JPH05280163A - Waterproof sheet and manufacture thereof - Google Patents

Abstract

PURPOSE:To execute firm waterproof lining, which is executed simply, by using a filled fiber layer, in which inorganic fibers are dispersed into a thermoplastic material, as a base. CONSTITUTION:In the waterproof sheet 10, an adhesive layer 13 is formed onto the rear of a filled fiber layer 11, in which the air gaps of, an inorganic fibrous nonwoven fabric are filled with a thermoplastic material. A thin smooth thermoplastic layer 12 is formed onto the surface of the filled fiber layer 11. The filled fiber layer 11 is formed in such a manner that a laminated sheet, in which the thermoplastic layer and a tacky plastic layer are shaped onto the surface and rear of a fiber layer composed of the inorganic fibrous nonwoven fabric respectively, is heated and pressed, and the thermoplastic layer and the tacky thermoplastic layer are fluidized and diffused into the fiber layer. The waterproof sheet 10 has large inter-layer peeling resistance because the filled fiber layer 11 is joined firmly with the thermoplastic layer 12 and the adhesive layer 13. Since the thermoplastic layer 12 as a surface layer has no defect such as a pore and is dense, it has excellent water repellency.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a waterproof sheet having good water repellency and sufficient strength, and a method for producing the same.

[0002]

2. Description of the Related Art When a steel plate or the like is used as a building material such as a slate, it is coated with a material that prevents rusting, generation, etc. and improves durability. The design is enhanced by the painting pattern,
It may improve the appearance of the building. When the coating film formed on the surface of the steel sheet is exposed to the outside air for a long period of time, microcracks and the like are likely to occur due to temperature change, thermal expansion difference from the base steel, and the like.

When water comes into contact with such a coating film, the water penetrates through the microcracks to the base steel and corrosion of the base steel proceeds. Moisture may be permeated from the surface on the opposite side of the steel plate through a hole formed at a place where the steel plate is attached to the beam, a butted portion of the steel plate, or the like. Therefore, when a steel sheet is used by making the best use of the coated surface, the durability of the coated steel sheet is improved by lining a waterproof sheet on the surface opposite to the steel sheet.

Among other buildings and structures, those that are exposed to a humid atmosphere or those that require humidity adjustment of the atmosphere are appropriately waterproofed. As a commonly used waterproof sheet, there is one in which a pressure-sensitive adhesive, a heat-sensitive adhesive or the like is coated on one surface of a synthetic resin film. The adhesive application surface is attached to the surface of the base material, and the base material is protected by the synthetic resin film. However, a waterproof sheet made of a synthetic resin film is apt to deteriorate in an atmosphere irradiated with ultraviolet rays such as sunlight, and has a problem in durability.

[0005]

Therefore, a thermoplastic resin, a rubber-like material, an asphalt-like material or the like (which will hereinafter be generically referred to as a thermoplastic material) which is fluidized by heating at a high temperature is used in place of the synthetic resin film. Attempts are being made. In this case, the thermoplastic material in a fluidized state, which is heated to a high temperature, is applied to the surface of the substrate either directly or after attaching an appropriate protective sheet. The thermoplastic material is cooled and solidified to form a strong and dense lining layer on the surface of the base material.

The thermoplastic material, depending on its material, is 1
It may be used in a molten state by heating to a high temperature of more than 50 ° C. Therefore, a facility for heating the thermoplastic material is required at the waterproofing construction site,
Not practical. Moreover, when a high temperature thermoplastic material is applied to the surface of a base material such as a steel plate, the heat of the thermoplastic material heats the base material to a high temperature, causing problems due to thermal deformation or residual stress. In particular, in the case where a coated film such as a coated steel plate is formed, discoloration or cracks may occur in the coated film heated to high temperature. For this reason, the method of applying the waterproof lining with the thermoplastic material in a high temperature fluid state is limited by the applicable base material.

The present invention has been devised to solve such a problem, and a strong waterproof layer is formed on the surface of a base material by infiltrating a thermoplastic material into an inorganic fiber to form a waterproof layer. It is an object of the present invention to provide an inexpensive tarpaulin suitable for

[0008]

The waterproof sheet of the present invention comprises:
In order to achieve the object, rock wool, a void of inorganic fiber nonwoven fabric such as slag wool is provided with a filled fiber layer filled with a thermoplastic material, and an adhesive layer provided on the back surface of the filled fiber layer, A dense and smooth thermoplastic layer is formed on the surface of the filled fiber layer.

This waterproof sheet is obtained by heating and pressing a laminated sheet in which a thermoplastic layer and an adhesive plastic layer are formed on the front and back surfaces of a fiber layer made of an inorganic fibrous nonwoven fabric such as rock wool and slag wool. It is manufactured by fluidizing the plastic layer and the adhesive thermoplastic layer to permeate the fiber layer, and filling the voids of the fiber layer with a thermoplastic material.

