JP6275389B2 - Resin coated nonwoven fabric - Google Patents
Resin coated nonwoven fabric Download PDFInfo
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- JP6275389B2 JP6275389B2 JP2013055656A JP2013055656A JP6275389B2 JP 6275389 B2 JP6275389 B2 JP 6275389B2 JP 2013055656 A JP2013055656 A JP 2013055656A JP 2013055656 A JP2013055656 A JP 2013055656A JP 6275389 B2 JP6275389 B2 JP 6275389B2
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- 239000004745 nonwoven fabric Substances 0.000 title claims description 131
- 229920005989 resin Polymers 0.000 title claims description 122
- 239000011347 resin Substances 0.000 title claims description 122
- 238000004049 embossing Methods 0.000 claims description 40
- 239000000835 fiber Substances 0.000 claims description 18
- 229920000728 polyester Polymers 0.000 claims description 6
- 229920003002 synthetic resin Polymers 0.000 claims description 6
- 239000000057 synthetic resin Substances 0.000 claims description 6
- 238000005452 bending Methods 0.000 claims description 3
- 229920001577 copolymer Polymers 0.000 description 22
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical group C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 20
- 239000005977 Ethylene Substances 0.000 description 20
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical group CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 18
- 238000000576 coating method Methods 0.000 description 16
- 238000004519 manufacturing process Methods 0.000 description 16
- 238000000034 method Methods 0.000 description 16
- 239000011248 coating agent Substances 0.000 description 15
- 230000000052 comparative effect Effects 0.000 description 14
- 238000011156 evaluation Methods 0.000 description 14
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 11
- 239000011342 resin composition Substances 0.000 description 10
- 238000013461 design Methods 0.000 description 9
- 239000000839 emulsion Substances 0.000 description 9
- 239000004744 fabric Substances 0.000 description 9
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 8
- 229920000139 polyethylene terephthalate Polymers 0.000 description 8
- 239000005020 polyethylene terephthalate Substances 0.000 description 8
- 230000003287 optical effect Effects 0.000 description 7
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 description 6
- 238000007598 dipping method Methods 0.000 description 6
- -1 polyethylene terephthalate Polymers 0.000 description 6
- 239000013585 weight reducing agent Substances 0.000 description 6
- 239000000203 mixture Substances 0.000 description 5
- 239000004800 polyvinyl chloride Substances 0.000 description 5
- 229920000915 polyvinyl chloride Polymers 0.000 description 5
- 238000005470 impregnation Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000000178 monomer Substances 0.000 description 4
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 238000002788 crimping Methods 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 2
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 2
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 2
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 239000012736 aqueous medium Substances 0.000 description 2
- 238000007334 copolymerization reaction Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 210000003746 feather Anatomy 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920002689 polyvinyl acetate Polymers 0.000 description 2
- 239000011118 polyvinyl acetate Substances 0.000 description 2
- 238000009987 spinning Methods 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 125000000954 2-hydroxyethyl group Chemical group [H]C([*])([H])C([H])([H])O[H] 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 241000270722 Crocodylidae Species 0.000 description 1
- 239000012963 UV stabilizer Substances 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 229920006243 acrylic copolymer Polymers 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 230000003712 anti-aging effect Effects 0.000 description 1
- 239000002518 antifoaming agent Substances 0.000 description 1
- 125000001797 benzyl group Chemical group [H]C1=C([H])C([H])=C(C([H])=C1[H])C([H])([H])* 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 125000000113 cyclohexyl group Chemical group [H]C1([H])C([H])([H])C([H])([H])C([H])(*)C([H])([H])C1([H])[H] 0.000 description 1
- LNNWVNGFPYWNQE-GMIGKAJZSA-N desomorphine Chemical compound C1C2=CC=C(O)C3=C2[C@]24CCN(C)[C@H]1[C@@H]2CCC[C@@H]4O3 LNNWVNGFPYWNQE-GMIGKAJZSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 150000002170 ethers Chemical class 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 150000002576 ketones Chemical class 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920005672 polyolefin resin Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229920000468 styrene butadiene styrene block copolymer Polymers 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- YLQBMQCUIZJEEH-UHFFFAOYSA-N tetrahydrofuran Natural products C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 239000004034 viscosity adjusting agent Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Landscapes
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Nonwoven Fabrics (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Chemical Or Physical Treatment Of Fibers (AREA)
- Laminated Bodies (AREA)
Description
本発明は、車両内装材、壁紙、ベッド部材、椅子部材等に使用可能なシート状の樹脂コート不織布に関するものであり、特に、軽量でかつエンボス模様がはっきりと賦形されている意匠性に優れた樹脂コート不織布に関する。 The present invention relates to a sheet-like resin-coated non-woven fabric that can be used for vehicle interior materials, wallpaper, bed members, chair members, etc., and is particularly lightweight and has an excellent design with an embossed pattern clearly shaped. The present invention relates to a resin-coated nonwoven fabric.
車両内装材、特にトノカバーに用いられているシートには、織物、編物、不織布等にポリ塩化ビニルシートを積層した塩ビレザーが主流として用いられてきたが、塩ビレザーは目付けが５００ｇ／ｍ2以上あって重いため、近年の車両全体の軽量化の要求に対応できなくなってきた。こういったことから、本願出願人は、スパンボンド不織布と樹脂とを組合せて、樹脂の易成型性を利用することできれいに凹凸模様が賦形された意匠性に優れたレザー調不織布やトノカバー用シート等の樹脂コート不織布を多数提案してきた（特許文献１〜３等）。 For seats used for vehicle interior materials, especially tonneau covers, PVC leathers in which polyvinyl chloride sheets are laminated on woven fabrics, knitted fabrics, nonwoven fabrics, etc. have been used as the mainstream, but the basis weight of PVC leathers is 500 g / m 2 or more. Due to its heavy weight, it has become impossible to meet the recent demand for weight reduction of the entire vehicle. For this reason, the applicant of the present invention combines a spunbond nonwoven fabric and a resin, and uses a resin-like moldability to form a concavo-convex pattern for excellent leather-like nonwoven fabric and tonneau cover. Many resin-coated non-woven fabrics such as sheets have been proposed (Patent Documents 1 to 3, etc.).
しかし、これらの従来技術が出願された時代から１０年以上経過した現在、樹脂コート不織布に対する要求レベルは一層高まっており、高速製造が可能な工程通過性、軽量性、かつ、はっきりとしたエンボス模様を有しているという意匠性が必要になってきた。 However, now that more than 10 years have passed since the time when these prior arts were filed, the level of demand for resin-coated nonwoven fabrics has further increased, and process emphasis, light weight, and a clear embossed pattern that enable high-speed production. It has become necessary to have a design property of having.
近年の樹脂コート不織布としては、強度確保のためにニードルパンチされたスパンボンド（長繊維）不織布を基布とし、工程通過性（張力に耐え得る強力）を確保するために基布に樹脂を含浸させ、より鮮明に凹凸模様が賦形されるようにさらに樹脂をコートしたものが用いられている。 As a recent resin-coated nonwoven fabric, needle-punched spunbond (long fiber) nonwoven fabric is used as the base fabric to ensure strength, and the base fabric is impregnated with resin to ensure processability (strength that can withstand tension). In addition, a resin-coated material is used so that the uneven pattern is shaped more clearly.
上記構成の樹脂コート不織布において、より軽量化のために樹脂のコートを止めると、外側から不織布の繊維が見え、見栄えが悪いという問題があった。一方、樹脂の含浸を止めると、高速での製造加工の際、不織布連続体を走行方向に引っ張る力（張力）に不織布の強力が耐えられず、不織布が伸びてその幅が狭くなってしまう「幅入り」という現象が起きてしまう。また、樹脂コート面の裏面側に毛羽立ちが起こるという問題もあった。 In the resin-coated nonwoven fabric having the above-described configuration, when the resin coating is stopped for further weight reduction, there is a problem in that the fibers of the nonwoven fabric can be seen from the outside and the appearance is poor. On the other hand, if the impregnation of the resin is stopped, the strength of the nonwoven fabric cannot withstand the force (tension) that pulls the nonwoven fabric continuum in the running direction during high-speed manufacturing, and the nonwoven fabric stretches and its width becomes narrow. The phenomenon of “width” will occur. There is also a problem that fuzz occurs on the back side of the resin-coated surface.
