JP2008045239A - Nonwoven fabric and method for producing nonwoven fabric - Google Patents
Nonwoven fabric and method for producing nonwoven fabric Download PDFInfo
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本発明は不織布及び不織布の製造方法に関する。より具体的には、玄武岩繊維を含む、難燃性、耐熱性及び引張強さ等の強度の優れる不織布、及びその製造方法に関する。 The present invention relates to a nonwoven fabric and a method for producing the nonwoven fabric. More specifically, the present invention relates to a nonwoven fabric containing basalt fibers and having excellent strength such as flame retardancy, heat resistance and tensile strength, and a method for producing the same.
玄武岩繊維はガラス繊維に比べて難燃性、耐熱性、引張り強さ等に優れており、また、焼却炉内において液化せず、結晶化することから焼却炉を損傷しない、環境に優しい繊維として注目を集めている。そのため、玄武岩繊維の耐熱性等を利用したマット等が提案されている。例えば、「ポリフェニレンベンツビスオキサゾール等の有機短繊維と、玄武岩短繊維とから構成される繊維基材に、熱硬化性樹脂が含浸・硬化された耐熱成形体」が提案されている（特許文献１）。この耐熱成形体においては、熱硬化性樹脂の含浸量の調整や、圧縮比のコントロールによる繊維密度の調整によって、ハードタイプの耐熱成形体であっても、表面がビロード様の柔軟性を有するソフトタイプの耐熱成形体であっても作りわけできるように、また、熱硬化性樹脂の含浸量が少ない場合であっても高い強度を保持できるように、繊維基材として厚手のフェルトが用いられている。より具体的には、実施例において、厚さ１０ｍｍ、目付４．２ｋｇ／ｍ２のフェルトが繊維基材として使用されている。 Basalt fiber is superior to glass fiber in terms of flame retardancy, heat resistance, tensile strength, etc., and does not liquefy and crystallize in the incinerator. Has attracted attention. Therefore, mats using the heat resistance of basalt fibers have been proposed. For example, “a heat-resistant molded article in which a thermosetting resin is impregnated and cured on a fiber base composed of organic short fibers such as polyphenylenebenzbisoxazole and basalt short fibers” has been proposed (Patent Document 1). ). In this heat-resistant molded product, the surface of the hard-type heat-resistant molded product has a velvety flexibility by adjusting the impregnation amount of the thermosetting resin and adjusting the fiber density by controlling the compression ratio. Thick felt is used as a fiber base so that it can be made even with a heat-resistant molded body of a type, and high strength can be maintained even when the amount of impregnation of thermosetting resin is small. Yes. More specifically, in the examples, a felt having a thickness of 10 mm and a basis weight of 4.2 kg / m 2 is used as the fiber base material.
しかしながら、このような繊維基材はフェルト、つまりニードルにより絡合させたものであるため、製造上、ある程度の量の繊維を必要とし、重く、厚いものであり、使用用途が限定されるものであった。 However, since such a fiber base material is entangled with a felt, that is, a needle, it requires a certain amount of fiber in production, is heavy and thick, and uses are limited. there were.
本発明は前記問題点を解決するためになされたものであり、玄武岩繊維の難燃性、耐熱性、引張り強さ等の性質を有効に利用することのできる、薄く、従来適用できなかった用途に適用できる不織布、及び不織布の製造方法を提供することを目的とする。 The present invention was made in order to solve the above-mentioned problems, and can be effectively used for properties such as flame retardancy, heat resistance, tensile strength, etc. of basalt fiber, and it has been thinly used in the past. An object of the present invention is to provide a non-woven fabric that can be applied to the fabric and a method for producing the non-woven fabric.
本発明の請求項１にかかる発明は、「玄武岩繊維が無機接着剤によって結合していることを特徴とする不織布。」である。 The invention according to claim 1 of the present invention is “a non-woven fabric characterized in that basalt fibers are bonded by an inorganic adhesive”.
本発明の請求項２にかかる発明は、「玄武岩繊維の繊維長が２０ｍｍ以下であることを特徴とする、請求項１に記載の不織布。」である。 The invention according to claim 2 of the present invention is "the nonwoven fabric according to claim 1, wherein the basalt fiber has a fiber length of 20 mm or less."
