JP3753235B2 - Glass fiber reinforced laminated nonwoven fabric - Google Patents
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Description
【０００１】
【発明の属する技術分野】
本発明は、ガラス繊維で補強された不織布に関するものであり、高弾性で高強力を有し、産業用資材、建築用資材などの分野で基布として使用できるものであり、特に基布切断端面でのガラス繊維の飛出しが防止され、防水材などの基布として好適に使用できる不織布である。
【０００２】
【従来の技術】
従来より、建築分野で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、その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事から広く使用されている。
アスファルト防水工法におけるアスファルト防水基布として、特にポリエステル不織布が多く使用され、最近ではポリエステル不織布にガラス繊維を複合したアスファルト防水基布が使用されている（例えば、特許第３１０３２５３号公報や米国特許第５１８５５０号など）。
【０００３】
しかしながら、前者は、ポリエステル不織布層とガラス繊維とをニードルパンチで絡合させて積層し、加熱処理及び／又は樹脂含浸処理してアスファルトルーフィング基布とするものであるが、該アスファルトルーフィング基布を検査工程でスリットする場合、スリット面（基布切断面）端部にガラス繊維が飛び出す欠点があった。このような基布をアスファルト加工すると、端部に飛出したガラス繊維が作業者の手に突き刺さったり、加工工程中のエッジポジションコントロールの誤作動が発生したり、加工製品端面にガラス繊維が飛出し、外観的に見劣りすることが問題であった。
【０００４】
更に、スリット面（基布切断面）端部にガラス繊維が飛び出さない様にガラス繊維を予め挿入せずに樹脂加工すると、樹脂加工工程の乾燥ゾーン及びセット工程で収縮応力の影響で補強糸を入れない箇所に膨れが発生し、その箇所から折れジワが助長される結果となり、製品収率が悪化する欠点があり、得られた基布は、外観的にはスリット面（基布切断面）端部にガラス繊維が飛び出さないが、アスファルト加工する際に端部にガラス繊維の補強糸が挿入されていない為、アスファルト含浸時の熱応力により耳垂れが発生し工程通過性が著しく悪化するという欠点があった。また、得られた、アスファルト防水基布も熱的歪を受けている為、製品端部に波打ちが発生し防水層としての機能を果たせないという欠点がある。
また、後者は、ポリエステル不織布製造工程でガラス繊維をクリルより引き出し、ポリエステル不織布の中間層にガラス繊維を挿入するものであり、製造工程中のガラス繊維切断時の修正やボビン替え、品番切替等の作業性が非常に悪く、また、ポリエステル不織布製造工程でガラス繊維を挿入するため、設備費及び設置場所が大きくなってしまい、コスト高になるなどの問題があった。
【０００５】
【発明が解決しようとする課題】
本発明は、従来のアスファルト防水などの基布における上記のような欠点、即ちガラス繊維補強層に掛かるコストの過剰上昇がなく、基布端部からのガラス繊維飛出しによる不具合を解消し、基布とアスファルトなどの含浸剤との一体性に優れ、初期強力が高く加工性に優れた防水材などの基布として好適なガラス繊維補強積層不織布を提供する事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、上記目的に適合する本発明は、以下のとおりである。
１．二層の不織布の間に複数本のガラス繊維、複数本のガラス繊維以外の補強糸及び／又は原着糸とが挿入された積層不織布であり、ガラス繊維及びガラス繊維以外の補強糸及び／又は原着糸が積層不織布の長手方向に互いに平行して存在し、かつ該ガラス繊維以外の補強糸及び／又は原着糸が積層不織布の少なくとも両端部に存在することを特徴とするガラス繊維補強積層不織布。
２．二層の不織布の間に複数本のガラス繊維及び複数本のガラス繊維以外の補強糸及び／又は原着糸が挿入されてニードルパンチ処理され、次いで加熱圧着処理及び／又は樹脂含浸処理が施されたガラス繊維補強積層不織布であり、前記ガラス繊維以外の補強糸及び／又は原着糸が仕立て巾に応じて挿入されてなり、該挿入糸が両端に存在するように切断して仕立てることにより、切断端面でのガラス繊維の飛び出しが防止されていることを特徴とするガラス繊維補強積層不織布。３．前記ガラス繊維以外の補強糸及び／又は原着糸の比容積が、ガラス繊維の比容積の０．６〜１．８であることを特徴とする前記１または２のいずれかに記載のガラス繊維補強積層不織布。
４．前記補強糸の全挿入量が８〜２５ｇ／ｍ2で、かつ該補強糸の内のガラス繊維以外の補強糸及び／又は原着糸の割合が全挿入糸に対して３〜１５質量％であることを特徴とする前記１〜３のいずれかに記載のガラス繊維補強積層不織布。
【０００７】
【発明の実施の形態】
、
本発明における不織布としては、長繊維不織布、短繊維不織布のいずれでもよいが、アスファルト含浸などで高強力を必要とする場合は、長繊維不織布が好ましい。
長繊維不織布としては、例えば、公知のスパンボンド方式やメルトブロー方式により形成され、必要により熱圧着されているものである。
短繊維不織布としては、公知のニードルパンチ不織布、熱圧着不織布、バインダー処理不織布などが使用でき、特に限定されるものではない。
【０００８】
不織布の素材としては、木綿、羊毛、絹などの天然繊維、レーヨンなどの半合成繊維、ポリエステル、ポリアミド、ポリオレフィン、ＰＶＡ、ビニロンなどの合成繊維、高強力ポリエチレン繊維、アラミド系繊維などのハイモジュラス繊維などであり、特に限定されるものではない。