そこで、本発明では、高速製造が可能な工程通過性、軽量性、かつ、はっきりとしたエンボス模様を有しているという意匠性を兼ね備えた樹脂コート不織布の提供を課題として掲げた。 In view of this, the present invention has been aimed at providing a resin-coated non-woven fabric having a processability, a lightweight property capable of high-speed manufacturing, and a design property of having a clear embossed pattern.
このように、基布にニードルパンチ不織布を使うと種々の不都合があったため、本発明者等は、より軽量化が目指せるエンボス仕様のスパンボンド不織布を基布として用い、さらなる検討を続けた。その結果、エンボス仕様のスパンボンド不織布を用いて、樹脂コートのみを施すと、上記課題を解決し得ることを見出し、本発明に到達した。 Thus, since there existed various inconveniences when the needle punch nonwoven fabric was used for the base fabric, the present inventors continued to further study using an embossed spunbond nonwoven fabric that can be further reduced in weight as the base fabric. As a result, the inventors have found that the above-mentioned problems can be solved by applying only a resin coat using an embossed spunbond nonwoven fabric, and the present invention has been achieved.
上記課題を解決した本発明は、繊維がエンボス処理により熱圧着されたポリエステル系スパンボンド不織布の片面のみに合成樹脂がコートされた樹脂コート不織布であって、この樹脂コート不織布は、目付けが１００〜２５０ｇ／ｍ2で、かつ、実質厚みと見掛け厚みとの比：見掛け厚み／実質厚みが２以上であることを特徴とする。 The present invention that has solved the above problems is a resin-coated nonwoven fabric in which a synthetic resin is coated only on one surface of a polyester-based spunbonded nonwoven fabric in which fibers are thermocompression bonded by embossing treatment, and the resin-coated nonwoven fabric has a basis weight of 100 to 100. 250 g / m 2 , and the ratio between the substantial thickness and the apparent thickness: the apparent thickness / the substantial thickness is 2 or more.
樹脂コート不織布の実質厚みは、０．３ｍｍ以下であることが好ましく、見掛け厚みは０．４ｍｍ以上であることが好ましい。また、片面のみがエンボス処理されたポリエステル系スパンボンド不織布のエンボス面に合成樹脂がコートされ、さらにエンボス加工が施されてなる樹脂コート不織布が、本発明の最も好ましい実施態様である。 The substantial thickness of the resin-coated nonwoven fabric is preferably 0.3 mm or less, and the apparent thickness is preferably 0.4 mm or more. A resin-coated nonwoven fabric in which a synthetic resin is coated on an embossed surface of a polyester spunbonded nonwoven fabric embossed only on one side and further embossed is the most preferred embodiment of the present invention.
本発明によれば、高速製造が可能な工程通過性、軽量性、かつ意匠性を兼ね備えた樹脂コート不織布を提供することができた。 ADVANTAGE OF THE INVENTION According to this invention, the resin coat nonwoven fabric which has the process passability in which high-speed manufacture is possible, the lightness, and the designability was able to be provided.
エンボス仕様のスパンボンド不織布は、エンボス処理による熱接着で繊維が結合しているため、ある程度の強力を有しているが、より高い強力を与えるために樹脂を含浸させると、樹脂が含浸し切れていないところの不織布の繊維が外観不良を与えることがわかった。そこで、樹脂含浸を止めて、樹脂コートだけにすると、外観のみならず、優れた工程通過性、軽量性、はっきりしたエンボス模様を有する樹脂コート不織布を得ることが出来た。以下、本発明を詳細に説明する。 The embossed spunbond nonwoven fabric has some strength because the fibers are bonded by thermal bonding by embossing treatment. However, if the resin is impregnated to give higher strength, the resin will be completely impregnated. It was found that the non-woven fabric fibers had a poor appearance. Therefore, when the resin impregnation was stopped and only the resin coat was used, a resin-coated nonwoven fabric having not only the appearance but also excellent process passability, light weight, and a clear embossed pattern could be obtained. Hereinafter, the present invention will be described in detail.
［不織布］
本発明では、基布となる不織布として、ポリエステル系スパンボンド（長繊維）不織布を用いる。高速生産に向いており安価に入手できるためである。中でも、ポリエチレンテレフタレート（ＰＥＴ）製不織布が好ましい。ＰＥＴは、力学的特性や熱的特性に優れているからである。なお、１０質量％以下であれば、ＰＥＴ以外のポリエステルがブレンドされていてもよい。ポリエステルの固有粘度は、特に限定されないが、０．５８ｄｌ／ｇ以上が好ましい。
[Nonwoven fabric]
In the present invention, a polyester spunbond (long fiber) non-woven fabric is used as the non-woven fabric to be the base fabric. This is because it is suitable for high-speed production and can be obtained at low cost. Among these, a polyethylene terephthalate (PET) non-woven fabric is preferable. This is because PET is excellent in mechanical properties and thermal properties. In addition, if it is 10 mass% or less, polyesters other than PET may be blended. The intrinsic viscosity of the polyester is not particularly limited, but is preferably 0.58 dl / g or more.
スパンボンド不織布を構成する長繊維（単繊維）の繊維径は、０．１〜１０ｄｔｅｘ程度が好ましく、より好ましくは１〜５ｄｔｅｘ程度である。また、樹脂コート前の不織布の目付けは、７０〜１５０ｇ／ｍ2程度が好ましい。繊維径や目付けが上記範囲内であれば、得られる樹脂コート不織布の強力、軽量性、意匠性等の各特性をバランスよく優れたものにすることができる。 The fiber diameter of the long fibers (single fibers) constituting the spunbonded nonwoven fabric is preferably about 0.1 to 10 dtex, more preferably about 1 to 5 dtex. Moreover, the basis weight of the nonwoven fabric before the resin coating is preferably about 70 to 150 g / m 2 . If the fiber diameter and the basis weight are within the above ranges, the obtained resin-coated nonwoven fabric can be excellent in balance in properties such as strength, lightness and design.
スパンボンド不織布のままでは、引張強度や引裂き強度が若干不足する場合があるので、圧着率（ロール側凸部の頂部の面積割合）２〜５０％程度のエンボスロールを通して加熱圧着する（不織布製造時のエンボス加工）。加熱方法は特に限定されないが、１５０〜２６０℃程度で行うことが好ましく、線圧としては、３０〜１２０ｋＮ／ｍ程度が好ましい。また、不織布製造時のエンボス加工では、エンボスロールの対向ロールはステンレス鋼製のフラットロールであることが好ましい。なお、通常のスパンボンド不織布の製造ラインには熱エンボス工程が組み込まれている。 If the spunbonded nonwoven fabric is used as it is, the tensile strength and tear strength may be slightly insufficient, so heat-pressure bonding is performed through an embossing roll with a crimping rate (the area ratio of the top of the convex portion on the roll side) of about 2 to 50%. Embossing). Although a heating method is not specifically limited, It is preferable to carry out at about 150-260 degreeC, and as a linear pressure, about 30-120 kN / m is preferable. Moreover, in embossing at the time of nonwoven fabric manufacture, it is preferable that the opposing roll of an embossing roll is a flat roll made from stainless steel. In addition, the heat embossing process is integrated in the production line of the usual spun bond nonwoven fabric.
