JP3181108U - Composite nonwoven fabric - Google Patents

Abstract

A composite nonwoven fabric having flexibility is provided.
A glass yarn (B) is disposed between a long fiber web (A) and a long fiber web (C), and the long fiber web (A), the glass yarn (B), and the long fiber. A web (C) is a composite nonwoven fabric having a thickness of 0.50 mm or less, which is three-dimensionally entangled and integrated with a needle punch and impregnated with a thermosetting resin and / or a thermoplastic resin, (A) and (C) have a basis weight of 40 to 100 g / m ² , respectively, (A) and (C) have a fineness of 1 to 5 dtex, and the ratio of the major axis to the minor axis of the fiber cross section (major axis) (/ Minor axis) is composed of long fibers having a flat fiber cross section of 1.5 to 10, or composed of long fibers having a fineness of 1 to 4 dtex and a circular fiber cross section. A composite nonwoven fabric having a fineness of less than 67.5 tex.
[Selection] Figure 1

Description

  The present invention relates to a composite nonwoven fabric, and more particularly to a composite nonwoven fabric that can be used as a base material for waterproof materials.

  The roofs of houses and buildings are waterproofed such as asphalt waterproofing, urethane coating waterproofing, and sheet waterproofing. Nonwoven fabric is used as a base material for waterproofing materials used when performing these waterproofing processes. As the nonwoven fabric constituting the base material, a long fiber nonwoven fabric, a short fiber nonwoven fabric, a wet nonwoven fabric or the like is used.

  In order to prevent shrinkage during processing at the factory, or to prevent water leakage due to heat shrinkage after laying on the roof, the nonwoven fabric base material constituting the waterproof material is usually melamine resin or acrylic. A resin excellent in heat resistance such as a resin is impregnated. For the purpose of improving heat resistance, a mesh or yarn having high heat resistance is compounded in the nonwoven fabric base material. By combining these resins with impregnations, yarns, etc., and combining them, the nonwoven fabric exhibits excellent heat resistance and helps to maintain waterproof performance.

However, since the nonwoven fabric base material is thickened and hardened by impregnating the resin and by combining the mesh and the thread, the waterproof material composed of this nonwoven fabric base material is a thick and hard product. I had to be. Such a waterproof material, when applied on the roof, may be difficult to deform in accordance with these shapes in parts with complex irregularities such as the rooftop and around the role, and adheres to the ground There was a case where the sex decreased. In particular, in asphalt waterproofing construction in winter, this problem may become remarkable because the flexibility of the base material impregnated with asphalt is reduced due to the temperature sensitivity of the asphalt. Therefore, a lot of labor is required to secure waterproofness during construction.
Moreover, since the nonwoven fabric base material impregnated with resin or combined with a mesh or yarn has a large thickness, there is also a problem that it cannot meet the demand for increasing the winding length of the nonwoven fabric base material roll.

  Therefore, the nonwoven fabric base material constituting the waterproof material is required to reduce the thickness of the nonwoven fabric base material and thereby improve the flexibility of the waterproof material. However, in response to this demand, for example, if the nonwoven fabric is heat calendered and thinned, the fibers constituting the nonwoven fabric and the fibers constituting the mesh or yarn will be damaged. It cannot be used as a base material for waterproof materials.

Japanese Patent No. 3103253

   This invention solves said problem and provides the composite nonwoven fabric which has a softness | flexibility.

As a result of intensive studies to solve the above problems, the present inventors have determined that the above problems can be solved by specifying the shape and thickness of the fibers constituting the nonwoven fabric and the thickness of the glass yarn to be combined. The headline, the present invention was reached.
That is, the gist of the present invention is as follows.
(1) The glass yarn (B) is disposed between the long fiber web (A) and the long fiber web (C), and the long fiber web (A), the glass yarn (B), and the long fiber web. (C) is a composite nonwoven fabric having a thickness of 0.50 mm or less, which is three-dimensionally entangled and integrated by a needle punch and impregnated with a thermosetting resin and / or a thermoplastic resin,
The basis weights of the long fiber web (A) and the long fiber web (C) are 40 to 100 g / m ² , respectively.
Each of the long fiber web (A) and the long fiber web (C) has a fiber cross section in which the fineness is 1 to 5 dtex, and the ratio of the major axis to the minor axis (major axis / minor axis) is 1.5 to 10. It is composed of flat fibers that are flat, or composed of long fibers that have a fineness of 1 to 4 dtex and a circular fiber cross-section,
A composite nonwoven fabric, wherein the fineness of the glass yarn (B) is less than 67.5 tex.
(2) The composite nonwoven fabric according to (1), wherein the glass yarn (B) is arranged at an interval of 3 to 10 mm in the width direction of the composite nonwoven fabric.
(3) A waterproof material comprising the composite nonwoven fabric according to (1) or (2) as a base material.
(4) A waterproof sheet comprising the composite nonwoven fabric described in (1) or (2) as a base material, and the base material impregnated with asphalt.