本発明の請求項３にかかる発明は、「玄武岩繊維の不織布における質量比率が８０％以上であることを特徴とする、請求項１又は請求項２に記載の不織布。」である。 The invention according to claim 3 of the present invention is “the nonwoven fabric according to claim 1 or 2, wherein the mass ratio of the basalt fiber in the nonwoven fabric is 80% or more”.
本発明の請求項４にかかる発明は、「湿式法により製造された不織布であることを特徴とする、請求項１〜請求項３のいずれかに記載の不織布。」である。 The invention according to claim 4 of the present invention is “the nonwoven fabric according to any one of claims 1 to 3, which is a nonwoven fabric manufactured by a wet method”.
本発明の請求項５にかかる発明は、「目付が３０〜２００ｇ／ｍ２であることを特徴とする、請求項１〜請求項４のいずれかに記載の不織布。」である。 The invention according to claim 5 of the present invention is “the nonwoven fabric according to any one of claims 1 to 4, wherein the basis weight is 30 to 200 g / m 2 ”.
本発明の請求項６にかかる発明は、「厚さが０．２〜１ｍｍであることを特徴とする、請求項１〜請求項５のいずれかに記載の不織布。」である。 The invention according to claim 6 of the present invention is “the nonwoven fabric according to any one of claims 1 to 5, wherein the thickness is 0.2 to 1 mm”.
本発明の請求項７にかかる発明は、「玄武岩繊維が分散したスラリーを形成し、前記スラリーを抄き上げた後に、無機接着剤を付与し、乾燥する、玄武岩繊維が無機接着剤によって結合した不織布の製造方法。」である。 The invention according to claim 7 of the present invention is as follows: “After forming a slurry in which basalt fibers are dispersed and making the slurry, an inorganic adhesive is applied and dried. The basalt fibers are bonded by an inorganic adhesive. Manufacturing method of nonwoven fabric. "
本発明の請求項１にかかる発明は、玄武岩繊維が無機接着剤によって結合しているため、薄いものであることができ、従来適用できなかった用途に適用できるものである。 The invention according to the first aspect of the present invention can be thin because the basalt fibers are bonded by an inorganic adhesive, and can be applied to applications that could not be applied conventionally.
本発明の請求項２にかかる発明は、玄武岩繊維の繊維長が２０ｍｍ以下の比較的自由度の高い繊維であるため、玄武岩繊維が均一に分散し、地合いの優れる不織布であることができる。 Since the invention according to claim 2 of the present invention is a fiber having a relatively high degree of freedom in which the fiber length of the basalt fiber is 20 mm or less, the basalt fiber can be uniformly dispersed and can be a nonwoven fabric with excellent texture.
本発明の請求項３にかかる発明は、玄武岩繊維の比率が高いため、玄武岩繊維の難燃性、耐熱性、引張り強さなどの性能を十分に発揮できる不織布である。 Invention of Claim 3 of this invention is a nonwoven fabric which can fully exhibit performance, such as a flame retardance, heat resistance, and tensile strength, of a basalt fiber since the ratio of a basalt fiber is high.
本発明の請求項４にかかる発明は、湿式法により製造された不織布であるため、玄武岩繊維が均一に分散した、地合いの優れる不織布であることができる。 Since the invention concerning Claim 4 of this invention is a nonwoven fabric manufactured by the wet method, it can be the nonwoven fabric excellent in the texture in which the basalt fiber was disperse | distributed uniformly.
本発明の請求項５にかかる発明は、目付が３０〜２００ｇ／ｍ２の軽い不織布である。 The invention according to claim 5 of the present invention is a light nonwoven fabric having a basis weight of 30 to 200 g / m 2 .
本発明の請求項６にかかる発明は、厚さが０．２〜１ｍｍと薄く、今まで適用できなかった用途にも適用できるものである。 The invention according to claim 6 of the present invention is as thin as 0.2 to 1 mm, and can be applied to applications that could not be applied so far.