［樹脂］
本発明では、軽量化のため、樹脂の含浸（ディッピング）を行わず、スパンボンド不織布の片面にのみ、合成樹脂のコートを行う。ただし、樹脂をコートすると、その大部分は、不織布の厚み方向へ侵入して含浸状態となる。コートに用い得る合成樹脂としては、熱可塑性樹脂が好ましい。コート後のエンボス加工工程で、エンボス模様がはっきり賦形できるからである。熱可塑性樹脂としては、ポリエステル樹脂、アクリル樹脂、ウレタン樹脂、ＳＢＳ、ポリ塩化ビニル系樹脂、ポリオレフィン樹脂等が挙げられる。
[resin]
In the present invention, for weight reduction, resin impregnation (dipping) is not performed, and the synthetic resin is coated only on one side of the spunbonded nonwoven fabric. However, when the resin is coated, most of the resin penetrates in the thickness direction of the nonwoven fabric and becomes impregnated. As a synthetic resin that can be used for coating, a thermoplastic resin is preferable. This is because the embossed pattern can be clearly shaped in the embossing process after coating. Examples of the thermoplastic resin include polyester resin, acrylic resin, urethane resin, SBS, polyvinyl chloride resin, and polyolefin resin.
中でも、エチレンユニットと酢酸ビニルユニットとを含む樹脂であることが好ましい。酢酸ビニルユニットが高周波ウェルダーでの溶着を可能にし、エチレンユニットが樹脂にほどよい柔らかさ（柔軟性）を付与する。酢酸ビニルユニットは、樹脂の中に２０〜８０質量％含まれていることが好ましい。この範囲であれば、高周波ウェルダーでの溶着が可能であり、硬くなりすぎることがない。従ってエチレンユニットは２０質量％以下が好ましい。エチレンユニットが多くなると、得られる樹脂コート不織布表面にタックが発現し、例えば、巻回状態の樹脂コート不織布を巻き出す際に、ブロッキングを起こすことがあるため、好ましくない。一方、エチレンユニットが少なすぎると、しなやかさを樹脂コート不織布に与えることができないため、樹脂中に３質量％以上含まれていることが好ましい。酢酸ビニルユニットのより好ましい範囲は、３０〜６０質量％であり、エチレンユニットのより好ましい範囲は、５〜１５質量％である。 Especially, it is preferable that it is resin containing an ethylene unit and a vinyl acetate unit. The vinyl acetate unit enables welding with a high-frequency welder, and the ethylene unit imparts moderate softness (flexibility) to the resin. It is preferable that 20-80 mass% of vinyl acetate units are contained in resin. If it is this range, welding with a high frequency welder is possible, and it does not become too hard. Accordingly, the ethylene unit is preferably 20% by mass or less. An increase in the number of ethylene units is not preferable because tack is developed on the surface of the resulting resin-coated nonwoven fabric, and blocking may occur, for example, when the wound resin-coated nonwoven fabric is unwound. On the other hand, when there are too few ethylene units, since flexibility cannot be given to a resin coat nonwoven fabric, it is preferable that 3 mass% or more is contained in resin. A more preferable range of the vinyl acetate unit is 30 to 60% by mass, and a more preferable range of the ethylene unit is 5 to 15% by mass.
樹脂にエチレンユニットと酢酸ビニルユニットを含ませる態様としては、（１）樹脂が、エチレンユニットと酢酸ビニルユニットとを有する共重合体（３元以上の多元共重合体も含む）である態様、（２）樹脂が、エチレンユニットを含む（共）重合体と酢酸ビニルユニットを有する（共）重合体との混合物を含む態様が挙げられる。ここで（共）重合体とは、単独重合体または共重合体である。 As an aspect in which the resin includes an ethylene unit and a vinyl acetate unit, (1) an aspect in which the resin is a copolymer having an ethylene unit and a vinyl acetate unit (including a ternary or higher multi-component copolymer); 2) The aspect in which resin contains the mixture of the (co) polymer containing an ethylene unit and the (co) polymer which has a vinyl acetate unit is mentioned. Here, the (co) polymer is a homopolymer or a copolymer.
（１）の態様において、上記共重合体はエチレンユニットと酢酸ビニルユニット以外の他のユニットを有していてもよく、このような他のユニットを与える単量体としては、例えば、塩化ビニル；スチレン；メチル（メタ）アクリレート、エチル（メタ）アクリレート、ブチル（メタ）アクリレート、２−エチルヘキシル（メタ）アクリレート、シクロヘキシル（メタ）アクリレート、ベンジル（メタ）アクリレート、２−ヒドロキシエチル（メタ）アクリレート等の（メタ）アクリレート類等が挙げられる。中でも塩化ビニルユニットが好ましく、後述する三酸化アンチモンと組み合わせることで、樹脂コート不織布の難燃性が向上する。 In the embodiment of (1), the copolymer may have other units other than the ethylene unit and the vinyl acetate unit. Examples of the monomer that gives such other unit include vinyl chloride; Styrene; methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, cyclohexyl (meth) acrylate, benzyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, etc. Examples include (meth) acrylates. Among these, a vinyl chloride unit is preferable, and the flame retardancy of the resin-coated nonwoven fabric is improved by combining with an antimony trioxide described later.
他のユニットがある場合、すなわち、エチレンと酢酸ビニルに加えて他の単量体を共重合する場合は、得られる共重合体において、酢酸ビニルユニットやエチレンユニットの量が上記好適範囲になるように共重合比を調整することが好ましい。例えば、エチレンと酢酸ビニルと塩化ビニルとの共重合体においては、エチレン５〜２０質量％、酢酸ビニル２０〜８０質量％、塩化ビニル５〜４０質量％とすることが好ましい。 When there are other units, that is, when other monomers are copolymerized in addition to ethylene and vinyl acetate, the amount of vinyl acetate units and ethylene units in the resulting copolymer is within the above preferred range. It is preferable to adjust the copolymerization ratio. For example, in the copolymer of ethylene, vinyl acetate, and vinyl chloride, it is preferable to set it as ethylene 5-20 mass%, vinyl acetate 20-80 mass%, and vinyl chloride 5-40 mass%.
上記（２）の態様では、樹脂が、（２−１）ポリエチレンとポリ酢酸ビニルとの混合物を含む態様、（２−２）ポリエチレンと、酢酸ビニルユニットを含む共重合体との混合物を含む態様、（２−３）エチレンユニットを含む共重合体と、ポリ酢酸ビニルとの混合物を含む態様、（２−４）エチレンユニットを含む共重合体と、酢酸ビニルユニットを含む共重合体との混合物を含む態様、とに分けられる。（２−２）〜（２−４）における各共重合体を構成するユニットは、上記で例示した他のユニットを与える単量体由来のユニットである。中でも塩化ビニルユニットが好ましい。 In the above aspect (2), the resin includes (2-1) an aspect including a mixture of polyethylene and polyvinyl acetate, and (2-2) an aspect including a mixture of polyethylene and a copolymer including a vinyl acetate unit. , (2-3) an embodiment containing a mixture of a copolymer containing ethylene units and polyvinyl acetate, (2-4) a mixture of a copolymer containing ethylene units and a copolymer containing vinyl acetate units It is divided into the aspect containing this. The unit which comprises each copolymer in (2-2)-(2-4) is a unit derived from the monomer which gives the other unit illustrated above. Of these, vinyl chloride units are preferred.
本発明において、不織布にコートする樹脂は、エチレンユニットと酢酸ビニルユニットのいずれも含まない（共）重合体をさらに含むものであってもよい。すなわち、上記で例示した他のユニットを与える単量体を１種または２種以上、重合した（共）重合体を、上記（１）または（２）の態様に加えた態様（３）である。この（３）の態様において、好ましいのは、塩化ビニルとアクリル酸エステルとの共重合体である。この共重合体においては、塩化ビニルユニットが５０〜９５質量％となるように共重合することが好ましい。また、（メタ）アクリレート類の（共）重合体も好ましい。 In the present invention, the resin coated on the non-woven fabric may further contain a (co) polymer that does not contain either an ethylene unit or a vinyl acetate unit. That is, in the embodiment (3), a (co) polymer obtained by polymerizing one or more monomers giving other units exemplified above is added to the embodiment (1) or (2). . In the embodiment (3), a copolymer of vinyl chloride and acrylate is preferable. In this copolymer, it is preferable to carry out copolymerization so that a vinyl chloride unit may be 50-95 mass%. Also preferred are (co) polymers of (meth) acrylates.
