JP2012158039A - Foam layer laminated body and method for manufacturing the same, as well as structural material, heat insulating material or sound insulator using the foam layer laminated body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a foam layer laminated body that can reliably prevent floating of a fabric layer due to buckling, or separation in a boundary between a foam layer and the fabric layer and obtain sufficient strength and rigidity, even if bending deformation or torsional deformation caused by an external force is applied thereto, and to provide a method for manufacturing the same, as well as a structural material, an insulating material or a sound insulator using the foam layer laminated body.SOLUTION: In the foam layer laminated body 1 including two fabric layers 1A, 1B composed of a web and the foam layer 2 provided between the fabric layers 1A, 1B, a synthetic fiber monofilament yarn 3 that connects each of the fabric layers 1A, 1B to be arbitrarily spaced through the foam layer 2.

Description

  The present invention relates to a foam layer laminate in which a foam is used as a core material, and in particular, relates to a laminate composed of two fabric layers made of a woven fabric and a foam layer provided between these fabric layers.

  In general, foam layer laminates with polyurethane foam as the core material include building materials such as wall panels, heat insulation panels, and sound insulation panels, automotive instrument panels, sound absorbing floor structures for railway vehicles, and vibration control. It is used in many applications such as composite plates and shock absorbers. In short, the functions of the foam, such as lightness, heat insulation, vibration damping, and sound insulation, are utilized.

  Many foam layer laminates have a so-called sandwich structure in which a foam layer is used as a core material, and FRP, a metal plate, ceramic, or the like is used as a surface material depending on the application. Then, by combining the function of the highly lightweight foam and the function of the surface material, a function that cannot be handled by a single material is exhibited.

  By the way, strength and rigidity functions are emphasized as basic functions in the laminate. However, in the foam layer laminate, due to the structure of the foam, a decrease in strength and rigidity function cannot be denied compared to the non-foamed material.

  Therefore, conventionally, a foam layer laminate is known which is composed of two fabric layers made of a woven fabric such as a skin sheet and a fiber sheet, and a foam layer provided between these fabric layers. (For example, refer to Patent Document 1). In this foam layer laminate, the overall strength / rigidity function can be improved by combining fabrics having excellent strength / rigidity.

JP-A-9-39078

  However, since the fabric layers 91 and 92 as the reinforcing layers are merely bonded to the foam layer 93 by adhesion or welding as shown in FIG. When torsional deformation is applied, as shown in FIG. 14 (a), one fabric layer 91 (upper fabric layer in FIG. 14) is lifted by buckling, and as shown in FIG. 14 (b), the other Peeling may occur at the boundary between the fabric layer 92 and the foam layer 93, and sufficient strength and rigidity as the foam layer laminate 9 cannot be obtained.

  The present invention has been made in view of the above points, and the object of the present invention is to lift the fabric layer due to buckling or foam layer and fabric layer even when bending deformation or torsional deformation due to external force is applied. A foam layer laminate capable of preventing peeling at the boundary and obtaining sufficient strength and rigidity, a manufacturing method thereof, and a structural material, a heat insulating material, or a sound insulating material using the foam layer laminate There is to do.

  In order to achieve the above object, the present invention is premised on a foam layer laminate comprising two fabric layers made of woven fabric and a foam layer provided between the fabric layers. And it comprises the pile which consists of a monofilament thread | yarn of the synthetic fiber which penetrates the said foam layer and connects between each said fabric layers at an appropriate space | interval.

  By this specific matter, since the fabric layers are connected to each other at appropriate intervals through the foam layer by a pile of monofilament yarns of synthetic fibers, the compressive strength in the thickness direction of the foam layer laminate and Compression rigidity is improved. Further, even when bending deformation or torsional deformation occurs in the foam layer laminate, the fabric layer can be prevented from being lifted due to buckling or peeling at the boundary between the fabric layer and the foam layer. Thereby, sufficient strength and rigidity of the foam layer laminate can be obtained against bending deformation and torsional deformation.

  Each of the fabric layers may be formed of two base fabrics constituting a double pile fabric, and a pile warp yarn constituting the double pile fabric may be used as the pile.

  In this case, each fabric layer is formed by two base fabrics constituting a double pile fabric, and the pile warp yarn of the double pile fabric is applied as a pile. There is no need to connect the fabric layers to each other, and the fabric layers can be easily connected by a pile. In addition, if a foam material is inserted or injected between base fabrics connected by pile warp threads, a foam layer can be easily obtained, and a foam layer laminate can be easily produced.

  Moreover, it is preferable to apply a hard foam resin whose raw material is liquid as the foam of the foam layer.

  In this case, the liquid hard foamed resin can be easily injected between the fabric layers. In addition, the hard foamed resin is composed of closed cells and has excellent mechanical properties such as strength and rigidity, so the strength and rigidity of the foam layer can be improved, and it has excellent durability and vibration damping properties. A foam layer can be provided.

  In addition, a new fabric layer is provided on the antifoam layer side of at least one of the fabric layers so as to face the one fabric layer, and a new fabric layer is provided between the fabric layers facing each other. A foam layer is provided. And you may provide the new pile which consists of the monofilament thread | yarn of the synthetic fiber which penetrates the said new foam layer and connects between the said fabric layers which face each other at appropriate intervals.

  In this case, a thick foam layer laminate in which a foam layer is also provided between at least one of the fabric layers and a new fabric layer facing the fabric layer is obtained. On the other hand, even more sufficient strength and rigidity can be obtained.

  Furthermore, it is preferable to apply a reinforced fabric layer containing glass fibers as each of the fabric layers.

  In this case, by applying a reinforced fabric layer containing glass fibers as each fabric layer, the strength and rigidity of each fabric layer can be further increased, and the strength and rigidity functions of the foam layer laminate as a whole can be further increased. Can be improved.

  Moreover, in order to achieve the said objective, it is characterized by providing the structural material, heat insulating material, or sound insulation material provided with the said foam layer laminated body as another solution means.

  In this case, a structural material with high strength and rigidity is obtained by the foam layer laminate that has improved compressive strength and compressive rigidity in the thickness direction and has sufficient strength and rigidity against bending deformation and torsional deformation. It becomes possible to provide a heat insulating material or a sound insulating material.

