JP6439195B1 - Moisture permeable waterproof sheet and manufacturing method thereof - Google Patents

Abstract

A moisture-permeable waterproof sheet that has high waterproofness and moisture permeability, high strength and durability, can be manufactured quickly at low cost, and a method for manufacturing the moisture-permeable waterproof sheet. A moisture-permeable waterproof sheet 1 has a water-drop impermeable and moisture-permeable gap, a porous and / or fused part 21b by a nonwoven fiber 21 formed of a hot-melt adhesive containing a moisture-permeable resin. The non-woven sheets 10 and 30 are respectively bonded to both surfaces of the moisture-permeable adhesive layer 20 having adhesiveness by a hot-melt adhesive at some fusion sites 21b of the moisture-permeable adhesive layer 20, In the manufacturing method, a hot melt adhesive is thermally melted and sprayed onto the first nonwoven sheet to form a hot web in which the nonwoven fibers are overlapped with each other, and the second nonwoven sheet is stacked on the first nonwoven sheet. A laminated body composed of a sheet, a hot web, and a second non-woven sheet is subjected to a thermocompression process, and the non-woven fibers are crushed and bonded together while the first and second non-woven sheets are bonded to the hot web. To form the moisture-permeable adhesive layer 20.[Selection] Figure 1

Description

  The present invention relates to a moisture-permeable waterproof sheet exhibiting high waterproofness, moisture permeability, waterproofness, and durability, and a method for producing the same.

  Condensation that occurs inside the outer wall, behind the shed or under the floor due to raindrops that enter the wooden house and water vapor generated during breathing, heating, bathing, or cooking, rots the wood that is the body of the wooden house. It has been known. In order to prevent this, a moisture-permeable waterproof sheet having waterproof properties and moisture-permeable properties is used as a base for roofs and outer walls. The moisture-permeable waterproof sheet prevents raindrops from entering the interior of the wooden house due to its waterproofness, and allows moisture to permeate and releases it outside the wooden house. . Thus, the moisture-permeable waterproof sheet used for the purpose of preventing the endurance of the wooden house is also called a house wrap material.

  House wrap having a multilayer structure in which a metal vapor-deposited layer and a protective layer are laminated on one surface of a porous or non-porous moisture-permeable waterproof film and a fabric is laminated on the other surface as a moisture-permeable waterproof sheet A material is disclosed in US Pat. The moisture permeable and waterproof properties of this house wrap material depend on the moisture permeable and waterproof film material. Such a moisture permeable and waterproof film is expensive and easily causes wrinkles in the process of laminating a fabric and a protective layer, so that the manufacturing cost is increased and defective products due to wrinkles are caused. Moreover, when laminating a moisture-permeable waterproof film and a protective layer or a fabric, it is necessary to laminate via an adhesive so that they do not peel off. Since the adhesive covers the surface of the moisture permeable waterproof film, the porosity of the moisture permeable waterproof film is blocked, resulting in a decrease in the moisture permeability of the moisture permeable waterproof film, and the moisture permeability of the house wrap material is impaired.

  On the other hand, a moisture-permeable and waterproof nonwoven fabric having an upper layer made of a thermoplastic synthetic fiber having a surface layer in which a plurality of single fibers are crushed to form a film and a lower layer that is a laminated nonwoven sheet A sheet is disclosed in Patent Document 2. This moisture permeable and waterproof nonwoven sheet is formed by crushing short fibers on the upper layer surface by thermocompression performed by passing between hot rolls to form a surface layer. Manufactured by crimping. According to this moisture-permeable and waterproof nonwoven sheet, an expensive and moisture-permeable and waterproof film that is easily prone to wrinkles is not required, so that it can be manufactured with a low yield using inexpensive raw materials.

  However, the moisture-permeable waterproof sheet of Patent Document 2 has a low adhesive strength between the upper layer and the lower layer, which are non-woven sheets, only by thermocompression bonding, and easily peels between the two. Therefore, for example, in the durability defined in JIS A6111 (2016), it is difficult to provide a strength that exceeds the water pressure of 8 kPa or more. In addition, since at least two thermocompression bonding steps of forming the surface layer and laminating the upper and lower layers are required, the manufacturing process becomes complicated and the manufacturing cost increases.

JP2013-76210A Japanese Patent Laid-Open No. 6-200464

  The present invention has been made to solve the above-described problems, and provides a moisture-permeable waterproof sheet that has high waterproofness and moisture permeability, has high strength and durability, and can be manufactured quickly and inexpensively, and a method for manufacturing the moisture-permeable waterproof sheet. The purpose is to do.

The moisture-permeable waterproof sheet of the present invention made to achieve the above object is a water-permeable impermeable and moisture-permeable gap, porous and / or non-woven fabric formed of a non-woven fiber formed of a hot-melt adhesive containing a moisture-permeable resin. A nonwoven sheet is fused at each of the fusion-bonded portions of the moisture-permeable adhesive layer on both surfaces of the moisture-permeable adhesive layer having a fusion-bonded portion and having adhesion by the hot melt adhesive , nonwoven sheet is a laminated sheet der shall the meltblown nonwoven sheet and spunbond nonwoven sheet.

  Examples of the moisture-permeable waterproof sheet include those in which the main component of the moisture-permeable resin is a saturated polyester resin.

  In the moisture permeable waterproof sheet, it is preferable that the moisture permeable resin contains a reactive urethane prepolymer.

