JPH04370278A - Production of resin-coated sheet - Google Patents

Abstract

PURPOSE:To provide a thin and light-weight sheet having excellent thermal creep resistance, crease resistance and welder-bonding strength, free from migration of water in the texture because of the impregnation of thermoplastic resin even to the gap between filament yarns and cuttable without causing fraying. CONSTITUTION:A vinyl-coated yarn is produced by applying a paste of a vinyl chloride resin compounded with a flame-proofing agent, a stabilizer, etc., to a 1000D/192F polyester stock yarn by a nozzle process at a rate of 120%. The vinyl-coated yarn is woven at a warp and a weft density of 29X19/inch and the obtained fabric is subjected to stretch heat-treatment at 190 deg.C for 2min with a tenter machine to cause the flow of the resin and fill the gap in the fabric with the resin.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a lightweight and highly durable sheet that can be widely used as a cover sheet for outdoor storage sheets, truck sheets, floor sheets, tents, container bags, etc.

0002

BACKGROUND OF THE INVENTION Sheets used for track sheets, open pile sheets, etc., coated with thermoplastic resins such as vinyl chloride resins and ethylene-vinyl acetate copolymer resins have been well known. These are manufactured by coating a fabric woven using spun yarn or long fiber yarn of polyamide, polyester, vinylon, etc. with a thermoplastic resin by methods such as dipping, coating, and topping.

[0003] The reasons why vinyl chloride resins are widely used are that they have excellent processability and can be used in a variety of processing methods, and that the flexibility of the resin can be adjusted by adjusting the plasticizer. Utilizing the feature that heat is generated by high-frequency dielectric, sewing can be performed by high-frequency welder fusion processing. Sheets coated with ethylene-vinyl acetate copolymer resin are used for food and feed-related products where the plasticizer used when processing vinyl chloride resin may cause problems. .

[0004] In all of the above product processing methods, textiles are used as a base fabric and coated with resin, but since the adhesion between the fibers and the resin is poor, the amount of resin coated is increased to fill the voids in the textiles. At the same time, the fabric is manufactured with the idea of preventing the resin film from peeling off from the fibers by giving the surface of the base fabric a thickness that provides a certain level of film strength.

As mentioned above, sheets obtained by coating textiles with a predetermined resin as a base fabric generally have poor adhesion between the fibers and the resin, so it is necessary to thicken the surface resin layer, resulting in a decrease in fabric weight. The sheet is large and has poor workability when performing various tasks, so a light and easy-to-handle sheet is desired. In addition, when the resin of the above-mentioned sheet is damaged in some way, water permeates through the damaged area and diffuses between the single fibers that make up the threads by capillary phenomenon, and the resin layer is damaged due to swelling or freezing of the water. It has the disadvantage of increasing damage. Furthermore, if tension continues to be applied to the part sewn by high-frequency adhesive, especially if the sheet temperature becomes high,
There is a disadvantage that the sewn portion breaks due to the thread coming out of the sewn portion (poor heat-resistant creep property). For example, when products that have gone through the drying process are packed into container bags before they have completely cooled, problems have occurred in which the high-frequency sewn parts of the container bags break. Furthermore, when conventional sheets are cut for sewing, the threads at the cutting edge become frayed and remain on the surface of the sheet as thread waste, causing problems such as becoming foreign objects to the items packed in the container bag. Sometimes.

[0006]

[Problems to be Solved by the Invention] The present invention was made in view of the current situation, and consists of a sheet made of a woven fabric using synthetic long fiber yarn as a base fabric and coated with a thermoplastic resin, and a strong, Although the basic properties such as elongation are at the same level, the aim is to provide a sheet that is lightweight, easy to handle, has less damage to the resin film due to water penetration between the fibers, and has excellent durability.

[0007]

[Means for Solving the Problems] The present invention solves the above problems and has the following configuration. The present invention involves weaving a woven fabric using synthetic filament yarn coated with a thermoplastic resin using a nozzle method, and heat-treating this woven fabric to cause the coated thermoplastic resin to flow and fill the voids in the woven fabric. The gist of the present invention is a method for manufacturing a resin-coated sheet, which is characterized by filling.

The synthetic fiber long fiber yarn used in the present invention includes not only mass-produced synthetic fibers such as nylon, ester, and vinylon, but also aromatic polyamide fibers, fully aromatic polyester fibers, polyamide-imide fibers, and polyphenylene sulfide fibers. You can choose from a variety of fibers that have been developed as high-performance fibers for industrial materials, such as fibers and polyetheretherketone fibers.