本発明の請求項７にかかる発明は、請求項１にかかる不織布、つまり薄い不織布を製造できる方法である。 Invention of Claim 7 of this invention is a method which can manufacture the nonwoven fabric concerning Claim 1, ie, a thin nonwoven fabric.
本発明の不織布は難燃性、耐熱性、引張り強さなどの諸性能に優れているように、玄武岩繊維を含んでいる。この玄武岩繊維は天然の玄武岩を溶融炉で溶かして紡糸した繊維であり、市場で入手可能である。 The nonwoven fabric of the present invention contains basalt fibers so as to be excellent in various properties such as flame retardancy, heat resistance, and tensile strength. This basalt fiber is a fiber obtained by melting natural basalt in a melting furnace and spinning it, and is available on the market.
この玄武岩繊維の平均繊維径は特に限定するものではないが、薄く、軽い不織布の地合いが均一であるように、３〜２３μｍであるのが好ましく、９〜１５μｍであるのがより好ましい。本発明における「繊維径」は、顕微鏡で繊維又は不織布の拡大写真（５００倍）をとり、その拡大写真から計測した値を意味し、「平均繊維径」は繊維１０本の繊維径の算術平均値をいう。 The average fiber diameter of the basalt fiber is not particularly limited, but is preferably 3 to 23 μm, and more preferably 9 to 15 μm so that the texture of the thin and light nonwoven fabric is uniform. “Fiber diameter” in the present invention means a value obtained by taking an enlarged photograph (500 times) of a fiber or a nonwoven fabric with a microscope and measuring from the enlarged photograph, and “average fiber diameter” is an arithmetic average of fiber diameters of 10 fibers. Value.
また、玄武岩繊維の繊維長は比較的自由度が高く、玄武岩繊維が均一に分散した地合いの優れる不織布であるように、２０ｍｍ以下であるのが好ましく、１５ｍｍ以下であるのがより好ましく、１３ｍｍ以下であるのが更に好ましい。なお、玄武岩繊維の繊維長の下限は特に限定するものではないが、不織布の引張り強さなどの強度が低下しないように、３ｍｍ以上であるのが好ましい。本発明における「繊維長」は、ＪＩＳ Ｌ １０１５の８．４．１（直接法（Ｃ法））に規定する方法で測定した平均繊維長をいう。 Further, the fiber length of the basalt fiber is relatively high, and is preferably 20 mm or less, more preferably 15 mm or less, and more preferably 13 mm or less so that the basalt fiber is a non-woven fabric excellent in texture in which the basalt fiber is uniformly dispersed. More preferably. In addition, although the minimum of the fiber length of a basalt fiber is not specifically limited, It is preferable that it is 3 mm or more so that strength, such as the tensile strength of a nonwoven fabric, may not fall. “Fiber length” in the present invention refers to an average fiber length measured by a method defined in 8.4.1 (direct method (method C)) of JIS L 1015.
このような玄武岩繊維の不織布中における質量比率は、玄武岩繊維の難燃性、耐熱性、引張り強さなどの性能を十分に発揮できるように、８０％以上であるのが好ましい。より好ましくは８５％以上であり、更に好ましくは９０％以上であり、更に好ましくは９３％以上である。なお、玄武岩繊維を結合して不織布形態を保持することができるように、無機接着剤を含んでいるため、玄武岩繊維の不織布中における質量比率は９７％以下であるのが好ましい。 The mass ratio of the basalt fiber in the nonwoven fabric is preferably 80% or more so that the basalt fiber can sufficiently exhibit the flame retardancy, heat resistance, tensile strength, and the like. More preferably, it is 85% or more, More preferably, it is 90% or more, More preferably, it is 93% or more. In addition, since the inorganic adhesive is included so that a basalt fiber can be couple | bonded and a nonwoven fabric form can be hold | maintained, it is preferable that the mass ratio in a nonwoven fabric of a basalt fiber is 97% or less.
本発明の不織布は玄武岩繊維を結合して不織布形態を保持できるように、無機接着剤を含んでいる。この無機接着剤も難燃性で、比較的耐熱性に優れ、しかも玄武岩繊維の接着性に優れている。 The nonwoven fabric of the present invention contains an inorganic adhesive so that the basalt fibers can be bonded to keep the nonwoven fabric form. This inorganic adhesive is also flame retardant, relatively excellent in heat resistance, and excellent in basalt fiber adhesion.