【０００９】
合成繊維の中で、製造のし易さ、性能とコストのバランス、リサイクル材料の利用などの観点からポリエステル系繊維が好ましい。
ポリエステル系繊維としては、ポリエチレンテレフタレート、ポリブチレンテレフタレートなどはもとより、イソフタル酸、アジピン酸、ジエチレングリコール、トリメチレングリコール、ポリテトラメチレングルコールなどの共重合成分の共重合ポリエステル、ポリエチレンナフタレート及びこれらの共重合物も使用することができる。
【００１０】
積層される不織布の目付は、求められる特性によって適宜選択されるが、通常４０〜５００g／ｍ2であり、性能、製品重量、コストなどの関係から４０〜２００g／ｍ2が好ましい。
不織布の繊度は、特に限定されないが、通常１〜２０デニールであり、製造のし易さから２〜１５デニールが好ましい。
【００１１】
不織布が合成繊維の場合、通常、溶融紡糸されてウェッブが形成されるが、必要に応じて、溶融紡糸の段階で開繊性改良剤を、また紡糸或はウェッブ形成の段階で酸化防止剤、安定剤、紫外線吸収剤などを付与することができる。
不織布が合成繊維でない場合や熱可塑性でない場合は、ポリエステル、ポリアミド、ポリエチレンなどの公知のホットメルト型のバインダー繊維を混用することができる。
【００１２】
二層の不織布の間に挿入されるガラス繊維としては、マルチフィラメント、モノフィラメントの何れでも良く、公知のガラス繊維を使用することができる。
ガラス繊維の繊度は、通常３０〜７５tex程度が使用され、線径としては、0.5ｍｍ以下が好ましい。ガラス繊維の繊度を大きくすると繊維が表面に浮き出て凸凹が生じ易く、また繊度を小さくすると求める初期強度が得られ難くなる。
【００１３】
本発明における補強糸（繊維）の挿入量は、質量目付で８〜２５ｇ／ｍ2が好ましい。この補強繊維の内でガラス繊維以外の補強繊維（糸）の割合は全挿入繊維に対して３〜１５質量％であることが好ましい。ガラス繊維以外の補強糸の割合が１５質量％を超える場合、積層不織布の端部強力が低下しアスファルト含浸工程で耳垂れが発生する可能性が考えられる。又、ガラス繊維以外の補強糸の割合が３質量％未満の場合は、積層不織布の端部よりガラス繊維飛出しの可能性がある。
【００１４】
本発明におけるガラス繊維以外の補強繊維（糸）としては、高強力の合成繊維、炭素繊維、金属繊維などが使用できるが、合成繊維としては、例えばポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリアラミド系、ポリエーテルケトン、ポリエーテルスルホン、ポリベンゾオキサゾールなどの繊維を挙げることができる。これらの繊維は、引張り強さが4.0g／ｄｔｅｘ以上、伸度が40％以下、180℃乾熱収縮率が3.0％以下であることが好ましい。引張り強さが4.0g／ｄｔｅｘ未満であると、補強効果が低く、又180℃乾熱収縮率が3.0％を超えると、アスファルト加工の際、熱履歴により収縮しアスファルト製品としてソリが発生することがある。
【００１５】
本発明におけるガラス繊維以外の補強糸の比容積は、ガラス繊維の比容積の０．６~１．８の範囲内である繊度であることが好ましい。ガラス繊維の比重は、日本板硝子株式会社 1998年3月発行のカタログによるとガラス密度は２．６g／cm3であり、比容積に換算すると0.385 cm3／gである。上記記載の詳細説明でガラス繊維は一般的公知の３４ｔｅｘ用いた場合、ガラス繊維以外の補強糸の繊度は(３４０dtex×0.385 cm3／g ×０．６)〜（３４０dtex×0.385 cm3 ／g×１．８）＝７８〜209dtexとなる。即ち、本発明におけるガラス繊維以外の補強糸の比容積は、ガラス繊維の比容積の０．６~１．８の範囲内である。好ましくは０．８〜１．２範囲内である。ガラス繊維の比容積の０．６未満であると、加熱処理時に、エンボスロールとフラットカレンダー間で熱圧着する際に、ガラス繊維以外の補強糸に線圧荷重が掛からず熱圧着できず、補強繊維としての効果を得ることが出来ない。又、逆にガラス繊維の比容積の１．８を超えるガラス繊維以外の補強糸を用いた場合は、ガラス繊維以外の補強糸に線圧荷重が掛かり過ぎ、繊維補強層を破壊し補強繊維としての効果が得られない。本発明の適正領域にて実施する事で、エンボスロールとフラットカレンダー間で熱圧着する際に、ガラス繊維およびガラス繊維以外の補強糸に線圧荷重が均等に掛かり本発明の効果を得る事が出来る。
【００１６】
本発明における原着糸とは、紡糸された段階で着色している繊維、あるいは紡糸後に着色処理された繊維であり、例えばポリエステルなどの紡糸ドープに着色剤を加えて紡糸した繊維、炭素繊維などの元から着色している繊維などであり、不織布の間に挿入されて目視で他の繊維と識別ができるものであれば使用でき、この糸を目印にしてスリットを入れて仕立てることにより、切断端面でのガラス繊維の飛出しが防止できる。
【００１７】
本発明における複数本のガラス繊維は、不織布の長手方向に平行に所定の間隔で挿入されるが、挿入ピッチは、３〜３０ｍｍが好ましく、３〜１０ｍｍがより好ましい。挿入ピッチを大きくするとアスファルトなどの含浸後に不織布の収縮により表面に凸凹が発生しやすくなり、又挿入ピッチを小さくすると物性上の問題はないが、繊維使用量が増大し不経済である。
【００１８】
複数本のガラス繊維以外の補強糸及び／又は原着糸もガラス繊維と同様に挿入されるが、これらの繊維は、仕立て巾に切断された際に、両端部にはこれらの繊維が存在するように仕立て巾に応じて適宜挿入され、切断端面でのガラス繊維の飛出しを防止することができる。