  In the moisture permeable waterproof sheet, for example, the fusion site is an interface between the moisture permeable adhesive layer and the nonwoven sheet, and the melt blown nonwoven sheet of the melt blown nonwoven sheet and / or the spunbond fiber of the spunbond nonwoven sheet. The thing melt | dissolved by surface contact is mentioned.

It is preferable that the moisture-permeable waterproof sheet has a basis weight of the moisture-permeable adhesive layer of 10 to 50 g / m ² .

  The method for producing a moisture-permeable waterproof sheet of the present invention includes a step of heat-melting a hot-melt adhesive containing a moisture-permeable resin, and a hot roll in which nonwoven fibers are overlapped by spraying this on one surface of the first nonwoven sheet. A step of forming a web, a step of superimposing a second nonwoven sheet on the hot web, and a thermocompression-bonding process on a laminate comprising the first nonwoven sheet, the hot web, and the second nonwoven sheet. The first non-woven sheet and the second non-woven sheet are pressed against the hot web and pressed between the non-woven sheets while crushing at least a part of the non-woven fibers by Forming a wet adhesive layer.

  In the method for producing a moisture-permeable waterproof sheet, it is preferable that the nonwoven fibers in the hot web have a fiber diameter of 50 μm at the maximum.

  In the method for producing a moisture permeable waterproof sheet, the non-woven fiber when the thermocompression bonding process is performed may be uncured.

  The moisture-permeable waterproof sheet of the present invention has a size in which the non-woven fiber of the moisture-permeable adhesive layer made of hot melt adhesive containing a moisture-permeable resin does not transmit water droplets and allows vapor particles to pass through by maintaining the fiber shape. It has a fusion part that forms fine gaps and pores, and forms a sheet by fusing the non-woven fibers together while exhibiting high strength and waterproof / breathability by the moisture permeability of the moisture-permeable resin. Therefore, it has much higher durability than a collection of fibers that are simply overlapped or entangled while maintaining the fiber shape, and has both high moisture permeability and high waterproofness. .

  In a moisture-permeable waterproof sheet, if the main component of the moisture-permeable resin is a saturated polyester resin, the moisture-permeable adhesive layer expresses a high adhesive force and firmly presses against the non-woven sheet so that they are not peeled off. Therefore, even if it is a sheet-like fusion site, high moisture permeability can be obtained, and high durability is exhibited by being difficult to hydrolyze.

  In a moisture-permeable waterproof sheet, when the nonwoven sheet is a laminated sheet of meltblown nonwoven sheet and spunbond nonwoven sheet, when the moisture-permeable waterproof sheet is fixed to the building material with a fastener such as a nail or a spelling needle Since the meltblown fibers in the laminated sheet are firmly entangled with the fastener, a high nail hole water-stopping property can be obtained.

  In the moisture-permeable waterproof sheet, at the interface between the moisture-permeable adhesive layer and the nonwoven sheet, the melt-blown nonwoven sheet and / or the spunbond fibers of the spunbond nonwoven sheet are in surface contact and fused. Since the fusion site covers at least a part of the fibers and adheres over a wide range, and the adhesion between each layer can be increased to prevent the separation thereof, higher strength can be imparted to the moisture permeable waterproof sheet. .

  Since the moisture permeable waterproof sheet easily causes wrinkles in the manufacturing process and does not require an expensive moisture permeable waterproof film, the raw material cost and the manufacturing cost can be reduced, and it can be quickly manufactured with a general-purpose material.

  According to the method for producing a moisture-permeable waterproof sheet of the present invention, the pressure-bonding process is only required once, so that the moisture-permeable waterproof sheet can be produced quickly and inexpensively and the surface of the nonwoven sheet sandwiching the moisture-permeable adhesive layer can be produced. Does not cause excessive smoothing. Therefore, it is possible to prevent a worker who lays the moisture-permeable waterproof sheet at a high place such as a roof, and contributes to improvement of worker safety and workability.

It is a schematic cross section which shows one form of the moisture-permeable waterproof sheet to which this invention is applied. It is a schematic diagram which shows one form of the manufacturing method of the moisture-permeable waterproof sheet to which this invention is applied. It is a partially notched perspective view which shows an example of the usage method of the moisture-permeable waterproof sheet to which this invention is applied.

  Hereinafter, although the form for implementing this invention is demonstrated in detail, the scope of the present invention is not limited to these forms.

  A schematic cross-sectional view of one embodiment of the moisture-permeable waterproof sheet of the present invention is shown in FIG. The moisture permeable waterproof sheet 1 has a base layer 10 and a surface layer 30 that are non-woven sheets fused to both surfaces of a moisture permeable adhesive layer 20. The base layer 10, the moisture permeable adhesive layer 20, and the surface layer 30 are overlapped and stacked in this order. Since the moisture permeable waterproof sheet 1 is a thin sheet, it is soft and flexible. The moisture permeable waterproof sheet 1 is fixed to a building material such as a field board or a wall board of a wooden house.

  The moisture-permeable adhesive layer 20 is an aggregate of innumerable nonwoven fibers 21 as shown in the partially enlarged schematic cross-sectional view of FIG. The non-woven fiber 21 is formed by spinning a hot melt adhesive containing a moisture permeable resin by a melt blown method and then crushing it with a thermocompression roll (see FIG. 2). As a result, the moisture permeable adhesive layer 20 has a fiber portion 21a in which the non-woven fibers 21 holding the fiber shape are irregularly overlapped or entangled with each other, and a part of the non-woven fibers 21 is crushed by crushing. It has the fusion | melting site | part 21b which lost the shape and was mutually fuse | fused.