このような無機接着剤は特に限定するものではないが、例えば、水ガラス、リン酸アルミニウム、シリカゾル、アルミナゾル、ジルコニアゾル、酸化マグネシウム、窒化ホウ素、窒化アルミニウムなどを挙げることができる。これらの中でも耐熱温度が高く、玄武岩繊維との接着性が高い、アルミナゾルが好適である。 Such an inorganic adhesive is not particularly limited, and examples thereof include water glass, aluminum phosphate, silica sol, alumina sol, zirconia sol, magnesium oxide, boron nitride, and aluminum nitride. Among these, an alumina sol having a high heat-resistant temperature and high adhesion to basalt fibers is preferable.
この無機接着剤の不織布中における質量比率は、玄武岩繊維の性能を損なわないように、２０％以下であるのが好ましく、１５％以下であるのがより好ましく、１０％以下であるのが更に好ましく、７％以下であるのが更に好ましい。他方で、不織布形態を保持できるように、３％以上含まれているのが好ましい。 The mass ratio of the inorganic adhesive in the nonwoven fabric is preferably 20% or less, more preferably 15% or less, and still more preferably 10% or less so as not to impair the performance of the basalt fiber. More preferably, it is 7% or less. On the other hand, it is preferable that 3% or more is contained so that the nonwoven fabric form can be maintained.
本発明の不織布は前述のような玄武岩繊維と無機接着剤を含むものであるが、玄武岩繊維の性能と無機接着剤の結合力を損なわない範囲内で、その他の繊維（例えば、天然繊維のパルプ、合成繊維のパルプ等）を含んでいることができる。しかしながら、玄武岩繊維と無機接着剤のみからなるのが最も好ましい。 The non-woven fabric of the present invention contains basalt fiber and an inorganic adhesive as described above, but other fibers (for example, natural fiber pulp, synthetic fiber, etc. within the range not impairing the performance of the basalt fiber and the bonding strength of the inorganic adhesive) Fiber pulp, etc.). However, it is most preferable to consist only of basalt fibers and an inorganic adhesive.
本発明の不織布は湿式法で製造されたものであるのが好ましい。湿式法によれば、玄武岩繊維を均一に分散させることができるためである。この湿式法により製造する場合、常法の湿式抄紙機を用いることにより製造できる。例えば、抄き網として円網、短網、或いは長網等を用いて、抄き網を単独で、又は抄き網を組み合せて抄き合わせて抄造することができる。抄き合わせることによって、玄武岩繊維がより均一に分散した地合いの優れる不織布とすることができる。 The nonwoven fabric of the present invention is preferably produced by a wet method. This is because the basalt fiber can be uniformly dispersed according to the wet method. When manufacturing by this wet method, it can manufacture by using a conventional wet paper machine. For example, a circular net, a short net, or a long net can be used as the net, and the net can be made by combining the nets alone or in combination. By making the sheets together, it is possible to obtain a non-woven fabric with excellent texture in which basalt fibers are more uniformly dispersed.
本発明の不織布は軽量で取り扱い性に優れ、しかも従来適用できなかった用途にも適用できるように、目付は３０〜２００ｇ／ｍ２であるのが好ましい。目付が３０ｇ／ｍ２未満では不織布形態を維持するのが難しく、２００ｇ／ｍ２を超えると重くなるためで、５０〜１５０ｇ／ｍ２であるのがより好ましい。本発明における目付は、ＪＩＳ Ｐ ８１２４（紙及び板紙−坪量測定方法）に規定する方法に基いて得られる坪量をいう。 The nonwoven fabric of the present invention is lightweight and excellent in handleability, and preferably has a basis weight of 30 to 200 g / m 2 so that it can be applied to uses that could not be applied conventionally. Basis weight is difficult to maintain a nonwoven form is less than 30 g / m 2, in order to become heavier exceeds 200 g / m 2, and more preferably 50 to 150 g / m 2. The basis weight in the present invention refers to the basis weight obtained based on the method specified in JIS P 8124 (paper and paperboard—basis weight measurement method).
