after the template has been removed. Preferably, the second stabilizing layer and the membrane material form the final laminate. Preferably, the second stabilizing layer is made of a fabric. The fabric can be nonwoven, woven, knitted, crocheted, or felted.

[0061] Preferably, the washing process uses a temperature of 15°C to 80°C. When using acid, the acid concentration is preferably 10% to 80%. The washing speed, i.e., the time a section of the material web spends in the washing machine, is preferably 20 min to 200 min, providing a speed of 1 m / min to 20 m / min.

[0062] Preferably, the drying process uses a temperature of 50°C to 100°C. The drying rate is preferably 1 m / min to 30 m / min.

[0063] Preferably, no pressure is applied during the washing process and / or during the drying process. When drying, a clamping frame is preferably used to secure the film web.

[0064] Therefore, the method mentioned above can also be understood as a method for removing the template from the film. In this method for removing the template, it is preferable to remove the first layer of at least one layer before or after the material web is introduced into the washing machine.

[0065] In one aspect of the invention, a breathable waterproof membrane is manufactured according to the method mentioned above.

[0066] Other variations and embodiments of the invention are set forth in the dependent claims.

[0067] Unless otherwise stated, the following definitions shall apply to this document:

[0068] The width of a material, also referred to as the width of a fabric, web-like material, or material web, is a long sheet or continuous sheet having a length several times longer than its width. It can be rolled up or folded multiple times. It can have one or more layers combined or connected to each other, especially fixed or rolled together, such that an intermediate layer is formed between the windings of one layer and another. The description of the web defines the external shape of the material. The description of the web is not limited to a particular method of manufacturing the material itself.

[0069] Polymers are known in this art. The term refers to materials having repeating structural units (“monomers”), and particularly to synthetic polymers (including synthetic monomers). Therefore, the term includes homopolymers, copolymers, and blends thereof. Polymers may be crosslinked.

[0070] Membrane: a thin sheet or layer.

[0071] Template: Known in the art and encompassing crystalline or amorphous materials. This term includes uncoated and coated particles, as well as treated and untreated particles. Templates are also referred to as fillers or particles in the art. Templates according to this document are very small. Preferably, the template has a diameter in the submicron range, thereby the particle size is preferably between 5 nm and 15000 nm, for example, between 2000 nm and 8000 nm. Suitable particles can be obtained from a range of preparation methods including high-temperature gas-phase processes (e.g., flame synthesis, laser processes, and plasma processes) and liquid-phase chemical methods (e.g., precipitation and sol-gel processes), as well as particle milling. Particularly suitable particles in the context of this invention can be obtained by precipitation processes or by milling naturally occurring materials.

[0072] Retaining the template: refers to the template being located within the material, partially or completely enclosed by the material.

[0073] Stabilizing layer: A layer that can support and stabilize another layer.

[0074] Co-extrusion: Production is achieved by extruding two or more layers simultaneously. Attached Figure Description

[0075] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings, which are for illustrative purposes only and not for limiting the scope of the preferred embodiments of the invention. In the drawings,

[0076] Figure 1 A schematic perspective view of a first arrangement apparatus for performing the method according to the invention is shown;

[0077] Figure 2 A schematic perspective view of a second arrangement device for performing the method according to the invention is shown, and

[0078] Figure 3 A schematic perspective view of a third arrangement apparatus for performing the method according to the invention is shown. Detailed Implementation

[0079] Figure 1 A first mode for carrying out the method of the present invention is shown. An apparatus for carrying out the method is schematically shown.

[0080] The membrane material 1, including the template 2, is co-extruded with the first stabilizing layer 3. The membrane material 1 is preferably a polymer. The template 2 is also referred to in this art as a filler, granule, or template particle. The template 2 is preferably a salt or mineral. When the membrane material 1 is in a molten state, the template 2 is preferably mixed into the membrane material 1.

[0081] Typical dimensions for the material rolls are 150 cm to 160 cm wide and several hundred meters long, preferably 800 m to 1000 m long. Other dimensions are also possible.

[0082] The membrane material, i.e., the membrane-like membrane, is very thin. In the unwashed state, the typical thickness is between 25 μm and 60 μm, and preferably between 30 μm and 50 μm.