  Moreover, in order to achieve the said objective, the other manufacturing means presupposes the manufacturing method of the foam layer laminated body which consists of two fabric layers which consist of a textile fabric, and the foam layer provided between these fabric layers. . And the foam layer interposing step of interposing the foam layer between the fabric layers, and the foam layer interposed by the foam layer interposing step are penetrated by monofilament yarns of synthetic fibers, and the fabrics And a fabric layer connecting step of connecting the layers at appropriate intervals.

  By this specific matter, the foam layer interposed between the fabric layers is penetrated by the monofilament yarn of the synthetic fiber and connected between the fabric layers, so that the compressive strength and the compression rigidity in the thickness direction can be obtained. It is possible to provide a foam layer laminate that is improved and has sufficient strength and rigidity against bending deformation and torsional deformation.

  On the other hand, the manufacturing method of the foam layer laminate is similarly premised, and it has two piles of fabric layers that are woven fabrics and a pile of monofilament yarns of synthetic fibers that connect the fabric layers at appropriate intervals. A weaving process for weaving a double pile fabric (base material), an end sealing process for sealing the edges of the fabric layers connected by the pile, excluding the injection part of the foam material, and each of the above A foam filling step of filling the foam from the injection portion so that the foam layer is obtained between the fabric layers.

  Even in this case, it is possible to provide a foam layer laminate in which the compressive strength and compressive rigidity in the thickness direction are improved and sufficient strength and rigidity are obtained against bending deformation and torsional deformation. In addition, if the foam raw material is injected between the fabric layers connected by a pile of monofilament yarns of synthetic fibers and foamed and then cured, the foam layer can be easily obtained, and the foam layer A laminate can be easily manufactured.

  In short, the compressive strength and compressive rigidity in the thickness direction of the foam layer laminate can be obtained by penetrating the foam layer with a pile of monofilament yarns of synthetic fibers and connecting the fabric layers at appropriate intervals. Is improved, and it is possible to reliably prevent lifting due to buckling of the fabric layer and peeling at the boundary between the fabric layer and the foam layer when bending deformation or torsional deformation occurs in the foam layer laminate. Sufficient strength and rigidity of the foam layer laminate can be obtained against torsional deformation.

  In addition, by providing a structural material, a heat insulating material or a sound insulating material provided with the foam layer laminate, the compressive strength and compressive rigidity in the thickness direction are improved and sufficient strength against bending deformation and torsional deformation is obtained. The foam layer laminate having rigidity can provide a structural material, a heat insulating material, or a sound insulating material having high strength and rigidity.

  Further, the foam layer interposed between the fabric layers is penetrated by the monofilament yarn to connect the fabric layers, thereby improving the compressive strength and compression rigidity in the thickness direction and bending deformation and A foam layer laminate having sufficient strength and rigidity against torsional deformation can be provided.

  On the other hand, each base fabric is formed by forming each fabric layer with two base fabrics constituting a double pile fabric (base material), and using the pile warp yarn of the base material as a pile made of synthetic monofilament yarns. Compressive strength in the thickness direction by connecting the foams to each other at appropriate intervals and filling the foam between the base fabrics whose edges are sealed except for the injection part of the foam raw material to obtain a foam layer In addition, it is possible to provide a foam layer laminate having improved compression rigidity and sufficient strength and rigidity against bending deformation and torsional deformation. Moreover, a foam layer can be easily obtained by injecting a foam raw material between the fabric layers connected by a pile of synthetic filament monofilament yarns and foaming and curing the foam layer laminate. Can be manufactured.

It is sectional drawing which shows typically the foam layer laminated body which concerns on embodiment of this invention. It is sectional drawing which shows the state which cut | disconnected in parallel with the warp yarn the base material comprised from the fabric layer and monofilament yarn of the foam layer laminated body of FIG. It is sectional drawing of the foam layer laminated body which shows typically the state which the compression load by a bending moment is acting on the foam layer laminated body of FIG. 1 and the conventional foam layer laminated body, respectively, (a) Shows a conventional foam layer laminate, and (b) shows the foam layer laminate of FIG. It is a perspective view which shows typically an example of the manufacturing method of the foam layer laminated body of FIG. 1, (a) shows the base material woven in the weaving process, (b) is an edge sealing process. A state in which the mixed solution is injected from the injection portion after the end edges are stitched together is shown, and (c) shows a state in which the edges on the two sides are cut off after the foam is cured. 4 is a table showing details of a foam layer laminate of Experimental Example 1. It is sectional drawing which shows specifically the state cut | disconnected in parallel with the warp yarn of this base material in the manufacture procedure of Experimental example 2 for obtaining the base material of the foam layer laminated body of FIG. 1, Comprising: (a) is a velvet loom (B) shows the base material in a state in which the water-soluble weft yarn of the woven pile fabric is dissolved, and (c) shows the base material of the pile by the dissolved weft yarn. The base material in a state where the length is about three times is shown. 6 is a table showing details of a foam layer laminate of Experimental Example 2. 5 is a table showing details of a foam layer laminate of Comparative Example 1. It is a characteristic view which shows the characteristic in the compression test of the thickness direction of the foam layer laminated body of Experimental example 2 and Comparative example 1. FIG. It is a characteristic view which shows the characteristic in the bending test of the foam layer laminated body of Experimental example 2 and Comparative example 1. FIG. A foam schematically showing a state in which a pile of synthetic filament monofilament yarns is connected to a fabric layer of a foam layer laminate according to a modification of the present invention without being orthogonally crossed and cut parallel to the warp yarn of the fabric layer. It is sectional drawing of a layer laminated body. Sectional drawing of the foam layer laminated body which shows the state cut | disconnected in parallel with the weft yarn from which the fabric layer of the foam layer laminated body which concerns on the other modification of this invention was woven with the weft yarn from which a thermal contraction rate differs mutually It is. Sectional drawing of the foam layer laminated body which changes the length of the pile of the foam layer laminated body which concerns on the other modification of this invention to the warp direction of the fabric layer, and shows the state cut | disconnected in parallel with the warp yarn It is. It is sectional drawing which shows typically the foam layer laminated body which concerns on a prior art example, Comprising: (a) shows the state which the lifting of the fabric layer by buckling produced when bending deformation and torsion deformation were added, (b ) Shows a state where peeling occurs at the boundary between the fabric layer and the foam layer.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention. In addition, the following embodiment is an example which actualized this invention, Comprising: The thing of the character which limits the technical scope of this invention is not.