  The non-woven fiber 21 in the fusion bonded portion 21b is subjected to thermocompression bonding (see FIG. 2), and is crushed and spread in an uncured softened state, loses its fiber shape, and is fused to each other as a sheet. It has a form. Therefore, the fusion-bonded portion 21b existing at the interface 22 between the moisture-permeable adhesive layer 20, the base layer 10 and the surface layer 30 is fused while covering and covering the fibers of both layers 10 and 30. As a result, the layers 10, 20, and 30 are firmly bonded to each other, so that the moisture-permeable waterproof sheet 1 exhibits a waterproof property that can withstand a water pressure of 8 kPa or more in the durability defined in JIS A6111 (2016).

  Moreover, since the moisture-permeable adhesive layer 20 formed of the hot melt adhesive contains a moisture-permeable resin, the moisture permeability is not impaired even if it has the sheet-like fused portion 21b. The fusion bonding portions 21 b are scattered innumerably in the moisture-permeable adhesive layer 20. Thereby, the tensile strength and tear strength of the moisture-permeable adhesive layer 20 are much higher than those of the fiber aggregates that are merely overlapped or entangled while maintaining the fiber shape.

  In the filament part 21a, the non-woven fiber 21 forms a fine gap or porosity between them by overlapping or entanglement. Furthermore, the line portion 21a existing at the interface 22 between the moisture permeable adhesive layer 20, the base layer 10 and the surface layer 30 is formed on the fibers of both layers 10 and 30 by the adhesive force of the hot melt adhesive as the material. Contact and adhere.

  The gaps and the width of the pores in the filament region 21a are preferably 10 to 80 μm, more preferably 10 to 50 μm, and even more preferably 10 to 30 μm. As a result, the gaps and pores exhibit, for example, water resistance and steam with a diameter on the order of nanometers while exhibiting waterproofness without allowing drizzle having a diameter of 100 to 500 μm or raindrops having a diameter exceeding 500 μm to pass through. It also expresses moisture permeability.

Basis weight of the moisture-permeable adhesive layer 20 is preferably from 10 to 50 g / ^{m 2,} more preferably from 10 to 30 g / ^{m 2,} and even more preferably from 10 to 20 g / ^{m 2.} If the basis weight is less than the lower limit value, the non-woven fibers 21 are insufficient, and the strength and waterproofness such as waterproofness are reduced. If the basis weight exceeds the upper limit value, the non-woven fibers 21 become excessive and the waterproofness is improved, but on the other hand, excessive narrowing of the gaps and porosity is caused and the moisture permeability is lowered.

  The main component of the hot melt adhesive forming the non-woven fiber 21 is a resin that expresses moisture permeability and adhesiveness. Specific examples of such resins include saturated polyester resins, polyolefin resins, polyurethane resins, And polyamide resin. Among these, a saturated polyester resin is preferable from the viewpoint of high moisture permeability, hardly hydrolyzable, and easy processability, and an amorphous saturated polyester resin is more preferable from the viewpoint of higher moisture permeability.

  Since the saturated polyester resin does not have an unsaturated bond in the molecule, the saturated polyester resin has higher stability and heat melting property than the unsaturated polyester resin having the unsaturated bond. The amorphous saturated polyester resin has randomly arranged molecular chains. For this reason, the molecular chain density is sparse compared to a crystalline saturated polyester resin having regularly and densely arranged molecular chains, so that the molecular chain arrangement does not hinder the permeation of water vapor particles. Thus, the amorphous saturated polyester resin is considered to exhibit high moisture permeability. Such an amorphous saturated polyester resin is a chart in which the horizontal axis represents temperature (° C.) and the vertical axis represents differential scanning calorific value (W), for example, when the transition heat is measured according to JIS K7122 (1987). It is preferable to show an exothermic peak due to base shift and / or crystallization due to glass transition and an endothermic peak due to melting.

  The saturated polyester resin is a copolymer of a polyvalent carboxylic acid and a polyhydric alcohol having no polymerizable unsaturated bond in the main chain and / or side chain. Examples of the polyvalent carboxylic acid include terephthalic acid, isophthalic acid, orthophthalic acid, dimethyl terephthalate, trimellitic acid, pyromellitic acid, α-naphthalenedicarboxylic acid, β-naphthalenedicarboxylic acid, and dimethyl 2,6-naphthalenedicarboxylate. Aromatic carboxylic acids such as: succinic acid, itaconic acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,9-nonanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, and esters thereof Aliphatic polycarboxylic acids such as derivatives; alicyclic polycarboxylic acids such as 1,4-cyclohexanedicarboxylic acid, tetrahydrophthalic anhydride, and hexahydrophthalic anhydride.

