JP2005022401A - Non-sticky felt material and its manufacturing process - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a felt material non-sticky like a non-woven fabric made of a 100% PTFE fiber and useful as a cushioning material for assembling a liquid crystal cell, a cushioning material for molding a resin plate or a heat insulating sheet or the like. <P>SOLUTION: The felt material is made by unifying card wraps constructed of heat resistant organic filaments with a melting temperature of ≥250°C or having no melting temperature with needle punching and a heat meltable fluororesin layer is adhered to the one side or the both sides of the felt material obtained as above or a dispersion of a fluororesin is immersed on the surface of the felt material, then a porous film made of the fluororesin is laminated on the one side or both sides of the sheet. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  TECHNICAL FIELD The present invention relates to a non-adhesive felt material in which a hot-melt fluororesin layer and / or a fluororesin porous film is bonded to a felt sheet, and relates to a liquid crystal cell assembly cushion material, a resin plate molding cushion material, or a heat insulation sheet material. It relates to felt materials that are useful as such.

  In press molding of a resin plate such as a fluorescent lamp hood on the ceiling, an acrylic resin sheet or the like comes into close contact with a pair of heated male and female molds, and the molded product cannot be peeled off from the mold after heat processing. . For this reason, the molded product can be peeled from the male and female molds by coating the male and female mold surfaces with polytetrafluoroethylene (PTFE) resin, or by attaching a polyester nonwoven fabric to the mold surface.

  Also, for press assembly of the liquid crystal cell, two glass substrates connected with electrodes are arranged at a predetermined interval, and the adhesive printed on the periphery is cured by heat and pressure, and sealed. Cost. The current assembly press increases productivity by stacking and pressing a number of pre-heated two glass substrates on the bed. During pressurization in this assembly process, a cushioning material is interposed between each liquid crystal cell in order to avoid local stress concentration on each glass substrate and to keep a fine interval between each pair of glass substrates stable. It must be easy to peel off after pressing. A conventional cushion material is made of a thin non-woven fabric made of 100% PTFE fiber, and is very expensive for using a large number of disposable materials, and the influence on the sales cost of the liquid crystal display panel cannot be ignored.

There are various types of molding cushion materials other than the non-woven fabric which is 100% PTFE fiber. For example, in JP-A-8-183123, a fluororesin powder is sintered on the surface of an inorganic fiber woven fabric, or in JP-A-9-262856, an aramid fiber nonwoven fabric is formed on both sides of a glass cloth impregnated with a fluororesin. A fluoro rubber sheet is laminated. These cushion materials have variations in quality and have a high manufacturing cost due to a multilayer structure, and are not practical than a nonwoven fabric made of 100% PTFE fiber as a cushion material for assembling a liquid crystal cell.
JP-A-8-183123 JP-A-9-262856

  In press molding of resin plates, if the male and female mold surfaces are coated with PTFE resin, the molded product can be separated from the male and female molds, but the molded product is distorted by localized stress concentration due to uneven pressing. Or scratches on the surface of the molded product due to compression during thermal processing. When a polyester nonwoven fabric is pasted on the mold surface, even if local stress concentration can be avoided, dust and burrs adhere to the nonwoven fabric, and the problem of scratches in the molded product is hardly solved. Even if a non-woven fabric made of 100% PTFE fiber is preferably used instead of a resin coating or a polyester nonwoven fabric, it cannot be used in terms of cost.

  A non-woven fabric made of 100% PTFE fiber is often used because of its high cost, which is not sufficient in terms of cushioning properties, and local stress concentration problems may recur during molding. An inexpensive sponge or non-woven fabric, which is an alternative to expensive non-woven fabric of PTFE fiber, is considerably inferior in terms of non-adhesiveness, low friction resistance, water repellency, etc. It cannot be replaced in terms of scratch prevention, cushioning and breathability.

  The present invention has been proposed in order to improve the above-mentioned problems related to conventional press cushioning materials and resin coatings, and provides a non-adhesive felt material having both the fluororesin film and the original characteristics of felt. The purpose is to do. Another object of the present invention is to provide an inexpensive cushioning material for assembling liquid crystal cells, a cushioning material for molding a resin plate, and a heat insulating sheet material, which are excellent in various physical properties, based on a felt material. Another object of the present invention is to provide a non-adhesive felt material that does not cause evaporation of impregnating additives and the like even when heated at a high temperature during use.

  The non-adhesive felt material according to the present invention comprises a card wrap made of heat-resistant organic fibers having a melting point of 250 ° C. or higher or a non-melting point, integrated by needle punching, and melted on one or both sides of the obtained felt material. A type fluororesin layer is adhered, and a predetermined thickness and density are determined by heating and pressing. In the felt material of the present invention, a porous film can be further laminated on the fluororesin layer. Preferably, the card wrap is integrated by needle punching by interposing a textile base fabric mainly composed of heat-resistant organic fibers. The card wrap preferably contains 0.5 to 10% by weight of conductive fiber.

  In another felt material of the present invention, card wraps made of heat-resistant organic fibers are integrated by needle punching, and the surface of the obtained felt material is impregnated with a dispersion of fluororesin. Next, it is necessary to laminate a fluororesin porous film on one side or both sides of the obtained sheet, and to determine a predetermined thickness and density by heating and pressing.