  FIG. 1 is a cross-sectional view schematically showing a configuration of a foam layer laminate according to an embodiment of the present invention. In FIG. 1, one fabric layer 1A is disposed on the uppermost surface of the foam layer laminate 1, and the other fabric layer 1B is disposed on the lowermost surface. Each fabric layer 1A, 1B is woven by a woven fabric. The foam layer laminate 1 forms a three-layer sandwich structure in which the foam layer 2 is sandwiched between one fabric layer 1A and the other fabric layer 1B. Further, one fabric layer 1A and the other fabric layer 1B are connected by a monofilament yarn 3 of synthetic fibers having the same length at all positions. For this reason, one fabric layer 1A and the other fabric layer 1B are kept substantially parallel and have a plate shape with a uniform thickness. Further, any two monofilament yarns 3 are substantially parallel to each other. That is, the distance between the connection points where any two monofilament yarns 3 and 3 are connected to one fabric layer 1A and the distance between the connection points connected to the other fabric layer 1B are as follows. Are almost equal. Therefore, the foam layer laminate 1 has a flat plate shape having no curvature.

  FIG. 2 is a cross-sectional view of the base material 11 composed of the fabric layers 1A and 1B and the monofilament yarn 3 of the foam layer laminate 1 cut in parallel with the warp yarn. As shown in FIG. 2, as the foam layer laminate 1 in which one fabric layer 1A and the other fabric layer 1B are connected by a monofilament yarn 3, two base fabrics 11A and 11B are connected by a pile 31. Double pile fabric is applied. The two base fabrics 11A and 11B are composed of warp threads 12A and 12B and weft threads 13A and 13B, respectively. In this case, in FIG. 2, the thickness of the weft yarns 13A and 13B is shown to be considerably thicker than that of the warp yarns 12A and 12B and the pile 31. However, the thicknesses of the warp yarns 12A and 12B, the weft yarns 13A and 13B, and the pile 31 do not differ as much as illustrated.

  The pile 31 is woven into the base cloth 11A on the upper side and joined to the base cloth 11A, and the lower side is woven into the base cloth 11B and joined to the base cloth 11B. Further, the pile 31 has a columnar portion that is not woven into either of the base fabrics 11A and 11B after being woven into one of the base fabrics 11A and before being woven into the other base fabric 11B. The thickness of the foam layer 2 is determined by the length of the columnar portion. That is, as the pile 31, a pile warp yarn constituting the substrate 11 is applied. In FIG. 2, one base fabric 11A corresponds to one fabric layer 1A, the other base fabric 11B corresponds to the other fabric layer 1B, and a pile 31 corresponds to the monofilament yarn 3. Moreover, the base material 11 is comprised by both base fabric 11A, 11B and the pile thread | yarn 31, and the foam layer laminated body 1 is comprised by interposing the foam 20 used as the foam layer 2 in this base material 11. FIG.

  A double pile fabric constituting the foam layer laminate 1 of the present invention in which one fabric layer 1A and the other fabric layer 1B are connected by a monofilament yarn 3 is, for example, a knife slider (weaving two woven fabrics) of a velvet loom. And a base fabric 11A and the other base fabric 11B are connected to each other with the pile 31 and wound by the winding device. . In addition, the structure | tissue of the textile fabric which is the base fabrics 11A and 11B may be a three-way structure such as a plain weave or a twill weave, or a changed structure such as a dobby structure.

Here, the fabric layers 1A and 1B and the monofilament yarn 3 will be described in detail.
The yarns constituting both fabric layers 1A and 1B may be of any structure that can be used for weaving spun yarns, multifilament yarns, monofilament yarns, and the like. The types of fibers that make up the yarn are natural fibers such as cotton and hemp, recycled fibers such as rayon, synthetic fibers such as nylon and polyester, or inorganic fibers such as carbon fibers and glass fibers depending on the application. It is done. Furthermore, it is also possible to use different types of fibers in combination by a known method such as blending or synthetic yarn. In short, various structures and fiber types can be used for the yarns constituting the fabric layers 1A and 1B. However, when the strength and rigidity of the foam layer laminate 1 are more important, aramid fibers, carbon High-strength and high-elasticity fibers such as fibers and glass fibers are used. Depending on the application, it is economical to use filament yarns of synthetic fibers such as polyester.

  Also, the yarn constituting each of the one fabric layer 1A and the other fabric layer 1B may be the same type or different types, but the flat foam layer laminate 1 having no curvature may be used. Therefore, it is preferable to use the same type of yarn. On the other hand, it is also possible to give the foam layer laminate 1 a curvature in the thickness direction by positively using different types of yarns. This point will be described in detail later.

  As the fibers constituting the monofilament yarn 3, synthetic fibers such as nylon, polyester, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, fluororesin, or polyphenylene sulfide are used.

Next, the thickness of the yarn constituting the fabric layers 1A and 1B and the thickness of the monofilament yarn 3 constituting the pile 31 will be described.
The thicknesses of the yarns constituting the base fabrics 11A and 11B are not particularly limited to the warp yarns 12A and 12B and the weft yarns 13A and 13B. When polyester multifilament yarns are used, weaving is performed as long as 100 to 1000 dtex. Is easy. Further, although an appropriate range varies depending on the material of the yarn, it can be appropriately selected within a range where weaving is possible.

  The thickness of the pile 31 is appropriately selected within the range in which weaving is possible. When a pile made of polyester monofilament yarn is used, the pile 31 can be woven if it is 100 to 800 dtex. Further, considering the compressive strength and compressive rigidity in the thickness direction of the foam layer laminate, 200 dtex is preferable, and 600 dtex or less is preferable from the viewpoint of ease of weaving. Depending on the material of the yarn, the appropriate range varies, but it is appropriately selected within the range where weaving is possible.