  Polyhydric alcohols include ethylene glycol, diethylene glycol, triethylene glycol, 1,2-propanediol, 1,3-propanediol, 2,2-diethyl-1,3-propanediol, 1,3-butanediol, 2,4-butanediol, 1,5-pentanediol, 3-methylpentanediol, 2,2,3-trimethylpentanediol, neopentyl glycol, 1,3-hexanediol, 1,4-hexanediol, 1,6 -Hexanediol, 2,5-hexanediol, 2-ethyl-1,3-hexanediol, 1,2-octanediol, 1,8-octanediol, 2-methyl-1,8-octanediol, 1,10- Decanediol, 1,12-dodecanediol, and 1,18-octadecanediol, 1,20-e Aliphatic polyhydric alcohols such as cosandiol; alicyclic polyhydric alcohols such as 1,4-cyclohexanedimethanol and hydrogenated bisphenol A; catechol, 4-t-butylcatechol, resorcinol, hydroquinone, 2-t -Butylhydroquinone, 2,5-dihydroxytoluene, 2,6-dihydroxytoluene, 3,4-dihydroxytoluene, 1,3-dihydroxynaphthalene, 1,5-dihydroxynaphthalene, 1,6-dihydroxynaphthalene, 2,3- Such as dihydroxynaphthalene, 2,6-dihydroxynaphthalene, 2,7-dihydroxynaphthalene, 2,2′-dihydroxydiphenyl, 2,3-dihydroxydiphenyl, 4,4′-dihydroxydiphenyl, bisphenol A, and phloroglicinol Aromatic polyhydric alcohols; Glycerin, trimethylol ethane, trimethylol propane, polyhydric alcohols such as pentaerythritol.

  The saturated polyester resin is preferably a copolymer having one and / or a plurality of structural units of these polycarboxylic acid and polyhydric alcohol. For example, a saturated polyester having an aromatic carboxylic acid unit and an aliphatic and / or alicyclic polyhydric alcohol unit is preferable because it is amorphous.

  Specific examples of the saturated polyester resin include polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate (ester of dimethyl 2,6-naphthalenedicarboxylate (NDC) and ethylene glycol), polybutylene naphthalate (NDC and 1,3). -Ester with propanediol (PDO)), polycyclohexanedimethyl terephthalate (ester with terephthalic acid and 1,4-cyclohexanedimethanol (CHDM)), polycyclohexane dimethyl phthalate (ester with NDC and CHDM), polytrimethylene At least one selected from terephthalate (ester of terephthalic acid and PDO) and polytrimethylene naphthalate (ester of NDC and PDO) can be preferably used.

  According to the hot melt adhesive mainly composed of a saturated polyester resin, it is possible to easily produce ultrafine nonwoven fibers 21 using a melt blown method and to obtain nonwoven fibers 21 that are difficult to hydrolyze. Therefore, even if the moisture permeable waterproof sheet 1 is exposed to steam or raindrops, the moisture permeability and adhesiveness are not impaired, and performance and strength are not reduced. The content of the saturated polyester resin is preferably 50 to 100% by mass in the moisture-permeable resin, more preferably 60 to 100% by mass, and still more preferably 75 to 100% by mass.

  Specific examples of the hot-melt adhesive mainly composed of a moisture-permeable resin, which is a saturated polyester resin, include, for example, Polyester (registered trademark) series manufactured by Nippon Synthetic Chemical Industry Co., Ltd. and Byron manufactured by Toyobo Co., Ltd. (Registered trademark) series.

  The hot melt adhesive may contain a reactive urethane prepolymer in addition to the saturated polyester resin as a main component. According to this, the moisture permeability and flexibility of the moisture permeable waterproof sheet 1 and the adhesive strength of each layer 10, 20, 30 can be further improved. The reactive urethane prepolymer is preferably a moisture-curing type that is cured by moisture (water) in the air. Such a reactive urethane prepolymer can be obtained by reacting a polyester polyol and an isocyanate compound.

  The polyester polyol forming the reactive urethane prepolymer is obtained by a condensation reaction of a polyvalent carboxylic acid and a polyhydric alcohol. As polyvalent carboxylic acid, in addition to those forming the above saturated polyester resin, oxalic acid, malonic acid, glutaric acid, methyl succinic acid, dimethyl malonic acid, β-methyl glutaric acid, ethyl succinic acid, isopropyl malonic acid, tridecanedicarboxylic acid And aliphatic carboxylic acids having 2 to 24 carbon atoms such as tetradecanedicarboxylic acid, hexadecanedicarboxylic acid, octadecanedicarboxylic acid, eicosanedicarboxylic acid, maleic acid, fumaric acid, citraconic acid, and mesaconic acid.

  Examples of the polyhydric alcohol include aliphatic polyhydric alcohols, alicyclic polyhydric alcohols, and / or aromatic polyhydric alcohols that are the same as those forming the saturated polyester resin.

  Examples of isocyanate compounds that form reactive urethane prepolymers include methylene diphenyl diisocyanate (MDI), tolylene diisocyanate (TDI), hydrogenated methylene diphenyl diisocyanate (hydrogenated MDI), hexamethylene diisocyanate (HMDI), and Forone diisocyanate (IPDI).

  It is preferable that 0.7-1.2 mass% of isocyanate groups (-N = C = O) remain in the reactive urethane prepolymer. If the isocyanate group is less than this lower limit, the effect of improving the adhesive strength of the hot melt adhesive cannot be obtained, and if this upper limit is exceeded, carbon dioxide gas is generated due to reaction with moisture in the air, The adhesive will foam. Moreover, when the reactive urethane prepolymer is contained in the moisture-permeable resin, the content thereof is preferably 50% by mass or less, more preferably 5 to 50% by mass in the moisture-permeable resin, More preferably, it is 5-25 mass%. Specific examples of such reactive urethane prepolymers include Tyforce (registered trademark) series manufactured by DIC Corporation.