  Another felt material of the present invention is obtained by integrating a card wrap composed of heat-resistant organic fibers by needle punching, fusing one side or both sides of the obtained felt material, and then melting one side of the felt material. Alternatively, a fluororesin porous film may be laminated on both sides. In this case, it is necessary to further determine the predetermined thickness and density by pressing.

  As one aspect of the present invention, a cushion material for assembling a liquid crystal cell is obtained by integrating card wrap containing PTFE fibers by needle punching, impregnating a fluororesin dispersion on the sheet surface, and then applying one or both sides of the felt material. A porous film of fluororesin is laminated on the substrate, and the thickness and density are determined by heating and pressing. A woven fabric may be interposed in the cushion material, and it can also be used for press processing of a printed circuit board.

  As another aspect of the present invention, the cushioning material for resin plate molding is integrated by needle punching with a woven base fabric mainly composed of heat-resistant organic fibers interposed between card wraps made of heat-resistant organic fibers, The surface of the obtained felt material is impregnated with a fluororesin dispersion. Next, it is only necessary to laminate a porous film of a fluororesin on one side of the obtained felt material, and further, a predetermined thickness and density are determined by heating and pressing.

  As another aspect of the present invention, the heat insulating sheet material is a felt obtained by integrating a card wrap composed of heat-resistant organic fibers by needle punching with a woven base fabric mainly composed of heat-resistant organic fibers interposed After the surface of the material is impregnated with a dispersion of fluororesin, a porous film of fluororesin is laminated on one or both sides of the sheet, and the thickness and density are determined by heating and pressing. Applications of this heat insulating sheet material are tent materials, roof materials for tent warehouses, heat resistant heat insulating materials in chemical plants, etc., and can be applied to packing when impregnated with resin.

  The method for producing a non-adhesive felt material according to the present invention is to integrate a card wrap composed of heat-resistant organic fibers by needle punching, and then laminate a hot-melt type fluororesin film on one or both sides of the felt material. Further, a protective film is laminated on the film. The laminated felt material is heated and pressurized through a pair of rolls at a temperature of 250 to 320 ° C. and a linear pressure of 750 to 2500 N / m, so that the protective film is peeled off after bonding the felt material and the hot-melt fluororesin film. .

  In another method for producing a felt material according to the present invention, a card wrap composed of heat-resistant organic fibers is integrated by needle punching, and then a hot-melt type fluororesin film is laminated on one or both sides of the felt material. A fluororesin porous film is laminated on the film. The laminated felt material is heated and pressurized through a pair of rolls at a temperature of 250 to 320 ° C. and a linear pressure of 750 to 2500 N / m, thereby bonding the felt material to the heat-melting fluororesin film and the fluororesin porous film. .

  The present invention will be described with reference to the drawings. As shown in FIG. 1 and FIG. 2, the felt material according to the present invention can be obtained from FIG. 3 even if the hot melt type fluororesin layer 2 is bonded to one or both sides of the felt material 1. As shown in FIG. 5, a fluororesin porous film 5 may be laminated on one or both sides of a felt material 3 impregnated with a fluororesin dispersion. These felt materials have the original properties of fluororesin and felt, and the original felt cushioning, vibration proofing, sound absorption, breathability, waterproof / moisture permeable, heat insulation / heat retention, etc., and derived from the fluororesin film Excellent non-adhesiveness, low friction resistance, water repellency and the like. Since these felt materials have high non-adhesiveness and heat resistance, when used as cushion materials for assembling liquid crystal cells, cushion materials for processing printed circuit boards, and cushion materials for resin plate molding, compared to non-woven fabric with 100% PTFE fiber Economically advantageous. These felt materials can be applied to various uses by utilizing the above-mentioned properties.

  The organic fiber used in the present invention is a relatively soft heat-resistant fiber, and preferably has a melting point of 250 ° C. or higher or no melting point. The felt material of the present invention requires, for example, no change in dimensions when used as a cushioning material for assembling a liquid crystal cell in a high temperature environment, and the ordinary temperature of the cushioning material is around 200 ° C. If the melting point of the heat-resistant organic fiber to be added is not 250 ° C. or higher, the dimensional stability is lacking. “Non-melting point” means a fiber whose melting point is difficult to measure because the decomposition temperature is lower than the melting temperature when heated, and the fiber does not thermally decompose even when heated to about 250 ° C.

  PTFE fiber (melting point: 327 ° C), polyphenylene sulfide (PPS) fiber (melting point: 287 ° C), polytetrafluoroethylene fiber, polyetheretherketone fiber, 66 nylon as preferred organic fibers having a melting point of about 250 ° C or higher Examples thereof include fibers (melting point: 250 to 260 ° C.), polyester fibers (melting point: 255 to 260 ° C.), and heterocyclic fibers. Examples of the non-melting heat-resistant organic fiber include polyimide fiber, paraphenylene terephthalamide fiber, metaphenylene isophthalamide fiber, parabenzamide fiber, copolymerized aramid fiber, flame resistant fiber, rayon and the like. These fibers may be used in the form of a composite fiber or mixed fiber.

