JP3611123B2 - Asphalt waterproofing fabric and method for producing the same - Google Patents
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Description
【０００１】
【発明の属する技術分野】
本発明は、アスファルト防水用基布に関し、特に引裂き強さに優れ尚且つ、アスファルト加工時の寸法安定性や工程通過性に優れた屋根下材、壁材、屋上材等の構築物用防水シートとして有用なアスファルト防水用基布及びその製造方法に関する。
【０００２】
【従来の技術】
従来より構築物用防水シートとして使用されているアスファルトルーフィング材としては、アスファルトをラグ紙、エンボス熱圧着したスパンボンド不織布や樹脂含浸した不織布などにアスファルト含浸、アスファルトコートしたものが使用されている。これらは、種々の防水工法において、アスファルト防水工法は防水性、耐久性及び信頼性に優れており、そのうえ施工性が容易で経済的にも有利なことから広く使用されている。
ところで、アスファルトルーフィングにおいて、アスファルトを樹脂加工した不織布などに含浸処理すると、不織布を構成する繊維及び樹脂接点がアスファルトでブロッキングされてしまい、繊維自由度が低下するとともに引裂き応力が分散出来ずにアスファルトルーフィングとしての引裂き強さが低下し、施工時に例えば風にあおられて下地材への固定部分が破れたりすることがある。従って、万一破れた場合には漏水が生じる為、相当注意して作業を行わなければならなかった。
引裂き強さを改善する方法として、不織布を構成する繊維の配向結晶を制御し未延伸長繊維からなる不織布において繊維の伸度で引裂き応力の分散により改善が提案されている（例えば、特許文献１参照）。しかしながら、上記方法では、配向結晶を低く設定し未延伸糸からなる繊維で構成されている為、アスファルト加工上の特性である。熱時の初期モジュラスが低くアスファルト加工工程では出来るだけ低張力で加工しないと巾入り、シワ入り等のトラブルが予想されものである。
【０００３】
【特許文献１】
特開平９−１９５４５８３号公報
【０００４】
又、最近では、アスファルト加工コストを出来る限り削減する為、高張力下で加工速度を上げる方策が採られており熱時初期モジュラスの低い不織布は加工上不向きである。
【０００５】
【発明が解決しようとする課題】
本発明は、上記従来のアスファルト防水基布における上記欠点即ち、アスファルトによるブロッキング作用に伴う繊維及び樹脂接点の自由度を低下させることなく基布とアスファルトとの一体性に優れ引裂き強度と初期強力が高く加工性に優れたアスファルト防水基布を提供することを目的とするものである
【０００６】
【課題を解決するための手段】
即ち、本発明のポイントは、アスファルトのブロッキング作用に伴う繊維及び樹脂接点の自由度の低下が引裂き応力分散に支障をきたすと考え、上記改善を鋭意検討した結果、以下の発明に至った。
１．シングルタング法による引裂き強さが、タテ方向が４０Ｎ以上、ヨコ方向が４４Ｎ以上であって、１８０℃乾熱収縮率がタテ・ヨコ方向ともに５．０％以下の長繊維不織布からなることを特徴とするアスファルト防水用基布。
２．シングルタング法による引裂き強さが、タテ方向が４３Ｎ以上、ヨコ方向が４６Ｎ以上であることを特徴とする上記第１記載のアスファルト防水用基布。
３．タテ方向の１６０℃における３％伸張時の応力が４０Ｎ／５ｃｍ以上の長繊維不織布からなることを特徴とする上記第１記載のアスファルト防水用基布。
４．長繊維不織布が、目付が８０ｇ／ｍ２〜４００ｇ／ｍ２のポリエステル繊維からなることを特徴とする上記第１記載のアスファルト防水用基布。
５．長繊維不織布にバインダー樹脂とシリコン系樹脂が付与されてなることを特徴とする上記第１記載のアスファルト防水用基布。
６．長繊維不織布にニードルパンチ処理及び／又は加熱圧着処理を施した不織布にバインダー樹脂とシリコン系樹脂を同浴含浸処理することを特徴とするアスファルト防水用基布の製造方法。
