JP6671690B2 - 繊維ボードの製造方法 - Google Patents
繊維ボードの製造方法 Download PDFInfo
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- JP6671690B2 JP6671690B2 JP2017082599A JP2017082599A JP6671690B2 JP 6671690 B2 JP6671690 B2 JP 6671690B2 JP 2017082599 A JP2017082599 A JP 2017082599A JP 2017082599 A JP2017082599 A JP 2017082599A JP 6671690 B2 JP6671690 B2 JP 6671690B2
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- 239000011094 fiberboard Substances 0.000 title claims description 39
- 238000004519 manufacturing process Methods 0.000 title claims description 13
- 239000000835 fiber Substances 0.000 claims description 58
- 239000000306 component Substances 0.000 claims description 47
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims description 42
- 239000002131 composite material Substances 0.000 claims description 36
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 claims description 36
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 claims description 32
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 claims description 26
- 238000005452 bending Methods 0.000 claims description 22
- 239000008358 core component Substances 0.000 claims description 22
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 claims description 18
- 229920001577 copolymer Polymers 0.000 claims description 16
- 239000002184 metal Substances 0.000 claims description 13
- 239000001361 adipic acid Substances 0.000 claims description 9
- 235000011037 adipic acid Nutrition 0.000 claims description 9
- 238000013001 point bending Methods 0.000 claims description 7
- 238000004080 punching Methods 0.000 claims description 7
- 238000000034 method Methods 0.000 description 15
- 238000010438 heat treatment Methods 0.000 description 12
- 238000003825 pressing Methods 0.000 description 10
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 8
- 238000002844 melting Methods 0.000 description 8
- 238000009987 spinning Methods 0.000 description 8
- 239000004745 nonwoven fabric Substances 0.000 description 7
- 230000008018 melting Effects 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- 150000002009 diols Chemical class 0.000 description 5
- 229920000728 polyester Polymers 0.000 description 5
- 229920000642 polymer Polymers 0.000 description 4
- 230000007423 decrease Effects 0.000 description 3
- 238000002074 melt spinning Methods 0.000 description 3
- 125000006850 spacer group Chemical group 0.000 description 3
- 230000009477 glass transition Effects 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- -1 polyethylene terephthalate Polymers 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000011358 absorbing material Substances 0.000 description 1
- 238000009960 carding Methods 0.000 description 1
- 238000004581 coalescence Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
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- D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
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- D21J1/04—Pressing
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- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
- D04H3/147—Composite yarns or filaments
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
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- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
- D01D5/30—Conjugate filaments; Spinnerette packs therefor
- D01D5/34—Core-skin structure; Spinnerette packs therefor
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- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
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- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
- D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
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- D04H1/55—Polyesters