  The fabric base cloth 7 illustrated in FIGS. 1, 2 and 4 is interposed in order to improve the dimensional stability of the felt material, and heat resistant organic fibers are used for the fabric base cloth 7 depending on the application. The woven fabric 7 is usually preferably a plain woven fabric or a twill woven fabric. The fibers constituting the fabric base fabric 7 are preferably high-tensile fibers such as polyester fibers, metaphenylene isophthalamide fibers, paraphenylene terephthalamide fibers, and carbon fibers, glass fibers, ceramic fibers, etc. may be used. . In the woven fabric 7, the high-tensile fiber may constitute the entire fabric or the warp, or only a part of the warp may be added.

  As shown in FIG. 1, the woven base fabric 7 is interposed between the card wraps 8 and 10 in two equal parts, or when the card wrap is thin, it is disposed above or below the card wrap. Two or more woven fabrics can be used in combination as the woven fabric base 7. The two woven fabrics may be arranged together or may be arranged separately in the middle and upper / lower direction of the wrap.

In order to obtain the felt materials 1 and 3, the laminated card wrap alone or the card wrap and the woven fabric cloth 7 are integrated by needle punching, and a water jet punching process is applied and integrated into a sheet shape as desired. The number of needles in this needle punch may be about 250 to 350 / cm ² .

  In order to adhere the hot-melt type fluororesin layer 2 to the felt material 1 without impregnating the resin dispersion, as shown in FIG. 6, the hot-melt type fluororesin film 12 and the protective film 14 are attached to the felt material 1. Are sequentially laminated, and the laminated felt material 15 is passed through a roll pair 16 and heated and pressurized. The protective film 14 may be peeled off after the felt material 1 and the film 12, that is, the fluororesin layer 2 are bonded by heating and pressing. Usually, the protective film 14 is wound up after peeling and used repeatedly.

  The protective film 14 is usually a polyimide film or other heat resistant film that does not soften at around 320 ° C. The roll pair 16 is usually a roll laminator, and sets the felt material to a predetermined thickness and density simultaneously with bonding by heating and pressing. The obtained felt material 18 (FIG. 1) does not need to impregnate the felt material 1 with a dispersion of fluororesin, and even when heated to a high temperature of about 200 ° C. as a cushioning material for liquid crystal cell assembly, the impregnation additive This is preferable because no evaporation occurs.

  In FIG. 6, instead of the protective film 14, when a fluororesin porous film is laminated on the fluororesin film 12 and passed through the roll pair 16, the porous film can be adhered as it is. The felt material laminated with the fluororesin porous film may be set to a predetermined thickness and density in a roll laminator that is the roll pair 16. Also in this case, it is not necessary to impregnate the felt material 1 with a dispersion of fluororesin, and even when heated to a high temperature of about 200 ° C., evaporation of the impregnating additive and the like does not occur.

  Generally, the porous film of fluororesin to be laminated is a porous film of PTFE resin having a thickness of 20 to 100 μm. The heat-resistant fluororesin may be a heat melting type such as tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) or tetrafluoroethylene-hexafluoropropylene copolymer (FEP). A fluororesin such as PTFE resin becomes a flexible and tough porous membrane when the fine powder is paste extruded and stretched.

  On the other hand, when the felt material 3 is impregnated with a dispersion of fluororesin in advance, the porous films 5 and 5 may be further laminated on the felt material 3 as illustrated in FIG. This dispersion is generally PTFE resin. The aqueous dispersion of PTFE resin has a concentration of around 60% by weight, and is usually stabilized by adding a nonionic surfactant. The dispersion may be a hot-melt type fluororesin such as PFA or FEP, and these are preferably dispersed in water or an organic solvent. The fluororesin dispersion is impregnated by dipping, coating, spraying with a spray gun, or the like.

  The felt material 3 is completely pressure-bonded to the porous films 5 and 5 by heating / pressing with a hot press, calendar, tenter plate or the like at the same time or immediately after the porous films 5 and 5 are attached. It is preferable to adjust the felt material to a predetermined thickness and density by this heating and pressing. This heating and pressurization may be performed at a temperature of about 200 to 300 ° C. for several minutes, and it is possible to perform heating alone and then cold press. If desired, in the felt material 20 (FIG. 5) in which the porous film is pressure-bonded to one surface, after the pressure bonding, the other surface to which the felt body film is not pressure-bonded is subjected to hair baking to remove loose hairs. May be.

  When a heat-resistant organic fiber such as polyester fiber is used as this felt material, if one or both sides of the felt material is subjected to a hair baking process, the melting point of that portion is melted to melt the surface of the fluororesin. The film can be applied as it is. The laminated felt material may be set to a predetermined thickness and density by pressing. In this case as well, it is not necessary to impregnate a fluororesin dispersion. The obtained felt material can be applied to a cushion material for molding a resin plate, a tent material, a heat insulating sheet material, a resin-impregnated packing, a sealing material, a spacer, and the like.