また、本発明の不織布は従来適用できなかった用途にも適用できるように、厚さは０．２〜１ｍｍであるのが好ましい。厚さが０．２ｍｍ未満では不織布形態を維持するのが難しく、１ｍｍを超えると剛性が高くなり、所望形状に変形させることが困難になったり、巻き取ることができなくなる場合があるためで、０．４〜０．８ｍｍであるのがより好ましい。本発明における「厚さ」は、ＪＩＳ Ｂ ７５０２に規定する方法による測定値、すなわち、５Ｎ荷重時の外側マイクロメーターによる測定値をいう。 Moreover, it is preferable that thickness is 0.2-1 mm so that the nonwoven fabric of this invention can be applied also to the use which was not able to be applied conventionally. If the thickness is less than 0.2 mm, it is difficult to maintain the nonwoven fabric form, and if it exceeds 1 mm, the rigidity becomes high, and it may be difficult to deform into a desired shape, or it may not be possible to wind up, More preferably, it is 0.4 to 0.8 mm. The “thickness” in the present invention refers to a measured value by a method defined in JIS B 7502, that is, a measured value by an outer micrometer at 5 N load.
このような本発明の不織布は、例えば、玄武岩繊維が分散したスラリーを形成し、スラリーを抄き上げた後に、無機接着剤を付与し、乾燥することによって製造することができる。 Such a nonwoven fabric of the present invention can be produced, for example, by forming a slurry in which basalt fibers are dispersed, forming the slurry, applying an inorganic adhesive, and drying the slurry.
玄武岩繊維は前述の通りの繊維径、繊維長のものを使用するのが好ましい。なお、必要に応じて、これら繊維以外の繊維（例えば、天然繊維のパルプ、合成繊維のパルプ等）を使用する。 It is preferable to use the basalt fiber having the fiber diameter and fiber length as described above. If necessary, fibers other than these fibers (for example, natural fiber pulp, synthetic fiber pulp, etc.) are used.
次いで、玄武岩繊維を水に投入して、玄武岩繊維が分散したスラリーを形成した後、このスラリーを公知の抄き網、例えば、円網、短網、或いは長網等を単独で、又は組み合せて抄き上げる。抄き網を組み合わせて抄き合わせることによって、玄武岩繊維がより均一に分散した地合いの優れる不織布を製造することができる。 Next, the basalt fiber is poured into water to form a slurry in which the basalt fiber is dispersed, and then the slurry is made of a known paper net, for example, a circular net, a short net, or a long net alone or in combination. Finish up. By combining papermaking nets, it is possible to produce a nonwoven fabric with excellent texture in which basalt fibers are more uniformly dispersed.
そして、抄き上げた繊維ウエブに、スプレー等の方法により無機接着剤を付与し、熱風循環式乾燥機、ヤンキー型乾燥機等で乾燥することによって、本発明の玄武岩繊維が無機接着剤によって結合した不織布を製造することができる。なお、無機接着剤は固形分量で不織布の質量の２０％以下（より好ましくは１５％以下、更に好ましくは１０％以下、更に好ましくは７％以下、好ましくは３％以上）となるように付与するのが好ましい。また、必要に応じて熱プレス加工等を更に行うこともできる。 Then, an inorganic adhesive is applied to the finished fiber web by a method such as spraying, and the basalt fiber of the present invention is bonded with the inorganic adhesive by drying with a hot air circulation dryer, Yankee type dryer, etc. Can be produced. The inorganic adhesive is applied so that the solid content is 20% or less of the mass of the nonwoven fabric (more preferably 15% or less, more preferably 10% or less, still more preferably 7% or less, preferably 3% or more). Is preferred. Moreover, a hot press process etc. can also be further performed as needed.
