JPH11137099A - Composite laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a thin, lightweight composite laminate having good handleability and rich light-shading property by adhering a resin to the surface or both the surfaces of a yarn fabric using spun-dyed yarns having a specific L-value. SOLUTION: This composite laminate is obtained by adhering a resin to the surface or both the surfaces of a yarn fabric partially using spun-dyed yarns having an L-value of <=50. The spun-dyed yarns preferably comprise black polyester multifilaments. The employment of the yarn fabric having a small fiber whiteness expressed by the L-value, namely having a large shading property, makes it possible to moderate a demand for the shading property of a resin layer coated on the fabric. The thickness of the resin coating film and the necessary concentration of a pigment or dye added to the resin can consequently be reduced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a waterproof composite laminate obtained by subjecting a fiber cloth to resin treatment, and more particularly to a composite laminate which is lightweight, has excellent handleability, and is excellent in light-shielding properties and antifouling properties. is there.

[0002]

2. Description of the Related Art Curtain materials used for darkening the inside of outdoor tents have applications in which light shielding properties are required in addition to waterproof and windproof properties. The curtain material used for the tent is made of a fiber fabric as the core to withstand the external force such as the weight of the curtain itself and wind pressure, and a vinyl chloride resin compound (excellent in durability and economical to provide waterproofness and windproofness). (Hereinafter abbreviated as PVC) has been used as a composite laminate in which an outer layer is coated, dipped, or laminated. In order to impart light-shielding properties to this, a method of blending carbon or a dark pigment with good light-shielding properties into PVC has been adopted. In addition, when the outer appearance of the tent and the inner appearance of the tent are disliked by the dark color, or when the inner surface of the tent is used as a projection screen, there are also provided those in which a white or another color PVC layer is further provided on the surface of the dark PVC layer. Have been.

[0003] In the prior art for providing light-shielding properties, light spots leaking from small spot-like defects that are thicker than the normal portions existing in the fiber cloth and small light-shielding portions of pinholes existing inside the PVC layer. There was a problem.
To prevent this, PVC with a dark color blend using a black pigment
Must be applied thickly so that light does not leak even if a point defect or a pinhole occurs in the fiber cloth. Further, when the surface is required to be white or light-colored, it is necessary to apply thickly to make the dark color of the base invisible. For those with a white or light-colored surface, in order to avoid such a thick coating, a lighter background color is used instead of a darker color, for example, a gray color is also available. Inferior, it is necessary to apply a thick undercoat to make up for this. In any case, a composite laminate with sufficient light-shielding properties will be heavy and heavy and difficult to handle with thick coating, and thin coating and light and easy to handle will cause point-like defects in fiber fabric and light leakage due to pinholes. There was a problem. The invention of a composite laminate which is thin, light, has good handleability, and has good light-shielding properties has been desired.

[0004]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a thin, lightweight, easy-to-handle, and light-shielding composite laminate.

[0005]

That is, according to the present invention, the L value is 5
A composite laminate characterized in that a resin is applied to one or both sides of a fiber cloth using at least a part of a soaked yarn of 0 or less, and the soaked yarn is preferably a black polyester multifilament. A composite laminate according to the above, characterized in that:

Hereinafter, the configuration and effect of the present invention will be specifically described. Conventionally, only P means
It was an ingenuity only for VC. On the other hand, the present invention aims to achieve the object of the present invention by improving the light shielding effect not only on PVC but also on fiber cloth, and by synergistic effects of both. By using a fiber cloth having a large light-shielding property, the requirement for the light-shielding property of the resin layer coated thereon can be relaxed. That is, it is possible to reduce the thickness of the resin coating and the required concentration of the pigment or colorant to the resin. It is important to reduce the whiteness of the fibers used, that is, to darken them, in order to enhance the light-shielding properties of the fiber cloth. The whiteness of the fiber is related to the light-shielding property, and the smaller the whiteness, the greater the light-shielding property. The whiteness of the fiber required to impart sufficient light-shielding properties to the fiber cloth is preferably 50 or less, more preferably 40 or less, and even more preferably 30 or less, as represented by the L value.