  The felt material according to the present invention has a structure in which a heat-melting type fluororesin layer 2 is bonded to a felt material or a porous film of a fluororesin is laminated, and has the original characteristics of fluororesin and felt. Yes. The felt material of the present invention is much cheaper than a non-woven fabric made of 100% PTFE fiber, and is superior in cushioning properties, vibration proofing properties, sound absorption properties, etc., non-adhesiveness, low friction resistance, water repellency, etc. The point is almost the same. For this reason, the felt material of the present invention has a problem of local stress concentration at the time of molding by using a sufficiently thick material even in a liquid crystal cell assembly press machine that consumes a large number of sheets in one press. It does not occur.

  Since the felt material of the present invention has high non-adhesiveness and cushioning properties, it can be substituted for various industrial applications in which a simple resin coating or non-woven fabric of PTFE fibers is pasted. For example, the felt material of the present invention is not only a cushion material for assembling liquid crystal cells, but also a printed circuit board cushion material, a cushion material for resin plate molding, a tent material, a roof material for a tent warehouse, and a heat and heat insulation material in a chemical plant. It can be applied to heat insulating sheet materials, resin-impregnated packing, sealing materials, spacers, gaskets, O-rings, and the like.

  Next, the present invention will be described based on examples, but the present invention is not limited to the examples.

A card wrap is formed from 100% metaphenylene isophthalamide fiber (trade name: Cornex, manufactured by Teijin) having a fineness of 2.2 decitex, and the card wrap has a basis weight of 110 g / m ² . The card wraps 8 and 10 (FIG. 1) are laminated via a plain fabric base fabric 7 made of metaphenylene isophthalamide fiber, and the whole is integrated by needle punching. Further, this is subjected to a water jet punch process to obtain a heat-resistant fiber felt material 1 having a basis weight of 260 g / m ² .

  As shown in FIG. 6, a 25 μm thick FEP film 12 (trade name: Toyoflon, manufactured by Toray Synthetic Film) and a 25 μm thick polyimide film (trade names: Kapton, Toray DuPont) are provided on both sides of the heat-resistant fiber felt material 1. ), And the felt material 1 and the FEP film 12 are adhered using a roll laminator 16 under conditions of a temperature of 290 ° C. and a linear pressure of 1500 N / m, and then the protective film 14 is peeled off and heat is applied to both sides. A non-adhesive felt material 18 having a three-layer structure having melt-type fluororesin layers 2 and 2 is obtained. The obtained felt material 18 has sufficient cushioning and releasability as a cushioning material for assembling a liquid crystal cell, and can be repeatedly used without problems even when used at a high temperature of about 200 ° C. Further, the felt material 18 does not evaporate the impregnating additive or the like even when heated to a high temperature of about 200 ° C. as a cushioning material for assembling the liquid crystal cell.

Example 1
FIG. 7 schematically shows a press machine 24 used when assembling the liquid crystal cell as an example of use of the cushion material for assembling the liquid crystal cell. The press machine 24 shows a mode in which the upper and lower glass substrates 30 and 32 heated in advance are bonded to each other between the upper and lower plates 26 and 28, respectively. A cushion material 34 that is the felt material 18 is arranged between the pair of glass substrates 30 and 32. The cushioning material 34 uniformly crushes the sealing material 35 between the glass substrates 30 and 32 to keep the gap between the upper and lower glass substrates constant, and a spacer (not shown) is provided between each pair of glass substrates 30 and 32. ).

  The liquid crystal display plates which are the glass substrates 30 and 32, that is, each set of liquid crystal cells, can be easily peeled off from the press machine 24 after pressure molding by the intervention of the cushion material 34. The cushion material 34 has sufficient elasticity in the press assembly of the liquid crystal cell, and is comparable to a non-woven fabric made of 100% PTFE fiber in terms of non-adhesiveness, low friction resistance, water repellency and the like. The cushion material 34 can be used repeatedly, and even if a large number of disposable materials are used as disposable materials, the impact on the sales cost of the liquid crystal display panel is small.

  As shown in FIG. 2, a porous film made of 25 μm thick FEP film 35 and 30 μm thick PTFE resin (trade name: Poeflon, manufactured by Sumitomo Fine Polymer Co., Ltd.) is formed on both surfaces of the heat-resistant fiber felt material 1 obtained in Example 1. 36) and heated and pressurized by the roll laminator 16 (FIG. 6) under the same conditions as in Example 1 to obtain five layers of non-adhesive felt material 37.

  The obtained non-adhesive felt material 37 has sufficient cushioning properties and releasability as a cushioning material for assembling a liquid crystal cell, and can be repeatedly used without problems even when used at a high temperature of about 200 ° C. Even if this felt material is heated to a high temperature of about 200 ° C. as a cushioning material 34 for assembling a liquid crystal cell, the impregnation additive and the like do not evaporate.

  A heat-resistant fiber treated in the same manner as in Example 1 except that 95% by weight of metaphenylene isophthalamide fiber having a fineness of 2.2 dtex and 5% by weight of conductive polyester fiber having a fineness of 2.2 dtex are mixed as the web. A felt material 1 is obtained. The felt material 1 is treated in the same manner as in Example 2 to obtain a five-layer non-adhesive felt material.