７．バインダー樹脂付着量に対してシリコン樹脂が固形分で１ｗｔ％〜１０ｗｔ％付与することを特徴とする上記第６記載のアスファルト防水用基布の製造方法。
【０００７】
先ず、本発明の長繊維不織布としては、例えば、スパンボンド方式により形成され、熱圧着されいるものである。長繊維不織布はポリエステルテレフタレート、ポリブチレンテレフタレート等をはじめ、イソフタル酸を含むポリエステル及びこれらの共重合物からなるポリエステルからなることが好ましい。従って、ポリエチレンナフタレートレ等もこれに含まれる。
【０００８】
本発明の不織布は、シングルタング法による引裂き強さが、タテ方向が４０Ｎ以上、好ましくは４３Ｎ以上、８０Ｎ以下、ヨコ方向が４４Ｎ以上、好ましくは４６Ｎ以上、１００Ｎ以下である長繊維不織布からなる。これらの引裂き強さを下回るとアスファルト加工後の所望、引裂き裂き強力が得られなくなり本発明の所期の目的を達成することが困難となる。
また、当該不織布のタテ方向の１６０℃における３％伸長時応力は４０Ｎ／５ｃｍ以上、好ましくは ４５Ｎ／５ｃｍ以上であることが望ましい。
【０００９】
また本発明の長繊維不織布は、１８０℃乾熱収縮率がタテ・ヨコ方向ともに５．０％以下であることが望ましい。５．０％を超えるとアスファルト加工工程内で収縮による巾変動や、構造物に敷設処理した場合、夏冬の温度差でアスファルト残留収縮によりアスファルトルーフィングが伸び縮みし釘止めヵ所より雨漏れが発生する可能性が生じるからである。好ましくは１．５％以下、更に好ましくは０．１〜１．０％である。
【００１０】
更に、本発明の長繊維不織布は、目付が８０ｇ／ｍ２〜４００ｇ／ｍ２、さらに好ましくは１００〜３００ｇ／ｍ２である。８０ｇ／ｍ２未満であれば、１６０℃熱時３％伸長時応力が４０Ｎ／５ｃｍ以下となりアスファルト加工工程で加工張力に耐えきれずに巾入り、シワ入りといった製品外観上の欠点が発生する。逆に４００ｇ／ｍ２を超えると逆に４００ｇ／ｍ２を超える領域ではアスファルト加工上は特に支障はないが、コストが過剰に上昇するからである。
【００１１】
また本発明の長繊維不織布は、バインダー樹脂とシリコン系樹脂が付与されていることが望ましい。シリコン系樹脂を付与することにより、樹脂接点及び繊維表面にシリコン（滑剤）をまんべんなく塗布することが可能となり、滑剤の効果で引裂き応力に伴う樹脂接点破壊後、繊維交絡点の変形及び繊維間の摩擦係数を低下させ、ひいては引裂強度の向上を図ることができるからである。
【００１２】
次ぎに、上述のアスファルト防水用基布の製造例について述べるが、かかる新規な基布を製造する方法も新規且つ慎重に製造されるものである。
長繊維は、通常、溶融紡糸でにより形成された、エジェクターで牽引された後、ネットに捕集し形成されるが、紡糸速度は３５００ｍ／ｍｉｎ以上であることが望ましい。３５００ｍ／ｍｉｎ未満であると、樹脂加工工程における熱処理で収縮によるシワが発生し、不織布の安定生産を図ることが困難となるからである。溶融紡糸の段階で開繊性改良剤、酸化防止剤、安定剤、紫外線吸収剤等は紡糸時或は、ウェッブ形成およびその前後で付与する。
長繊維不織布の繊度は、１〜２０デニールで特に２〜１５デニールが好ましい。 ニードルパンチ処理する際には針密度を３５〜１２０本／ｃｍ２に設定することにより繊維を交絡させ強度を向上させるために好ましい。
ニードルパンチ工程で一体形成された不織布を加熱圧着処理する目的は、表裏の繊維を固定するとともに繊維間距離を最密充填する事でアスファルト防水基布としての剛性を付与するためである。又、製品設計上の厚みを重要視する場合には、加熱圧着処理をしなくても良い。加熱熱処理の方法としては、エンボスロールとフラットカレンダー間で熱圧着する、加工温度は１５０℃〜２００℃の範囲で特に好ましくは１６０〜１９０℃である。加工時の線圧は５〜５０ｋｇ／ｃｍで好ましくは、２０〜３０Ｋｇ／ｃｍである。低線圧の場合は二層の長繊維不織布の熱固定が不十分でアスファルト防水基布としての剛性を得ることが困難となる。又、高線圧の領域で加工すると出来あがった樹脂加工品がペーパーライクで引裂きが低下する。