上記いずれの場合も、樹脂全体として、エチレンが５〜２０質量％、酢酸ビニルが２０〜８０質量％となるように、調整することが好ましい。 In any of the above cases, it is preferable to adjust the total resin so that ethylene is 5 to 20% by mass and vinyl acetate is 20 to 80% by mass.
コートする樹脂は、有機溶剤系でも構わないが、水性媒体のエマルジョンであることが好ましい。複数の（共）重合体から樹脂が構成されている場合でも、エマルジョン同士を混合して撹拌すれば、均一な樹脂エマルジョンが簡単に得ることができる。また、得られる樹脂エマルジョン（コート液）の粘度も低く抑えることができ、さらに環境にも優しい。なお、水性媒体には水の他に、メタノール、エタノール、イソプロパノール等のアルコール類；アセトン等のケトン類；テトラヒドロフラン等のエーテル類が含まれていてもよい。 The resin to be coated may be an organic solvent type, but is preferably an emulsion in an aqueous medium. Even when the resin is composed of a plurality of (co) polymers, a uniform resin emulsion can be easily obtained by mixing and stirring the emulsions. Moreover, the viscosity of the resulting resin emulsion (coating solution) can be kept low, and it is also environmentally friendly. The aqueous medium may contain, in addition to water, alcohols such as methanol, ethanol and isopropanol; ketones such as acetone; ethers such as tetrahydrofuran.
上記樹脂は、樹脂量（不揮発分）が３０〜１２０ｇ／ｍ2となるようにコートすることが好ましい。少ないと、エンボス模様がはっきりせず、多すぎると軽量化の目的に反するとともに、風合いが硬くなり好ましくない。より好ましい付着量は４０〜１１０ｇ／ｍ2の範囲である。コートによる付着量が上記好適範囲となるように、エマルジョンの濃度を調整するとよい。 The resin is preferably coated so that the resin amount (nonvolatile content) is 30 to 120 g / m 2 . If the amount is too small, the embossed pattern will not be clear. If the amount is too large, it will be contrary to the purpose of weight reduction, and the texture will become hard. A more preferable adhesion amount is in the range of 40 to 110 g / m 2 . It is advisable to adjust the concentration of the emulsion so that the amount of adhesion by the coating falls within the above-mentioned preferred range.
［樹脂組成物］
本発明において、不織布に樹脂をコートする際には、樹脂（エマルジョン）に、公知の架橋剤、難燃剤、湿潤剤、粘性調節剤、増粘剤、消泡剤、改質剤、顔料、着色剤、充填剤、老化防止剤、紫外線吸収剤、紫外線安定剤等の添加剤を、本発明の目的を阻害しない範囲で加えてもよく、これらを混合した樹脂組成物の形態で用いることが好ましい。樹脂が塩化ビニルユニットを含む場合、三酸化アンチモンを５〜１０質量％（樹脂＋三酸化アンチモンを１００質量％とした場合）程度添加すると難燃効果が発現するため、好ましい実施態様である。
[Resin composition]
In the present invention, when the nonwoven fabric is coated with a resin, a known crosslinking agent, flame retardant, wetting agent, viscosity modifier, thickener, antifoaming agent, modifier, pigment, coloring is applied to the resin (emulsion). Additives such as additives, fillers, anti-aging agents, UV absorbers, UV stabilizers and the like may be added within a range that does not impair the object of the present invention, and it is preferable to use them in the form of a resin composition in which these are mixed. . In the case where the resin contains a vinyl chloride unit, the addition of about 5 to 10% by mass of antimony trioxide (when resin + antimony trioxide is 100% by mass) exhibits a flame retardant effect, which is a preferred embodiment.
［樹脂コート不織布の製造方法］
本発明の樹脂コート不織布の好適な製造方法の一例を説明する。まず、公知の方法でスパンボンド不織布を製造する。続いて、前記したように、エンボスロールを通して圧着する。これで、基布としての不織布が完成する。
[Method for producing resin-coated nonwoven fabric]
An example of the suitable manufacturing method of the resin coat nonwoven fabric of this invention is demonstrated. First, a spunbond nonwoven fabric is produced by a known method. Subsequently, as described above, pressure bonding is performed through an embossing roll. This completes the nonwoven fabric as the base fabric.
次いで、この不織布の片面に上記樹脂組成物をコートする。このとき、不織布製造時のエンボス面側に樹脂コートを施すことが好ましい。不織布製造時のエンボス面側に樹脂コートを施すと、樹脂コート不織布の幅方向端部のカールを防止できるためである。コートによって樹脂は不織布の内部に侵入するが、コート面の反対側の表面にまで達する（きれいに裏面まで含浸する状態）とは限らないため、得られる樹脂コート不織布は樹脂が不織布に含浸した層と含浸していない不織布だけの層とに分かれる場合がある。これらの２層の熱収縮挙動の異なることが、上記カールの原因ではないかと考えられる。不織布製造時にエンボス加工を施すと、エンボスロールの凸部によって圧縮された部分の不織布は繊維が密になっているが、押圧されていない部分は繊維が粗のままのため、エンボス面側から樹脂コートを行うことで、繊維が粗な部分を通じて樹脂が含浸しやすくなり、カールを抑制できるのではないかと考えられる。カールは、後述する測定方法で測定される値として３０ｍｍ以下が好ましい。 Next, the resin composition is coated on one side of the nonwoven fabric. At this time, it is preferable to apply a resin coat to the embossed surface side during the production of the nonwoven fabric. This is because when the resin coating is applied to the embossed surface side during the production of the nonwoven fabric, curling of the end portion in the width direction of the resin coated nonwoven fabric can be prevented. The resin penetrates into the inside of the nonwoven fabric by the coat, but it does not always reach the surface opposite to the coated surface (a state where it is impregnated into the back surface cleanly). It may be divided into a layer of only non-impregnated non-woven fabric. The difference in the heat shrinkage behavior of these two layers is considered to be the cause of the curl. When embossing is performed during the manufacture of the nonwoven fabric, the nonwoven fabric in the portion compressed by the convex portion of the embossing roll has dense fibers, but the unpressed portion remains rough and the resin from the embossed surface side By performing the coating, it is considered that the resin is easily impregnated through a portion where the fibers are rough, and curling can be suppressed. The curl is preferably 30 mm or less as a value measured by a measurement method described later.
コート法としては特に限定されないが、ナイフコート法、グラビアコート法、エアーナイフコート法等が採用可能であり、含浸性がよい点で、ナイフコート法、エアーナイフコート法が好ましい。 Although it does not specifically limit as a coating method, A knife coat method, a gravure coat method, an air knife coat method, etc. can be employ | adopted and a knife coat method and an air knife coat method are preferable at the point with good impregnation property.
本発明では、コート後の樹脂コート不織布にエンボス加工を施して、断面を波形状（サインカーブ状）にする。このとき、エンボスロールの対向ロールとしてペーパーロールを用いるか、凸部を有するロールと、前記凸部に嵌合する凹部を有するロールの間を通過させて、凹凸模様を付けて、断面を波形状にすることが好ましい。これにより、樹脂コート不織布の見掛け厚みを実質厚みの２倍以上にすることができる。 In this invention, embossing is given to the resin-coated nonwoven fabric after coating, and a cross section is made into a wave shape (sine curve shape). At this time, a paper roll is used as an opposing roll of the embossing roll, or a section having a concavo-convex pattern is formed by passing between a roll having a convex part and a roll having a concave part fitted to the convex part, and the cross section is corrugated It is preferable to make it. Thereby, the apparent thickness of a resin coat nonwoven fabric can be made into 2 times or more of substantial thickness.