[0010]

[Working] The waterproof sheet of the present invention mainly comprises a layer in which fibers between rock wool or slag wool are filled with a thermoplastic material. If the waterproof sheet is made of only thermoplastic material, it will break, crack, or break when a moment such as bending is applied.
Chips are likely to occur. This strength problem is overcome by dispersing the inorganic fibers in the thermoplastic material. That is, because of the three-dimensional entanglement of the inorganic fibers,
The force applied to the waterproof sheet is wholly received through the entangled inorganic fibers, and local stress that causes breakage, cracking, chipping, or the like does not occur.

Since the inorganic fiber integrated with the thermoplastic material is rock wool or slag wool, which can be obtained relatively inexpensively, it does not increase the cost of the waterproof sheet itself. Rock wool or slag wool improves the handleability of the waterproof sheet without being separated into small pieces such as glass wool and causing a tingling sensation when touching the skin. Moreover, it is superior in heat resistance and durability as compared with organic fibers such as synthetic resins.

In the waterproof sheet 10 of the present invention, as shown in FIG. 1, a dense and smooth thermoplastic layer 12 is formed on the surface side of the filled fiber layer 11, and an adhesive layer is formed on the back side of the filled fiber layer 11. 13 is formed. A release paper 14 such as oil paper or silicone paper may be attached to the adhesive layer 13.

The waterproof sheet 10 is manufactured in the following steps. First, as shown in FIG. 2, the thermoplastic layer 12a is bonded to the surface of the fiber layer 11a directly or with an adhesive.
On the back surface of the fiber layer 11a, a thermoplastic layer 13 having an adhesive property
a is bonded directly or with an adhesive 16a. The thermoplastic layers 12a and / or 13a can also be formed by applying an appropriate thermoplastic material to the fiber layer 11a by applying, impregnating, dipping or the like.

As the fiber layer 11a, a nonwoven fabric knitted from rock wool or slag wool is used. When rock wool or slag wool is processed into a non-woven fabric, an appropriate binder is added to bind the portions where adjacent fibers intersect with each other, and a non-woven fabric in which the fibers do not fall off can be obtained. The thickness of the non-woven fabric is preferably 0.5 to 10 mm in order to obtain a predetermined waterproof action and avoid thickening of the sheet.

The thermoplastic material integrated on the surface of the fiber layer 11a is a synthetic resin such as polyolefin or nylon, a synthetic or natural rubber material, an asphalt material such as blown asphalt, straight asphalt, or goose asphalt. , Paraffin materials, wax materials, etc. This thermoplastic material has a softening point of 40 to 2
Viscosity at 50 ° C and melt at 150 ° C is 1000-4
It is preferably 000 cP.

As the thermoplastic material forming the thermoplastic layer 13a, the same material as the thermoplastic material integrated on the surface of the fiber layer 11a or a thermoplastic material having high adhesiveness is used. Depending on the adhesiveness of the thermoplastic material, an adhesive, an adhesive, etc. may be mixed in a proportion of 7 to 75% by weight, if necessary.

Examples of the adhesives and pressure sensitive adhesives used include hot melt adhesives and pressure sensitive adhesives of synthetic rubber type or synthetic resin type having an initial tack, which have excellent adhesiveness to steel floorboards. It is preferable that it is flexible and has excellent thermal stability at about 150 ° C.

The thickness ratio of the thermoplastic layer 12a and the adhesive thermoplastic layer 13a to the fiber layer 11a is such that after lining, the filled fiber layer 11 is formed in which the voids of the fiber layer 11a are substantially filled with the thermoplastic material, and There is no particular limitation as long as the dense and smooth thermoplastic layer 12 is formed on the surface. Specifically, when the thickness of the fiber layer 11 a is t, the thermoplastic layer 12 depends on the density of the fiber layer 11.
a is (0.4 to 2) × t, and the adhesive thermoplastic layer 13a is (0.1 to 2) × t, and the total thickness of the thermoplastic layer 12a and the adhesive thermoplastic layer 13a is (0.5 to 4) × t is preferable.

The fibrous layer 11a having the thermoplastic layer 12a and the adhesive thermoplastic layer 13a adhered on both front and back sides is heated and pressed by a heating roller, a hot plate or the like. The heating / pressurizing conditions can be variously selected depending on the thermoplastic material used as long as the thermoplastic layer 12a and the adhesive thermoplastic layer 13a melt and fluidize and penetrate into the fiber layer 11a.

Thermoplastic layer 12a and adhesive thermoplastic layer 1
3a is melted and fluidized by heating and pressurization, and the fiber layer 11
permeates a. As a result, as shown in FIG. 1, the filled fiber layer 11 filled with the thermoplastic material is formed without leaving the voids originally present in the fiber layer 11a.
A surface layer 12 derived from the thermoplastic layer 12a is formed on the surface of the filled fiber layer 11. Since the surface layer 12 is pressed by a heating roller or the like, the surface layer 12 has a flat and dense surface without defects such as pores. The adhesive layer 13 derived from the adhesive thermoplastic layer 13 a remains on the back surface of the filled fiber layer 11. The adhesive layer 13 exhibits adhesiveness to the surface of the base material to be waterproofed.