  The obtained non-adhesive felt material has sufficient cushioning properties and releasability as a cushioning material for assembling liquid crystal cells. Furthermore, this felt material is less likely to generate static electricity due to the addition of conductive fibers, and the liquid crystal cell can be assembled more smoothly.

A web is produced by uniformly blending 100% PTFE fiber having a fineness of 7 denier. The webs are laminated to form a card wrap with a weight of 600 g / m ² , and the entire wrap is needle punched. In FIG. 3, in order to obtain the felt material 3, the integrated sheet is immersed in a PTFE resin dispersion, and the resin is impregnated with 300 g / m ² in a dry amount. Next, the porous films 5 and 5 of PTFE resin having a thickness of 30 μm are bonded to both sides of the felt material 3 by hot pressing. When the hot pressing is performed at a temperature of 250 ° C. for 60 seconds, a felt material 38 (FIG. 3) having a weight of 900 g / m ² , a thickness of 0.5 mm, and a dimension of 370 × 320 mm is obtained.

  The non-adhesive felt material 38 has sufficient elasticity as a cushioning material in the press assembly of a liquid crystal cell, and is also comparable to a non-adhesive, low friction resistance, water repellency, etc., with 100% PTFE fiber non-woven fabric. Even if a large number of disposable materials are used, there is little effect on the sales cost of the liquid crystal display panel. As the felt material 38, it is desirable to use a dispersion that does not cause evaporation of the impregnating additive when heated at a high temperature, or to use at a temperature within a range where evaporation of the impregnating additive does not occur.

A web is produced by uniformly blending 50% by weight of PTFE fiber having a fineness of 7 denier and 50% by weight of metaphenylene isophthalamide fiber (trade name: manufactured by Cornex, Teijin) having a fineness of 2 denier. The webs are laminated to form a card wrap having a weight of 300 g / m ² , and the entire wrap is needle punched. The obtained felt material 3 is immersed in a dispersion of PTFE resin, and the resin is impregnated with 300 g / m ² in a dry amount. Pressed in the same manner as in Example 4, and a porous film 5 or 5 of PTFE resin having a thickness of 30 μm was bonded to both sides of the sheet, and felt material having a weight of 600 g / m ² , a thickness of 0.5 mm, and a dimension of 370 × 320 mm. 38 is obtained.

  When the felt material 38 produced in Example 5 is used as a cushioning material for press assembly of a liquid crystal cell, the cushioning material has sufficient elasticity, and also in terms of non-adhesiveness, low friction resistance, water repellency and the like. Comparable to 100% PTFE non-woven fabric. Even if many cushion materials are used as disposable materials, the impact on the sales cost of the liquid crystal display panel is relatively small.

A web is produced by uniformly blending 50% by weight of PTFE fiber having a fineness of 7 denier and 50% by weight of metaphenylene isophthalamide fiber (trade name: Conex) having a fineness of 2 denier. This web is laminated to form a card wrap weighing 250 g / m ² . As shown in FIG. 4, a multifilament weave of metaphenylene isophthalamide fiber (trade name: Conex) having a weight of 50 g / m ² as a woven fabric 7 between two equal card wraps 39, 40. Needle punching with a cloth interposed.

The obtained felt material is immersed in a dispersion of PTFE resin, and the resin is impregnated in a dry amount of 200 g / m ² . In the same manner as in Example 4, the porous membranes 42 and 44 of PTFE resin having a thickness of 30 μm are bonded to both sides of the sheet. A felt material 46 having a weight of 500 g / m ² , a thickness of 0.4 mm, and a dimension of 370 × 320 mm is obtained.

  When the felt material 46 manufactured in Example 6 is used as a cushioning material for press assembly of a liquid crystal cell, the cushioning material has sufficient elasticity, and also in terms of non-adhesiveness, low friction resistance, water repellency and the like. Comparable to 100% PTFE non-woven fabric. Even if many cushion materials are used as disposable materials, the impact on the sales cost of the liquid crystal display panel is relatively small.

A web is produced by uniformly blending 50% by weight of PTFE fiber having a fineness of 7 denier and 50% by weight of metaphenylene isophthalamide fiber (trade name: Conex) having a fineness of 2 denier. The webs are laminated to form a card wrap having a weight of 300 g / m ² , and the entire wrap is needle punched. A dispersion of PTFE resin is sprayed on both sides of the obtained felt material 3, and the resin is impregnated with a dry amount of 20 g / m ^{2 on} one side.

Porous films 5 and 5 of PTFE resin having a thickness of 30 μm are bonded to both sides of the sheet by hot pressing. When the hot pressing is performed at a temperature of 280 ° C. for 30 seconds, a felt material 38 having a weight of 350 g / m ² , a thickness of 0.4 mm, and a dimension of 370 × 320 mm is obtained.

  When the felt material 38 manufactured in Example 7 is used as a cushioning material 34 for press assembly of a liquid crystal cell, the cushioning material has sufficient resilience and has non-adhesiveness, low friction resistance, water repellency and the like. But it is comparable to 100% PTFE non-woven fabric. Even if many cushion materials are used as disposable materials, the impact on the sales cost of the liquid crystal display panel is relatively small.