[0083] The first stabilizing layer 3 is preferably made of one of polyolefin, polyamide, polyester, polymethyl methacrylate, or a combination thereof. The thickness of the first stabilizing layer 3 is preferably between 10 μm and 50 μm.

[0084] The width of the first stabilizing layer 3 may be greater than the width of the membrane material 1. In some variations, the first stabilizing layer 3 and the membrane material 1 have the same dimensions. However, for better understanding, the accompanying drawings show different widths of the stabilizing layer and the membrane material. The first stabilizing layer 3 preferably has a boundary 30 formed on each side of the membrane material 1, and the boundary 30 extends along the entire length of the material web.

[0085] The material web is preferably configured in the shape of a wound section, wherein the material web is preferably wound onto the support roller 6. This enables the handling, transport, and storage of the co-extruded product.

[0086] The fabric web is unrolled and fed into washing machine 50. The washing machine is a machine known in the textile industry, such as a flat-width washing machine. In other variations, machines typically used for dyeing but also for washing are used. The machine preferably includes a bath or other device for washing the unrolled portion or rolled-up portion of the fabric web.

[0087] In the washing machine 50, the film material 1, including or preferably including a first stabilizing layer 3 and a retaining template 2, is washed in one or more steps. Washing is preferably done with acid and / or water. The acid is preferably one of formic acid, acetic acid, hydrochloric acid, citric acid, or sulfonic acid.

[0088] As a result of the washing process, the template 3 is removed from the membrane material 1, thereby creating pores 7 in the membrane material 1.

[0089] Washing machine 50 includes a dryer or drying machine 51 following washing machine 50. In other variations, the drying step is not a sequential step within the same system, but rather the drying step is subsequently performed in another system or environment.

[0090] The thickness of the membrane material after washing is preferably between 15 μm and 25 μm.

[0091] After washing and preferably after drying, the washed material web is conveyed to a first assembly station 8, in which the second stabilizing layer 4 is connected to the material web.

[0092] The second stabilizing layer 4 is disposed on the opposite side of the first stabilizing layer 3. Preferably, the second stabilizing layer 4 is a matrix or fabric, such as a nonwoven, woven, or knitted fabric based on polyester, polyamide, cotton, polypropylene, polyethylene, elastic fibers, cellulose cotton, polyester or polyamide, or combinations thereof. More preferably, the second stabilizing layer 4 has a content of 10 g / m³. 2 Up to 300 g / m 2 The weight of the fabric. More precisely, the second stabilizing layer 4 can be typically lightweight (10 g / m²). 2 Up to 60 g / m 2 The so-called backing fabric or usually heavier (60 g / m²) 2 Up to 300 g / m 2 And more preferably 80 g / m 2 Up to 200 g / m 2The so-called surface fabric is the second stabilizing layer. A third layer with the same properties as the second stabilizing layer can also be added via dot-lamination before washing, thus completing the 3L structure during washing. All the fabrics mentioned preferably have a tensile elongation between 50% and 200% on both sides, as measured by ASTM D882-12 (ISO 527-3) or ISO 13934, for defect-free washing results.

[0093] The weight of the second stabilizing layer 4 is preferably 10 g / m³. 2 Up to 300 g / m 2 This can depend on whether the second stabilizing layer 4 is a lighter backing fabric or a thicker surface fabric.

[0094] The stabilizing layer 4 is fixed to the membrane material 1. The stabilizing layer 4 is preferably laminated to the membrane material 1. Preferably, the stabilizing layer 4 is laminated via dot-matrix adhesive bonding. The assembly station 8 may include a calendering device. Other techniques known in the art for joining the second stabilizing layer to the membrane material may also be used.

[0095] Preferably, the second stabilizing layer 4 is wider than the membrane material 1 and has boundaries 40 formed on both sides. Preferably, the first stabilizing layer has the same width as the membrane material 1.

[0096] In the next step, the first stabilizing layer 3 can be separated from the membrane material 1 and removed from the membrane material 1. The removal station 9 can be a tensioned roll-to-roll / unwinding manufacturing system.