[0009] Thermoplastic resins to be coated on the synthetic filament yarn include vinyl chloride resin, vinylidene chloride resin, ethylene-vinyl acetate copolymer resin, urethane resin, fluororesin, nylon resin, polyester resin, etc. Use these resins in paste form. For example, vinyl chloride resins include vinyl chloride polymers, vinyl chloride-acrylic acid ester copolymers, vinyl chloride-vinyl acetate copolymers, vinyl chloride-vinylidene chloride copolymers, etc. A paste is used by mixing a copolymer mixture with stabilizers, plasticizers, flame retardants, and other additives.

[0010] Methods for coating the yarn with the thermoplastic resin paste include a roller adhesion method in which the yarn is run in contact with the surface of a rotating roller and the resin paste adheres to the surface of the roller, and a roller adhesion method in which the yarn is coated with the resin paste on the surface of the roller. There is the dip method, in which the coating is immersed in water and then squeezed with a squeezing roll to obtain a targeted adhesion, but in the present invention, the nozzle method is used as a coating method that takes advantage of its characteristics. The nozzle method is a method in which yarn is immersed in resin paste and drawn out through a nozzle with a fixed hole diameter. In this case, in order to precisely control the amount of resin paste that adheres, there is a method of measuring and supplying the amount of resin paste to each nozzle. The reasons why the coating method using the nozzle method is adopted in the present invention are that the adhesion ratio of the thermoplastic resin to the synthetic fiber long fiber yarn to be fed can be increased, and that the thermoplastic resin It is easy to get between the single threads.

[0011] The adhesion ratio of the thermoplastic resin to the fed synthetic fiber long fiber yarn varies depending on the design. In general, if the density of the fabric is high, it may be small, but if the density is low and the fabric design is coarse, the adhesion ratio should be increased to fill the voids between the threads of the fabric.

The weaving process uses a shuttle loom, a rapier loom, etc., which are generally used for weaving fabrics for industrial materials. Generally, in order to obtain a lightweight fabric with a certain strength, it is sufficient to make a fabric with a coarse density using yarns with high strength, but this results in looseness occurring at the winding part of the loom or during processing in later processes. , there is a possibility that it may become partially mottled. In contrast, in the present invention, a thermoplastic resin is coated before weaving, and as a result, yarns thicker than the raw yarns to be fed are used for the warp and weft for weaving. As a result, even if the sheet is woven with a coarse density, it is difficult to cause misalignment, which is advantageous in obtaining a sheet with uniform weave.

In the present invention, the woven fabric is heat treated. This heat treatment softens and fluidizes the thermoplastic resin coated on the yarn, thereby bonding the warp and weft, filling the gaps between the warp and weft with the resin, and This is done in order to bring about effects such as ensuring that the resin enters between the constituent single yarns.

[0014] This heat treatment is carried out using a tenter or the like that can control the tension of the fabric during heat treatment by gripping both ears and using feed rolls and pull-out rolls. The heat treatment temperature is higher than the softening point of the coated resin, and is selected depending on the thermal characteristics of the resin. By applying appropriate tension to the fabric during heat treatment, the adhesion between the warp and weft becomes more reliable, and the resin also enters between the constituent single yarns. Bending caused by the tissue can be reduced, and the thickness of the finished fabric can be reduced.

[0015]

[Function] In the present invention, coated yarns in which a thermoplastic resin is applied to synthetic fiber long fiber yarns by coating them through a nozzle are used for the warp and weft yarns, and weaving is performed at a density that provides a predetermined strength. After that, it is heat treated at a temperature higher than the softening point of the thermoplastic resin, so the warp,
The resin flow caused by the softening of the vinyl chloride resin in the weft can be used to fill the gaps between the weaving yarns, and even if the resin has a small basis weight compared to the yarn basis, it has good adhesion, and is lightweight and easy to handle. The thermoplastic resin penetrates between the single threads of the yarn structure, making it difficult for water to penetrate between the single threads, resulting in a highly durable sheet with less damage to the resin film.