【００１９】
本発明で二層の不織布の間に複数本のガラス繊維及び複数本のガラス繊維以外の補強糸及び／又は原着糸が挿入されて直ちにニードルパンチ処理される。
ニードルパンチ処理は、挿入糸と不織布とを交絡させて積層不織布としての強度を向上させるために行なわれるが、ニードルパンチ処理における針密度は、２０〜１２０本／ｃｍ2にすることが好ましい。針密度が２０本／ｃｍ2未満では、交絡性が悪く積層効果が発現され難く、針密度が１２０本／ｃｍ2を超えると、積層不織布の表面の凹凸が大きくなったり、ガラス繊維の破断が起こりやすくなる。
【００２０】
ニードルパンチ処理された積層不織布は、次いで加熱圧着処理及び／又は樹脂含浸処理が施されれる。
ニードルパンチ工程で一体化された不織布をさらに加熱処理する目的は、表裏の繊維を固定するとともに繊維間距離を最密充填させる事で基布としての剛性を付与するためである。加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ことが好ましい。この方法により、初期強力低下を抑制して、剛性を付与することができる。加工時の線圧は５〜５０ｋｇ／ｃｍが好ましく、より好ましくは１０〜３０ｋｇ／cmである。低線圧の場合は二層の繊維不織布の熱固定が不十分で基布としての剛性が得られにくい。又、高線圧の領域で加工すると中間層に挿入したガラス繊維がエンボスロールにより切断されて、得られる基布の初期応力が大巾に低下する傾向がある。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不織布が熱圧着され繊維間距離を最密充填する事は可能であるがドレープ性が増してしまう。
【００２１】
ニードルパンチ処理で一体化し、さらに不織布を加熱圧着処理した不織布は、不織布の繊維間どうしの交点を強固に固定するために、バインダー樹脂含浸処理することが好ましい。但し、前記のバインダー繊維が不織布に混用されている場合は、バインダー樹脂含浸処理は、省略することができる。
【００２２】
使用されるバインダー樹脂としては、尿素系、メラミン系、アクリル系、エポキシ系等の熱硬化性樹脂、熱可塑性樹脂など公知のものを使用することができ、これらは適宜併用して使用される。
バインダー樹脂の付着量は、積層された不織布の３〜５０質量％が好ましく、５〜３０質量％が特に好ましい。バインダーの付着量が多すぎると、あとで含浸させるアスファルトなどの含浸性が低下する。逆に少なすぎるとアスファルト含浸工程などでの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ことがある。
【００２３】
本発明のガラス繊維補強積層不織布は、防水材、断熱材、防音材、絶縁材、補強材などの様々な基布として、アスファルトなどの防水剤、エポキシ樹脂、不飽和ポリエステル樹脂などの熱硬化性樹脂、ポリビニルアルコール樹脂、ポリウレタン樹脂などの熱可塑性樹脂が含浸されたり、積層されたりして様々の用途で使用される。
【００２４】
【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。
（実施例１）
融点２６０℃、極限粘度０．６３（ｄｌ/ｇ）の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７０ｇ／ｍ2であった。
【００２５】
上記製造法で得られた不織布の二層が平行でそれぞれが走行できるように設置し、かつ該二層の不織布の間に、ガラス繊維、ガラス繊維以外の補強糸及び原着糸を、所望の本数、所望の間隔で不織布の長手方向にそれぞれ平行にクリルから走行させることができるように設置した。
【００２６】
ガラス繊維は、繊度３４texのガラス繊維（ＥＣ９ ３４ Ｚ２８ Ｔ３０ VETROTEX社製）、ガラス繊維以外の補強糸は、東洋紡績社製160dtex/48ｆのポリエステルマルチフィラメント（ガラス繊維の比容積で示すと３４０dtex×0.385cm3/g×１．２）を用い、原着糸は着色剤としてカーボンを用いた５６dtex２４fのポリエステルマルチフィラメント（東洋紡績社製）を使用した。挿入ピッチは、長手方向にお互いに平行に３ｍｍピッチとし、全挿入補強糸の挿入量は、目付で１１ｇ／m2、ポリエステルマルチフィラメント挿入量はその５質量％とし、ポリエステルマルチフィラメント糸は積層不織布の少なくとも両端部（原着糸は最端部）に位置するように設定した。
【００２７】
二層の不織布及び挿入糸をそれぞれ走行させながら重ね合わされた所で、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。
【００２８】
このニードルパンチ処理して得られた積層不織布を、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の混合樹脂を常法によって含浸させ、乾燥、熱処理後、仕立て巾に長手方向に切断して得られたガラス繊維補強積層不織布の性状を表１に示す。得られたガラス繊維補強積層不織布の切断された端面には全くガラス繊維の飛出しが認められなかった。
【００２９】
（比較例１）
実施例１においてガラス繊維以外の補強糸を使用しない以外は実施例１と同様にして得られたガラス繊維補強積層不織布を表１に示す。得られたガラス繊維補強積層不織布の切断された端面には多くのガラス繊維の飛出しが認められ、外観が悪く、取り扱い上も危険なものであり、このものをアスファルト含浸工程で使用した場合、トラブル発生が予想されるものであった。
【００３０】
（比較例２）