When the adhesive strength of the adhesive layer 13 is insufficient, an appropriate adhesive may be applied again to the back surface of the waterproof sheet that has been heated and pressed. The release paper 14 is attached to the adhesive layer 13 to which a predetermined adhesive force is applied to prevent deterioration of the adhesive layer 13. The release paper 14 is also effective when the waterproof sheet 10 is wound into a roll and stored. The fiber layer 11a
Layer 12a and tacky thermoplastic layer 13a for
The permeation treatment can also be performed on the surface of the substrate to be waterproofed.

The surface layer 12 is of the same quality as the thermoplastic material of the filled fiber layer 11 and does not form a clear interface with the filled fiber layer 11. Therefore, even when a shearing force is applied, delamination does not occur between the filled fiber layer 11 and the surface layer 12.
Further, the surface layer 12 has a flat and dense surface texture free from defects such as pores, and therefore exhibits excellent water repellency. On the other hand, the filled fiber layer 11 has a structure in which the inorganic fibers are dispersed in the matrix of the thermoplastic material, and thus has sufficient strength.

[0023]

EXAMPLE As shown in FIG. 2, a thermoplastic layer 12a is formed on the surface.
As the fiber layer 11a provided with, a mineral fiber made of granulated blast furnace slag or the like and knitted to a thickness of 2 mm was used. As the thermoplastic layer 12a, a blown asphalt containing a petroleum resin having a melting point of about 90 ° C. and an inorganic filler and formed into a sheet having a thickness of 1.5 mm was used.

A blown asphalt mixed with 50% by weight of a synthetic rubber adhesive is attached to the back surface of the fiber layer 11a in an amount of 5
The adhesive thermoplastic layer 13a was formed by applying 50 g / m ² (0.5 mm in terms of thickness).

Thermoplastic layer 12a and adhesive thermoplastic layer 1
The fiber layer 11a in which 3a is laminated is placed on the release paper 14 spread in a mold equipped with a heating mechanism, and a pressing plate is pressed from above with a pressing force of 0.1 kgf / mm ² , and a temperature of 190 ° C.
Held for 5 minutes. After heating and pressurizing, the fibrous laminate was taken out from the mold, and the waterproof sheet 10 having the layered structure of FIG. 1 in which the thermoplastic material penetrated into the fibrous material 11a was obtained.

This waterproof sheet 10 comprises a filled fiber layer 11 having an average thickness of 2 mm and a thermoplastic layer 12 having an average thickness of 1.5 mm.
And a three-layer structure of the adhesive layer 13 having an average thickness of 0.5 mm, and the total thickness was 2 mm. The filled fiber layer 11 was completely filled with the thermoplastic material that had penetrated from the thermoplastic layer 12a and the adhesive thermoplastic layer 13a without leaving the voids between the fibers found in the original fiber layer 11a. ..

The interface between the filled fiber layer 11 and the thermoplastic layer 12 and the adhesive layer 13 was not clear, and the dispersion of fibers from the filled fiber layer 11 to the thermoplastic layer 12 and the adhesive layer 13 was continuously reduced. The thermoplastic layer 12 had an extremely smooth and dense surface. Release the release paper 14 and remove the adhesive layer 13
Was exposed, and its adhesive strength was examined to find that it was 8 kgf / c.
It exhibited a sufficient adhesive force of m ² . It was also found to have sufficient waterproofness.

[0028]

As described above, the waterproof sheet of the present invention is mainly composed of a strong filled fiber layer in which a thermoplastic resin is impregnated between nonwoven fabrics made of inorganic fibers, and the dense fiber layer is dense on the surface of the filled fiber layer. Since the smooth thermoplastic layer is provided on the back surface and the adhesive layer exhibiting sufficient adhesive force is provided on the back surface, it is possible to provide the excellent waterproof lining by a simple operation of simply sticking it to the surface of the base material. Since the formed waterproof lining is a filled fiber layer in which rockwool or slagwool fibers having excellent heat resistance and durability are dispersed in a matrix of a thermoplastic material, it firmly adheres to the substrate surface and It is highly durable without peeling.

[Brief description of drawings]

FIG. 1 is a waterproof sheet according to an embodiment of the present invention.

FIG. 2 Starting materials used in the same example

[Explanation of symbols]

11 Fiber Layer 12 Thermoplastic Layer 13 Adhesive Layer
14 Release paper

Claims (2)

[Claims] 1. An inorganic fibrous nonwoven fabric is provided with a filled fiber layer in which voids are filled with a thermoplastic material, and an adhesive layer provided on the back surface of the filled fiber layer, and the surface of the filled fiber layer is dense and smooth. A waterproof sheet having a transparent thermoplastic layer formed thereon. 2. A laminated sheet in which a thermoplastic layer and a tacky plastic layer are formed on the front surface and the back surface of a fiber layer made of rock wool or slag wool nonwoven fabric, respectively, by heating and pressurizing the thermoplastic layer and the tacky heat layer. A method for producing a waterproof sheet, comprising fluidizing a plastic layer to permeate the fiber layer and filling a void portion of the fiber layer with a thermoplastic material.