  The base layer 10 and the surface layer 30 mainly give strength to the moisture permeable waterproof sheet 1 and improve the handleability during transportation, storage, and construction of the moisture permeable waterproof sheet 1. The nonwoven sheets of the base layer 10 and the surface layer 30 are formed by stacking different kinds of nonwoven sheets. The nonwoven sheet is, for example, a meltblown nonwoven sheet and / or a spunbond nonwoven sheet. When the non-woven sheet is formed by lamination, the meltblown non-woven sheet (M) and the spunbond non-woven sheet (S) are formed between the spunbond non-woven sheets, for example, S / M / M / S. It is preferable that the meltblown nonwoven sheets are laminated to each other. High fiber density meltblown nonwoven with spunbond nonwoven sheet which has higher strength due to spunbond fibers which are continuous long fibers and meltblown fibers which are super short fibers which are irregularly arranged and overlapped and entangled with each other By stacking the sheets, the moisture-permeable waterproof sheet 1 can be provided with high tensile strength, tear strength, durability, and high flexibility.

  Furthermore, when the moisture permeable waterproof sheet 1 is fixed to the base plate or the wall plate, a fastener such as a nail, a screw, or a spelling needle penetrates the seepage plate (see FIG. 3). Since the base layer 10 and the surface layer 30 are laminated sheets such as S / M / M / S, the ultrafine fibers of the meltblown nonwoven sheet are entangled and adhered to the penetrating fasteners. The gap between the hole opened by the fastener and the fastener can be reliably closed. Therefore, a high nail hole water-stopping property can be imparted to the moisture-permeable waterproof sheet 1.

  The meltblown nonwoven sheet and the spunbond nonwoven sheet may be bonded to each other by a thermal bond method, a needle punch method, a spunlace method, and / or a chemical bond method. When bonded by the needle punch method, the surface of the spunbond nonwoven sheet as the outermost layer becomes more fuzzy, and the surface area can be increased. Thereby, the adhesion area is increased by increasing the adhesion area with the moisture-permeable adhesive layer 20, or the outermost surface 30a of the surface layer 30 and / or the outermost surface 10a of the base layer 10 is non-smoothed. Thus, it is possible to prevent the operator from sliding down when fixed to the base plate.

  The material of the non-woven sheet of the base layer 10 and the surface layer 30 is based on the softening temperature (glass transition temperature) or melting point of the hot-melt adhesive forming the moisture-permeable adhesive layer 20 and the surface temperature of the thermocompression bonding rolls 48a and 48b on both sides. Of these, a thermoplastic resin having a high heat-resistant temperature is preferable. This heat-resistant temperature means the maximum temperature at which the heated thermoplastic resin does not soften or melt. According to this, the hot web 42a which becomes the non-woven fiber 21 without softening or melting the non-woven sheet of the base layer 10 and the surface layer 30 in the thermocompression bonding step when manufacturing the moisture-permeable waterproof sheet 1. The uncured nonwoven fibers can be crushed or fused (see FIG. 2). Further, when the outermost surfaces 10a and 30a are in direct contact with the both-side thermocompression-bonding rolls 48a and 48b, smoothing thereof can be suppressed.

  Specific examples of such a material include saturated polyester resins different from the hot melt adhesive forming the moisture-permeable adhesive layer 20. In addition, polyolefin homopolymers such as polyethylene and polypropylene; α-olefin copolymers such as propylene-α-olefin copolymers and ethylene-α-olefin copolymers; polyamides such as aramids; polyurethanes; natural rubber, synthetic rubber, polybutadiene-based elastomers, Examples include elastomers such as styrene-butadiene elastomers, styrene-isoprene elastomers, and styrene-isobutylene elastomers. These may be used alone or in combination.

  As described above, according to the moisture-permeable adhesive layer 20 formed of the hot-melt adhesive containing the moisture-permeable resin, the filament region 21a of the nonwoven fiber 21 that maintains the fiber shape and is complicatedly overlapped or entangled is formed. The melt-bonded fiber and / or span of the base layer 10 and the surface layer 30 at the interface 22 is not only the moisture-permeable and waterproof property, but the fusion-bonded portion 21b that expresses moisture-permeable and waterproof properties and loses its fiber shape and is fused to each other. The moisture-permeable waterproof sheet 1 has the characteristics of high moisture permeability, high waterproofness, and high durability due to a synergistic effect of expressing high strength by being in surface contact with the bond fiber and firmly fusing. Further, since the melt blown nonwoven sheet (M) is entangled with the fastener by the base layer 10 and the surface layer 30 being an S / M / M / S laminate sheet, the moisture-permeable waterproof sheet 1 It also has high nail hole water resistance.

  The base layer 10 and the surface layer 30 may be a laminated nonwoven sheet of S / M / S, and may be a single-layer nonwoven sheet of a meltblown nonwoven sheet (M) or a spunbond nonwoven sheet (S). Or may have embossing. The base layer 10 and the surface layer 30 may be the same or different. Furthermore, the base layer 10 and / or the surface layer 30 may have a metal vapor deposition layer such as aluminum that improves heat shielding properties. Moreover, the base layer 10 and / or the surface layer 30 may have anti-slip | slip like rubber | gum in those outermost surfaces 10a and 30a.