  FIG. 3 schematically shows cross sections of a conventional foam layer laminate 9 and a foam layer laminate 1 of the present invention that are subjected to a bending moment. 3A shows a conventional foam layer laminate 9 in which the fabric layers 91 and 92 and the foam layer 93 are bonded, and FIG. 3B shows the deformation state of the foam layer laminate 1 of the present invention. Represents. As shown in FIG. 3 (a), the foam layer laminate 9 in which bending deformation has occurred is compressed along the fabric layers 91 and 92 on the inside (thin arrows in the figure), and on the outside is the tensile load. (Thin arrow in the figure) occurs. The resultant force of the loads along the fabric layers 91 and 92 generates a compressive load (thick arrow in the figure) in the thickness direction of the foam layer laminate 9. Therefore, when bending deformation is applied to the conventional foam layer laminate 9, it can be seen that the thickness is reduced at the bent portion and the rigidity is lowered. This is because the foam layer 93 is formed of a series of structural units called cells in which the space is covered with thin wall-like or thin column-like real parts, so that the wall-like or columnar real parts against the compressive load. This is because buckling is likely to occur even when the load is low.

  On the other hand, in the foam layer laminate 1 of the present invention, as shown in FIG. 3 (b), the foam 20 is filled around the pile 31 made of the monofilament yarn 3, so that the seat of the pile 31 is The degree of freedom of bending necessary for bending is hindered by the foam, and as a result, a compressive load (thick arrow in the figure) can be applied in the axial direction of the monofilament yarn 3. Thereby, the monofilament yarn 3 functions as a column supporting a compressive load in the thickness direction, prevents the bending portion of the foam 20 from being thinned, and reduces the rigidity of the foam layer laminate 1. Has the effect of preventing.

  Next, by using monofilament yarn instead of multifilament yarn or spun yarn for bonding the fabric layers, the buckling load between the fabric layers 1A and 1B is increased, and the rigidity and strength of the foam layer laminate 1 are increased. Explain the grounds for improvement.

  According to Euler's formula, the buckling load Wc is

Thus, the buckling load is proportional to the sectional moment I of the column. Here, n represents a terminal condition coefficient, π represents a circular ratio, E represents a Young's modulus, and l represents a pile length.
Here, let us consider a filament yarn in which m single fibers having a circular cross section of diameter d ₀ are gathered and the total cross sectional area is A. The cross-sectional secondary moment I ₀ of the single fiber is expressed by the following formula.

On the other hand, since the cross-sectional secondary moment I of the filament yarn is the sum of the cross-sectional secondary moments of the fiber, I = m · I ₀ .

であるので、 The relationship between the fiber diameter d ₀ and the cross-sectional area sum A is

So

  Therefore, if the filament yarn has the same cross-sectional area (thickness), the smaller the number m of the fibers, the greater the cross-sectional secondary moment and the greater the buckling load.

In short, when a monofilament yarn that forms a yarn with a single filament is used, compressive deformation in the thickness direction at the bent portion of the foam layer laminate 1 is smaller than when multifilaments and spun yarn of the same thickness are used.
From this result, it is advantageous in improving the rigidity and strength of the foam layer laminate 1 by using the monofilament yarn 3 as the pile 31 rather than using multifilament yarn or spun yarn in which thin fibers are assembled. It turns out that it is.

  Next, an example of the manufacturing method of the foam layer laminated body 1 which forms the foam layer 3 between both fabric layers 1A and 1B is demonstrated based on FIG.

  First, as shown in FIG. 4A, in the weaving process, as described above, the two base fabrics 11A and 11B constituting the one fabric layer 1A and the other fabric layer 1B are respectively warped and wefted. A double pile fabric in which the base fabrics 11A and 11B are connected by a pile 31 made of monofilament yarn 3 is applied. That is, in the weaving process, the two base fabrics 11A and 11B constituting the double pile fabric are woven, and the fabric layers 1A and 1B are connected to each other with a pile warp at an appropriate interval to form the base material 11 (double Woven pile fabric). At this time, the pile 31 is woven into the upper base fabric 11A and joined to the base fabric 11A, and is woven into the lower base fabric 11B and joined to the base fabric 11B. A pile warp yarn of the base material 11 is used as the pile 31. Further, the pile 31 has a columnar portion that is not woven into either of the base cloths 11A and 11B after being woven into the one base cloth 11A and before being woven into the other base cloth 11B. The length of the columnar portion is uniform. In this case, the base material 11 is a double-structured fabric, and the production method thereof includes, for example, a warp pile fabric using a background double structure.

  Next, as shown in FIG. 4 (b), as the edge sealing step, the edges of the fabric layers 1A and 1B woven in the weaving step are excluded except for the injection portion 15 for inserting or injecting the foam material. Keep sealed. For example, the edges of the fabric layers 1A and 1B are brought into close contact with each other, and the edges of the fabric layers 1A and 1B are sealed by sewing them using a sewing machine or the like except for the injection portion 15. Moreover, the edge except the injection | pouring part 15 can be sealed also by welding by a heat-fusion sheet | seat and adhesion | attachment by an adhesive agent. This prevents leakage of the foam material from the edges of the fabric layers 1A and 1B.

  An existing material may be used for the foam 20, and raw materials can be inserted or injected between the fabric layers 1 </ b> A and 1 </ b> B, and the substrate 11 can withstand the heating required for foaming or the temperature rise due to reaction heat. Anything can be used. For example, a rigid polyurethane foam generates heat of reaction during foaming and curing, but does not increase in temperature to the glass transition point (Tg) of a synthetic fiber such as polyester. It is possible to combine with the foam layer 2 of rigid polyurethane foam.

  Rigid polyurethane foam is used for many applications and is excellent in economic efficiency. Further, it is possible to easily foam and cure by mixing and stirring the isocyanate and the polyol. Moreover, since the ratio of closed cells occupies about 90%, the rigid polyurethane foam can be a highly rigid foam layer laminate. Furthermore, since the rigid polyurethane foam has self-adhesive properties, it can be bonded to a pile made of monofilament yarns of the fabric layers 1A and 1B and synthetic fibers to obtain a stronger foam layer laminate.