According to the present invention, flexibility can be imparted to the composite nonwoven fabric. Therefore, since the waterproof material composed of this as a base material has flexibility, it can be easily deformed according to these shapes in the construction of parts with complicated irregularities such as the rise of the rooftop and around the role. It can be brought into close contact with the base and can secure waterproofness. Moreover, since the waterproof material has flexibility even in winter, it can exhibit excellent workability.
Moreover, since the composite nonwoven fabric of the present invention is thin, a roll with an increased winding length can be obtained.

It is sectional drawing of the width direction of the composite nonwoven fabric by this invention. It is sectional drawing of the rising part used in order to evaluate the softness | flexibility of the waterproof sheet of this invention. It is sectional drawing which constructed the waterproof sheet of this invention in the standing part.

  As shown in FIG. 1, the composite nonwoven fabric of the present invention comprises a glass fiber (B) disposed between a long fiber web (A) and a long fiber web (C). The glass yarn (B) and the long fiber web (C) are three-dimensionally entangled and integrated by a needle punch, and are impregnated with a thermosetting resin and / or a thermoplastic resin. is there.

In the present invention, as the long fibers constituting the long fiber web (A) and the long fiber web (C), a long fiber having a flat fiber cross section or a long fiber having a circular shape is used.
When a long fiber having a flat fiber cross section is used, a fiber having a fineness of 1 to 5 dtex and a ratio of a major axis to a minor axis (major axis / minor axis) of the fiber section of 1.5 to 10 is used. If the fineness exceeds 5 dtex or the major axis / minor axis is less than 1.5, the composite nonwoven fabric of the present invention may not be thinned and flexibility may not be imparted. On the other hand, if the fineness is less than 1 dtex or the major axis / minor axis exceeds 10, long fibers may be cut in the needle punching process, and the composite nonwoven fabric of the present invention may have low strength.
Moreover, when using the long fiber whose fiber cross section is circular, that whose fineness is 1-4 dtex is used. If the fineness exceeds 4 dtex, the composite nonwoven fabric of the present invention cannot be thinned and flexibility may not be imparted. On the other hand, when the fineness is less than 1 dtex, long fibers may be cut in the needle punching process, and the composite nonwoven fabric of the present invention may have low strength.

In the present invention, the long fibers constituting the long fiber web (A) and the long fiber web (C) are preferably thermoplastic synthetic fibers.
Examples of the thermoplastic resin constituting the thermoplastic synthetic fiber include polyester polymers such as polyethylene terephthalate and polybutylene terephthalate; acid components such as phthalic acid, isophthalic acid, glutaric acid, adipic acid and sulfoisophthalic acid, and diethylene glycol. Polyester copolymer in which diol components such as propylene glycol, 2,2-bis (4-hydroxyethoxyphenyl) propane, bisphenol A, polyalkylene glycol and the like are copolymerized in the range of up to 15 mol%; polyethylene, Polyolefin polymers such as polypropylene; polyamide polymers such as nylon 6 and nylon 66, and the like.
As the long fiber, any of a fiber composed of these (co) polymers alone, a bonded composite fiber combining two or more polymers, and a core-sheath composite fiber can be used.

  As the long fiber web (A) and the long fiber web (C) in the present invention, for example, those produced by a spunbond method known as a method for producing a long fiber nonwoven fabric can be used.

In the present invention, as the long fiber web (A) and the long fiber web (C), those having a basis weight of 40 to 100 g / m ² are used. If the basis weight exceeds 100 g / m ² , the composite nonwoven fabric of the present invention cannot be thinned and flexibility may not be imparted. On the other hand, if the basis weight is less than 40 g / m ² , the composite nonwoven fabric of the present invention may have low strength.

  In the present invention, the long-fiber web (A) and the long-fiber web (C) may have the same basis weight, the cross-sectional shape of the constituent long fibers, and the fineness may be the same or different.

In the composite nonwoven fabric of the present invention, the glass yarn (B) is disposed between the long fiber web (A) and the long fiber web (C).
As the glass yarn (B), one having a fineness of less than 67.5 tex is used. When the fineness is 67.5 tex or more, the composite nonwoven fabric of the present invention cannot be thinned and flexibility may not be imparted. In consideration of the strength of the composite nonwoven fabric, the fineness of the glass yarn (B) is preferably 30 tex or more.