実施例１においてガラス繊維以外の補強糸を使用せずに、予め端部となる箇所のガラス繊維を抜いた（抜いたガラス繊維はピッチ３ｍｍ×１５列=４５ｍｍ）以外は実施例１と同様にして得られたガラス繊維補強積層不織布を表１に示す。得られたガラス繊維補強積層不織布の切断された端面にはガラス繊維の飛出しは認められないが、製品端部のガラス繊維を抜いている為、巾方向の物性平均値も低下し、樹脂含浸工程でシワが発生し安定生産出来る状態ではなかった。又、得られた製品をアスファルト含浸工程に仕掛けた所、含浸工程で両端部の耳垂れが発生し、防水基布としての外観及び性能に劣るものであった。
【００３１】
【表１】
なお、表１中の物性の測定は、以下の方法によったものである。
・積層不織布の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（オリエンテック社製テンシロン）を用いて積層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３％伸張時応力と引張強さの平均値を3%伸張時応力(N／5cm)と引張強さ(N／5cm)とした。
【００３３】
【発明の効果】
本発明によれば、スリット面（基布切断面）端部にガラス繊維が飛び出す欠点がなく、アスファルト加工などの際に、端部に飛出したガラス繊維が作業者の手に突き刺さったり、加工工程中のエッジポジションコントロールの誤作動が発生するなどの問題がなく、防水材、断熱材、防音材、絶縁材、補強材などの様々な基布として有用なガラス繊維補強積層不織布を提供することが出来る。
【図面の簡単な説明】
【図１】本発明のガラス繊維補強積層不織布において、カッティング処理前における補強糸の挿入状態を例示する模式図である。
【符号の説明】
１…ガラス繊維以外の補強糸
２…ガラス糸
３…原着糸
４及び５…製品仕立て巾
６…切断用ナイフ
７…ガラス繊維補強積層不織布[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a nonwoven fabric reinforced with glass fibers, has high elasticity and high strength, and can be used as a base fabric in fields such as industrial materials and building materials, and in particular, a cut end surface of the base fabric This is a non-woven fabric that can be suitably used as a base fabric such as a waterproof material.
[0002]
[Prior art]
Conventionally, asphalt waterproofing methods have been widely used in the construction field because they have excellent waterproofness, durability and reliability, and are easy to work and economically advantageous.
As the asphalt waterproofing base fabric in the asphalt waterproofing construction method, a polyester nonwoven fabric is often used, and recently, an asphalt waterproofing base fabric in which a glass fiber is combined with a polyester nonwoven fabric is used (for example, Japanese Patent No. 3103253 and US Pat. No. 518550). Issue).
[0003]
However, in the former, the polyester nonwoven fabric layer and the glass fiber are entangled with a needle punch and laminated, and heat treatment and / or resin impregnation treatment is performed to obtain an asphalt roofing base fabric. In the case of slitting in the inspection process, there is a drawback that the glass fiber jumps out at the end of the slit surface (base fabric cut surface). When such a base fabric is processed with asphalt, the glass fiber that has jumped out to the end may pierce the operator's hand, the edge position control may malfunction during the processing process, or the glass fiber may fly to the end surface of the processed product. The problem was that the appearance and appearance were inferior.