エンボスの形状としては、円柱形状、三角柱形状、四角柱形状等の多角柱形状、円錐台形状、三角錐台形状、四角錐台形状等の多角錐台形状等が挙げられ、これらの中でも四角錐台形状が好ましい。エンボス形状のサイズは、樹脂コート不織布平面において、当該エンボス模様の輪郭線上の任意の２点をその間の長さが最大となるように選んだときの長さが５００μｍ〜２０００μｍであるのが好ましく（より好ましくは７００μｍ〜１６００μｍ、さらに好ましくは１０００μｍ〜１３００μｍ）、高さは、２５０μｍ〜７００μｍであるのが好ましい（より好ましくは３００μｍ〜６５０μｍ、さらに好ましくは３５０μｍ〜６００μｍ）。 Examples of the embossed shape include a polygonal prism shape such as a cylindrical shape, a triangular prism shape, and a quadrangular prism shape, a truncated cone shape, a triangular truncated pyramid shape such as a triangular truncated pyramid shape, and the like. A trapezoidal shape is preferred. The size of the embossed shape is preferably 500 μm to 2000 μm when the length between the two arbitrary points on the contour line of the embossed pattern is maximized in the resin-coated nonwoven fabric plane ( More preferably 700 μm to 1600 μm, still more preferably 1000 μm to 1300 μm), and the height is preferably 250 μm to 700 μm (more preferably 300 μm to 650 μm, still more preferably 350 μm to 600 μm).
また、樹脂コート不織布におけるエンボス模様の配列としては、エンボス模様が格子状に配列されている態様、千鳥配列されている態様、ランダムに配列されている態様等が挙げられる。最も好ましいエンボスの態様は、樹脂コート面側から見て、逆四角錐台形状の凹部が千鳥配列した態様（逆台形格子型）である。 Moreover, as an arrangement | sequence of the embossing pattern in a resin coat nonwoven fabric, the aspect by which the embossing pattern is arranged in the grid | lattice form, the aspect by which zigzag arrangement | sequence is arranged, the aspect by which it arranges at random, etc. are mentioned. The most preferable embossing mode is a mode (inverted trapezoidal lattice type) in which the concave portions of the inverted quadrangular pyramid shape are arranged in a staggered manner when viewed from the resin coated surface side.
図１に、逆台形格子型のエンボスの態様の一例を示した。この逆台形格子型の凹部は、凹部底面の一辺が２５０μｍ〜４００μｍ程度の略正四角形であり、頂面（凹部の開放面）の一辺が９００μｍ〜１２００μｍ程度の略正四角形である四角錐台の形状を有している。なお、四角錐台の高さ（凹部の深さ）は３５０μｍ〜６００μｍ程度が好ましい。 FIG. 1 shows an example of an inverted trapezoidal lattice type embossing mode. The recessed part of the inverted trapezoidal lattice type is a quadrangular pyramid having a substantially square shape with one side of the bottom surface of the recessed part being about 250 μm to 400 μm and a side of the top surface (opening surface of the recessed part) being a substantially square shape having about 900 μm to 1200 μm. It has a shape. The height of the quadrangular pyramid (the depth of the recess) is preferably about 350 μm to 600 μm.
また、上記逆台形格子型のエンボス模様以外にも、いろんな模様を採用することができる。例えば、図３には円柱状（コイン状）の凸部が千鳥配列されているエンボス模様が示されている。図４には四角柱状の凸部が押しつけられた形（形成されているのは凹部）が規則的に並んだエンボス模様が、図５には鱗状の凸部が若干不規則な部分を有するが全体としては比較的規則的に並んだエンボス模様が示されている。図６には、四角柱状の凸部が押しつけられた形（形成されているのは凹部）が、左右部と中央部で並び方が異なるワニ革状のエンボス模様が示されている。図７には六角柱状の凹部が規則的に並んだエンボス模様が、図８には十字状の凸部が規則的に並んだエンボス模様が、そして、図９には織物調に見えるエンボス模様が示されている。 In addition to the inverted trapezoidal lattice type embossed pattern, various patterns can be adopted. For example, FIG. 3 shows an embossed pattern in which cylindrical (coin-shaped) convex portions are arranged in a staggered manner. FIG. 4 shows an embossed pattern in which square columnar convex portions are pressed (the concave portions are formed) regularly arranged. In FIG. 5, the scale-like convex portions have slightly irregular portions. As a whole, embossed patterns arranged relatively regularly are shown. FIG. 6 shows a crocodile leather-like embossed pattern in which the shape in which the quadrangular prism-shaped convex portions are pressed (the concave portions are formed) are arranged differently in the left and right portions and the central portion. 7 shows an embossed pattern in which hexagonal columnar concave portions are regularly arranged, FIG. 8 shows an embossed pattern in which cross-shaped convex portions are regularly arranged, and FIG. 9 shows an embossed pattern that looks like a fabric. It is shown.
エンボス加工は、樹脂コート不織布が１３０〜１８０℃程度になるように加熱して行うことが好ましく、このとき、エンボス加工の線圧は、４０〜１００ｋＮ／ｍ程度が好ましい。 The embossing is preferably performed by heating so that the resin-coated nonwoven fabric has a temperature of about 130 to 180 ° C. At this time, the linear pressure of the embossing is preferably about 40 to 100 kN / m.
［樹脂コート不織布］
本発明の樹脂コート不織布の最終目付けは、１００〜２５０ｇ／ｍ2とする。小さすぎると強力が不充分となるが、大きすぎると軽量化の目的に反するからである。
[Resin coated nonwoven fabric]
The final basis weight of the resin-coated nonwoven fabric of the present invention is 100 to 250 g / m 2 . If it is too small, the strength will be insufficient, but if it is too large, it will be against the purpose of weight reduction.
本発明の樹脂コート不織布は、見掛け厚み／実質厚みが２以上である。これにより、軽量で、しかも、優れた意匠性（エンボス模様がはっきりと見える）を有するものとなる。ここで、樹脂コート不織布の見掛け厚みとは、テクロック社製のダイヤルシックネスゲージ（型番ＳＭ−１１２）で、樹脂コート不織布に荷重がかからないようにして実際に測定した値であり、図２における上側の太線と下側の太線の間の距離に相当する。また、実質厚みとは、図２に示すように、樹脂コート不織布の断面をＳＥＭで観察したときの厚みを意味し、最も小さい部分の厚みを測定するものとする。図２では、細線と下側の太線との間の距離を実質厚みとした。 The resin-coated nonwoven fabric of the present invention has an apparent thickness / substantial thickness of 2 or more. Thereby, it is lightweight and has excellent design properties (embossed pattern can be clearly seen). Here, the apparent thickness of the resin-coated nonwoven fabric is a value actually measured by a dial thickness gauge (model number SM-112) manufactured by Teclock Co., Ltd. so that no load is applied to the resin-coated nonwoven fabric. Corresponds to the distance between the thick line and the lower thick line. Moreover, substantial thickness means the thickness when the cross section of a resin coat nonwoven fabric is observed by SEM, as shown in FIG. 2, and shall measure the thickness of the smallest part. In FIG. 2, the distance between the fine line and the lower thick line is defined as the substantial thickness.
図２に示すように、断面がサインカーブ状を示し、実質厚みに対する見掛け厚み比（見掛け厚み／実質厚み）が２以上の樹脂コート不織布であれば、樹脂量が従来に比べて少なくても、エンボス模様がはっきりと見え、意匠性かつ軽量性に優れたものとなる。 As shown in FIG. 2, if the cross-section shows a sine curve shape and the resin-coated nonwoven fabric has an apparent thickness ratio to the actual thickness (apparent thickness / substantial thickness) of 2 or more, even if the amount of resin is smaller than the conventional one, The embossed pattern is clearly visible, and the design and lightness are excellent.