  Each layer 10, 20, 30 may contain a water-absorbing resin. According to this, since this water-absorbent resin absorbs raindrops and the like, it is possible to more reliably prevent rainwater from penetrating into the field plate and the wall plate. Such water-absorbing resins include polyacrylates, polysulfonates, maleic anhydrides, polyacrylamides, polyvinyl alcohols, polyethylene oxides, and polyamines; polyaspartates, polyglutamates, polyalginates And natural product-derived polymers such as salts, starches, celluloses, polyglycols, and derivatives thereof. It is preferable to support these water-absorbing resins in a powder form on the nonwoven fibers of the respective layers 10, 20, and 30.

  The manufacturing method of the moisture-permeable waterproof sheet 1 of this invention is demonstrated referring FIG.

First, S / M / M / S laminated non-woven sheets to be the base layer 10 and the surface layer 30 are set on the first supply roll 41 and the second supply roll 47, respectively. Hot melt adhesive pellets 42 mainly composed of a saturated polyester resin are put into an applicator 43 and heated to 100 to 250 ° C., preferably 110 to 230 ° C., and melted. The applicator 43 is connected to the base end of the die 45 having the nozzle portion 45a, which is a narrowed tip, via a pipe 43a. The nozzle portion 45a opens at the tip of the nozzle portion 45a, extends in a straight line to the pipe 43a, communicates with the discharge nozzle 45a ₁ for discharging the molten hot melt adhesive, and is disposed so as to sandwich the hot nozzle 45a ₁ and a blowing nozzle 45a ₂ for blowing out 46. The nozzle portion 45 a of the die 45 is fixed so that the discharge nozzle 45 a ₁ is at an angle of 10 to 90 ° with respect to the surface of the belt 44 a of the conveyor 44. A die 45 having a hole diameter D of the discharge nozzle 45a ₁ of, for example, 200 to 1000 μm, preferably 300 to 700 μm, can be suitably used.

The melted hot melt adhesive is sent to the die 45 having the nozzle portion 45a. The conveyor 44 is operated to feed the first S / M / M / S laminated nonwoven sheet from the first supply roll 41 at a speed of 5 to 100 m / min, preferably 20 to 40 cm / min. The molten hot melt adhesive blown out from the nozzle part 45a at a discharge amount of 5 to 50 g / m ² , preferably 10 to 30 g / m ² , has a flow rate of 0.1 to 0.7 cm / second, preferably 0.2 to The S / M / M / S laminated non-woven sheet on the conveyor 44 is sprayed with hot air 46 having a temperature of 180 to 250 ° C., preferably 190 to 230 ° C. A hot web 42a is formed. The hot web 42a has uncured nonwoven fibers having an average fiber diameter of 5 to 50 μm, preferably 5 to 20 μm. Since the uncured nonwoven fiber is blown by the hot air 46, it forms a fiber shape at a high temperature and in an uncured state, and the uncured nonwoven fibers overlap without aligning in a specific direction without being aligned. The hot web 42a is formed in a network shape like a spider web.

  A second S / M / M / S laminated non-woven sheet serving as the surface layer 30 is fed out from the second supply roll 47 and stacked on the hot web 42a. The laminated body composed of the first S / M / M / S laminated nonwoven sheet, the hot web 42a, and the second S / M / M / S laminated nonwoven sheet is immediately put on the upper thermocompression-bonding roll 48a and the lower thermocompression bonding. The S / M / M / S laminated nonwoven sheet is thermocompression bonded to both sides of the hot web 42a through the roll 48b. The surface temperature of the upper thermocompression-bonding roll 48a is 80 to 180 ° C, preferably 80 to 130 ° C, and the surface temperature of the lower thermocompression-bonding roll 48b is 80 to 180 ° C, preferably 80 to 130 ° C. If the surface temperature of both-side thermocompression-bonding rolls 48a and 48b is not less than the softening point of the saturated polyester resin-containing hot melt adhesive and less than the softening point of the resin that forms the outermost layer of the S / M / M / S laminated nonwoven sheet. These may be the same or different from each other.

  In this thermocompression bonding step, the uncured meltblown fibers in the hot web 42a are crushed by the pressing of the thermocompression-bonding rolls 48a and 48b on both sides, partly flattened, and they are in close contact with each other. Fusing while maintaining the flat fiber shape. Here, due to the difference in fiber density in the base layer 10 and the surface layer 30 which are S / M / M / S laminated nonwoven sheets stacked on the hot web 42a, the pressing force of the both-side thermocompression-bonding rolls 48a and 48b is the hot web. It does not hang evenly on 42a.

  Therefore, the uncured nonwoven fiber of the hot web 42a that has received the concentration of the pressing force is deformed into a sheet shape while spreading each other by being crushed under high pressure under a temperature condition equal to or higher than the softening point of the hot melt adhesive. However, it fuse | melts and it becomes the melt | fusion part 21b, and the melt | fusion part 21b which exists in the interface 22 is pressed against the fiber of the base layer 10 and the surface layer 30, and surface-contacts them. On the other hand, uncured nonwoven fibers that have undergone stress relaxation due to the S / M / M / S laminated nonwoven sheet absorbing part of the pressing force of the thermocompression-bonding rolls 48a and 48b on both sides shorten the distance between them. Thus, the line portion 21a has a maximum gap of 80 μm that does not allow raindrops or the like to pass therethrough. The moisture-permeable adhesive layer 20 having the nonwoven fibers 21 is formed by cooling the uncured nonwoven fibers. The moisture permeable waterproof sheet 1 is completed. After the completed moisture-permeable waterproof sheet 1 is cooled, it is wound up by a winding roll 49.