さらに、加熱圧着処理において、フラット／フラットのカレンダーロールを使用すると二層の長繊維不織布が熱圧着され繊維間距離を最密充填することは可能であるがドレープ性が増し、アスファルト防水基布としての剛性を得ることが困難となる。
【００１３】
かくして、ニードルパンチで一体形成し得られた不織布を加熱圧着処理した
不織布の繊維間同士の交点を固定する為、ケミカルバインダーを使用する。
バインダーは尿素、メラミン系、アクリル系及びエポキシ系等の熱硬化性樹脂又は熱可塑性樹脂を使用し、併用或は混合体を使用しても良い。
バインダーの付着量は長繊維不織布の目付に対して３〜４０ｗｔ％で特に５〜３０ｗｔ％が好ましい。バインダーの付着量が多いと、アスファルトの含浸性が低下すると共に樹脂接点強力が高くなり引裂き応力が接点及び繊維に集中し引裂き強力が低下し易くなる。逆に少ないとアスファルト含浸工程で工程張力に絶えきれずに破断や捲き付きトラブルを発生する。
シリコン系の樹脂（滑剤）の付着率は、バインダーの付着量に対して１ｗｔ％〜１０ｗｔ％で特に好ましくは３ｗｔ％〜７ｗｔ％が好ましい。１ｗｔ％以下の場合は、シリコンの滑剤としての効果が発揮出来ず引裂き強力が低く、逆に１０ｗｔ％を超える領域では、シリコン樹脂が樹脂接点の阻害となり、得られた樹脂加工品の熱時モジュラスが低下する原因となる。
【００１４】
本発明の長繊維不織布の製造法として最も重要な点は、バインダー樹脂とシリコン系樹脂を同浴処理することである。同浴処理することにより、樹脂接点及び繊維表面にシリコン樹脂をまんべんなく均一に塗布することが可能となり、滑剤の効果で引裂き応力に伴う樹脂接点破壊後、繊維交絡点の変形及び繊維間の摩擦係数を低下させ、引裂き応力を分散させることができる。シリコン樹脂、等の滑剤を紡糸積層工程及び／又はニードルパンチ工程の前工程でスプレー塗布、等の付与を行なった場合、滑剤の影響によりニードリングすると繊維交絡不良や巾入りといったトラブルが生じる。又、樹脂加工後にシリコン樹脂、等の滑剤を塗布すると既に樹脂接点が形成されていることから、繊維交絡点の変形及び繊維間の摩擦低下には寄与せず、引裂き強さの向上といった効果が認められなかった。
【００１５】
【実施例】
以下に、本発明を実施例によって説明するが、本発明は何らこれらに限定されるものではない。
なお、実施例中の物性の測定は、以下の方法によったものである。
不織布の引裂き強さ（Ｎ）：ＪＩＳ Ｌ−１０９６に記載のシングルタング法に従い、定速伸長型引張試験機（オリエンテック製テンシロン）で不織布の製品巾から巾５０ｍｍ 長さ２００ｍｍ 試料片 ２０点につき、試験片の短辺の中央に短辺と直角に１００ｍｍの切れ目を入れる。試験片のつかみ間隔１００ｍｍとして切れ目を入れた方の両端をつかみ、引張り速度２００ｍｍ／分で測定し得られた引裂き強さの平均値を引裂き強さ（Ｎ）とした
【００１６】
不織布の３％伸張時応力及び引張強さ（Ｎ／５ｃｍ）：ＪＩＳ Ｌ−１０９６に記載のカットストリップ法に従い、定速伸長型引張試験機（オリエンテック製テンシロン）と同試験機の恒温を用いて１６０℃雰囲気下で不織布の製品巾から巾５０ｍｍ 長さ２００ｍｍ 試料片 ２０点につき、つかみ間隔１００ｍｍで引張り速度２００ｍｍ／分で測定し得られた１６０℃熱時の３％伸張時応力の平均値を１６０℃熱時３％伸張時応力（Ｎ／５ｃｍ）
とした。
【００１７】
不織布の１８０℃乾熱収縮率（％）：ＪＩＳ Ｌ−１０９６に記載の熱収縮率法に従い、不織布の製品巾から２５０ｍｍ×２５０ｍｍの試験片を１ｍ当り３枚採取しタテ．ヨコそれぞれ３ヵ所に正確に２００ｍｍの長さのを示す印を付ける。この試験片を１８０℃の恒温槽に１０分間熱処理を実施し、取り出して室温まで冷却後に以下の方法で求めた収縮率の平均値を１８０℃乾熱収縮率 （％）とした。
計算式 収縮率（％）＝（Ｌ−Ｌ１）×１００÷（Ｌ）
Ｌ は加熱前の試験片の３線の長さの合計（ｍｍ）
Ｌ１は加熱後の試験片の３線の長さの合計（ｍｍ）
【００１８】
（実施例１）