In order to obtain such low whiteness, there are a method of dyeing a fiber cloth and a method of using a dyed yarn. However, it is not preferable because the economical efficiency and the strength of the cloth and yarn in the dyeing process are reduced. In this regard, it is preferable to use a soaked colored yarn at the raw material stage of spinning. The color is preferably black, which is the easiest to obtain the light blocking effect. In particular, it is preferable to use a soaked yarn made of powdered carbon which is economical and hardly causes color transfer. Although it is preferable to configure the fiber cloth with only the original yarns in order to increase the light shielding property,
If the entire surface of the fabric can be covered with either the warp or the weft, such as a woven fabric, the original yarn may be used for only one of the warp or the weft. In addition, by using fibers having an L value of 50 or less, the stain is not conspicuous and an antifouling effect can be obtained. For applications that bring out this effect more, it is preferable to use a woven fabric in which the fibers are arranged in the warp and the weft. In the case of a woven fabric, the cover factor CF of either the warp or the weft obtained by the product of the square root of the fineness denier of the used yarn and the woven fabric density (book / in.) May be 400 or more.
It is preferably 440 or more, more preferably 470 or more. The CF is also designed based on the mechanical properties such as the tensile strength at break and the tear strength required for the fiber cloth, and may be set to a range that satisfies both properties. The form of the fiber fabric may be any of a woven fabric, a knitted fabric, and a nonwoven fabric, but a woven fabric that is thin for the strength of the fabric, light, and easy to handle is preferable. Woven fabrics are particularly good for medium-sized and large curtain applications where high fabric strength is desired.

It is needless to say that it is preferable to design the fiber cloth so that the mechanical properties are in the same direction as the curtain material. In a woven fabric, it is most preferable to adopt a flat structure in terms of design and economy. The principle of the present invention can be applied to any resin, such as a vinyl chloride resin, an acrylic resin, a polyester resin, and a polyolefin resin, as a resin composited with the fiber cloth. The resin coating layer may be on one side or both sides of the fiber cloth, but it is preferable to cover both sides to protect the fiber layer.

In order to increase the light-shielding property of the resin layer, there is a method of blending carbon powder, a pigment or a dye with the resin. The thickness of the resin layer varies depending on the light-shielding properties of the compounded resin. The thickness of this layer must take into account the thickness at the convex portion of the cross section of the fiber fabric which is the thinnest. This is because the concave portion has a thicker resin layer and has a greater light shielding effect than the convex portion. Further, it is necessary to consider the light-shielding property of the pinhole portion generated in the resin layer. In particular, if a pinhole is generated in a thin resin layer having a convex portion in the cross section of the fiber fabric, a problem of light leakage is caused. In addition, it is necessary to consider a resin thickness sufficient to sufficiently cover a defective portion which is thicker than a normal portion generated on the surface of the fiber cloth. However, the use of the fiber fabric of the present invention is preferable because the occurrence of this problem can be further reduced.

When the color of the surface of the composite laminate is white or light color, it is necessary to select a colorant in consideration of preventing contamination of the colorant of the yarn due to transfer to the resin layer on the surface. Particularly when PVC is used as the resin, the colorant of the yarn is preferably carbon or an inorganic pigment. The fiber material used for the fiber cloth is preferably a thermoplastic synthetic fiber such as polyester, nylon 6, nylon 66, olefin or the like, or an acrylic fiber. Polyester having a high melting point, easy to process with resin, easy to economically obtain a yarn having high tensile breaking strength, and good dimensional definition is preferable. The use of a yarn having a high tensile strength at break is important for obtaining a thin and light composite laminate because the fiber material required for obtaining a constant tensile strength at break of a fiber fabric is reduced. When light-shielding properties are required and the appearance of the composite laminate is desired to be white or light-colored, the resin layer needs to be a multi-layer of an undercoat and an overcoat. The undercoat is made of a resin considering light shielding, and the overcoat is made of a resin suitable for the appearance. If the color density of the undercoat is high, the overcoat layer must be thick to prevent the undercoat color from being seen through. However, the use of the fiber fabric having an improved light-shielding property, which is a requirement of the present invention, satisfies the light-shielding property of the fiber composite even when the color density of the undercoat resin is reduced, that is, reduced.
By lowering the color density of the undercoat resin, it is possible to make the overcoat layer necessary to prevent the color of the undercoat from being seen through, thereby obtaining a thin, lightweight, and easy-to-handle fiber composite as a whole. it can. The color of the undercoat resin may be selected from the same hue as the color of the overcoat.

In such an application, the composite laminate exhibiting the effects of the present invention to the maximum has a structure in which a woven fabric of black-dyed yarn is used for the fiber cloth, the undercoat resin is gray, and the overcoat resin is white or pale. The form of the yarn used for the fiber cloth may be a multifilament yarn or a spun yarn for a woven or knitted fabric, but the former is preferable because a yarn having a high tensile breaking strength is easily obtained. When a multifilament yarn is used, a loop-processed yarn such as a Taslan-processed yarn or a false-twisted yarn may be used. Such a processed yarn is preferable because the apparent outer diameter is increased due to the loop or crimped form, and the light shielding effect is increased. In particular, looped yarn is suitable for processing of large fineness,
It is more preferable that the light shielding effect is large and that the adhesion to the resin layer is good.