見掛け厚み／実質厚みが２より小さいと、エンボスがぼやけ、意匠性に劣るものとなるため好ましくない。よって、意匠性を高めるためのエンボス加工は、不織布製造時のエンボス加工とは異なり、エンボスロールの対向ロールをペーパーロールにするか、第１ロールと対向ロールが嵌合可能な一対のロールにする必要がある。 When the apparent thickness / substantial thickness is smaller than 2, the embossing is blurred and the design property is inferior. Therefore, the embossing for improving the design is different from the embossing at the time of manufacturing the nonwoven fabric, the opposing roll of the embossing roll is a paper roll or a pair of rolls that can be fitted to the first roll and the opposing roll. There is a need.
実質厚みは、軽量化の観点から０．３ｍｍ以下とすることが好ましく、０．２５ｍｍ以下がより好ましい。実質厚みの下限は、強力の観点から０．１ｍｍ程度が好ましい。一方、見掛け厚みは、意匠性の観点から０．４ｍｍ以上が好ましく、トノカバーをロール状にして収納しておく際の収納性の観点から、上限は０．８ｍｍ程度が好ましい。 The substantial thickness is preferably 0.3 mm or less, and more preferably 0.25 mm or less from the viewpoint of weight reduction. The lower limit of the substantial thickness is preferably about 0.1 mm from the viewpoint of strength. On the other hand, the apparent thickness is preferably 0.4 mm or more from the viewpoint of design properties, and the upper limit is preferably about 0.8 mm from the viewpoint of storage properties when storing the tonneau cover in a roll shape.
本発明の樹脂コート不織布は、ＪＩＳ Ｌ １９１３ ６．７．２（２０１０）に記載のカンチレバー式で測定した剛軟度が経緯とも１２０ｍｍ以下であると、しなやかさが確保されている目安となるため好ましい。 In the resin-coated nonwoven fabric of the present invention, when the bending resistance measured by the cantilever method described in JIS L 1913 6.7.2 (2010) is 120 mm or less, it is a guideline for ensuring flexibility. preferable.
以下実施例によって本発明をさらに詳述するが、下記実施例は本発明を制限するものではなく、本発明の趣旨を逸脱しない範囲で変更実施をすることは全て本発明の技術的範囲に包含される。なお、特に断らない限り、「部」は「質量部」を、「％」は「質量％」をそれぞれ意味する。 The present invention will be described in more detail with reference to the following examples. However, the following examples are not intended to limit the present invention, and all modifications made without departing from the spirit of the present invention are included in the technical scope of the present invention. Is done. Unless otherwise specified, “part” means “part by mass” and “%” means “% by mass”.
［特性評価方法］
＜目付＞
ＪＩＳ Ｌ １９１３ ６．２（２０１０）記載の方法に準拠し、２０ｃｍ×２０ｃｍのサイズで不織布の目付けを測定した。なお、樹脂コート不織布の目付けは、不織布の目付けとコート量から算出した。
[Characteristic evaluation method]
<Unit weight>
Based on the method described in JIS L 1913 6.2 (2010), the basis weight of the nonwoven fabric was measured at a size of 20 cm × 20 cm. The basis weight of the resin-coated nonwoven fabric was calculated from the basis weight of the nonwoven fabric and the coating amount.
＜コート前不織布の厚み、樹脂コート不織布の厚み＞
コート前不織布（不織布製造時のエンボス加工後の不織布）の厚みは、東洋精機社製デジシックネステスター（ＤＰ−ＩＤＸ２６４−５０１）を用いて５．１ｋＰａｓで測定し、樹脂コート不織布の厚みは、テクロック社製のダイヤルシックネスゲージ（型番ＳＭ−１１２）で、コート前不織布または樹脂コート不織布に荷重がかからないようにして測定した値である。
<Thickness of non-coated nonwoven fabric, thickness of resin-coated nonwoven fabric>
The thickness of the non-coated non-woven fabric (non-embossed non-woven fabric during the production of the non-woven fabric) was measured at 5.1 kPas using a Toyo Seiki Digithic Tester (DP-IDX264-501). It is a value measured with a dial thickness gauge (model number SM-112) manufactured by the company so that no load is applied to the non-coated non-woven fabric or the resin-coated non-woven fabric.
＜樹脂コート不織布の実質厚み＞
剃刀（フェザー安全剃刀株式会社製、フェザー（登録商標）剃刀Ｓ片刃）を使用して樹脂コート不織布の平面に垂直な断面を露出させ、株式会社日立製作所製Ｓ−８００型電界放出形走査電子顕微鏡により断面を撮影する（断面写真の調製）。得られた断面写真において、最も小さい厚みの部分（図２における細線と下側の太線の間の距離）の厚みを測定し、実質厚みとした。
<Real thickness of resin-coated nonwoven fabric>
Using a razor (Feather Safety Razor Co., Ltd., Feather (registered trademark) Razor S single blade), a cross section perpendicular to the plane of the resin-coated nonwoven fabric is exposed, and an S-800 field emission scanning electron microscope manufactured by Hitachi, Ltd. A cross section is photographed by (preparation of a cross-sectional photograph). In the obtained cross-sectional photograph, the thickness of the portion with the smallest thickness (the distance between the fine line and the lower thick line in FIG. 2) was measured and made the substantial thickness.
＜意匠性＞
不織布の繊維が見えず、エンボス加工がはっきりしているものを○、エンボス加工がはっきりしていないもの、すなわち厚み比が２より低いものを△、不織布の繊維が見えるものを×として評価した。
<Designability>
The case where the fibers of the non-woven fabric were not visible and the embossing was clear was evaluated as ◯, the case where the embossing was not clear, that is, the case where the thickness ratio was lower than 2, and the case where the fibers of the non-woven fabric were visible were evaluated as x.
＜カール＞
樹脂コート不織布を、幅７５ｍｍ、長さ２０５ｍｍに裁断したものを試料とし、９０℃、絶乾状態で２４時間放置し、側部の反り上がった最大高さ（ｍｍ）を測定した。
<Curl>
A resin-coated non-woven fabric cut into a width of 75 mm and a length of 205 mm was used as a sample, and was allowed to stand at 90 ° C. in an absolutely dry state for 24 hours, and the maximum height (mm) at which the side was warped was measured.
＜加工時の幅入り＞
コート前不織布を、幅５ｃｍ、縦（製造時の走行方向）２０ｃｍに裁断したものを試料とし、縦方向が鉛直方向になるようにし、２０Ｎ／５ｃｍの荷重１０ｃｍの試料にかけて伸び率を測定した。伸びが１％以下のものを○、伸びが１％より大きく５％以下のものを△、伸びが５％よりも大きいものを×とした。
<With width during processing>
An uncoated non-woven fabric cut to a width of 5 cm and a length (running direction during production) of 20 cm was used as a sample, and the elongation was measured over a sample of 20 N / 5 cm and a load of 10 cm with the vertical direction being the vertical direction. The case where the elongation was 1% or less was rated as “◯”, the case where the elongation was larger than 1% and 5% or less was Δ, and the case where the elongation was larger than 5% was rated as “X”.
＜毛羽＞
最終エンボス加工前の樹脂コート不織布の非コート面（コート面の反対面）に毛羽立ちがないものを○、毛羽立っているものを×とした。
<Fuzzy>
A non-coated surface (opposite surface of the coated surface) of the resin-coated non-woven fabric before final embossing was evaluated as “◯”, and a non-coated surface as “×”.
＜剛軟度＞
ＪＩＳ Ｌ １９１３ ６．７．２（２０１０）に記載のカンチレバー式で測定した。
<Bending softness>
It measured by the cantilever type | system | group as described in JISL1913 6.7.2 (2010).
＜強力＞
幅３０ｍｍ、長さ２００ｍｍに裁断した試料を、引張試験機（島津製作所社製「オートグラフ（登録商標）」）の上下のチャックに、チャック間距離が１００ｍｍとなるように試験片を挟み、引張速度２００ｍｍ／分で引っ張って破断時の数値を読み取った。
<Strong>
A specimen cut into a width of 30 mm and a length of 200 mm is sandwiched between upper and lower chucks of a tensile tester (“Autograph (registered trademark)” manufactured by Shimadzu Corporation), and the test piece is sandwiched between the chucks so that the distance between chucks is 100 mm. The value at break was read by pulling at a speed of 200 mm / min.