A web is produced by uniformly blending 100% of metaphenylene isophthalamide fiber (trade name: Conex) having a fineness of 2 denier. This web is laminated to form a card wrap weighing 250 g / m ² . Thereafter, the same processing as in Example 4 is performed to obtain a felt material 38 having a weight of 300 g / m ² , a thickness of 0.4 mm, and a dimension of 370 × 320 mm.

  When the felt material 38 manufactured in Example 8 is used as a cushioning material 34 for press assembly of a liquid crystal cell, the cushioning material has sufficient elasticity, and also has non-adhesiveness, low friction resistance, water repellency and the like. But it is comparable to 100% PTFE non-woven fabric. Even if many cushion materials are used as disposable materials, the impact on the sales cost of the liquid crystal display panel is relatively small.

A web is produced by uniformly blending 30% by weight of polyimide fiber (trade name: P-84) having a fineness of 3 denier and 70% by weight of metaphenylene isophthalamide fiber (trade name: Conex) having a fineness of 2 denier. To do. This web is laminated to form a card wrap having a weight of 300 g / m ² . Thereafter, the same processing as in Example 5 is performed to obtain a felt material 38 having a weight of 600 g / m ² , a thickness of 0.5 mm, and a dimension of 370 × 320 mm.

  When the felt material 38 produced in Example 9 is used as a cushioning material 34 for press assembly of a liquid crystal cell, the cushioning material has sufficient elasticity, and also has non-adhesiveness, low friction resistance, water repellency and the like. But it is comparable to 100% PTFE non-woven fabric. Even if many cushion materials are used as disposable materials, the impact on the sales cost of the liquid crystal display panel is relatively small.

A web is produced by uniformly blending 50% by weight of PTFE fiber having a fineness of 7 denier and 50% by weight of metaphenylene isophthalamide fiber (trade name: Conex) having a fineness of 2 denier. The webs are laminated to form a card wrap with a weight of 500 g / m ² , and the entire wrap is needle punched. In order to obtain the felt material 3, a dispersion of PTFE resin is sprayed on both sides of the integrated sheet, and the resin is impregnated with a dry amount of 20 g / m ^{2 on} one side.

In the same manner as in Example 4, the PTFE resin porous films 5 and 5 having a thickness of 80 μm are bonded to both sides of the sheet. A felt material 38 having a weight of 550 g / m ² , a thickness of 1.0 mm, and a size of 400 × 500 mm is obtained.

Example 2
FIG. 8 shows a method of manufacturing a flexible printed circuit board (FPC) on which circuit components such as automobile electrical component units, accessories, and switches are mounted as an example of use of the printed circuit board cushioning material. The base film 50 such as polyester wound around the roll 48 and the copper foil 54 wound around the roll 52 are drawn out from each other and stacked one above the other. Furthermore, the felt material 38 of Example 10 was manufactured in a long size, and this was wound around a roll 58 as a long size cushion material 56. The cushion material was pulled out and stacked under the base film 50, and a heating mold 60 was obtained. And supplied between the tables 62. In the heating mold 60, a plurality of rows of protruding blades and grooves corresponding to the conductor pattern to be formed are alternately formed at a predetermined width and pitch on the processed surface. The heating mold 60 pressurizes the base film 50, the copper foil 54 and the cushion material 56, and thermocompression-bonds the base film 50 and the copper foil 54. As a result, the copper foil 54 and the conductive pattern portion of the base film 50 are cut by the protruding blades of the heating mold 60, pressed against the cushion material 56, and the corresponding portion of the cushion material is heated by being compressed. Absorbs the pressing force of the mold 60. In the copper foil 54, the surface of the contact surface with the base film 50 is roughened. The conductor pattern portion of the copper foil 54 pressed against the base film 50 is pressure-bonded to the base film 50 with a predetermined adhesive strength, and then wound around a roll 49. The remaining portion of the copper foil 54 and the cushion material 56 are wound around a roll 53 or 57 and used for recycling.

  In this manufacturing method, since the cushion material 56 is always interposed between the heating mold 60 and the work table 62, the pressurizing force to the table 62 can be reliably relieved by its high elasticity, and the mold itself is deformed. And the deformation | transformation of the workpiece surface in the table 62 can be prevented beforehand. According to this manufacturing method, the service life of the heating mold 60 and the table 62 is increased, and it is possible to reduce equipment costs and member replacement costs, and it is possible to suppress an increase in manufacturing costs.

A web is produced by uniformly blending 100% of metaphenylene isophthalamide fiber (trade name: Conex) having a fineness of 2 denier. The webs are laminated to form a card wrap having a weight of 250 g / m ² , and the entire wrap is needle punched. Thereafter, when treated in the same manner as in Example 4, a felt material 38 having a weight of 550 g / m ² , a thickness of 1.3 mm, and a size of 400 × 500 mm is obtained.

  When the felt material 38 of Example 11 is manufactured in a long size, and this is used as a long cushion material 56 for press processing of a printed circuit board, the pressure applied to the table 62 can be reliably relieved by high elasticity, and gold The deformation of the mold itself and the work surface of the table 62 are prevented in advance. With this cushion material, the service life of the heating mold 60 and the table 62 is extended, and the equipment cost and the member replacement cost can be reduced.