  When a rigid polyurethane foam is used for the foam layer 2 of the present invention, the nozzle 41 is provided in the injection portion 15 at the edge of the fabric layers 1A and 1B after mixing and stirring the isocyanate and the polyol and before starting the foaming of the mixed solution. And the mixed solution is injected between the fabric layers 1A and 1B by the injector 4. When the mixed solution is injected, the mixed solution may leak through the fabric layers 1A and 1B, which are woven fabrics. However, the fabric layers 1A and 1B, that is, the fabrics of the base fabrics 11A and 11B may be increased, or the polyurethane raw material By changing the liquid to one having a high viscosity, leakage of the mixed liquid is prevented.

  Further, as a means for preventing leakage of the foam raw material, a mixed liquid retaining portion in which a part of the base fabric 11A, 11B is sealed with a film or the like may be provided. That is, as shown in FIG. 4 (b), when the fabric layers 1A and 1B are held in the vertical direction and the mixed solution is injected from the upper injection portion 15, the mixed solution is caused by gravity below the fabric layers 1A and 1B. It collects in. At this time, if the liquid mixture retaining portion where the mixed liquid of the fabric layers 1A and 1B is stored is sealed, the mixed liquid is held between the fabric layers 1A and 1B until the start of foaming without leaking the mixed liquid.

  The liquid mixture that has started foaming flows upward from the liquid mixture storage part to the space between the fabric layers 1A and 1B while expanding so as to expand the fabric layers 1A and 1B by the foaming pressure. In addition, since the mixed liquid that flows while foaming is less likely to permeate the fabric layers 1A and 1B than before foaming, it is not necessary to seal the entire fabric layers 1A and 1B.

  At this time, if the injection amount of the mixed liquid is insufficient, the foam layer 2 cannot be formed on the entire fabric layers 1A and 1B, and therefore it is necessary to inject a sufficient amount of the mixed liquid. For example, when the dimension is a rectangular base material 11 having a long side x and a short side y, and the length of the pile 31 is a constant value z in the whole base material 11, a sufficient mixed solution is injected. Then, the foam layer laminated body 1 whose volume is xyz can be formed. Therefore, when the foaming ratio of the mixed solution is α, it is necessary to inject a mixed solution in an amount of xyz / α or more. However, when the liquid mixture expands, it is necessary to rise against gravity, and it is necessary to sew the gap of the pile 31 to flow, so it is preferable to inject more than the calculated value. In addition, since the expansion ratio α may vary depending on various conditions such as temperature and humidity, it is preferable to obtain the injection amount by an experiment under actual manufacturing conditions.

  Further, if the injection portion 15 is closed before the foam reaches the injection portion 15 above the fabric layers 1A and 1B, leakage from the injection portion 15 is prevented, and the pile of the entire fabric layers 1A and 1B is prevented by the foaming pressure. 31 is stretched to form a foam layer laminate 1 having a desired thickness.

Note that if the air permeability of the fabric layers 1A and 1B is about 10 to 30 cm ³ / cm ² · s, the air is easily pushed through the fabric layers 1A and 1B during foaming. Since it does not permeate and is held between the fabric layers 1A and 1B, the entire fabric layers 1A and 1B are filled with the foam 20 even if the injection portion 15 is closed. However, since the optimum air permeability varies depending on the viscosity of the foam raw material, it is preferable to confirm an appropriate air permeability by a test in advance during production.

  Further, when the injection amount is too large, the foaming pressure becomes too high inside the fabric layers 1A and 1B, so that excess is actively leaked from the injection portion 15 or foamed when the pressure becomes a certain level or more. It is preferable to provide minute holes in the fabric layers 1A and 1B so that the liquid leaks out.

  Then, as shown in FIG. 4 (c), after foaming / curing of the mixed solution, the edges of the fabric layers 1A and 1B are cut out, and the fabric layers 1A and 1B pass through the foam layer 2 to form the monofilament yarn. A foam layer laminate 1 having a three-layer structure connected by 3 is obtained.

  As a material for the foam layer of the foam layer laminate of the present invention, resin foams such as polystyrene foam, phenol foam, urea foam, melanin foam, and epoxy foam can be used in addition to the above-mentioned rigid polyurethane foam.

  Next, the foam layer laminate 1 of the present invention will be described based on Experimental Examples 1 and 2 and Comparative Example 1 in which different materials and production methods are used. The present invention is not limited to the following experimental examples.

[Experimental Example 1]
With a velvet loom (VMV-22, manufactured by Van De Ville) with the knife slider removed, a double pile fabric having a plain weave in both layers was woven. As shown in FIG. 5, a polyester multifilament yarn (333 dtex, number of components 72, twist 259 T / m) is used as the warp yarn of the base fabric, and a polyester multifilament yarn (999 dtex, number of components 216 is twisted) as the weft. 912 T / m), and monofilament yarn (280 dtex) made of polyester was used for the pile. The density of the warp of the base fabric is 50 / inch, the weft is 60 / inch, and the pile is 7 / inch. The pile length was 17 mm, and the pile length was uniform throughout the substrate.
The woven double pile fabric was cut into a 30 cm × 30 cm square to form a substrate.

The air permeability of the base material at this time was 22 cm ³ / cm ² · s. In addition, the air permeability of the base fabric is determined based on the air permeability tester FX-3300 manufactured by Textect (pressure setting 125 Pa) according to the air permeability test method (Fragile method) of JIS L1096 (2010) for one base fabric from which the pile is cut. ).

  Next, both the fabric layers were overlapped on the edge of the substrate except for the injection part for injecting the foam material, and the edges were sealed by sewing with a sewing machine.

  Then, the base was held so that the fabric layer was vertical with the injection part facing upward, and the raw material liquid of rigid urethane foam was injected from the injection part. The raw material is a mixture of polyol (Instapack Rigid 200 polyurethane resin manufactured by Shield Air) and isocyanate (Instapack Rigid 200 Crude MDI manufactured by Shield Air) at a liquid temperature of 62 ° C in a ratio of approximately 1: 1. is there. The total injection amount is about 80 g.