[0016]

[Examples] Next, the present invention will be explained in more detail with reference to Examples. Performance measurements and evaluations in the Examples were carried out in the following manner. (1) Based on basis weight JIS L-1096. (2) Thickness According to JIS L-1096. (3) Tensile strength Complies with JIS L-1096. (4) Cutting elongation According to JIS L-1096. (5) Water absorption according to JIS L-1096 Byreck method, width 2
A test piece measuring 5 mm x 20 cm long is suspended by pins on a horizontal rod supported at a constant height above a water tank containing distilled water at 20 ± 2°C. Make sure that the bottom 1 cm of the test piece is just submerged in water, and measure the height of water rise after leaving it for 10 minutes. (6) Air permeability according to JIS L-1096 A method, width 20cm x
After attaching a test piece with a length of 20 cm to one end of a cylinder using a Frazier type testing machine, adjust the suction pump using a variable resistor so that the inclined barometer indicates a pressure of 1.27 cm of water injection, and then From the pressure indicated by the vertical barometer and the type of air hole used, the amount of air passing through the test piece (cm3
/cm2/sec). (7) Rub resistance According to JIS K-6722, width 3cm x length 12c
A test piece of m is tested with a specified load of 2 using a Scotto type testing machine.
After rubbing the product a specified number of times under the following conditions: kg, reciprocating distance of 5 cm, and speed of 120 times/min, the state of damage is examined. (8) Heat-resistant creep properties A resin-processed sheet with a welder width of 3cm and a geta-shaped welding process was adjusted to a width of 1.5cm and a length of 15cm with the fused part located in the center, and Yasuda Co., Ltd. No. manufactured by Seiki Seisakusho. Using a 145-LCT creep tester, a load of 20 kg was applied and the specimen was left at 50°C.
The time required for the fused portion to be pulled out was measured. The larger the value, the better the heat resistance creep property. (9) Flapping test Fix one end of a sheet with a width of 5 cm and a length of 30 cm, and let the sheet flap in the wind at a wind speed of 40 m/sec.
A 1 cm square iron rod was provided 2 cm from the free end of the sheet, and the sheet was left for one week in a state where it was hit against the iron rod. Thereafter, the damaged parts were comparatively observed and judged in the following two stages. ○─── Almost no damage △─── Damage

[
Example 1 A paste containing polyester long fiber yarn 1000 denier/192 filament having an intrinsic viscosity (IV) of 0.98 and a strength of 9.5 g/d, a vinyl chloride resin, a plasticizer, a flame retardant, a stabilizer, etc. was coated using a nozzle method to obtain a PVC coated yarn with a coating weight of 120%. This PVC-coated yarn was processed using a rapier loom to reduce the density of the warp and weft to 29.
Weaving was performed at ×19 pieces/inch. Next, this fabric was subjected to tension heat treatment for 2 minutes at a temperature of 190° C. using a tenter machine to obtain the sheet of Example 1.

For comparison with the present invention, vinyl chloride resin was applied to a fabric woven using a rapier loom at a warp and weft density of 29 x 19 threads/inch using the same polyester long fiber yarn as in the example for the warp and weft threads. was subjected to topping processing to obtain a sheet of Comparative Example 1. Table 1 shows the physical property evaluation results of the sheets of Example 1 and Comparative Example 1.
Shown below.

[0019]

[Table 1]

As is clear from Table 1, the sheet produced by the method of the present invention has: (1) no peeling of PVC (good heat-resistant creep properties);
■It has the following characteristics: ■No water transfers into the tissue (no water is absorbed); ■It is resistant to abrasion (good resistance to rubbing); ■It is strong, light, and thin.

[0021]

[Effects of the invention] The voids between the warp and warp yarns of a fabric woven with synthetic filament yarns coated with thermoplastic resin using a nozzle method are filled with the flow of thermoplastic resin through tension heat treatment. The sheet according to the present invention is superior to sheets obtained by conventional topping or laminating methods.
It is thin and lightweight, with excellent heat resistance, creep resistance, and welder adhesion. In addition, since the thermoplastic resin is impregnated between the filaments of the long fiber yarn, there is no damage to the thermoplastic resin coating caused by water moving through the tissue, and the filaments are also bonded by the resin. There are no loose threads from the cut parts.

Claims (1)

[Claims] Claim 1: A woven fabric is woven using synthetic filament yarn coated with a thermoplastic resin using a nozzle method, and the woven fabric is heat-treated to cause the coated thermoplastic resin to flow, thereby reducing the voids in the woven fabric. A method for producing a resin-coated sheet, characterized by filling.