[0004]
Furthermore, if resin processing is performed without inserting the glass fiber in advance so that the glass fiber does not protrude at the end of the slit surface (cutting surface of the base fabric), the reinforcing yarn is affected by the shrinkage stress in the drying zone and setting process of the resin processing process. As a result, blistering occurs at the part where no squeeze is added, resulting in folds being promoted from that part, resulting in a deterioration in product yield, and the resulting base fabric has a slit surface (base fabric cut surface). ) Glass fiber does not jump out at the end, but because no glass fiber reinforcement thread is inserted into the end when asphalt processing, ear drooping occurs due to thermal stress during asphalt impregnation and process passability is significantly deteriorated. There was a drawback. In addition, since the obtained asphalt waterproofing base fabric is also subjected to thermal strain, there is a drawback in that the product end portion is wavy and cannot function as a waterproof layer.
In the latter, the glass fiber is drawn from the creel in the polyester nonwoven fabric manufacturing process, and the glass fiber is inserted into the intermediate layer of the polyester nonwoven fabric. Workability was very poor, and glass fibers were inserted in the polyester nonwoven fabric manufacturing process, resulting in problems such as increased equipment costs and installation locations, resulting in higher costs.
[0005]
[Problems to be solved by the invention]
The present invention eliminates the above-described drawbacks of base fabrics such as conventional asphalt waterproofing, that is, the excessive increase in cost applied to the glass fiber reinforcing layer, and eliminates problems caused by glass fiber jumping from the edge of the base fabric. An object of the present invention is to provide a glass fiber reinforced laminated non-woven fabric that is suitable as a base fabric for a waterproof material or the like that is excellent in integrity between a cloth and an impregnating agent such as asphalt, and has high initial strength and excellent workability.
[0006]
[Means for Solving the Problems]
That is, the present invention that meets the above object is as follows.
1. A laminated nonwoven fabric in which a plurality of glass fibers, reinforcing yarns other than a plurality of glass fibers and / or original yarns are inserted between two layers of nonwoven fabric, and reinforcing yarns other than glass fibers and glass fibers and / or A glass fiber reinforced laminate, wherein the original yarn is present in parallel to the longitudinal direction of the laminated nonwoven fabric, and the reinforcing yarn and / or the original yarn is present at least at both ends of the laminated nonwoven fabric. Non-woven fabric.
2. A plurality of glass fibers and reinforcing yarns and / or original yarns other than the plurality of glass fibers are inserted between the two layers of nonwoven fabric and subjected to needle punching, and then subjected to thermocompression treatment and / or resin impregnation treatment. Glass fiber reinforced laminated nonwoven fabric, reinforcing yarns other than the glass fiber and / or the original yarn is inserted according to the tailoring width, by cutting and tailoring so that the insertion yarn exists at both ends, A glass fiber reinforced laminated nonwoven fabric characterized in that the glass fiber is prevented from jumping out at the cut end face. 3. 3. The glass fiber according to either 1 or 2 above, wherein the specific volume of the reinforcing yarn and / or the original yarn other than the glass fiber is 0.6 to 1.8 of the specific volume of the glass fiber. Reinforced laminated nonwoven fabric.
4). The total insertion amount of the reinforcing yarn is 8 to 25 g / m 2 , and the proportion of the reinforcing yarn other than glass fiber and / or the original yarn is 3 to 15% by mass with respect to the total inserting yarn. The glass fiber reinforced laminated nonwoven fabric according to any one of 1 to 3, which is characterized in that it exists.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
,
The non-woven fabric in the present invention may be either a long-fiber non-woven fabric or a short-fiber non-woven fabric, but a long-fiber non-woven fabric is preferred when high strength is required for asphalt impregnation.
The long fiber nonwoven fabric is formed by, for example, a known spunbond method or melt blow method, and is thermocompression bonded as necessary.
As a short fiber nonwoven fabric, a well-known needle punch nonwoven fabric, a thermocompression bonding nonwoven fabric, a binder processing nonwoven fabric, etc. can be used, and it is not specifically limited.
[0008]
Nonwoven fabric materials include natural fibers such as cotton, wool and silk, semi-synthetic fibers such as rayon, synthetic fibers such as polyester, polyamide, polyolefin, PVA and vinylon, high modulus fibers such as high-strength polyethylene fibers and aramid fibers. There is no particular limitation.
[0009]
Among synthetic fibers, polyester fibers are preferred from the viewpoints of ease of production, balance between performance and cost, utilization of recycled materials, and the like.
Polyester fibers include polyethylene terephthalate, polybutylene terephthalate, and the like, as well as copolymerized polyesters such as isophthalic acid, adipic acid, diethylene glycol, trimethylene glycol, and polytetramethylene glycol, polyethylene naphthalate, and copolymers thereof. Polymers can also be used.
[0010]
Basis weight of the nonwoven fabric to be laminated may be appropriately selected by properties sought is usually 40~500g / m 2, performance, product weight, is 40~200g / m 2 from the relationship of cost preferred.