実施例１
固有粘度０．６５のポリエチレンテレフタレート（ＰＥＴ）を用い、紡糸温度２８５℃、単孔吐出量１．２ｇ／分で溶融紡糸し、エジェクターで引き取りつつ開繊して、ネットコンベア上に繊維配列がランダムになるように速度調整して堆積させた。単糸繊度２．４ｄｔｅｘの長繊維からなる目付１００ｇ／ｍ2のスパンボンド不織布を得た。次いで圧着面積率９％の角錐台形状の凸部が千鳥配列されたエンボスロールで、２３０℃、線圧４０ｋＮ／ｍでエンボス加工を行い、厚み０．４６ｍｍの熱圧着タイプのスパンボンド不織布を得た。
Example 1
Polyethylene terephthalate (PET) with an intrinsic viscosity of 0.65 is melt-spun at a spinning temperature of 285 ° C. and a single-hole discharge rate of 1.2 g / min, and is opened while being pulled by an ejector. The speed was adjusted so that A spunbonded nonwoven fabric having a basis weight of 100 g / m 2 made of long fibers having a single yarn fineness of 2.4 dtex was obtained. Next, embossing is performed at 230 ° C. with a linear pressure of 40 kN / m with an embossing roll in which the pyramidal trapezoidal convex portions with a crimping area ratio of 9% are arranged in a staggered manner, and a thermocompression bonding type spunbond nonwoven fabric having a thickness of 0.46 mm is obtained. It was.
エチレン、酢酸ビニルおよび塩化ビニルの共重合体エマルジョン（エチレン／酢酸ビニル／塩化ビニル＝１５／６０／２５；住友化学株式会社製「スミカフレックス（登録商標）８０１ＨＱ」）が固形分で６７％、アクリル酸エステル共重合体エマルジョン（新中村化学工業株式会社製「ニューコート９５００」）が固形分で１５％、塩化ビニルとアクリルの共重合体エマルジョン（塩ビ／アクリル＝８０／２０；日信化学工業株式会社製「ビニブラン（登録商標）２７８」）が固形分で１８％となるように、各成分をよく混合し、樹脂組成物１を得た。 Copolymer emulsion of ethylene, vinyl acetate and vinyl chloride (ethylene / vinyl acetate / vinyl chloride = 15/60/25; “Sumikaflex (registered trademark) 801HQ” manufactured by Sumitomo Chemical Co., Ltd.) is 67% in solid content, acrylic Acid ester copolymer emulsion (“New Coat 9500” manufactured by Shin-Nakamura Chemical Co., Ltd.) is 15% in solids, vinyl chloride and acrylic copolymer emulsion (PVC / acrylic = 80/20; Nissin Chemical Industry Co., Ltd.) Each component was mixed well so that “ViniBran (registered trademark) 278” manufactured by the company had a solid content of 18%, and a resin composition 1 was obtained.
上記の熱圧着タイプのスパンボンド不織布のエンボス面側に、乾燥後の樹脂付着量（以下、樹脂付着量とは全て乾燥後の値である）が１１０ｇ／ｍ2となるように、ナイフコーターで上記樹脂組成物１をコートして、乾燥させた後、台形格子型のエンボスロールで、１５３℃、線圧７０ｋＮ／ｍでエンボス加工した。なお、対向ロールにはペーパーロールを用いた。評価結果を表１に示す。 With a knife coater, the resin adhesion amount after drying (hereinafter, the resin adhesion amount is all the value after drying) is 110 g / m 2 on the embossed surface side of the thermocompression bonding type spunbond nonwoven fabric. The resin composition 1 was coated and dried, and then embossed with a trapezoidal lattice type embossing roll at 153 ° C. and a linear pressure of 70 kN / m. In addition, the paper roll was used for the opposing roll. The evaluation results are shown in Table 1.
実施例２
スパンボンド不織布を、目付け８０ｇ／ｍ2、厚さ０．４１ｍｍのものに代え、樹脂付着量を４０ｇ／ｍ2とした以外は、実施例１と同様にして、エンボス加工された樹脂コート不織布を得た。評価結果を表１に示す。
Example 2
An embossed resin-coated nonwoven fabric was prepared in the same manner as in Example 1 except that the spunbonded nonwoven fabric was replaced with one having a basis weight of 80 g / m 2 and a thickness of 0.41 mm, and the resin adhesion amount was 40 g / m 2. Obtained. The evaluation results are shown in Table 1.
実施例３
スパンボンド不織布を、目付け１５０ｇ／ｍ2、厚さ０．６ｍｍのものに代え、樹脂付着量を８０ｇ／ｍ2とした以外は、実施例１と同様にして、エンボス加工された樹脂コート不織布を得た。評価結果を表１に示す。
Example 3
An embossed resin-coated nonwoven fabric was prepared in the same manner as in Example 1 except that the spunbonded nonwoven fabric was replaced with a fabric having a basis weight of 150 g / m 2 and a thickness of 0.6 mm, and the resin adhesion amount was 80 g / m 2. Obtained. The evaluation results are shown in Table 1.
実施例４
樹脂コートをエンボス面ではなく、エンボス面の反対側に行った以外は、実施例１と同様にして、エンボス加工された樹脂コート不織布を得た。評価結果を表１に示す。
Example 4
An embossed resin-coated nonwoven fabric was obtained in the same manner as in Example 1 except that the resin coating was performed not on the embossed surface but on the opposite side of the embossed surface. The evaluation results are shown in Table 1.
比較例１
実施例１に記載の熱圧着タイプスパンボンド不織布を用い、樹脂組成物１をコートするのではなく、ディッピング法によって含浸させて、樹脂付着量が７０ｇ／ｍ2のエンボス加工された樹脂含浸不織布を得た。評価結果を表１に示す。
Comparative Example 1
An embossed resin-impregnated nonwoven fabric with a resin adhesion amount of 70 g / m 2 is impregnated by dipping rather than coating the resin composition 1 using the thermocompression bonding type spunbond nonwoven fabric described in Example 1. Obtained. The evaluation results are shown in Table 1.
比較例２
スパンボンド不織布を、目付け５０ｇ／ｍ2、厚さ０．３ｍｍのものに代え、樹脂付着量を４０ｇ／ｍ2とした以外は、実施例１と同様にして、エンボス加工された樹脂コート不織布を得た。評価結果を表１に示す。
Comparative Example 2
An embossed resin-coated non-woven fabric was prepared in the same manner as in Example 1 except that the spunbonded non-woven fabric was replaced with one having a basis weight of 50 g / m 2 and a thickness of 0.3 mm, and the resin adhesion amount was 40 g / m 2. Obtained. The evaluation results are shown in Table 1.
比較例３
スパンボンド不織布を、目付け１８０ｇ／ｍ2、厚さ０．６２ｍｍのものに代え、樹脂付着量を１７０ｇ／ｍ2とした以外は、実施例１と同様にして、エンボス加工された樹脂コート不織布を得た。評価結果を表１に示す。
Comparative Example 3
An embossed resin-coated nonwoven fabric was prepared in the same manner as in Example 1 except that the spunbonded nonwoven fabric was replaced with one having a basis weight of 180 g / m 2 and a thickness of 0.62 mm, and the amount of resin adhesion was 170 g / m 2. Obtained. The evaluation results are shown in Table 1.