A web is produced by uniformly blending 100% of metaphenylene isophthalamide fiber (trade name: Conex) having a fineness of 2 denier. The webs are laminated to form a card wrap with a weight of 500 g / m ² , and the entire wrap is needle punched. Thereafter, when treated in the same manner as in Example 4, a felt material 38 having a weight of 800 g / m ² , a thickness of 1.3 mm, and a dimension of 400 × 500 mm is obtained.

  When the felt material 38 of Example 12 is manufactured in a long size, and this is used as a long cushion material 56 for press processing of a printed circuit board, the pressure applied to the table 62 can be reliably relieved by high elasticity, and gold The deformation of the mold itself and the work surface of the table 62 are prevented in advance. With this cushion material, the service life of the heating mold 60 and the table 62 is extended, and the equipment cost and the member replacement cost can be reduced.

A web is produced by uniformly blending 100% of metaphenylene isophthalamide fiber (trade name: Conex) having a fineness of 2 denier. This web is laminated to form a card wrap weighing 370 g / m ² . As shown in FIG. 5, a multifilament weave of metaphenylene isophthalamide fiber (trade name: Conex) having a weight of 80 g / m ² as a woven fabric 7 between two equal card wraps 64 and 66. Needle punching with a cloth interposed.

The obtained felt material is immersed in a dispersion of PTFE resin, impregnated with 100 g / m ^{2 of the} resin in a dry amount, and a porous film 68 of PTFE resin having a thickness of 30 μm is bonded to one side of the sheet by hot pressing. When this hot press is pressed for 30 seconds at a temperature of 250 ° C., a felt material 20 having a weight of 550 g / m ² , a thickness of 1.5 mm, and a size of 950 × 1900 mm is obtained.

Example 3
FIG. 9 shows a press mold 70 used when press-molding an acrylic hood or the like of an indoor fluorescent lamp as an example of use of a resin plate-forming cushion material. Cushion materials 76 and 76, which are the felt material 20, are respectively attached to the mold surfaces of the female mold 72 and the male mold 74 of the mold 70 with an adhesive. At this time, the porous film 68 is disposed outside. A sheet-like acrylic plate (not shown), which is a raw material, is heated to an appropriate temperature and then cold-pressed in a press die 70.

  When the acrylic plate comes into contact with the cushion materials 76, 76, stress concentration does not occur locally at the time of molding, and the obtained molded product can be easily peeled off from the press die 70, and the cushion materials 76, 76 have dust. And burr does not adhere. Further, even if some dust or burrs remain, they can be easily removed from the mold surface, so that the problem of scratches is almost completely eliminated.

A felt material is manufactured using the same card wraps 64 and 66 and the woven fabric cloth 7 as in the thirteenth embodiment. After spraying a dispersion of FEP resin on one side of the obtained felt material and impregnating the resin with 20 g / m ² in a dry amount, a porous film 68 of PTFE resin having a thickness of 30 μm is applied on one side of the sheet by hot pressing. to paste together. When the hot pressing is performed at a temperature of 250 ° C. for 30 seconds, a felt material 20 having a weight of 475 g / m ² , a thickness of 1.5 mm, and a size of 950 × 1900 mm is obtained.

  When the felt material 20 manufactured in Example 14 is used as a cushioning material 76, 76 (FIG. 9) for press molding of a resin plate, the cushioning material has sufficient cushioning properties and locally concentrates stress during molding. There is no. The obtained molded product can be easily peeled off from the press die 70, and dust and burrs do not adhere to the cushion materials 76 and 76.

A web is produced by uniformly blending 100% polyester fiber having a fineness of 3 denier. This web is laminated to form a card wrap weighing 380 g / m ² . Needle punching is performed between the two equal card wraps 64 and 66 by interposing a polyester fiber multifilament woven fabric having a weight of 70 g / m ² as the woven base fabric 7.

One side of the obtained felt material is fried and melted, and then a porous film 68 of PTFE resin having a thickness of 30 μm is bonded to one side of the sheet through a pair of calendar rolls. The roll pair has a temperature of 220 ° C., a pressure of 0.15 MPa, and is pressed at a speed of 2.5 m / min to obtain a felt material having a weight of 475 g / m ² and a thickness of 1.5 mm.

  When the felt material manufactured in Example 15 is used as a cushion material 76, 76 for press molding of a resin plate, the cushion material has sufficient cushioning properties and does not concentrate stress locally during molding. The obtained molded product can be easily peeled off from the press die 70, and dust and burrs do not adhere to the cushion materials 76 and 76.

A web is produced by uniformly blending 100% of metaphenylene isophthalamide fiber (trade name: Nomex, manufactured by EI DuPont) having a fineness of 2 denier. This web is laminated to form a card wrap weighing 65 g / m ² . Needle punching is performed by interposing a multi-filament plain woven fabric of metaphenylene isophthalamide fiber (trade name: Nomex) having a weight of 55 g / m ² as a fabric base fabric 7 between two equal card wraps. Dry after punching by water jet punching.

