JPS6140544B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a felt material, and an object of the present invention is to provide a method that can accurately produce felt material made of new fine powder fibers that has been provided with a covering for beautification or waterproofing purposes. It is something.

Felt has excellent performance as a cushioning material, a heat insulating material, and a heat insulating material, and in particular, such felt is usually made from fine fibers generated as waste fibers at various textile factories. It has the advantage of being relatively inexpensive and has been widely used. However, this felt is a collection of fine fiber waste that seems to be suspended in the air in the factory, and it is essential to process it with needles to complete the fastening structure.
Although this results in an integrated plate-like body, as mentioned above, it is not possible to secure a favorable integration relationship with the fine fibers by mere needle processing, so the fibers are further processed by spraying, impregnation, or powder methods. Generally, a binding component such as a resin is added to strengthen the bond between fibers using a fiber method. However, the surface of the felt made of fine fibers obtained in this manner is quite fluffy, and layering a film such as a resin film on this felt can provide an effective fluff-preventing effect. Even if this is extremely important, it is impossible to stably bond such a resin film. Similarly, as mentioned above, when attempting to bond paper or other decorative materials, the bonding results in point-like bonding to the tips of the fibers, and no stable bonding can be formed no matter how large the bonding points between the microfibers are. It is the same. For this reason, felt materials are only used in a so-called shaded manner, where the surface is covered with other decorative materials, and if it is used with the surface exposed, its beauty will be impaired. Moreover, it is inevitably inferior in terms of waterproofness and other properties.

The present invention was created through repeated research to overcome the fatal disadvantages and drawbacks of the conventional fine fiber felt materials as described above. That is, the present invention aims at adhesion of the facing material by applying an adhesive to the surface of the felt as described above, and as a method for this adhesion, a press using a plate-shaped press mechanism is used to the extent that the applied adhesive oozes onto the surface of the felt. It is proposed that the adhesive be cured by maintaining the operating conditions.More specifically, the adhesive applied to the felt surface will penetrate into the felt structure over time, but the adhesive will harden. Due to the adhesiveness of the adhesive, a large amount of adhesive adheres to the surface side, and if a facing material is placed on the adhesive-coated object and the press operation conditions as described above are established, what will happen? Even if the felt is rough, the adhesive oozes out from the surface as a phenomenon opposite to the above-mentioned penetration, which is the same as when trying to drain water by squeezing wet clothing. By holding and curing the adhesive, it is possible to accurately form a stable adhesion state in a plane.

By the way, there is one more thing about felt material like this.
One of its drawbacks is that it absorbs water, and this is also the decisive reason why felt cannot be used as a surface material. It has a remarkable staining property because it is adsorbed to.
However, as a method to eliminate such stain resistance and water absorption, a synthetic resin film is used as the covering material as described above, but on the other hand, curing of the adhesive as described above is generally done by heating. is essential for completing bonding quickly.
In particular, this is an important requirement when maintaining the press operating conditions as described above for curing, and under these circumstances, if heating is performed, it will be compatible with the structural conditions of the felt surface. Over time, the synthetic resin film becomes deformed, causing wrinkles and other damage, and in some cases, wear-and-tear parts occur.Especially when using a film with a design for aesthetic purposes, the design may become large. It would inevitably collapse and spoil its aesthetic appearance. Therefore, in the present invention, a paper material is used in combination, that is, a paper material on which a pattern is printed is coated with a resin film in advance, or a synthetic resin film is simultaneously fed onto the paper material as described above. The adhesive is cured under such press operating conditions, thereby smoothly producing a facing felt without the above-mentioned disadvantages.

The adhesive curing treatment under the press operation conditions described above involves intermittent press conditions in which the felt and the paper material, etc. are sandwiched between the steel plates, and the adhesive oozes out from the surface as described above. Of course, you can work with it. However, as a method for carrying out such work industrially advantageously, a steel plate conveyor is adopted, in other words, a press roller or the like disposed on the inner surface of the steel plate conveyor is sandwiched between the opposed steel plate conveyors. The materials are transferred sequentially while forming special press conditions. In this way, continuous operation is possible and a desirable product can be obtained with high efficiency, and there are no wrinkles, undulations, or other deformations on the surface of the product.