  Thus, according to the manufacturing method of the moisture-permeable waterproof sheet 1, the layers 10, 20, and 30 can be laminated while forming the moisture-permeable adhesive layer 20 with a single line, and these can be bonded by a single thermocompression bonding process. it can. Furthermore, since an expensive moisture-permeable and waterproof film that is prone to wrinkles is not required, the moisture-permeable and waterproof sheet 1 can be manufactured quickly and inexpensively.

  In addition, when cooling the moisture-permeable waterproof sheet 1, it is preferable to rapidly cool it down to room temperature to 50 ° C., for example, 5 ° C./min, preferably 10 ° C./min, more preferably 15 ° C./min. . According to this, it is possible to obtain the moisture-permeable adhesive layer 20 including the amorphous polyester resin that suppresses the crystallization of the saturated polyester resin in the hot melt adhesive and expresses higher moisture permeability.

  The moisture permeable waterproof sheet 1 can be suitably used as a foundation for a roof of a wooden house. FIG. 3 shows a partially cutaway perspective view of the moisture permeable waterproof sheet 1 applied to the wooden house 50. The roof 51 of the wooden house 50 is covered with a number of slate tiles 51b.

  The moisture permeable waterproof sheet 1 is uniformly laid on the field board 51 c of the roof 51. The moisture-permeable waterproof sheet 1 is fixed to the base plate 51c by a spelling needle 53 that passes through the moisture-permeable waterproof sheet 1. Further, a nail 52 fixing the crosspiece 51a to the base plate penetrates the moisture permeable waterproof sheet 1. A slate roof tile 51b is fixed to the pier 51a. The roof 51 is sometimes exposed to heavy rain. Accordingly, even if raindrops enter between the slate roof tiles 51b, the moisture-permeable waterproof sheet 1 has high waterproofness, so that the raindrops do not enter the field board 51c. Furthermore, even if a large amount of rainwater flows between the slate roof tile 51b and the moisture-permeable waterproof sheet 1, the highly waterproof moisture-permeable waterproof sheet 1 does not peel off at the respective layers 10, 20, and 30. Intrusion can be reliably prevented.

  On the other hand, water vapor generated by heating in the wooden house 50 or cooking using fire rises and reaches the back of the hut in the wooden house 50. Since the moisture-permeable waterproof sheet 1 has high moisture permeability, the moisture-permeable waterproof sheet 1 can quickly permeate and release the water vapor to the outdoors. As a result, the moisture-permeable waterproof sheet 1 does not cause dew condensation even in an environment where the temperature difference between the low temperature outdoors and the wooden house 50 is large and the dew condensation is likely to occur on the field board 51c, especially in winter. No mold or decay occurs on the pillars and beams exposed at the pier 51a, the field plate 51c, and the back of the hut.

  Although the outermost surfaces 10a and 30a of the moisture-permeable waterproof sheet 1 are in direct contact with the both-side thermocompression-bonding rolls 48a and 48b in the manufacturing process thereof, they are not smooth because they are not softened or melted. When the waterproof sheet 1 is laid on the base plate 51 c and then the pier 51 a is fixed, an operator walking on the moisture-permeable waterproof sheet 1 does not slide or fall from the roof 51. Thus, the moisture-permeable waterproof sheet 1 contributes to the safety of workers and the improvement of workability.

  The moisture permeable waterproof sheet 1 can also be suitably used as a base for the outer wall 54 of the wooden house 50. In this case, it is preferable to cover the wall plate 54a with the moisture-permeable waterproof sheet 1 and fix it. The outer wall 54 has a lath 54b, a mortar 54c, and a coating film 54d stacked in this order on the moisture-permeable waterproof sheet 1. Even when the moisture-permeable waterproof sheet 1 is used for the outer wall 54, rainwater does not enter the outer wall 54 due to excellent waterproofness, and further, no condensation occurs on the outer wall 54 due to moisture permeability.

  Examples of moisture permeable waterproof sheets to which the present invention is applied are shown below.

Example 1
The moisture permeable waterproof sheet of the Example was produced as follows. 10 kg of saturated polyester resin pellets (trade name: Polyester, manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) and 3 kg of reactive urethane prepolymer pellets (manufactured by DIC Corporation) are mixed to contain a moisture-permeable resin. Hot melt adhesive pellets were prepared and melted at 120 ° C. A polypropylene S / M / M / S laminated nonwoven sheet was fed out from the supply roll at a speed of 20 m / min. The melted hot melt adhesive was sprayed onto the S / M / M / S laminated nonwoven sheet from the die at a discharge rate of 800 g / min and hot air at a discharge rate of 2 to ³ m ³ / min. As a result, a hot web having a basis weight of 20 g / m ² and an average diameter of 10 to 50 μm and super fine uncured meltblown nonwoven fibers overlapped in a network was obtained. Immediately after stacking another polypropylene S / M / M / S laminated nonwoven sheet on this hot web, the two S / M / M / S laminated nonwoven sheets and an uncured hot web sandwiched between them The laminated sheet made of was passed through between upper and lower thermocompression-bonding rolls adjusted to a surface temperature of 100 ° C. and thermocompression bonded to produce a moisture-permeable waterproof sheet. The moisture permeable waterproof sheet was blown with cold air, cooled to room temperature at 10 to 15 ° C./min, and then wound up. As a result, the moisture-permeable waterproof sheet of Example 1 was obtained.