本発明の不織布は玄武岩繊維の難燃性、耐熱性、耐薬品性等の性質を有効に利用することができ、しかも薄いものであるため、従来適用できなかった用途、例えば、ＦＲＰ用強化材（自動車外板、船体、引抜き成型品、高温高圧パイプ）、土壌安定剤、アスファルト路面強化材、カバー材、スピーカーコーン用基材、マフラー用消音シート、ブレーキパッド材、ブレーキライニング材、遮熱材、電磁波シールド材、断熱材、プリント基板、研磨材として使用できるものである。 The nonwoven fabric of the present invention can effectively utilize the properties of basalt fiber such as flame retardancy, heat resistance, chemical resistance and the like, and is thin, so that it has not been conventionally applicable, for example, a reinforcing material for FRP. (Automobile outer panels, hulls, pultruded products, high-temperature and high-pressure pipes), soil stabilizers, asphalt road surface reinforcing materials, cover materials, base materials for speaker cones, muffler silencing sheets, brake pad materials, brake lining materials, heat insulation materials It can be used as an electromagnetic shielding material, a heat insulating material, a printed circuit board, and an abrasive.
以下に、本発明の実施例を記載するが、本発明は以下の実施例に限定されるものではない。 Examples of the present invention will be described below, but the present invention is not limited to the following examples.
（実施例１）
玄武岩繊維（Ｓｕｄａｇｌａｓｓ Ｆｉｂｅｒ Ｔｅｃｈｎｏｌｏｇｙ社製、溶融温度：１４５０℃、密度：２．７ｇ／ｃｃ、平均繊維径：１４μｍ、平均繊維長：１３ｍｍ）を用意した。
(Example 1)
Basalt fiber (manufactured by Sudaglass Fiber Technology, melting temperature: 1450 ° C., density: 2.7 g / cc, average fiber diameter: 14 μm, average fiber length: 13 mm) was prepared.
次いで、玄武岩繊維を水に投入して、玄武岩繊維が分散したスラリーを形成した後、短網傾斜方式により湿式繊維ウエブ（目付：４５ｇ／ｍ２）を形成した。 Next, the basalt fiber was poured into water to form a slurry in which the basalt fiber was dispersed, and then a wet fiber web (weight per unit area: 45 g / m 2 ) was formed by a short mesh inclination method.
次いで、湿式繊維ウエブに対して固形分で５ｇ／ｍ２のアルミナゾルバインダーをスプレーにより付与した後、温度１５０℃に設定した熱風循環式乾燥機により乾燥して、アルミナで接着結合して、目付５０ｇ／ｍ２、厚さ０．７ｍｍの湿式不織布を製造した。この湿式不織布を温度５００℃で６０分間熱処理したが、湿式不織布の長手方向及びよこ方向に熱収縮は全く認められず、また、温度５００℃で６０分間熱処理した前後において、引っ張り強度に変化のない、耐熱性の優れるものであった。また、湿式不織布の燃焼試験を実施したところ、ＵＬ−９４ Ｖ−０（サンプルを垂直に固定し、プロパンガスバーナーの炎をサンプルの下端に１０秒間あて、炎を取り去った後の残炎・残じんが無い）に適合する、難燃性の優れるものであった。
Next, after applying an alumina sol binder having a solid content of 5 g / m 2 to the wet fiber web by spraying, the wet fiber web is dried by a hot air circulating drier set at a temperature of 150 ° C., adhesively bonded with alumina, and has a basis weight of 50 g. / M 2 , a wet nonwoven fabric having a thickness of 0.7 mm was produced. This wet nonwoven fabric was heat treated at a temperature of 500 ° C. for 60 minutes, but no thermal shrinkage was observed in the longitudinal direction and the transverse direction of the wet nonwoven fabric, and there was no change in tensile strength before and after the heat treatment at a temperature of 500 ° C. for 60 minutes. It was excellent in heat resistance. In addition, when a wet nonwoven fabric combustion test was performed, UL-94 V-0 (the sample was fixed vertically, the flame of the propane gas burner was applied to the lower end of the sample for 10 seconds, and after the flame was removed, It is excellent in flame retardancy and conforms to (no dust).
Claims (7)
The manufacturing method of the nonwoven fabric with which the basalt fiber couple | bonded with the inorganic adhesive agent which forms the slurry which disperse | distributed the basalt fiber, and after making the said slurry, provides an inorganic adhesive agent and dries.
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