Describing a specific embodiment of the present invention as shown in the accompanying drawings, one example of an apparatus for carrying out the present invention is as shown in FIG. On the other hand, an adhesive application mechanism 3 and a feeding mechanism for paper material 4 are disposed above it, and a feeding mechanism for resin film 6 is also provided as required. However, an adhesive curing chamber 8 is provided in front of such a conveyor 2, but steel strip conveyors 7, 7 are installed opposite to the adhesive curing chamber 8, and these steel strip conveyors 7, 7 are is equipped with a pressure roll 9 and a steel strip conveyor 7,
7. Appropriate pressurizing operation can be applied to the felt plate fed into the space between 7 and 7.

That is, according to the configuration shown in FIG. 1, the material coated with adhesive and paper is transferred while being held between the steel strip conveyors 7, 7, and the material is transferred to the steel strip conveyors 7, 7. A pressing effect is applied by the pressure roll 9, and the curing process is performed for a certain period of time while the pressure conditions are maintained. As for the pressure rolls 9, at least those for the upper conveyor 7 are heated by steam, electricity, etc., and in some cases, it is natural that the curing process is accelerated by heating the entire inside of the curing process chamber 8. It is.

The configuration of FIG. 1 as described above can also be modified and implemented as shown in FIG. 2. That is, a hot press mechanism 5 using the same steel strip conveyor 7 as the hardening chamber 7 as described above may be substituted for the hot press mechanism 10 installed in front of the conveyor 2 as shown in FIG. As described above, the steel strip conveyor exhibits a stable effect regardless of whether it is employed in the adhesion or hot pressing process, and achieves a desirable hot pressing effect as well as an adhesion effect. In particular, the use of such a mechanism in the curing process produces a final straightening effect on the finished felt, that is, even if the surface has been slightly disturbed during the previous process, the resulting felt is smooth. To ensure preferable smoothness of the structure, especially the surface of the paper material or resin film that forms the surface and is bonded.

In addition, in a case like Example 3 described later, it is natural that a coating mechanism, a drying mechanism, and other equipment will be appropriately installed in addition to the material obtained from the curing chamber 8 as described above. be.

Specific examples according to the present invention will be described below.

Example 1 A fabric with a unit weight of 1.2 kg/m ² and a thickness of 13 mm was obtained by needle processing in a conventional manner using a known general felt fiber material obtained as waste fiber from a textile processing factory or elsewhere. The felt board is sent to a conveyor 2 as shown in Fig. 1, and on this conveyor 2, a polyvinyl chloride adhesive is applied at a rate of 60 g/ ^m2 , and a synthetic resin film 6 is laminated with a strong toughness. After feeding the paper 4, it is fed into the steel plate conveyor 7, pressed to about 5 mm, and heated at 160℃.
Adhesive curing treatment for 35 seconds was completed under the above press conditions, and products were obtained one after another.

The obtained product was restored to a thickness of 9 mm, but the paper 5 described above was strongly and stably adhered to the surface of the felt, and the synthetic resin film layer was waterproof and stain resistant. It was possible to obtain a product which ensured prevention and could be used as a wall covering.