融点２６０℃、極限粘度０．６３からなるポリエチレンテレフタレートを口径０．３０ｍｍ、単孔吐出量１．５ｇ／分・孔、ホール数３００の紡糸ノズルを用いて、溶融温度２８５℃で紡糸ノズルより吐出し、紡糸速度４５００ｍ／分でエジェクターで牽引細化、冷却して引き取り後、繊維を金属ネット上に捕集してウェッブとした。このウェッブを熱圧着ロールで弱圧着し不織布とした。得られた不織布の目付は１００ｇ／ｍ２であった。
【００１９】
上記製造法で得られた不織布をニートルパンチ機で交絡処理した。ニードル針は、オルガン社製のニードル針（ＦＰＤ １−４０）を使用し、針密度は６０本／ｃｍ２とした。
【００２０】
このニードルパンチ処理して得られた不織布を１８５℃のエンボスロールとフラットカレンダー間で線圧２０ｋｇ／ｃｍで加熱圧着処理し、次いで尿素メラミン樹脂とアクリル系樹脂とシリコン系（滑剤）を同浴含浸処理をし、バインダー樹脂付着量に対してシリコン（滑剤）が固形分で５ｗｔ％の混合樹脂を常法によって含浸させ、乾燥、熱処理することにより不織布を得た。得られた１２０ｇ／ｍ２ の不織布の性状を表１に示す。得られた不織布の性状はタテ方向の１６０℃熱時３％伸長時応力が５４Ｎ／５ｃｍで１８０℃乾熱収縮率がタテ、ヨコ共に１．０％以下で引裂き強さはタテ、ヨコ共に７５Ｎからなるアスファルト防水用基布を得る事ができた。使用したシリコンは大日本インキ株式会社製のディックシリコンソフナー３００を用いた。
【００２１】
（比較例１）
実施例１において尿素メラミン樹脂とアクリル系樹脂とシリコン系（滑剤）を同浴含浸処理をしない以外は実施例１と同様にして得られた１２０ｇ／ｍ２ の不織布の性状を表１に示す。熱時特性及び寸法安定性はほぼ同等な物性が得られたが、引裂き強さはタテ．ヨコ共に３５Ｎ以下と低くアスファルト加工後の引裂き強さに乏しく破れといったトラブル発生が予想されるものであった。
（比較例２）
実施例１において紡糸速度３０００ｍ／分でエジェクターで牽引細化、冷却して引き取り後、繊維を金属ネット上に捕集してウェッブとした。このウェッブを熱圧着ロールで弱圧着し不織布とした。得られたニードルパンチ処理を施し、 実施例−１と同様な樹脂加工を実施した所、樹脂熱処理工程で収縮によるシワが発生し安定生産出来る状態ではなかった。
【００２２】
（比較例３）
実施例−１において、ウェッブを熱圧着ロールで弱圧着した不織布にスプレー塗布でシリコンを不織布目付１００ｇ／ｍ２に対して固形分で１ｗｔ％（１ｇ／ｍ２）付着させ後、捲取り。次に、該当、不織布をニードルパンチ機で交絡処理したが、シリコン（滑剤）の影響で繊維間摩擦及び金属．繊維摩擦係数低下に伴い、交絡不良及びニードルパンチ工程での巾入り等で安定生産出来る状態ではなかった。
【００２３】
（比較例４）
比較例−２から得られた、樹脂加工後の不織布にシリコンを樹脂量２０ｇ／ｍ２に対して５ｗｔ％（１ｇ／ｍ２）塗布した。しかしながら既に、樹脂によって接点が形成
されており後加工でシリコンを付与しても繊維交絡点の変形及び繊維間の摩擦
低下には寄与せず、引裂き向上といった効果は認められなかった。
【００２４】
【表１】
【発明の効果】
本発明によれば、アスファルト防水用基布として特に引裂き強さに優れ尚且つ、アスファルト加工時の寸法安定性や工程通過性に優れた特徴を有し屋根下材、壁材及び屋上材等の構築物用防水用の不織布を提供することができる。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a base fabric for waterproofing asphalt, particularly as a waterproof sheet for structures such as roofing materials, wall materials, roofing materials, etc. excellent in tearing strength and excellent in dimensional stability and processability during asphalt processing. The present invention relates to a useful asphalt waterproofing fabric and a method for producing the same.