The processing method of the loop-processed yarn may be any of a method of processing a single-dyed yarn or a plurality of raw yarns at different supply speeds. When a plurality of raw yarns are used, it is preferable that all yarns are original yarns.However, using a yarn with a larger fineness as an original yarn and a yarn with a smaller fineness as an unprimed yarn is within a range where light-shielding properties are allowed. It is preferable to improve economy. In this case, it is preferable to use a weight ratio of the original yarn in the loop processed yarn of 70% or more and the L value of the original yarn of 30 or less in order to maintain the light shielding property. The fineness of the yarn used for the fiber cloth is preferably from 150 denier to 3000 denier, and more preferably from 200 denier to 2000 denier. If the fineness is smaller than 150 denier, the number of yarns required to obtain a predetermined strength of the yarns increases, and the process in the fabric preparation stage becomes complicated. On the other hand, if it exceeds 3,000 denier, the thickness of the obtained fabric becomes large, or if the design breaking strength of the fabric is small, the required fabric density of the yarn becomes small and the light-shielding effect of the yarn cannot be used effectively, and even coating is performed. Therefore, the minimum resin coating amount required for the coating is large, and the laminate becomes thick and heavy, which is not good.

[0013] Further, it is preferable that the tensile strength at break of the yarn used for the fiber cloth is large because the amount of yarn used for obtaining the design strength required for the cloth is small, and the weight is reduced. In this regard, the tensile breaking strength of the yarn is preferably 6.0 gf / denier or more, more preferably 6.5 gf / denier. When used for loop processing, the strength of the yarn is reduced by the processing, so that it is preferably 6.5 gf / denier or more, more preferably 7.0 gf / denier or more. When loop processing is performed at different supply speeds using a plurality of yarns, it is preferable to supply a yarn with a large fineness at a low speed and a yarn with a small fineness at a high speed in order to increase the strong utilization rate of the yarn. . Needless to say, a yarn having a large strength is used for a yarn having a large fineness. Yarns having a small fineness used for loop processing performed at different supply speeds are used for the purpose of effectively generating loops, and the higher the breaking strength of the yarn, the better, but a yarn with a breaking strength of 4.0 gf / denier or more is sufficient.

[0014]

Next, an embodiment will be described. 7. Breaking strength
An unprimed polyester multifilament yarn of 1 gf / denier, L value of 90, a multifilament yarn of 1000 denier, and a filament of 96 denier are woven with S80 T / m and woven with a rapier loom to obtain a woven fabric having a woven fabric density of 20 / inch (Comparative Example). 1 to
4). In addition, a woven fabric similar to that described above was obtained using a black-dipped polyester multifilament yarn having a breaking strength of 8.0 gf / denier L value of 22 and a denier 96 filament yarn of 1000 denier (Examples 1, 2, 7, and 8). Furthermore, a woven fabric was prepared in the same manner by changing only the gray dyed yarn having an L value of 33 and an L value of 54 (Examples 3 and 4). Breaking strength 8.0 gf / denier, L
Black dyed polyester multifilament yarn 25 with value 22
0 denier 48 filaments, twisted with S120 T / m, woven by water jet loom, woven fabric density 35
A book / inch woven fabric was obtained (Example 5). Breaking strength 8.1
The unwoven polyester multifilament yarn having an L value of 90 and a gf / denier of 25 was woven by a 25 jet loom to obtain a woven fabric having a woven fabric density of 35 yarns / inch (Comparative Examples 5 and 6).

Polyester multifilament yarn 750
25 denier 96 filaments with L value 22
Fineness of 1 denier 48 processed using two black denatured yarns each having an L value of 22 and having a L value of 22 at different supply speeds.
A 100 denier yarn was twisted with S80 T / m and woven by a rapier loom to obtain a woven fabric having a woven fabric density of 18 yarns / inch (Example 6). For the black spun polyester multifilament yarn, the mixing ratio of high-concentration carbon-containing chips and ordinary carbon-free chips is changed during the melt spinning process.
Yarns with different values were obtained. The chips used were industrial ones. 100 parts of vinyl chloride resin paste, 60 parts of plasticizer DOP,
2 parts of Ba-Zn-based stabilizer, 5 parts of tansan calcium,
1 part of an isocyanate-based adhesion improver, 1 part of a benzophenone-based weather resistance improver, and 4 parts of a white coloring agent titanium oxide were used as a basic blend of a white resin, and carbon powder was blended with the blend to obtain a black or gray resin. The L values of the used white, black, and gray resin curtains were 91, 25, and 43, respectively. The resin was applied to the fabric by a hand coating method. 120 ° C after application
Drying was performed for 3 minutes, followed by heat treatment at 185 ° C. for 5 minutes. In the case of overcoating, the surface of the fabric dried under the same conditions after the undercoating was overcoated with a hand coat, and then dried and heat-treated under the same conditions.