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- D—TEXTILES; PAPER
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/558—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in combination with mechanical or physical treatments other than embossing
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
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- D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
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- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/10—Organic non-cellulose fibres
- D21H13/20—Organic non-cellulose fibres from macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D21H13/24—Polyesters
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- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H15/00—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution
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- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
- D21H21/18—Reinforcing agents
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- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
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- D10B2401/00—Physical properties
- D10B2401/06—Load-responsive characteristics
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Description
芯成分として、エチレングリコールとテレフタル酸の共重合体(融点260℃)を準備した。鞘成分として、エチレングリコール、ジエチレングリコール、アジピン酸、テレフタル酸及びイソフタル酸の共重合体(融点200℃)を準備した。なお、ジオール成分としてのエチレングリコールは99モル%でジエチレングリコールは1モル%であり、ジカルボン酸成分としてのアジピン酸は19モル%でテレフタル酸は78モル%でイソフタル酸は3モル%である。上記した芯成分と鞘成分の両者を、複合紡糸孔を持つ紡糸装置に供給して、溶融紡糸を行い、芯鞘型複合長繊維を得た。芯成分と鞘成分の重量割合は、芯成分:鞘成分=7:3であった。これを紡糸装置の下方に設けたエアーサッカーに導入し、高速で牽引細化した後、公知の開繊装置で開繊させ、移動するスクリーンコンベア上に捕集及び集積させて繊維ウェブを得た。この繊維ウェブをニードルパンチ装置に搬送し、パンチ密度90本/cm2及び針深度10mmでニードルパンチを施し、重量900g/m2のニードルパンチ不織布を得た。
200℃に加熱された一対の金属製平板に代えて、180℃に加熱された一対の金属製平板を用いる他は、実施例1と同一の方法で繊維ボードを得た。
60秒間加圧するのに代えて、15秒間加圧した他は、実施例1と同一の方法で繊維ボードを得た。
60秒間加圧するのに代えて、30秒間加圧した他は、実施例1と同一の方法で繊維ボードを得た。
60秒間加圧するのに代えて、45秒間加圧した他は、実施例1と同一の方法で繊維ボードを得た。
芯成分として、実施例1で用いた共重合体を準備した。鞘成分として、エチレングリコールとジエチレングリコールとテレフタル酸とイソフタル酸の共重合体(融点200℃)を準備した。鞘成分を構成する共重合体は、ジオール成分としてのエチレングリコールは99モル%でジエチレングリコールは1モル%であり、ジカルボン酸成分としてのテレフタル酸は80モル%でイソフタル酸は20モル%であった。この両重合体を、複合紡糸孔を持つ紡糸装置に供給して、溶融紡糸を行い、芯鞘型複合長繊維を得た。芯成分と鞘成分の重量割合は、芯成分:鞘成分=6:4であった。これを紡糸装置の下方に設けたエアーサッカーに導入し、高速で牽引細化した後、公知の開繊装置で開繊させ、移動するスクリーンコンベア上に捕集及び集積させて繊維ウェブを得た。この繊維ウェブをニードルパンチ装置に搬送し、パンチ密度90本/cm2及び針深度10mmでニードルパンチを施し、重量900g/m2のニードルパンチ不織布を得た。
実施例1〜5及び比較例1で得られた各繊維ボードから、長さ150mmで幅50mmの各試験片を採取した。なお、各試験片の厚さは一対の金属製平板間に3mmのスペーサーを挟んでいるので、3mm±0.4mm程度となっているが、小数点以下を丸めて3mmとした。各繊維ボードは機械方向(繊維ウェブの搬送方向)に芯鞘型複合長繊維が配列している傾向にあるので、機械方向を試験片の長さ方向に採取した場合が、最も高い曲げ強さが得られる。したがって、各繊維ボードの機械方向が各試験片の長さ方向となっている。そして、支点間距離100mmとした支点の上に試験片を置き、支点間の中央に押圧板を速度20mm/minの速度で降下させ、荷重を負荷した。繊維ボードが破壊する際の最大荷重を測定して、最大曲げ強さを算出し表1に示した。なお、算出は次式により行った。最大曲げ強さMPa=[6×(最大荷重N)×50mm]/[50mm×(3mm)2]
三点曲げ試験による最大曲げ強さの測定で得られた歪−曲げ荷重曲線から、初期勾配により初期曲げ弾性率を算出し表1に示した。なお、算出は次式により行った。初期曲げ弾性率MPa=[初期勾配×(100mm)3]/[4×50mm×(3mm)3]
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最大曲げ強さ(MPa) 初期曲げ弾性率(MPa)
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実施例1 9.1 470
実施例2 9.4 550
実施例3 8.7 490
実施例4 11.0 470
実施例5 7.8 440
比較例1 6.8 230
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Claims (6)
- 芯成分がエチレングリコールとテレフタル酸からなる共重合体よりなり、鞘成分がエチレングリコールとアジピン酸とテレフタル酸とイソフタル酸及び/又はジエチレングリコールからなる共重合体よりなる芯鞘型複合繊維を集積して繊維ウェブを形成した後、該繊維ウェブを厚み方向に圧縮すると共に加熱して、該鞘成分を軟化又は溶融させ該芯鞘型複合繊維相互間を融着させて、平板状に成型することにより、三点曲げ試験による初期曲げ弾性率が300MPa以上の繊維ボードの製造方法。
- 予め加熱された繊維ウェブを、常温の金属製板に挟んで、厚み方向に圧縮する請求項1記載の繊維ボードの製造方法。
- 常温の繊維ウェブを、加熱された金属製板に挟んで厚み方向に圧縮する請求項1記載の繊維ボードの製造方法。
- 繊維ウェブにニードルパンチを施して、芯鞘型複合繊維相互間を三次元的に交絡させた後に、厚み方向に圧縮すると共に加熱する請求項1記載の繊維ボードの製造方法。
- 繊維ボードの三点曲げ試験による最大曲げ強さが7.3MPa以上である請求項1記載の繊維ボードの製造方法。
- 芯鞘型複合繊維が、芯鞘型複合長繊維又は芯鞘型複合短繊維である請求項1記載の繊維ボードの製造方法。
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