比較例４
固有粘度０．６５のポリエチレンテレフタレート（ＰＥＴ）を用い、紡糸温度２８５℃、単孔吐出量１．２ｇ／分で溶融紡糸し、エジェクターで引き取りつつ開繊して、ネットコンベア上に繊維配列がランダムになるように速度調整して堆積させた。単糸繊度２．４ｄｔｅｘの長繊維からなる目付１２０ｇ／ｍ2のスパンボンド不織布を得た。次いで圧着面積率９％の角錐台形状の凸部が千鳥配列されたエンボスロールで、１８０℃、線圧４０ｋＮ／ｍでエンボス加工を行い、一旦巻き取った後、４０番手の針で、６５本／ｃｍ2、針深度１２ｍｍの条件でニードルパンチによる交絡処理を行って、ニードルパンチ不織布を得た。目付けは１２０ｇ／ｍ2、厚さ０．４６ｍｍであった。このニードルパンチ不織布の片面に、実施例１と同様にして樹脂組成物１をコートし、樹脂付着量が８０ｇ／ｍ2の樹脂コート不織布とした以外は、実施例１と同様にして、エンボス加工された樹脂コート不織布を得た。評価結果を表１に示す。
Comparative Example 4
Polyethylene terephthalate (PET) with an intrinsic viscosity of 0.65 is melt-spun at a spinning temperature of 285 ° C. and a single-hole discharge rate of 1.2 g / min, and is opened while being pulled by an ejector. The speed was adjusted so that A spunbonded nonwoven fabric having a basis weight of 120 g / m 2 consisting of long fibers having a single yarn fineness of 2.4 dtex was obtained. Next, it is embossed with an embossing roll with pyramidal trapezoidal convex portions with a crimping area ratio of 9%, staggered at 180 ° C. and linear pressure of 40 kN / m. The needle punch nonwoven fabric was obtained by performing the entanglement process by the needle punch under the conditions of / cm 2 and the needle depth of 12 mm. The basis weight was 120 g / m 2 and the thickness was 0.46 mm. Embossing is carried out in the same manner as in Example 1 except that one side of this needle punched nonwoven fabric is coated with the resin composition 1 in the same manner as in Example 1 to obtain a resin-coated nonwoven fabric with a resin adhesion amount of 80 g / m 2. A resin-coated nonwoven fabric was obtained. The evaluation results are shown in Table 1.
比較例５
比較例４で用いたニードルパンチ不織布に、樹脂組成物１をディッピング法で含浸させて、樹脂付着量が８０ｇ／ｍ2の樹脂含浸不織布とした以外は、実施例１と同様にして、エンボス加工された樹脂含浸不織布を得た。評価結果を表１に示す。
Comparative Example 5
Embossing is carried out in the same manner as in Example 1 except that the needle punched nonwoven fabric used in Comparative Example 4 is impregnated with the resin composition 1 by a dipping method to obtain a resin-impregnated nonwoven fabric with a resin adhesion amount of 80 g / m 2. A resin-impregnated nonwoven fabric was obtained. The evaluation results are shown in Table 1.
比較例６
比較例４で用いたニードルパンチ不織布に、樹脂組成物１をディッピング法で含浸させて、樹脂付着量が４０ｇ／ｍ2の樹脂含浸不織布を得た後、ナイフコーターで樹脂組成物１をコートした。コートによる樹脂付着量は４０ｇ／ｍ2であった。後は、実施例１と同様にして、エンボス加工された樹脂含浸・コート不織布を得た。評価結果を表１に示す。
Comparative Example 6
The needle punched nonwoven fabric used in Comparative Example 4 was impregnated with the resin composition 1 by a dipping method to obtain a resin-impregnated nonwoven fabric having a resin adhesion amount of 40 g / m 2 , and then the resin composition 1 was coated with a knife coater. . The amount of resin adhered by the coating was 40 g / m 2 . Thereafter, in the same manner as in Example 1, an embossed resin-impregnated / coated nonwoven fabric was obtained. The evaluation results are shown in Table 1.
比較例７
ディッピングによる樹脂付着量を８０ｇ／ｍ2に変更した以外は、比較例６と同様にして、エンボス加工された樹脂含浸・コート不織布を得た。評価結果を表１に示す。
Comparative Example 7
An embossed resin-impregnated / coated nonwoven fabric was obtained in the same manner as in Comparative Example 6 except that the resin adhesion amount by dipping was changed to 80 g / m 2 . The evaluation results are shown in Table 1.
比較例８
コートによる樹脂付着量を８０ｇ／ｍ2に変更した以外は、比較例６と同様にして、エンボス加工された樹脂含浸・コート不織布を得た。評価結果を表１に示す。
Comparative Example 8
An embossed resin-impregnated / coated nonwoven fabric was obtained in the same manner as in Comparative Example 6 except that the resin adhesion amount by coating was changed to 80 g / m 2 . The evaluation results are shown in Table 1.
比較例９
ディッピングによる樹脂付着量とコートによる樹脂付着量をいずれも８０ｇ／ｍ2に変更した以外は、比較例６と同様にして、エンボス加工された樹脂含浸・コート不織布を得た。評価結果を表１に示す。
Comparative Example 9
An embossed resin-impregnated / coated nonwoven fabric was obtained in the same manner as in Comparative Example 6 except that both the resin adhesion amount by dipping and the resin adhesion amount by coating were changed to 80 g / m 2 . The evaluation results are shown in Table 1.
本発明によれば、高速製造が可能な工程通過性、軽量性、かつ意匠性を兼ね備えた樹脂コート不織布を提供することができた。従って、本発明の樹脂コート不織布は、トノカバー等の車両内装材、壁紙、ベッド部材、椅子部材等に使用可能である。 ADVANTAGE OF THE INVENTION According to this invention, the resin coat nonwoven fabric which has the process passability in which high-speed manufacture is possible, the lightness, and the designability was able to be provided. Therefore, the resin-coated nonwoven fabric of the present invention can be used for vehicle interior materials such as tonneau covers, wallpaper, bed members, chair members, and the like.
Claims (4)
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| Application Number | Priority Date | Filing Date | Title |
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| JP2013055656A JP6275389B2 (en) | 2012-05-29 | 2013-03-18 | Resin coated nonwoven fabric |
| CN201310206333.5A CN103448307B (en) | 2012-05-29 | 2013-05-29 | A kind of resinous coat non-woven fabrics |
| CN201320302106.8U CN203472232U (en) | 2012-05-29 | 2013-05-29 | Resin coating non-woven fabric |
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| JP2012122302 | 2012-05-29 | ||
| JP2012122302 | 2012-05-29 | ||
| JP2013055656A JP6275389B2 (en) | 2012-05-29 | 2013-03-18 | Resin coated nonwoven fabric |
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| JP2017205526A Division JP6276462B2 (en) | 2012-05-29 | 2017-10-24 | Resin coated nonwoven fabric |
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| JP2014005584A JP2014005584A (en) | 2014-01-16 |
| JP6275389B2 true JP6275389B2 (en) | 2018-02-07 |
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| JP2017205526A Active JP6276462B2 (en) | 2012-05-29 | 2017-10-24 | Resin coated nonwoven fabric |
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| CN103448307B (en) * | 2012-05-29 | 2018-04-27 | 东洋纺株式会社 | A kind of resinous coat non-woven fabrics |
| CN109825948A (en) * | 2019-01-17 | 2019-05-31 | 福建金坛实业有限公司 | A kind of on-deformable dry and comfortable non-woven fabrics |
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| JPS5870777A (en) * | 1981-10-21 | 1983-04-27 | ダイニツク株式会社 | Anti-slip composite sheet material |
| JP3279719B2 (en) * | 1993-04-28 | 2002-04-30 | 東洋紡績株式会社 | Leather long-fiber non-woven fabric for chair members |
| JP3251388B2 (en) * | 1993-06-15 | 2002-01-28 | 東洋クロス株式会社 | Manufacturing method of flame retardant and water repellent sheet |
| JPH11241277A (en) * | 1998-02-24 | 1999-09-07 | Toyobo Co Ltd | Leather-like nonwoven fabric and its production |
| JP5697421B2 (en) * | 2010-04-07 | 2015-04-08 | 旭化成せんい株式会社 | Durable printing substrate |
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| JP2018009283A (en) | 2018-01-18 |
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| JP6276462B2 (en) | 2018-02-07 |
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