  The raw material liquid was collected at the bottom of the base material and remained without leaking from the fabric layer without foaming for about 10 seconds. The viscosity of the polyol was 77 mPa · s, and the viscosity of the isocyanate was 33 mPa · s. The viscosity is a value measured with an E-type rotational viscometer (set temperature: 62 ° C., rotation speed: 100 rpm) manufactured by Tokyo Keiki.

The raw material liquid that started foaming flowed while expanding between both fabric layers and reached the upper part of the base material. At that time, the expanding and flowing raw material liquid did not leak through the base fabric.
Moreover, since the injection | pouring part of the base material was block | closed with the clip, the pile between base fabrics became a tension | tensile_strength by the expansion pressure which arises by foaming, and it became a plate shape which has fixed thickness. At this time, the air between the base fabrics was easily discharged through the fabric layer, and the rigid urethane foam was filled between the base fabrics.

  After the foam 20 was cured, the edge of the foam layer laminate was cut to obtain a flat 25 cm square plate-like foam layer laminate having a thickness of 20 mm.

[Experiment 2]
With the same loom as in Experimental Example 1, as shown in FIG. 6 (a), a double pile fabric having a cross section in the warp direction as shown in the figure was woven. As shown in FIG. 7, 51 is the warp yarn of the base fabric 11A, 11B of the base material 11 (polyfilament yarn 333dtex made of polyester, 72 components, 259T / m of twist), 52 is the weft yarn of the base fabrics 11A, 11B (999-tex polyester multifilament yarn, 216 constituents, 912 T / m twist), 53 wefts of base fabrics 11A and 11B (spun yarn 193 dtex made of water-soluble vinylon), 54 pile (polyester monofilament yarn) (220 dtex)). The density of the warps 51 of the base fabrics 11A and 11B is 50 / inch, the wefts 52 and 53 are 60 / inch, the pile 54 is 7 / inch, and the weft is 14 / inch. The length of the pile 54 was 17 mm, and the pile length was uniform throughout the substrate 11.

As shown in FIG. 6B, the weave pile fabric is agitated in hot water at 70 ° C. to dissolve the wefts 53 of the base fabrics 11A and 11B, and the cross section in the warp direction is as shown in the figure. It was set to 11. That is, as shown in FIG. 6C, the base material 11 having a pile length approximately three times that of the woven pile fabric was prepared by dissolving the water-soluble weft 53. The length of the pile 54 of the base material 11 was 50 mm. The air permeability of the dried base fabrics 11A and 11B was 23 cm ³ / cm ² · s.

  Next, in the same manner as in Experimental Example 1, the edges were sealed except for the injection part, and leakage of the raw material liquid retention part was prevented.

  Except that the injection amount was about 120 g, the raw material liquid of rigid urethane foam was injected in the same manner as in Experimental Example 1, and a flat foam layer laminate having a thickness of 50 mm and a 25 cm square was obtained. At this time, the air permeability of the fabric layer was slightly larger than that of Experimental Example 1, but the raw material liquid that expanded and fluidized after foaming did not leak from the fabric layer.

[Comparative Example 1]
Using the same foamed polyurethane raw material as in Experimental Example 2, a molded product of a rigid polyurethane foam having a square with a side of 25 cm and a thickness of 50 mm was produced. Moreover, as shown in FIG. 8, the pile of the same base material as what was used in Experimental example 2 was cut | disconnected, and two base fabrics without a pile were produced. Prior to molding, these base fabrics are temporarily fixed in the mold so as to be bonded to both surfaces of the molded product, and by filling the foamed urethane between the base fabrics, the base fabrics are not connected by a pile. A similar foam layer laminate was prepared.

  A compression test in the thickness direction of the foam layer laminates of Experimental Example 2 and Comparative Example 1 was performed by the following method. That is, the foam layer laminate is cut along two surfaces parallel to the warp yarn intersecting at right angles to the fabric layer of the foam layer laminate, and similarly to two surfaces intersecting perpendicularly to the fabric layer and parallel to the weft yarn. A block-like sample having a square plane of 50 mm and the thickness (50 mm) of the original foam layer laminate was produced. A compression test in the thickness direction was performed by a method according to JIS K7220 (2006) to obtain a load-displacement curve. Instron 5569 type universal material testing machine was used for the test. The compression speed (moving speed of the test machine crosshead) was 5 mm / min. The obtained load-displacement curve is shown in FIG.

The initial slope of the load-displacement curve is larger in Experimental Example 2 than in Comparative Example 1. Therefore, it can be seen that a pile made of a synthetic filament monofilament serves as a pillar and supports the load.
In addition, when the yield point load (the columnar or wall-shaped real part constituting the foam cell and the load at which the pile begins to buckle) is reached, even if the displacement increases, the compressive load does not increase and becomes minute. Although vertical movement is exhibited, the load at this time is also larger in Experimental Example 2 than in Comparative Example 1. Therefore, it can be seen that the pile made of monofilament yarn improves the compressive strength.

  Next, the bending test of the foam layer laminates of Experimental Example 2 and Comparative Example 1 was performed by the following method.

  First, a test piece having a length of 220 mm, a width of 50 mm, and a thickness of 50 mm, in which the weft direction of the base material is the longitudinal direction, is prepared, and three-point bending in the thickness direction is performed in accordance with JIS K7221-1 and 2 (2006). A test was conducted. At this time, the distance between fulcrums was 180 mm. For the test, an Instron 5569 universal material testing machine was used. Furthermore, in order to suppress local depression of the foam layer at the fulcrum as much as possible, the pressure wedge and the fulcrum were each formed in a columnar shape with a radius of 15 mm. The bending speed (moving speed of the test machine cross head) was 20 mm / min.

  The obtained load-displacement curve is shown in FIG. The initial slope of the load-displacement curve is larger in Experimental Example 2 than in Comparative Example 1. Therefore, in Experimental Example 1, it can be seen that the bending rigidity is improved as a result of the thickness not being reduced because the pile made of monofilament yarn becomes a column and supports the compressive load generated in the thickness direction.

  In Comparative Example 1, when the bending deformation increased, the fabric layer partially peeled on the upper surface (inside the bend), but in Experimental Example 2, the fabric layer did not peel.