[0002]
[Prior art]
As the asphalt roofing material conventionally used as a waterproof sheet for a structure, asphalt impregnated and asphalt coated on rug paper, embossed thermocompression-bonded spunbond nonwoven fabric or resin-impregnated nonwoven fabric is used. These are widely used in various waterproofing methods because the asphalt waterproofing method is excellent in waterproofness, durability and reliability, and is easy in construction and economically advantageous.
By the way, in asphalt roofing, when the asphalt is impregnated into a non-woven fabric processed with resin, the fibers and resin contacts constituting the non-woven fabric are blocked with asphalt, the fiber freedom is reduced and the tear stress cannot be dispersed and asphalt roofing As a result, the tear strength may decrease, and the fixed portion to the base material may be torn, for example, by being blown by wind during construction. Therefore, in the unlikely event that it breaks, water leakage will occur, so work must be done with great care.
As a method for improving the tear strength, an improvement is proposed by controlling the oriented crystals of the fibers constituting the nonwoven fabric and dispersing the tear stress in the fiber elongation in the nonwoven fabric made of unstretched long fibers (for example, Patent Document 1). reference). However, in the above method, since the oriented crystals are set low and the fibers are made of undrawn yarn, the characteristics are asphalt processing. If the initial modulus during heating is low and the asphalt processing step is not performed at as low a tension as possible, troubles such as entering widths and wrinkles are expected.
[0003]
[Patent Document 1]
Japanese Patent Laid-Open No. 9-1954583
Recently, in order to reduce asphalt processing costs as much as possible, measures have been taken to increase the processing speed under high tension, and nonwoven fabrics with a low initial modulus when heated are unsuitable for processing.
[0005]
[Problems to be solved by the invention]
The present invention has the above disadvantages in the conventional asphalt waterproofing base fabric, that is, excellent integrity of the base fabric and asphalt without lowering the degree of freedom of fibers and resin contacts due to the blocking action by asphalt, and has a tear strength and initial strength. An object of the present invention is to provide an asphalt waterproof base fabric that is highly processable and excellent.
[Means for Solving the Problems]
That is, the point of the present invention is that the reduction in the degree of freedom of the fibers and the resin contacts accompanying the blocking action of asphalt hinders the tearing stress dispersion, and as a result of earnestly examining the above improvement, the following invention has been achieved.
1. The tear strength according to the single-tung method is characterized by comprising a long-fiber non-woven fabric having a vertical direction of 40N or more, a horizontal direction of 44N or more, and a 180 ° C dry heat shrinkage of 5.0% or less in both the vertical and horizontal directions. Asphalt waterproof base fabric.
2. The asphalt waterproofing base fabric according to the first aspect, wherein the tear strength according to the single tongue method is 43N or more in the vertical direction and 46N or more in the horizontal direction.
3. The base fabric for asphalt waterproofing according to the above-mentioned 1, characterized by comprising a long-fiber non-woven fabric having a stress when stretched by 3% at 160 ° C in the vertical direction of 40 N / 5 cm or more.
4). 2. The asphalt waterproofing base fabric according to the first aspect, wherein the long fiber nonwoven fabric is made of polyester fibers having a basis weight of 80 g / m 2 to 400 g / m 2.
5). The base fabric for waterproofing asphalt as described in the above item 1, wherein a long-fiber nonwoven fabric is provided with a binder resin and a silicon-based resin.
6). A method for producing a base fabric for waterproofing asphalt, wherein a non-woven fabric obtained by subjecting a long-fiber nonwoven fabric to needle punching and / or thermocompression treatment is impregnated with a binder resin and a silicon resin in the same bath.