The obtained felt material is immersed in a dispersion of PTFE resin, and the resin is impregnated and dried in a dry amount of 230 g / m ² . When pressed by a hot press, a felt material having a weight of 350 g / m ² and a thickness of 0.4 mm is obtained.

  When the felt material manufactured in Example 16 is used for press molding of a resin plate as the cushion materials 76, 76, the cushion material has sufficient cushioning properties and does not concentrate stress locally during molding. The obtained molded product can be easily peeled off from the press die 70, and dust and burrs do not adhere to the cushion materials 76 and 76.

It is an expanded sectional view showing an example of the felt material concerning the present invention. It is an expanded sectional view showing other examples of felt material. It is an expanded sectional view which shows the felt material which impregnated the resin dispersion. It is an expanded sectional view which shows the other example of the felt material which impregnated the resin dispersion. It is an expanded sectional view which shows another example of the felt material which impregnated the resin dispersion. It is a schematic sectional drawing which shows the aspect which adhere | attaches a fluororesin layer on a felt raw material. It is a schematic sectional drawing which shows the usage example of the cushioning material for liquid crystal cell assembly which is a felt material. It is a schematic sectional drawing which shows the usage example of the cushion material for printed circuit board processing which is a felt material. It is a schematic sectional drawing which shows the usage example of the cushion material for resin board shaping | molding which is a felt material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Felt material 2 Hot melt type fluororesin layer 3 Felt material impregnated with resin dispersion 5 Porous film of PTFE resin 7 Fabric base fabric 8, 10 Card wrap 14 Protective film 18 Felt material 34 Cushion material

Claims (11)

  The card wrap is made of heat-resistant organic fiber with a melting point of 250 ° C or higher or non-melting point and integrated by needle punching, and a hot-melt type fluororesin layer is bonded to one or both sides of the obtained felt material and heated / heated Non-adhesive felt material determined to a predetermined thickness and density by pressure.   The card wrap is composed of heat-resistant organic fibers having a melting point of 250 ° C. or higher or non-melting point, integrated by needle punching, and a hot-melt type fluororesin layer is bonded to one or both sides of the obtained felt material, and the fluororesin A non-adhesive felt material with a predetermined thickness and density determined by laminating a porous film of fluororesin on the layer and heating and pressing.   The card wrap is composed of heat-resistant organic fibers having a melting point of 250 ° C. or higher or non-melting point, integrated by needle punching, and a surface of the felt material is impregnated with a fluororesin dispersion. A non-adhesive felt material that has a predetermined thickness and density determined by laminating a porous film of fluororesin on one or both sides and then heating and pressing.   The card wrap is made of heat-resistant organic fiber, integrated by needle punching, and one side or both sides of the obtained felt material is fried and melted, and then the fluororesin porous on one side or both sides of the felt material Non-adhesive felt material that has a predetermined thickness and density by laminating a film and then pressing.   The felt material according to claim 1, 2, 3 or 4, wherein a woven base fabric mainly composed of heat-resistant organic fibers is interposed in a card wrap and integrated as a whole by needle punching.   The felt material according to claim 1, 2, 3 or 4, wherein the card wrap contains 0.5 to 10% by weight of conductive fibers.   A card wrap containing polytetrafluoroethylene fibers is integrated by needle punching, and the surface of the felt material is impregnated with a fluororesin dispersion, and then a porous film of fluororesin is formed on one or both sides of the felt material. A cushioning material for assembling liquid crystal cells, which is laminated and then set to a predetermined thickness and density by heating and pressing.   The card wrap made of heat-resistant organic fibers is integrated by needle punching with a textile base fabric mainly composed of heat-resistant organic fibers, and the surface of the felt material is impregnated with a fluororesin dispersion. From the above, a cushioning material for molding a resin plate, in which a porous film of a fluororesin is laminated on one side of the felt material, and is further set to a predetermined thickness and density by heating and pressing.   The card wrap made of heat-resistant organic fibers is integrated by needle punching with a textile base fabric mainly composed of heat-resistant organic fibers, and the surface of the felt material is impregnated with a fluororesin dispersion. A heat insulating sheet material in which a porous film of fluororesin is laminated on one side or both sides of the felt material, and the thickness and density are determined by heating and pressing.   A card wrap made of heat-resistant organic fibers is integrated by needle punching, then a hot-melt fluoropolymer film is laminated on one or both sides of the felt material, and a protective film is further laminated on the film, and this lamination is performed. Non-adhesive that peels off the protective film after bonding the felt material and the heat-melting fluororesin film by heating and pressurizing the felt material through a roll pair at a temperature of 250 to 320 ° C. and a linear pressure of 750 to 2500 N / m Manufacturing method of sex felt material. A card wrap made of heat-resistant organic fibers is integrated by needle punching, and then a hot-melt fluoropolymer film is laminated on one or both sides of the felt material, and a fluororesin porous film is laminated on the film. The laminated felt material is heated and pressurized through a pair of rolls at a temperature of 250 to 320 ° C. and a linear pressure of 750 to 2500 N / m, thereby forming a felt material, a heat-melting fluororesin film, and a fluororesin porous film. Manufacturing method of non-sticky felt material to be bonded.

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