[0097] The washed and porous membrane material 1 and the material web attached to the second stabilizing layer 4 are now preferably conveyed to the second assembly station 10. A third layer 11 is attached to the membrane material 1 and / or the second stabilizing layer 4, wherein the third layer 11 is attached to the opposite side of the second stabilizing layer 4. In other embodiments, the third stabilizing layer 11 is not added.

[0098] Preferably, the third stabilizing layer 11 is laminated to the membrane material 1. Preferably, the third stabilizing layer 11 is laminated in a similar manner to the second stabilizing layer 4.

[0099] The third stabilizing layer 11 is a matrix or fabric, such as a nonwoven, woven, or knitted fabric based on polyester, polyamide, cotton, polypropylene, polyethylene, elastic fibers, cellulose cotton, polyester or polyamide, or combinations thereof. More preferably, the third stabilizing layer 11 is a knitted or woven fabric.

[0100] The weight of the third layer is preferably 10 g / m³. 2 Up to 300 g / m 2 .

[0101] In this embodiment, the three layers, namely the washed membrane material, the second stabilizing layer 4, and the third stabilizing layer 11, are part of the final fabric, that is, the three layers are part of the final product.

[0102] Figure 2 A second embodiment of the method for carrying out the invention is shown. An apparatus for carrying out the method is schematically illustrated. Some of the method steps, apparatus, and materials used are related to those described above. Figure 1 The steps, apparatus, and materials described are the same. The method steps, apparatus, and materials will not be repeated.

[0103] According to Figure 1 The difference between the method and apparatus is that the second stabilizing layer 4 is attached to the material web before the material web is washed. Another difference is that the first stabilizing layer 1 is removed from the material web, including the already fixed second stabilizing layer 4, before the material web is washed. After the washing process, and preferably after the drying process, the third stabilizing layer 11 is fixed to the other side of the washed and now porous membrane material 1.

[0104] according to Figure 2 This method can be used with any washing machine. However, it is particularly suitable for jet overflow machines, skein dyeing machines, or flat-width washing machines. When using a beam dyeing machine, the material web is wound up after the first stabilizing layer is removed, and the wound is carried into the washing machine. Other types of layers can also be added. Not all layers must be stabilizing layers.

[0105] Depending on variations of this method, the material web, which always includes the membrane material, is preferably laminated in the form of 2L (with a fabric on one side), 2.5L (with a fabric on one side and a print on the other side), or 3L (with a fabric on each side of the membrane). As mentioned above, the material web can also be a co-extruded layer.

[0106] During washing, these laminates may exist on the material web in addition to or in place of the first co-extruded stabilizing layer.

[0107] When the material web is washed as a wound piece and / or when the film material is attached to the fabric during the washing process, it is preferable to then press it using a calendering step in order to accelerate the subsequent drying process.

[0108] During the drying process, tension is preferably applied to both sides of the material web. The tension is preferably applied through a stabilizing layer and / or through mechanical means, such as clamps.

[0109] about Figure 1In the method shown, the first stabilizing layer 1 can also be removed after drying but before attaching the second stabilizing layer. In some cases, the first stabilizing layer 1 can also be removed before drying.

[0110] about Figure 2 The method shown includes a washed membrane material and a second stabilizing layer web that can be rewound in this state, and the web can be later unwound to apply a third and even more layers.

[0111] Figure 3 A third method for carrying out the method of the present invention is shown. An apparatus for carrying out the method is schematically illustrated. Some of the method steps, apparatus, and materials used are related to those described above. Figure 1 and Figure 2 The steps, apparatus, and materials described are the same. The method steps, apparatus, and materials will not be repeated.

[0112] In this variation of the method of the present invention, the membrane material 1 is first fixed to the first stabilizing layer 3. Preferably, the first stabilizing layer 3 is co-extruded. At the first assembly station 8, the second stabilizing layer 4 is disposed on the side of the membrane material 1 opposite to the side of the first stabilizing layer 3. Figure 1 and Figure 2 In a variation, the second stabilizing layer 4 is preferably laminated to or otherwise fixed to the membrane material 1. In this variation, the second stabilizing layer 4 may also be fixed to the membrane material 1. However, the second stabilizing layer 4 is preferably disposed only on the side of the membrane material 1 that does not have any type of connector.