  Here, the apparent density of the foam layer laminated body of Experimental example 2 and Comparative example 1 is demonstrated.

  The apparent density of the foam layer laminates of Experimental Example 2 and Comparative Example 1 was determined by a method according to JIS K7222 (2005). In addition, the test piece used for the measurement of weight and volume was produced similarly to what was used for the compression test.

The apparent density of the foam layer laminate of Experimental Example 2 was 59.1 kg / m ³ . The apparent density of the foam layer laminate of Comparative Example 1 was 61.9 kg / m ³ .

  From this result, it is considered that Experimental Example 2 has a slightly higher expansion ratio because of its lower apparent density. Generally, if the expansion ratio is large, the strength and rigidity are considered to be small. Therefore, it was proved that it was not the difference in the expansion ratio that the experimental example 2 resulted in higher strength and rigidity than the comparative example 1.

  Therefore, in the above embodiment, the monofilament yarn 3 of synthetic fiber penetrates the foam layer 2 and the fabric layers 1A and 1B are connected to each other at appropriate intervals. The compressive strength and compressive rigidity in the vertical direction are improved. For this reason, even if bending deformation or torsional deformation is applied to the foam layer laminate, the thickness can be prevented from being reduced, and excellent strength and rigidity can be obtained. In addition, even when bending deformation or torsional deformation occurs in the foam layer laminate 1, the fabric layers 1A and 1B are lifted by buckling, and peeling at the boundary between the fabric layers 1A and 1B and the foam layer 2 is ensured. Is prevented. Thereby, sufficient intensity | strength and rigidity of the foam layer laminated body 1 can be acquired with respect to bending deformation or torsion deformation.

  Each fabric layer 1A, 1B is formed of two base fabrics 11A, 11B constituting a double pile fabric, and the pile warp yarn of the base material 11 is applied as a pile 31 (monofilament yarn 3). Therefore, it is not necessary to separately provide the monofilament yarn 3 to connect the fabric layers 1A and 1B, and the fabric layers 1A and 1B can be easily connected to each other by the monofilament yarn 3. Moreover, if the foam raw material is inserted or injected between the two base fabrics 11A and 11B connected by the pile warp yarn (pile 31), the foam layer 2 can be easily obtained, and the foam layer laminate 1 can be obtained. Easy to manufacture.

  Moreover, since the liquid hard foam resin is applied as a raw material of the foam layer 2, the liquid hard foam resin can be easily injected between the fabric layers 1A and 1B to obtain the foam layer 2 easily. In addition, the strength and rigidity of the foam layer 2 can be improved by the hard foam resin, and the foam layer laminate 1 having excellent durability and vibration damping properties can be provided.

  Moreover, if the reinforcement | strengthening fabric layer containing glass fiber is applied as each fabric layer 1A, 1B, the intensity | strength and rigidity of each fabric layer 1A, 1B will be raised further, and the foam layer laminated body 1 as a whole is improved. Strength and rigidity functions can be further improved.

  Furthermore, the double pile fabric (base material) which has the pile 31 which consists of the monofilament thread | yarn 3 of the synthetic fiber which connects two fabric layers 1A and 1B which are fabrics, and these fabric layers 1A and 1B at appropriate intervals. A weaving step of weaving, an end sealing step of sealing the edges of the fabric layers 1A and 1B connected by the monofilament yarn 3 except for the injection portion 15 of the foam material, and the fabric layers 1A and 1B. Since the foam layer laminate 1 is manufactured by the foam filling step of filling the foam from the injection portion 15 between them and obtaining the foam layer 2 after foaming and curing, the compressive strength and compression in the thickness direction are produced. The foam layer laminate 1 having improved rigidity and sufficient strength and rigidity against bending deformation and torsional deformation can be provided. Moreover, the foam layer 2 can be easily obtained by injecting the foam raw material between the fabric layers 1A and 1B connected by the pile 31 made of the monofilament yarn 3 of the synthetic fiber. Easy to manufacture.

  In addition, this invention is not limited to the said embodiment, Other various modifications are included. For example, in the above embodiment, each fabric layer is formed by two base fabrics constituting a double pile fabric (base material), and the pile warp yarn of the base material is used as a monofilament yarn. The foam layer laminate is manufactured by interposing the foam and connecting the fabric layers with the monofilament yarn of the synthetic fiber with the foam formed in a plate shape interposed therebetween. May be. Specifically, a foam layer intervening step in which a foam layer formed in advance is interposed between each base fabric made of woven fabric, and the foam layer interposed by the foam layer interposing step is a monofilament of synthetic fiber A fabric layer connecting step of penetrating through the yarn and connecting between the fabric layers at appropriate intervals. Even in this case, it is possible to provide a foam layer laminate having improved compressive strength and compressive rigidity in the thickness direction and sufficient strength and rigidity against bending deformation and torsional deformation.

  Moreover, in the said embodiment, although the two fabric layers 1A and 1B and the foam layer 2 comprised the foam layer laminated body 1 of the three-layer structure, the anti-foaming of at least one fabric layer of each fabric layer was carried out. A new fabric layer is provided on the body layer side so as to face one of the fabric layers, a new foam layer is provided between the fabric layers facing each other, and the new foam layer is penetrated. Thus, a new pile of monofilament yarns of synthetic fibers that connect the fabric layers facing each other at appropriate intervals may be provided. In this case, a thick foam layer laminate in which a foam layer is also provided between at least one of the fabric layers and a new fabric layer facing the fabric layer is obtained. On the other hand, it is possible to obtain more sufficient strength and rigidity.

  In the above embodiment, any two monofilament yarns 3, 3 are orthogonal to the fabric layers 1A, 1B and are substantially parallel to each other. However, as shown in FIG. May not be orthogonal to the fabric layers 1A, 1B. That is, one monofilament yarn 32 and the other monofilament yarn 33 may be inclined with respect to the fabric layers 1A and 1B and woven as adjacent piles in a double pile fabric as a base material. The monofilament yarns 32 and 33 are repeatedly arranged in order in the weft direction of the fabric layers 1A and 1B. In this case, although the monofilament yarns 32 and 33 are inclined with respect to the fabric layers 1A and 1B, since the monofilament yarns 32 and 33 are inclined at the same angle to the opposite side, the balance of force is achieved. It becomes possible to form the flat foam layer laminate 14.