Although the fineness of a nonwoven fabric is not specifically limited, Usually, it is 1-20 denier, and 2-15 denier is preferable from the ease of manufacture.
[0011]
When the nonwoven fabric is a synthetic fiber, it is usually melt-spun to form a web, but if necessary, an openability improving agent at the melt-spinning stage and an antioxidant at the spinning or web-forming stage, Stabilizers, ultraviolet absorbers and the like can be added.
When the nonwoven fabric is not a synthetic fiber or is not thermoplastic, a known hot melt type binder fiber such as polyester, polyamide, or polyethylene can be mixed.
[0012]
As a glass fiber inserted between two layers of nonwoven fabrics, either a multifilament or a monofilament may be used, and a known glass fiber can be used.
The fineness of the glass fiber is usually about 30 to 75 tex, and the wire diameter is preferably 0.5 mm or less. When the fineness of the glass fiber is increased, the fiber is likely to be raised on the surface and unevenness is likely to be generated.
[0013]
The insertion amount of the reinforcing yarn (fiber) in the present invention is preferably 8 to 25 g / m 2 in mass basis. The proportion of reinforcing fibers (threads) other than glass fibers in the reinforcing fibers is preferably 3 to 15% by mass with respect to all the inserted fibers. When the ratio of reinforcing yarns other than glass fibers exceeds 15% by mass, the strength of the end of the laminated nonwoven fabric is lowered, and there is a possibility that ear drooping may occur in the asphalt impregnation step. Moreover, when the ratio of reinforcing yarns other than glass fibers is less than 3% by mass, there is a possibility that the glass fibers jump out from the end of the laminated nonwoven fabric.
[0014]
As reinforcing fibers (threads) other than glass fibers in the present invention, high-strength synthetic fibers, carbon fibers, metal fibers, and the like can be used. Examples of synthetic fibers include polyethylene terephthalate, polybutylene terephthalate, polyaramid, and polyether. Mention may be made of fibers such as ketones, polyethersulfones and polybenzoxazoles. These fibers preferably have a tensile strength of 4.0 g / dtex or more, an elongation of 40% or less, and a 180 ° C. dry heat shrinkage of 3.0% or less. When the tensile strength is less than 4.0 g / dtex, the reinforcing effect is low, and when the 180 ° C dry heat shrinkage rate exceeds 3.0%, the asphalt product shrinks due to heat history during the asphalt processing, and warpage occurs as an asphalt product. There is.
[0015]
The specific volume of the reinforcing yarn other than the glass fiber in the present invention is preferably a fineness within the range of 0.6 to 1.8 of the specific volume of the glass fiber. According to the catalog issued by Nippon Sheet Glass Co., Ltd., published in March 1998, the glass fiber has a glass density of 2.6 g / cm 3 and a specific volume of 0.385 cm 3 / g. When the generally known 34 tex is used for the glass fiber in the detailed description above, the fineness of the reinforcing yarn other than the glass fiber is (340 dtex × 0.385 cm 3 /g×0.6) to (340 dtex × 0.385 cm 3 / g ×). 1.8) = 78 to 209 dtex. That is, the specific volume of the reinforcing yarn other than the glass fiber in the present invention is in the range of 0.6 to 1.8 of the specific volume of the glass fiber. Preferably it exists in the range of 0.8-1.2. If the specific volume of the glass fiber is less than 0.6, during heat treatment, when thermocompression bonding is performed between the embossing roll and the flat calender, the reinforcing yarn other than the glass fiber is not subjected to linear pressure load and cannot be thermocompression bonded. The effect as a fiber cannot be obtained. On the other hand, when a reinforcing yarn other than glass fiber with a specific volume of glass fiber exceeding 1.8 is used, the reinforcing yarn other than glass fiber is overloaded with linear pressure, and the fiber reinforcing layer is broken and used as reinforcing fiber. The effect of can not be obtained. By carrying out in the appropriate region of the present invention, when the thermocompression bonding is performed between the embossing roll and the flat calender, the linear load is uniformly applied to the reinforcing yarn other than the glass fiber and the glass fiber, and the effect of the present invention can be obtained. I can do it.
[0016]
The original yarn in the present invention is a fiber that is colored at the stage of spinning, or a fiber that has been colored after spinning. For example, a fiber that is spun by adding a colorant to a spinning dope such as polyester, a carbon fiber, or the like It can be used as long as it is a fiber that is colored from the base of the fiber and can be discriminated from other fibers by being inserted between the nonwoven fabrics, and cut by making a slit with this thread as a mark. The glass fiber can be prevented from jumping out at the end face.
[0017]
The plurality of glass fibers in the present invention are inserted at a predetermined interval parallel to the longitudinal direction of the nonwoven fabric, and the insertion pitch is preferably 3 to 30 mm, and more preferably 3 to 10 mm. If the insertion pitch is increased, unevenness is likely to occur on the surface due to shrinkage of the nonwoven fabric after impregnation with asphalt or the like, and if the insertion pitch is reduced, there is no problem in physical properties, but the amount of fibers used is increased, which is uneconomical.