Examples 7 and 8 Comparative Examples 3 and 4
Black resins were used in Examples 1, 3 to 7 Comparative Examples 1, 2, 5, and 6 Gray compounds were used in Examples 2 and 8, Comparative Examples 3 and 4. All resins were applied to both sides of the fiber fabric. Coating was performed so that the coating amount was the same on both sides. Table 1 shows the amount of resin applied in each example and comparative example. As is clear from Table 1, the laminate according to the present invention has a small amount of resin applied, and is therefore thin, light, excellent in handleability, and excellent in light-shielding properties. In the case of undercoating the resin, as shown in Comparative Example 3, when the fiber cloth is white, the color of the undercoating resin is made gray to reduce the color transfer of the undercoating (a phenomenon in which the color of the undercoating resin is seen through the overcoat layer). The light-shielding property cannot be improved. As shown in Comparative Example 4, in order to satisfy the light-shielding property, it is preferable to increase the application amount of the undercoating gray resin, but it is thick, heavy and inferior in handleability.

[0017]

[Table 1]

In the table, the density of the fabric is 20 × 20.
Means the density of longitude and latitude. The unit of the positive amount of the fabric and the positive amount of the composite laminate is g / square meter. The coating amount indicates the coating amount on both sides, and the unit is g / square meter. "Undercoat color transfer" refers to the phenomenon in which the color of the undercoat resin is visible through the overcoat resin layer, and "light-shielding" refers to the application of light from the middle of a dark room to the surface of each 50 cm sample cloth, and the back side of the light irradiation surface. The state of light leakage was observed and evaluated (the evaluation is indicated by an average of 10 samples).
O has almost no leakage, Δ leaks a little, but there is no practical problem.
X indicates that there is a leak. "Handling property" was evaluated by comparing the handling property within the same specification (positive amount of fabric, resin coating layer) in which the resin coating amount satisfied the light shielding property. O: good handleability, Δ: slightly good handleability X: poor handleability.

Observation of the light-shielding properties of the knot portion of one thread which was present in the woven fabric of the same composite laminate as in Example 1 and Comparative Example 1 showed that the light-shielding properties were satisfactory in the normal portions without knots. However, there was no light leakage in the knot portion of Example 1 using the woven fabric using the black plain yarn, but there was light leakage in the knot portion of Comparative Example 1 using the woven fabric using the white normal yarn. It can be seen that the laminate according to the present invention has an effect of preventing light leakage even at a defective portion of a fiber cloth.

The measuring method used in the present invention will be described. L value: A sample is prepared by winding a yarn around a 5 cm square flat plate without any gap, and the L value of the yarn on the flat plate is measured. The L value of the resin is 400 to 500 g by the same processing method as described above.
/ Create a square meter resin curtain and measure the L value as a 5 cm square sample. The measuring machine uses Tokyo Denshoku Co., Ltd. color computer model TC-1500MC-88. Yarn fineness: JIS L-1013 7.3 positive fineness Yarn rupture strength: JIS L-1013 7.5.1 Standard time test Constant speed elongation type Pulling speed 20 cm / min Grip distance 25 cm Fabric positive weight: JIS L-1096 6.4.1 Fabric density: JIS L-1096 6.65 cm
Measure the number of yarns in between. Resin coating amount: Determined by the following equation when the positive amount of the fabric before application is W0g and the positive amount of the fabric after application is Wg. (W-W0) × 25 g / square meter For the fabric positive amount, weigh a sample of 20 cm square.

[0021]

According to the present invention, it is possible to obtain a composite laminate which is thin, lightweight, easy to handle, and excellent in light shielding and antifouling properties.

Claims (2)

[Claims] 1. A composite laminate characterized in that a resin is applied to one or both surfaces of a fiber fabric using at least a part of an original yarn having an L value of 50 or less. 2. The composite laminate according to claim 1, wherein the original yarn is a black polyester multifilament.