  In the above embodiment, any two monofilament yarns 3 are substantially parallel to each other. However, as shown in FIG. 12, the distance between any two monofilament yarns 34, 34 is set between the two fabric layers 1A, 1B. The monofilament yarns 34 and 34 may not be parallel to each other but may be radial. That is, yarns having different heat shrinkage rates are used as weft yarns on one base fabric 11A (upper base fabric in FIG. 12) and the other base fabric 11B (lower base fabric in FIG. 12). When heated, the weft yarn having a high heat shrinkage rate is greatly shrunk, so that the base fabrics 11A and 11B, which had the same length before processing, have an unbalanced length in the weft direction. Therefore, when the space between the filament yarns 34 and 34 is reduced together with the other base fabric 11B using the weft yarn having a high heat shrinkage rate, and the foam layer 2 is formed on the base material 11 thus treated, the heat shrinkage rate is reduced. The foam layer laminated body 15 having a curvature such that the other base fabric 11B using the high weft is on the inside may be formed.

  Moreover, in the said embodiment, although one base fabric 11A and the other base fabric 11B were connected by the pile yarn 31 of the same length in all the positions, as shown in FIG. May be formed in the warp yarn direction of the base fabrics 11A and 11B, and the foam layer laminate 16 having portions having different thicknesses in the warp yarn direction may be formed. In this case, between the portions having different thicknesses, the fabric layers 1A and 1B are connected to each other by the monofilament yarn 35 whose length is gradually changed in the warp yarn direction so that no step is generated.

  Moreover, in the said embodiment, although fabric layer 1A, 1B was comprised by the woven fabric, you may provide the resin layer on the surface of the fabric layer. For example, after the foam is foamed and cured, an epoxy resin is applied and cured to form a resin layer on the surface of the fabric layer. In this case, it is possible to prevent buckling of the fabric layer that becomes the inner side when it is bent and to further increase the strength and rigidity of the foam layer laminate.

  Further, the same effect can be obtained by forming a foam layer on a base material made into a composite material by impregnating a fabric layer with a resin in advance.

  Moreover, if materials having other functions such as a heat reflecting sheet and a decorative board are laminated, a foam layer laminate having other functions in addition to the functions of the present invention can be obtained.

  In addition, the pile made of the synthetic filament monofilament yarn constituting the foam layer laminate of the present invention is composed of untwisted yarn in which two monofilaments are aligned even if each is a single monofilament. It may be. At this time, if three or more monofilaments are used, the thickness of the monofilament per filament has to be reduced due to difficulty in weaving, so the buckling load of the pile made of monofilament yarns is reduced, and the foam layer It becomes difficult to ensure the rigidity of the laminate. Further, when twisting is applied to a yarn in which a plurality of monofilaments are arranged, the linearity of the monofilament is lost, and the buckling load is reduced. On the other hand, in the case of a pile made of untwisted yarn in which two monofilaments are aligned, even if the thickness per monofilament is sufficiently large (for example, 200 to 500 dtex), there is a difficulty in weaving. In addition, the buckling load does not decrease because of no twisting.

  Furthermore, if the foam layer laminate is used as a structural material, a heat insulating material or a sound insulating material, the compressive strength and compressive rigidity in the thickness direction are improved, and sufficient strength and rigidity against bending deformation and torsional deformation are obtained. With the foam layer laminate, it is possible to provide a structural material, a heat insulating material, or a sound insulating material with high strength and rigidity.

DESCRIPTION OF SYMBOLS 1 Foam layer laminated body 1A, 1B Fabric layer 11 Base material 11A, 11B Base fabric 15 Injection | pouring part 2 Foam layer 20 Foam 3 Monofilament yarn

Claims (8)

A foam layer laminate comprising two fabric layers made of woven fabric and a foam layer provided between these fabric layers,
A foam layer laminate comprising a pile of monofilament yarns of synthetic fibers that penetrate through the foam layer and connect the fabric layers to each other at appropriate intervals.   2. The foaming according to claim 1, wherein each of the fabric layers is formed of two base fabrics constituting a double pile fabric, and a pile warp yarn constituting the double pile fabric is used as the pile. Body layer laminate.   The foam layer laminate according to claim 1 or 2, wherein a hard foam resin having a liquid material is applied as the foam of the foam layer. On the anti-foam layer side of at least one of the fabric layers, a new fabric layer is provided so as to face the one fabric layer, and between the fabric layers facing each other. Has a new foam layer,
A new pile of monofilament yarns of synthetic fibers that penetrate the new foam layer and connect the fabric layers facing each other at appropriate intervals is provided. 2. The foam layer laminate according to 1.   The foam layer laminate according to any one of claims 1 to 4, wherein a reinforcing fiber layer containing glass fibers is applied as each of the fabric layers.   A structural material, a heat insulating material, or a sound insulating material comprising the foam layer laminate according to any one of claims 1 to 5. A method for producing a foam layer laminate comprising two fabric layers made of woven fabric and a foam layer provided between the fabric layers,
A foam layer interposing step of interposing the foam layer between the fabric layers;
A fabric layer connecting step of penetrating the foam layer interposed by the foam layer interposing step with a monofilament yarn of synthetic fiber and connecting the fabric layers at appropriate intervals;
A method for producing a foam layer laminate, comprising: A method for producing a foam layer laminate comprising two fabric layers made of woven fabric and a foam layer provided between the fabric layers,
When weaving the fabric layers, the fabric layers are formed by two base fabrics constituting the double pile fabric, and the pile warp yarns constituting the double pile fabric are bonded to the fabric layers. Weaving process for weaving a double pile fabric, using as a pile of monofilament yarns of synthetic fibers connected at appropriate intervals;
An end sealing step for sealing the edges of the fabric layers connected by the pile, excluding the injection portion of the foam raw material,
A foam filling step of filling the foam from the injection portion so that the foam layer is obtained between the fabric layers;
A method for producing a foam layer laminate, comprising:

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