[0113] In removal station 9, the first stabilizing layer 3 is removed from the membrane material 1. Then, the combination of membrane material 1 and the second stabilizing material 4 is wound up, such that the second stabilizing material 4 forms an intermediate layer between the windings of membrane material 1. This wound then enters as a winding into a washing machine 50. This washing machine is preferably a warp dyeing machine. After washing out the template 2, the wound is dried in a drying machine 51, which may be part of the warp dyeing machine 50 or may be a separate machine. In other variations, the wound is unwound before drying, and the unwound material web is dried.

[0114] After drying, the dried membrane material 1, including the pores 7, is separated from the second stabilizing layer 4 in the second removal station 12.

[0115] Preferably, the second stabilizing layer 4 has an open knitted structure, meaning that the second stabilizing layer 4 is porous or has holes, allowing the template 7 to be washed out from the winding. The material of the second stabilizing layer 4 is preferably a thick fabric, such as a nonwoven material or a spacer fabric. "Thick" means preferably 500 micrometers to 20,000 micrometers.

[0116] The described method is industrially applicable to the manufacture of breathable waterproof membranes with minimal crease markings and weak points.

[0117] List of reference numerals

[0118] 1 membrane material

[0119] 2 templates

[0120] 3 First stable layer

[0121] 30 boundary

[0122] 4 Second stable layer

[0123] 40 boundary

[0124] 50 Washing Machine

[0125] 51 Drying Machine

[0126] 6 support rollers

[0127] 7 holes

[0128] 8 First Combined Station

[0129] 9 Remove station

[0130] 10 Second Group Station

[0131] 11 Third stable layer

[0132] 12 Second Removal Station

Claims

1. A method for manufacturing a breathable waterproof membrane, the method comprising the following steps: - Provide a material web comprising at least one stabilizing layer and a retaining template combined with a membrane material of the at least one stabilizing layer. - The material web is fed into the washing machine, and - The template is washed out of the membrane, thereby introducing the porous structure into the membrane material.

2. The method according to claim 1, wherein, The at least one stabilizing layer is fixed to the membrane material.

3. The method according to any one of claims 1 or 2, wherein, The material web is conveyed through the washing machine, whereby the template is washed out of the membrane and the porous structure is introduced into the membrane material.

4. The method according to claim 1, wherein, The material web is wound into the shape of a coil and then fed into the washing machine.

5. The method according to any one of claims 1 to 4, wherein, The washed material web, combined with the at least one stabilizing layer, is washed in a dyeing machine.

6. The method according to any one of claims 1 to 5, wherein, The membrane is a polymer membrane, and the template is a mineral or salt.

7. The method according to any one of claims 1 to 6, wherein, The washing machine is a roll dyeing machine or a jet overflow machine, a skein dyeing machine or a flat-width washing machine or a warp beam dyeing machine.

8. The method according to any one of claims 1 to 7, wherein, The first stabilizing layer of the at least one stabilizing layer is co-extruded together with the membrane material holding the template.

9. The method according to claim 8, wherein, The first stabilizing layer, together with the membrane material holding the template, is brought into the washing machine.

10. The method according to any one of claims 8 or 9, wherein, After the template has been removed, the first stabilizing layer is separated from the membrane material.

11. The method according to any one of claims 8 or 9, wherein, The second stabilizing layer of the at least one stabilizing layer is connected to the membrane material holding the template, wherein the second stabilizing layer is arranged on the side opposite to the first stabilizing layer.

12. The method according to claim 11, wherein, The first stabilizing layer is removed before the second stabilizing layer and the membrane material holding the template are introduced into the washing machine.

13. The method according to claim 11 or 12, wherein, After the template has been removed, the second stabilizing layer remains on the membrane material and forms part of the final fabric.

14. A method for manufacturing a breathable waterproof membrane, the method comprising the following steps: - A wet material web is provided, the wet material web comprising at least one stabilizing layer and a membrane material, the membrane material comprising pores created by washing away the template, the membrane material being combined with the at least one stabilizing layer. - The material web is fed into the drying machine, and - The material web is dried.

15. A breathable waterproof membrane manufactured by the method according to any one of claims 1 to 14.

Images