[0018]
Reinforcing yarns and / or original yarns other than a plurality of glass fibers are also inserted in the same manner as glass fibers, but when these fibers are cut into a tailored width, these fibers are present at both ends. Thus, the glass fiber can be appropriately inserted according to the tailoring width, and the glass fiber can be prevented from jumping out at the cut end face.
[0019]
In the present invention, a plurality of glass fibers and reinforcing yarns other than the plurality of glass fibers and / or original yarns are inserted between the two layers of nonwoven fabric and immediately subjected to needle punching.
The needle punching process is performed to entangle the insertion yarn and the nonwoven fabric to improve the strength of the laminated nonwoven fabric. The needle density in the needle punching process is preferably 20 to 120 / cm 2 . When the needle density is less than 20 / cm 2 , the confounding property is poor and the lamination effect is difficult to be exhibited. When the needle density exceeds 120 / cm 2 , the unevenness of the surface of the laminated nonwoven fabric becomes large, or the glass fiber breaks. It tends to happen.
[0020]
The laminated nonwoven fabric subjected to the needle punching process is then subjected to a thermocompression bonding process and / or a resin impregnation process.
The purpose of further heat-treating the nonwoven fabric integrated in the needle punching process is to provide rigidity as a base fabric by fixing the fibers on the front and back and filling the distance between the fibers most closely. As a heat treatment method, it is preferable to perform thermocompression bonding between an embossing roll and a flat calender. By this method, the initial strength reduction can be suppressed and rigidity can be imparted. The linear pressure during processing is preferably 5 to 50 kg / cm, more preferably 10 to 30 kg / cm. In the case of low linear pressure, the heat-fixing of the two-layer fiber nonwoven fabric is insufficient and it is difficult to obtain rigidity as a base fabric. Moreover, when processed in the region of high linear pressure, the glass fiber inserted in the intermediate layer is cut by the embossing roll, and the initial stress of the obtained base fabric tends to be greatly reduced. Further, in the thermocompression treatment, when a flat / flat calender roll is used, the two-layer nonwoven fabric can be thermocompression-bonded and the distance between fibers can be filled most closely, but the drape is increased.
[0021]
In order to firmly fix the intersection between the fibers of the nonwoven fabric, it is preferable to impregnate the nonwoven fabric obtained by integrating by needle punching and further heat-compressing the nonwoven fabric with a binder resin. However, when the binder fiber is mixed with a nonwoven fabric, the binder resin impregnation treatment can be omitted.
[0022]
As the binder resin used, known resins such as urea-based, melamine-based, acrylic-based, and epoxy-based thermosetting resins and thermoplastic resins can be used, and these are used in combination as appropriate.
3-50 mass% of the laminated nonwoven fabric is preferable, and, as for the adhesion amount of binder resin, 5-30 mass% is especially preferable. When the adhesion amount of the binder is too large, the impregnation property such as asphalt to be impregnated later is lowered. On the other hand, if the amount is too small, the process tension in the asphalt impregnation process or the like may not always be satisfied, and troubles with breakage and scoring may occur.
[0023]
The glass fiber reinforced laminated nonwoven fabric of the present invention is a thermosetting material such as a waterproofing agent such as asphalt, an epoxy resin, and an unsaturated polyester resin as various base fabrics such as a waterproofing material, a heat insulating material, a soundproofing material, an insulating material, and a reinforcing material. It is impregnated or laminated with a thermoplastic resin such as resin, polyvinyl alcohol resin and polyurethane resin, and used for various purposes.
[0024]
【Example】
EXAMPLES The present invention will be described below with reference to examples, but the present invention is not limited to these examples.
Example 1
Using a spinning nozzle with a melting point of 260 ° C. and an intrinsic viscosity of 0.63 (dl / g) polyethylene terephthalate having a diameter of 0.30 mm, a single hole discharge rate of 1.5 g / min / hole, and a hole number of 300, at a melting temperature of 285 ° C. After discharging from the spinning nozzle and pulling it with an ejector at a spinning speed of 4500 m / min, cooling it and taking it out, the fibers were collected on a metal net to form a web. The web was weakly pressed with a thermocompression-bonding roll to obtain a nonwoven fabric. The basis weight of the obtained nonwoven fabric was 70 g / m 2 .
[0025]
The two layers of the nonwoven fabric obtained by the above production method are installed so that they can run in parallel, and between the two layers of nonwoven fabric, glass fibers, reinforcing yarns other than glass fibers, and original yarns are desired. It installed so that it could be made to run from a creel in parallel with the longitudinal direction of a nonwoven fabric by the number and the desired space | interval respectively.