(Example 2)
Only the saturated polyester resin pellets used in Example 1 were used as hot melt adhesive pellets, the melting temperature of this hot melt adhesive was 190 ° C., and the hot air discharge amount was 5 to 7 m ^3. A moisture permeable waterproof sheet of Example 2 was produced in the same manner as in Example 1 except that the value was set to / min. In addition, the average diameter of the hot web of Example 2 was 30 micrometers.

(Moisture permeability and durability test)
In accordance with JIS A6111 (2016), moisture permeability resistance as moisture permeability and water pressure resistance as durability were measured. The moisture permeability resistance specified in the same standard is 0.19 (m ² · s · Pa / μg) or less for the moisture permeable waterproof sheet A for outer walls, and 0.13 (m ² · m for the moisture permeable waterproof sheet B for outer walls). s · Pa / μg) or less, and 0.65 (m ² · s · Pa / μg) or less for the moisture-permeable waterproof sheet for roofs, and the water pressure resistance for durability is 8 kPa or more for both the outer wall and the roof. . The measurement results are shown in Table 1.

  As can be seen from Table 1, the moisture permeable waterproof sheet to which the present invention is applied exhibits low moisture permeability resistance and high water pressure resistance, and is excellent in moisture permeability and durability. In particular, the moisture-permeable waterproof sheet of Example 1 has a moisture-permeable resistance significantly lower than the standard of the moisture-permeable waterproof sheet for outer walls of JIS A6111 (2016) and a water pressure resistance that greatly exceeds it, so that only for roofs. It could also be used as an external wall.

  The moisture permeable waterproof sheet of the present invention is used as a base for a roof of a house or an outer wall. The manufacturing method of the moisture-permeable waterproof sheet of this invention is used for manufacturing the moisture-permeable waterproof sheet which has high moisture permeability, waterproofness, and durability cheaply and rapidly.

1 is a moisture permeable waterproof sheet, 10 is a base layer, 10a is an outermost surface, 20 is a moisture permeable adhesive layer, 21 is a non-woven fiber, 21a is a filamentous part, 21b is a fusion part, 22 is an interface, 30 is a surface layer , 30a is the outermost surface, 41 is the first supply roll, 42 is the hot melt adhesive pellet, 42a is the hot web, 43 is the applicator, 43a is the pipe, 44 is the conveyor, 44a is the belt, 45 is the die, 45a is the nozzle 45a ₁ is a discharge nozzle, 45a ₂ is an outlet nozzle, 46 is hot air, 47 is a second supply roll, 48a is an upper thermocompression roll, 48b is a lower thermocompression roll, 49 is a take-up roll, and 50 is a wooden house. , 51 is a roof, 51a is a pier, 51b is a slate tile, 51c is a base plate, 52 is a nail, 53 is a spell, 54 is an outer wall, 54a is a wall plate, 54b is a lath, 54c is a mortar, 54d is Somaku, D is pore size.

Claims (8)

Moisture permeable adhesive having water droplets non-permeable and moisture permeable gaps, pores and / or fusion sites formed by a non-woven fiber formed of a hot melt adhesive containing a moisture permeable resin and having adhesion by the hot melt adhesive A non-woven sheet is fused on each side of the layer at each of the fusing sites of the moisture-permeable adhesive layer, and the non-woven sheet is a laminated sheet of a meltblown non-woven sheet and a spunbond non-woven sheet moisture-permeable waterproof sheet which is characterized in der Rukoto.   The moisture-permeable waterproof sheet according to claim 1, wherein a main component of the moisture-permeable resin is a saturated polyester resin.   The moisture-permeable waterproof sheet according to claim 2, wherein the moisture-permeable resin contains a reactive urethane prepolymer. The fusion bonded portion is in surface contact with the meltblown fiber of the meltblown nonwoven sheet and / or the spunbond fiber of the spunbond nonwoven sheet at the interface between the moisture-permeable adhesive layer and the nonwoven sheet. The moisture-permeable waterproof sheet according to any one of claims 1 to 3, wherein the moisture-permeable waterproof sheet is provided. The basis weight of the moisture-permeable adhesive layer, moisture permeable waterproof sheet according to any one of claims 1 to 4, characterized in that a 10 to 50 g / m ^2.   A step of heat-melting a hot-melt adhesive containing a moisture-permeable resin, a step of spraying the hot-melt adhesive on one surface of the first nonwoven sheet to form a hot web in which the nonwoven fibers are overlapped, (2) crushing at least a part of the non-woven fibers by applying a thermocompression process to the laminate comprising the non-woven sheet and the first non-woven sheet, the hot web, and the second non-woven sheet. The first nonwoven sheet and the second nonwoven sheet are bonded to the hot web while fusing them together to form a moisture-permeable adhesive layer sandwiched between the nonwoven sheets. A method for producing a moisture permeable waterproof sheet. The method for producing a moisture-permeable waterproof sheet according to claim 6 , wherein the nonwoven fiber in the hot web has a fiber diameter of 50 µm at the maximum. The method for producing a moisture-permeable waterproof sheet according to claim 6 or 7 , wherein the non-woven fiber when the thermocompression bonding is performed is uncured.

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