  In the present invention, the glass yarn (B) is preferably arranged at an interval of 3 to 10 mm in the width direction of the composite nonwoven fabric. When the glass yarn (B) is arranged at an interval of less than 3 mm, the composite nonwoven fabric of the present invention cannot be thinned and flexibility may not be imparted. On the other hand, when arranged at intervals exceeding 10 mm, the composite nonwoven fabric of the present invention cannot withstand the tension during asphalt processing because the number of glass yarns is too small. Distortion may increase.

The composite nonwoven fabric of the present invention is obtained by three-dimensionally interlacing and integrating a long fiber web (A), a glass yarn (B), and a long fiber web (C) with a needle punch.
In the needle punching process, the needle density is preferably 20 to 100 times / cm ² . When the needle density exceeds 100 times / cm ² , the confounding property is improved, but the surface of the composite nonwoven fabric becomes uneven due to the collision between the glass yarn (B) and the needle, or the friction of the needle or the needle breakage. May be. On the other hand, if the needle density is less than 20 times / cm ² , the entanglement may be reduced, and delamination may occur between the long fiber web (A) and the long fiber web (C).

The composite nonwoven fabric of the present invention is impregnated with a thermosetting resin and / or a thermoplastic resin.
Examples of the thermosetting resin to be impregnated include melamine resins, epoxy resins and phenol resins, and examples of the thermoplastic resins include acrylic resins.
As a method for impregnation, for example, a three-dimensionally entangled integrated material composed of the long fiber web (A), the glass yarn (B), and the long fiber web (C) is dispersed in the resin dispersion or solution. After dipping, squeezing with a squeezing means such as mangle roll, drying using a band dryer, or applying resin foam foamed with a foaming machine to an integrated product, then drying with a hot air dryer, etc. Can be mentioned.

  The composite nonwoven fabric of the present invention can be used as a waterproof material by being used as a base material, and can be made into a waterproof sheet by impregnating it with asphalt or the like.

The glass yarn (B) used in Examples and Comparative Examples is as follows.
-ECG150 1/0 (fineness 33.8 tex) manufactured by FULLTECH FIBER GLASS
-ECG75 1/0 (fineness 67.5 tex) manufactured by FULLTECH FIBER GLASS

The flexibility test of the waterproof sheet was performed by the following method.
The waterproof sheet obtained by impregnating the composite nonwoven fabric with asphalt and the rising portion shown in FIG. 2 were cured for 3 hours or more in a low temperature environment at 5 ° C. The height of the rising portion (E) is 450 mm, and the rising portion (E) is provided with a step of 13 mm at a position 150 mm above the flat field (F). Next, as shown in FIG. 3, the waterproof sheet (H) was applied to the rising portion so that the flat field (F) and the heaven field (G) were each attached to 70 mm. The flexibility of the waterproof sheet was evaluated based on the ease of bending of the waterproof sheet (H) against the unevenness of the rising portion (E) and the ease of handling of the tool during construction.

Example 1
Spinning polyethylene terephthalate using a nozzle for flat yarn, using fine fibers having a fineness of 3.5 dtex, a ratio of major axis to minor axis (major axis / minor axis) of 3.0, and a fiber having a flat fiber cross section, A long fiber web (A) having a basis weight of 70 g / m ² was prepared by the spunbond method. Subsequently, the long fiber web (A) was treated with a hot embossing roll to make the adhesion between fibers light, so that the adhesion between the fibers was easily released by the physical impact of the needle punch in the next step.
In the same manner as the above-mentioned long fiber web (A), a long fiber web (C) having a basis weight of 55 g / m ² was prepared, followed by hot emboss roll treatment.
Using a glass yarn having a fineness of 33.8 tex as the glass yarn (B), this is uniformly aligned in the longitudinal direction so as to be 10 mm apart in the width direction of the resulting composite nonwoven fabric, and the long fiber web (A) And the long fiber web (C).
The laminated long fiber web (A), glass yarn (B), and long fiber web (C), using a 40th needle made by FOSTER, punch density is 45 P / square inch, needle depth is 9 mm, They were entangled and integrated three-dimensionally by the needle punch method.
Next, the obtained integrated product was treated with a heat calender roll having a temperature of about 240 ° C., and the thickness was adjusted so that the thickness after drying was 0.5 mm or less.
On the other hand, a mixed emulsion having a concentration of about 15% was prepared by mixing melamine resin and acrylic resin so that the active ingredient ratio was 50/50. The resulting heat-calendered integrated product was immersed in the resulting mixed emulsion, and impregnated with melamine resin and acrylic resin.
After squeezing out the excess emulsion using a rubber roll at the exit of the impregnation tank, the composite nonwoven fabric having a basis weight of 155 g / m ² and a thickness of 0.40 mm was obtained by drying at about 180 ° C. .