[0026]
The glass fiber is a glass fiber having a fineness of 34 tex (EC9 34 Z28 T30 VETROTEX), and the reinforcing yarn other than the glass fiber is a 160 dtex / 48f polyester multifilament (340 dtex × 0.385 in terms of the specific volume of the glass fiber) manufactured by Toyobo Co., Ltd. cm 3 /g×1.2), and 56 dtex 24f polyester multifilament (manufactured by Toyobo Co., Ltd.) using carbon as a colorant was used as the original yarn. The insertion pitch is 3 mm parallel to each other in the longitudinal direction, the insertion amount of all insertion reinforcing yarns is 11 g / m 2 per unit weight, the polyester multifilament insertion amount is 5% by mass, and the polyester multifilament yarn is a laminated nonwoven fabric. Was set so as to be positioned at least at both ends (originally bonded yarn is the endmost portion).
[0027]
The two layers of the nonwoven fabric and the insertion yarn were respectively overlapped while running, and entangled with a neat punch machine. As the needle, an organ needle (FPD 1-40) was used, and the needle density was 60 / cm 2 .
[0028]
The laminated nonwoven fabric obtained by this needle punching treatment is subjected to heat pressure bonding treatment between an embossing roll at 185 ° C. and a flat calender, and then impregnated with a mixed resin of urea melamine resin and acrylic resin by a conventional method, dried and heat treated Table 1 shows the properties of the laminated glass fiber reinforced nonwoven fabric obtained by cutting the tailored width in the longitudinal direction. No glass fiber jumping out was observed on the cut end face of the obtained glass fiber reinforced laminated nonwoven fabric.
[0029]
(Comparative Example 1)
Table 1 shows glass fiber-reinforced laminated nonwoven fabrics obtained in the same manner as in Example 1 except that no reinforcing yarn other than glass fibers is used in Example 1. When the cut end face of the obtained glass fiber reinforced laminated nonwoven fabric has a lot of glass fiber popping out, the appearance is bad and it is dangerous to handle, and when this is used in an asphalt impregnation step, Trouble occurred.
[0030]
(Comparative Example 2)
Example 1 is the same as Example 1 except that the reinforcing fiber other than the glass fiber is not used, and the glass fiber at the end portion is previously extracted (the extracted glass fiber has a pitch of 3 mm × 15 rows = 45 mm). Table 1 shows the glass fiber reinforced laminated nonwoven fabric obtained in this manner. The glass fiber reinforced laminated nonwoven fabric is not cut out from the cut end face, but the glass fiber at the end of the product is pulled out, so the average value of the physical properties in the width direction also decreases, impregnating with resin Wrinkles were generated in the process, and it was not in a state where stable production was possible. Further, when the obtained product was subjected to an asphalt impregnation step, ear drooping occurred at both ends in the impregnation step, and the appearance and performance as a waterproof base fabric were inferior.
[0031]
[Table 1]
In addition, the measurement of the physical property in Table 1 is based on the following method.
-3% elongation stress and tensile strength (N / 5cm) of laminated nonwoven fabric: laminated nonwoven fabric using a constant speed stretch type tensile tester (Orientec Tensilon) according to the cut strip method described in JIS L-1096 Measured from a product width of 50 mm, length of 200 mm, and 20 specimens at a gripping interval of 100 mm and a tensile speed of 200 mm / min. The average value of 3% elongation stress and tensile strength obtained was 3% elongation. Stress (N / 5cm) and tensile strength (N / 5cm) were used.
[0033]
【The invention's effect】
According to the present invention, there is no defect that the glass fiber jumps out at the end of the slit surface (cutting surface of the base fabric), and the glass fiber that jumps out at the end pierces the operator's hand when processing asphalt or the like. To provide a glass fiber reinforced laminated non-woven fabric useful as various base fabrics such as waterproofing materials, heat insulating materials, soundproofing materials, insulating materials, and reinforcing materials without problems such as malfunction of edge position control during the process. I can do it.
[Brief description of the drawings]
FIG. 1 is a schematic view illustrating an insertion state of a reinforcing yarn before a cutting process in a glass fiber reinforced laminated nonwoven fabric of the present invention.
[Explanation of symbols]
DESCRIPTION OF
Claims (4)
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| CN103015038A (en) * | 2013-01-07 | 2013-04-03 | 辽阳艺蒙织毯有限公司 | Sound insulation and thermal insulation material and production method thereof |
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| JP2008144610A (en) * | 2006-12-06 | 2008-06-26 | Toyo Roki Mfg Co Ltd | Air cleaner of internal combustion engine |
| FR2949239B1 (en) * | 2009-08-21 | 2011-10-28 | Gilbert Chomarat | REINFORCEMENT HAVING GLASS THREAD PARRALLELES. |
| GB2521250B (en) * | 2012-04-10 | 2015-12-09 | Christopher Martin | A Fabricated Polymeric Strip For Soil Reinforcement And Other Uses |
| JP7206812B2 (en) * | 2018-10-31 | 2023-01-18 | 東洋紡株式会社 | Glass fiber reinforced laminated nonwoven fabric for asphalt waterproof base fabric |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN103015038A (en) * | 2013-01-07 | 2013-04-03 | 辽阳艺蒙织毯有限公司 | Sound insulation and thermal insulation material and production method thereof |
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