7). The method for producing a base fabric for asphalt waterproofing according to the sixth aspect, wherein the silicon resin is added in a solid content of 1 wt% to 10 wt% with respect to the binder resin adhesion amount.
[0007]
First, the long fiber nonwoven fabric of the present invention is, for example, formed by a spunbond method and thermocompression bonded. The long fiber non-woven fabric is preferably made of polyester including polyester terephthalate, polybutylene terephthalate, etc., polyester containing isophthalic acid and copolymers thereof. Accordingly, this includes polyethylene naphthalate and the like.
[0008]
The nonwoven fabric of the present invention comprises a long-fiber nonwoven fabric having a tear strength by a single tongue method of 40N or more, preferably 43N or more and 80N or less, and a horizontal direction of 44N or more, preferably 46N or more and 100N or less. Below these tear strengths, the desired and tear strength after asphalt processing cannot be obtained, making it difficult to achieve the intended purpose of the present invention.
In addition, the stress at 3% elongation at 160 ° C. in the vertical direction of the nonwoven fabric is 40 N / 5 cm or more, preferably 45 N / 5 cm or more.
[0009]
The long fiber nonwoven fabric of the present invention preferably has a 180 ° C. dry heat shrinkage of 5.0% or less in both the vertical and horizontal directions. If it exceeds 5.0%, the width changes due to shrinkage during asphalt processing, and when it is laid on a structure, the asphalt roofing expands and contracts due to residual shrinkage of the asphalt due to the temperature difference between summer and winter, and rain leaks from the nail locations. This is because there is a possibility of doing so. Preferably it is 1.5% or less, More preferably, it is 0.1 to 1.0%.
[0010]
Furthermore, long-fiber nonwoven fabric of the present invention, basis weight 80g / m 2 ~400g / m 2 , more preferably from 100 to 300 g / m 2. If it is less than 80 g / m 2 , the stress at 3% elongation when heated at 160 ° C. will be 40 N / 5 cm or less, and it will not be able to withstand the processing tension in the asphalt processing step, resulting in defects in the appearance of the product such as entering widths and wrinkles. Although there is no particular hindrance on asphalt processing in reverse to greater than 400 g / m 2 on the contrary more than 400 g / m 2 area, because the cost is excessively increased.
[0011]
The long fiber nonwoven fabric of the present invention is desirably provided with a binder resin and a silicon resin. By applying silicone resin, it becomes possible to evenly apply silicon (lubricant) to the resin contacts and the fiber surface. After the resin contact breakage due to tearing stress due to the effect of the lubricant, deformation of the fiber entanglement point and between the fibers This is because the coefficient of friction can be reduced, and consequently the tear strength can be improved.
[0012]
Next, although the example of manufacture of the above-mentioned asphalt waterproofing base fabric is described, the method for manufacturing such a new base fabric is also new and carefully manufactured.
The long fiber is usually formed by melt spinning, pulled by an ejector, and then collected by a net. The spinning speed is preferably 3500 m / min or more. If it is less than 3500 m / min, wrinkles due to shrinkage occur during heat treatment in the resin processing step, making it difficult to achieve stable production of the nonwoven fabric. In the melt spinning stage, the spreadability improver, antioxidant, stabilizer, ultraviolet absorber and the like are applied during spinning or before and after the web formation.
The fineness of the long fiber nonwoven fabric is preferably 1 to 20 denier, and particularly preferably 2 to 15 denier. When performing the needle punching process, it is preferable to set the needle density to 35 to 120 / cm 2 in order to entangle the fibers and improve the strength.
The purpose of thermocompression-bonding the nonwoven fabric integrally formed in the needle punching process is to provide rigidity as an asphalt waterproofing base fabric by fixing the fibers on the front and back sides and closely packing the distance between the fibers. Moreover, when the thickness in product design is regarded as important, it is not necessary to carry out the thermocompression treatment. As a heat treatment method, thermocompression bonding is performed between an embossing roll and a flat calender. The processing temperature is in the range of 150 ° C to 200 ° C, particularly preferably 160 to 190 ° C. The linear pressure during processing is 5 to 50 kg / cm, preferably 20 to 30 kg / cm. In the case of low linear pressure, heat fixation of the two-layer long-fiber nonwoven fabric is insufficient, and it becomes difficult to obtain rigidity as an asphalt waterproofing base fabric. Moreover, when processed in the region of high linear pressure, the finished resin processed product is paper-like and tearing is reduced.