Example 2
A composite nonwoven fabric having a basis weight after drying of 170 g / m ² and a thickness of 0.45 mm was obtained in the same manner as in Example 1 except that the basis weight of the long fiber web (C) was 70 g / m ² . .

Example 3
A composite nonwoven fabric having a basis weight after drying of 160 g / m ² and a thickness of 0.43 mm was obtained in the same manner as in Example 1 except that the distance between the glass yarns (B) was 5 mm.

Comparative Example 1
As the long fiber web (A), a long fiber web having a fineness of 3.5 dtex, a fiber having a circular fiber cross section (diameter: 19 μm) and a basis weight of 70 g / m ² is used as the long fiber web (C). A glass with a fineness of 67.5 tex is used as the glass yarn (B), using a long fiber web consisting of long fibers (diameter 19 μm) having a fineness of 3.5 dtex and a circular fiber cross section, and having a basis weight of 55 g / m ^2. A composite nonwoven fabric having a basis weight after drying of 155 g / m ² and a thickness of 0.52 mm was obtained in the same manner as in Example 1 except that the yarn was used.
In addition, when strongly pressed with a heat calender roll so that the thickness is 0.5 mm or less with this configuration, the long fiber web portion in the vicinity of the glass yarn (B) is transparently formed into a film, and a partial tear can be formed. Since it became an unpreferable state, the press pressure of the heat | fever calendar roll was lowered | hung and the said 0.52 mm-thick composite nonwoven fabric was obtained.

Comparative Example 2
Except for using the long fiber web having a basis weight of 70 g / m ² as the long fiber web (C), the basis weight after drying was 170 g / m ² and the thickness was 0.56 mm in the same manner as in Comparative Example 1. A composite nonwoven fabric was obtained.

  The composite nonwoven fabrics obtained in Examples 1 to 3 and Comparative Examples 1 and 2 were used as base materials, impregnated with asphalt to create waterproof sheets, and the results of evaluation of flexibility are shown in Table 1.

The composite nonwoven fabric obtained in Examples 1 to 3 is excellent in flexibility, and the waterproof sheet formed by using this as a base material and impregnated with asphalt is also excellent in flexibility, in an environment of 5 ° C assuming winter. However, it could be easily deformed according to the shape of the complex unevenness of the rising portion.
On the other hand, the composite nonwoven fabric obtained in Comparative Examples 1 and 2 is inferior in flexibility, and the waterproof sheet formed by impregnating asphalt using this as a base material is also inferior in flexibility, in an environment of 5 ° C. assuming the winter season, Under the influence of the temperature sensitivity of asphalt, it was difficult to deform according to the shape of the complex unevenness of the rising portion.

A long fiber web B glass yarn C long fiber web D composite nonwoven fabric E rising part F flat part G top part H waterproof sheet

Claims (4)

A glass yarn (B) is disposed between the long fiber web (A) and the long fiber web (C), and the long fiber web (A), the glass yarn (B), and the long fiber web (C). Is a composite nonwoven fabric having a thickness of 0.50 mm or less, which is three-dimensionally entangled and integrated by a needle punch and impregnated with a thermosetting resin and / or a thermoplastic resin,
The basis weights of the long fiber web (A) and the long fiber web (C) are 40 to 100 g / m ² , respectively.
Each of the long fiber web (A) and the long fiber web (C) has a fiber cross section in which the fineness is 1 to 5 dtex, and the ratio of the major axis to the minor axis (major axis / minor axis) is 1.5 to 10. It is composed of flat fibers that are flat, or composed of long fibers that have a fineness of 1 to 4 dtex and a circular fiber cross-section,
A composite nonwoven fabric, wherein the fineness of the glass yarn (B) is less than 67.5 tex.   The composite nonwoven fabric according to claim 1, wherein the glass yarn (B) is arranged at an interval of 3 to 10 mm in the width direction of the composite nonwoven fabric.   A waterproof material comprising the composite nonwoven fabric according to claim 1 as a base material.   A waterproof sheet comprising the composite nonwoven fabric according to claim 1 or 2 as a base material, and the base material impregnated with asphalt.

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