Example 2 The same material as in Example 1 was used as the raw material fiber material, and this raw material fiber material was disclosed in Patent Application No. 14528 (1973) (Japanese Patent Application Laid-open No. 106678-1983), which was separately proposed by the present inventors. ), a melamine urea phenol copolymer resin liquid with a resin content of 72% was sprayed at 19% by weight of the raw material fiber material, and about 17% by weight of asbestos powder was also sprayed before using a fan. The resin liquid is dispersed and mixed by pneumatic transfer through a suction tube, which is once received by a cyclone hopper, and then deposited on a conveyor. 1% by weight of the fiber material, 3% by weight of a diammonium phosphate salt flame retardant, and a small amount of an ammonium chloride catalyst were added, and this was mixed with a grooved roll having grooves perpendicular to the direction of transport of the fiber material. The fibers are sent into a beating cylinder under compressed conditions, and then combed by scraping claws on the circumferential surface of the beating drum, which rotates at a speed equivalent to about 40 times the fiber material feeding speed, and the fibers are combed as described above. A felt board with a unit weight of 1.2 kg/m ² and a thickness of 8 mm obtained by hot pressing a resin liquid evenly distributed over the entire fiber surface was used as the original felt board. . That is, as mentioned above, this felt board 1 is subjected to beating and combing treatment after being attached with the resin liquid, so that the strength and hardness of the fibers themselves are changed to a certain degree, and as mentioned above, even if the weight per unit area is the same, the thickness can be changed. is much smaller than that of Example 1, and therefore, even if one end of this 1 m square plate-shaped body is held and supported horizontally or vertically, it will hardly curve. The felt board of Example 1 has almost no flexibility, curvature, or bendability, which is typical of the felt board of Example 1.

However, the felt board 1 was placed on the conveyor 2 using the same vinyl chloride adhesive as in Example 1.
After applying the coating at a ^ratio of
The pieces were pressed to about 5.5 mm for 7 hours, and the adhesive was cured at 160°C for 25 seconds to produce products.

That is, this material can be widely used for ceiling materials, wall materials, etc., and can be obtained as an interior material with high aesthetic value by printing a pattern on the laminated paper 5 in advance. Ta.

Example 3 Only strong Japanese paper 1 was bonded to the same felt board 1 as in Example 2 in exactly the same manner as described in Example 2, hot pressed, and then a known polyurethane was applied to the top surface. An acrylic copolymer floor paint was applied to a thickness of about 1.5 mm using a roll coater, and the product was then dried at room temperature.

In other words, this product is intended to be used as a floor covering in place of a carpet, and the felt board 1 provides a soft feel when walking on it, and the amount of floor paint required is strong. Since it is limited only to the upper surface of the paper and does not penetrate into the felt board structure at all, a small amount is sufficient. When this floor paint is simply applied to a conventional felt board, most of the paint penetrates into the felt structure, so a large amount of paint is required and the felt structure is filled with the paint. Therefore, the soft feel of the felt layer was largely lost and the feel was similar to that of a mere paint plate, making it possible to obtain a new product that was extremely innovative.

[Brief explanation of the drawing]

The drawings illustrate embodiments of the invention,
FIG. 1 is a side explanatory view showing an example of an apparatus for carrying out the method of the invention, FIG. 2 is a similar perspective view of a modification thereof, and FIG. 3 is a section showing an example of a product according to the invention. Fig. 4 is a similar partial perspective view showing another example of the product. However, in these drawings, 1 is felt;
2 is a conveyor, 3 is an adhesive application mechanism, 4 is a paper material,
5 and 10 are hot press mechanisms, 6 is paper material, 7 is a steel strip conveyor, 8 is a curing chamber, 9 is a pressure roll, A is felt, B is an adhesive, and C is a paint layer. .

Claims (1)

[Scope of Claims] 1. After applying an adhesive to the surface of a felt made of fine powder fibers, a resin-coated paper material or a resin film and a paper material are polymerized, and the applied adhesive is applied to the felt surface by a plate-like press mechanism. A method for producing a facing felt material, characterized in that the adhesive is cured by maintaining press operation conditions such that the adhesive oozes. 2. After applying an adhesive to the surface of a felt made of fine powder fibers, the paper material is polymerized, and the adhesive is cured under press operating conditions such that the applied adhesive oozes onto the felt surface, and then paint is applied to the surface of the paper material. 2. A method for producing a facing felt material according to claim 1, wherein the coating material is coated to form a cured layer of the coating material.