Furthermore, in the thermocompression treatment, if a flat / flat calender roll is used, two layers of long-fiber non-woven fabric can be thermocompression-bonded, and the distance between fibers can be filled most closely. It is difficult to obtain the rigidity.
[0013]
Thus, a chemical binder is used in order to fix the intersection between the fibers of the nonwoven fabric obtained by thermocompression-bonding the nonwoven fabric integrally formed with the needle punch.
As the binder, a thermosetting resin or a thermoplastic resin such as urea, melamine, acrylic and epoxy may be used, or a combination or a mixture may be used.
The adhesion amount of the binder is preferably 3 to 40 wt%, particularly preferably 5 to 30 wt%, based on the basis weight of the long fiber nonwoven fabric. When the adhesion amount of the binder is large, the asphalt impregnation property is lowered and the resin contact strength is increased, and the tearing stress is concentrated on the contacts and the fibers, so that the tear strength is easily lowered. On the other hand, if the amount is too small, the asphalt impregnation process will not be able to keep up with the process tension, but will cause troubles with breaks and cracks.
The adhesion rate of the silicon-based resin (lubricant) is 1 wt% to 10 wt%, particularly preferably 3 wt% to 7 wt%, with respect to the adhesion amount of the binder. In the case of 1 wt% or less, the effect of silicon as a lubricant cannot be exhibited, and the tearing strength is low. On the contrary, in the region exceeding 10 wt%, the silicone resin becomes a hindrance to the resin contact, and the thermal modulus of the obtained resin processed product Cause a drop.
[0014]
The most important point as a method for producing the long-fiber nonwoven fabric of the present invention is that the binder resin and the silicon resin are treated in the same bath. By applying the same bath treatment, it becomes possible to evenly apply the silicone resin evenly to the resin contacts and the fiber surface. After the resin contact failure due to tear stress due to the effect of the lubricant, the deformation of the fiber entanglement point and the coefficient of friction between the fibers And the tearing stress can be dispersed. When a lubricant such as silicon resin is applied by spraying or the like in the pre-spinning process and / or the needle punching process, if it is needled due to the influence of the lubricant, troubles such as defective fiber entanglement and insertion of width occur. In addition, if a lubricant such as silicon resin is applied after resin processing, the resin contact has already been formed, so it does not contribute to deformation of the fiber entanglement point and lower friction between fibers, and has the effect of improving tear strength. I was not able to admit.
[0015]
【Example】
EXAMPLES The present invention will be described below with reference to examples, but the present invention is not limited to these examples.
In addition, the measurement of the physical property in an Example is based on the following method.
Tensile strength of nonwoven fabric (N): According to the single tongue method described in JIS L-1096, the width of the nonwoven fabric is 50 mm, the length is 200 mm, and the sample piece is 20 with a constant-speed extension type tensile tester (Orientec Tensilon). In the center of the short side of the test piece, a 100 mm cut is made at right angles to the short side. An average value of tear strengths obtained by grasping both ends of the test piece with a grip interval of 100 mm and measuring at a pulling speed of 200 mm / min was defined as tear strength (N).
3% elongation stress and tensile strength (N / 5cm) of nonwoven fabric: In accordance with the cut strip method described in JIS L-1096, using a constant-speed extension type tensile tester (Orientec Tensilon) and the constant temperature of the same tester The average value of the stress at 3% elongation when heated at 160 ° C., measured at a pulling rate of 200 mm / min with a grip interval of 100 mm per 20 points of the sample width of the nonwoven fabric in a 160 ° C. atmosphere. When heated at 160 ° C, stress at 3% elongation (N / 5cm)
It was.
[0017]
180 ° C. dry heat shrinkage rate (%) of non-woven fabric: According to the heat shrinkage rate method described in JIS L-1096, three test pieces of 250 mm × 250 mm were collected per 1 m from the product width of the non-woven fabric, and length. Mark the three sides horizontally to indicate the exact length of 200 mm. The test piece was heat-treated in a constant temperature bath at 180 ° C. for 10 minutes, taken out, cooled to room temperature, and the average shrinkage obtained by the following method was defined as 180 ° C. dry heat shrinkage (%).
Calculation formula Shrinkage rate (%) = (L−L1) × 100 ÷ (L)
L is the total length (mm) of the three wires of the specimen before heating
L1 is the total length (mm) of the three lines of the test specimen after heating
[0018]
Example 1
Polyethylene terephthalate having a melting point of 260 ° C and an intrinsic viscosity of 0.63 is discharged from the spinning nozzle at a melting temperature of 285 ° C using a spinning nozzle with a caliber of 0.30 mm, single hole discharge rate of 1.5 g / min / hole, and 300 holes. The fiber was collected on a metal net and made into a web after being pulled and thinned by an ejector at a spinning speed of 4500 m / min, cooled and taken up. The web was weakly pressed with a thermocompression-bonding roll to obtain a nonwoven fabric. The basis weight of the obtained nonwoven fabric was 100 g / m 2 .
[0019]
The nonwoven fabric obtained by the above production method was entangled with a neat punch machine. The needle used was an organ needle (FPD 1-40), and the needle density was 60 / cm 2 .
[0020]
The nonwoven fabric obtained by this needle punching treatment is heated and pressure-bonded between an embossing roll at 185 ° C. and a flat calender at a linear pressure of 20 kg / cm, and then impregnated with urea melamine resin, acrylic resin and silicone (lubricant) in the same bath The nonwoven fabric was obtained by carrying out the treatment, impregnating 5 wt% of a mixed resin having a solid content of silicon (lubricant) with respect to the amount of the binder resin adhered by a conventional method, drying and heat treatment. Properties of the obtained 120 g / m 2 nonwoven fabric are shown in Table 1. The properties of the obtained non-woven fabric were as follows: 3% stress when stretched at 160 ° C in the vertical direction was 54N / 5cm, 180 ° C dry heat shrinkage was 1.0% or less for both vertical and horizontal, and tear strength was 75N for both vertical and horizontal. An asphalt waterproofing fabric made of As the silicon used, Dick Silicon Softener 300 manufactured by Dainippon Ink Co., Ltd. was used.
[0021]
(Comparative Example 1)
Table 1 shows the properties of a 120 g / m 2 non-woven fabric obtained in the same manner as in Example 1 except that the urea melamine resin, the acrylic resin, and the silicon resin (lubricant) were not subjected to the same bath impregnation treatment. The thermal properties and dimensional stability were almost the same, but the tear strength was vertical. Both horizontal widths were as low as 35N or less, and it was expected that troubles such as tearing were poor due to poor tear strength after asphalt processing.
(Comparative Example 2)
In Example 1, the fiber was drawn on a metal net by pulling it with an ejector at a spinning speed of 3000 m / min, cooling it, and taking it up. The web was weakly pressed with a thermocompression-bonding roll to obtain a nonwoven fabric. When the obtained needle punching treatment was performed and the same resin processing as in Example-1 was performed, wrinkles due to shrinkage occurred in the resin heat treatment step, and it was not in a state where stable production was possible.
[0022]
(Comparative Example 3)
In Example 1, 1 wt% (1 g / m 2 ) of solid content was adhered to the nonwoven fabric with a web weight of 100 g / m 2 by spray coating on the nonwoven fabric weakly pressure-bonded with a thermocompression-bonding roll. Next, the nonwoven fabric was entangled with a needle punch machine, but due to the influence of silicon (lubricant), friction between fibers and metal. Along with a decrease in the coefficient of friction of the fiber, it was not in a state where stable production was possible due to poor entanglement and inclusion in the needle punching process.
[0023]
(Comparative Example 4)
5 wt% (1 g / m 2 ) of silicon was applied to the nonwoven fabric after resin processing obtained from Comparative Example- 2 with respect to the resin amount of 20 g / m 2 . However, since the contact point is already formed by the resin, even if silicon is applied in the post-processing, it does not contribute to the deformation of the fiber entanglement point and the friction reduction between the fibers, and the effect of improving the tearing is not recognized.
[0024]
[Table 1]
【The invention's effect】
According to the present invention, as an asphalt waterproofing base fabric, it is particularly excellent in tearing strength, and has characteristics that are excellent in dimensional stability and processability during asphalt processing, such as roofing materials, wall materials, and roofing materials. A waterproof nonwoven fabric for a structure can be provided.
Claims (6)
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