JPWO2010007917A1 - Heat-resistant cushioning material for molding press - Google Patents

Abstract

The heat-resistant cushioning material (10, 20) for molding press is configured by laminating a base (10B) and a felt material layer (1A, 1B, 1C, 1D). The cushion material (10, 20) has a felt material layer (1A, 1B, 1C, 1D) containing heat-resistant staple fibers, at least one layer for each of the front surface and the back surface of the base (10B). . Inside the cushion material (10, 20), a plurality of napped fiber bodies (30) made of fine staple fibers penetrate the base body (10B) and are formed in the thickness direction of the cushion material (10, 20). All felt material layers are connected. Thereby, cushion material (10, 20) becomes favorable in adjustment of a temperature increase rate, and cushioning properties.

Description

  The present invention relates to a heat-resistant cushioning material for molding press (hereinafter sometimes referred to as a cushioning material), and particularly relates to a heat-resistant cushioning material having an excellent temperature rise rate and high cushioning properties.

A product having a laminated structure (laminated product) is, for example, sandwiched between a plurality of hot plates and manufactured by hot pressing with these hot plates. An example of a laminated product manufactured by this method is as follows. In addition to the examples shown below, there are a wide variety of laminated products.
(1) Laminate board to be a printed wiring board substrate:
As this laminated board, there are a paper phenol laminated board made of kraft paper and phenol resin, and a glass epoxy laminated board made of glass fiber woven fabric and epoxy resin.
(2) Printed wiring board:
As this printed wiring board, a single-sided printed wiring board with a conductor pattern formed on one side of the board, a double-sided printed wiring board with a conductor pattern formed on both sides of the board, and a conductor pattern formed not only on the outside surface but also on the inside Multi-layer printed wiring boards.
(3) Flat panel display: Liquid crystal display, electroluminescence, etc.
(4) Semiconductor package: There is a chip size package (CSP) that is almost the same size as the chip.

  In the process of manufacturing these various laminated products (molded bodies) with a molding press apparatus, a cushion material is interposed between the hot platen and the laminated product. This cushion material has a cushioning property so that the hot platen and the laminated product do not directly contact each other, and also exhibits a function of uniformly transferring the heat generated by the hot plate to the entire surface of the laminated product.

A specific use example of this cushion material will be described with reference to FIG. FIG. 1 is a cross-sectional view illustrating an example of a laminated plate forming press in a double-sided printed wiring board manufacturing apparatus.
In the molding press apparatus 1 shown in FIG. 1, a pair of hot plates 40 arranged opposite to each other, a pair of cushion materials C arranged on the inner side of the pair of hot plates 40, and arranged on the inner side of the cushion materials C A pair of mirror plates 50, copper foil 60, and prepreg 70 are used.
Finally, a double-sided printed wiring board is formed by the prepreg 70 and the copper foil 60. The prepreg 70 is configured by stacking a plurality of plate materials in which a glass cloth is impregnated with an epoxy resin to form a semi-cured state.

The laminated plate is formed by applying heat and pressure with the hot plates 40, 40, but the molding conditions at this time differ depending on the composition of the epoxy resin raw material. Therefore, it is necessary to match the heat transfer amount (temperature increase rate: ° C./min) of the cushion material C used in the molding press process with the molding conditions.
If the heat transfer amount of the cushion material C does not match the molding conditions of the epoxy resin, there is a possibility that a physical property difference may occur in the laminated product. For example, a physical property difference is generated between a laminated product located in the immediate vicinity of the hot plates 40 and 40 and a laminated product located in the center between the hot plates 40 and 40 and away from the hot platen 40. Further, even in one laminated product, there may be a difference in physical properties between the central portion and the peripheral portion.

The reason for this is that in the manufacturing process in which the viscosity of the resin in the prepreg 70 is once lowered by the hot press and the resin is returned to a liquid state, and then the curing of the resin proceeds gradually. This is because the timing for increasing the pressure is shifted.
That is, the timing of the molding press by temperature and pressure for moving the resin to bond the prepregs 70, to bond the prepreg 70 and the copper foil 60, and to remove and subdivide the air contained in the resin. This is because it exceeds the allowable range.
For example, if pressure is applied to the prepreg 70 when the viscosity of the resin becomes too low, the resin flows more than necessary, and the thickness of the central portion of the laminated plate increases and the thickness of the peripheral portion decreases. As a result, there arises a disadvantage that the thickness of the finally manufactured laminated product becomes non-uniform.
On the other hand, if the pressure is applied to the prepreg 70 when the viscosity of the resin becomes too high, the resin does not flow sufficiently and the air contained in the resin does not disappear, which causes a problem in the insulation of the laminated product. Therefore, the cushion material C is required to have an excellent temperature rising rate.

Conventionally, craft paper or the like has been often used as a cushioning material in molding presses. However, in recent years, since the laminated product to be manufactured has been increased in size and precision, a cushioning material having further excellent characteristics has been demanded.
Examples of such cushion materials include those containing inorganic fibers and a heat-resistant aromatic polymer pulp (Japanese Patent Laid-Open No. 59-197295), and those containing aromatic polyamide fibers (Japanese Patent Laid-Open No. Sho). 62-156100). However, each cushion material has a short life because it is difficult to maintain the cushioning property.

For example, as such a cushion material, there is a heat-resistant cushion material C4 for forming press as shown in FIG. FIG. 6 is a cross-sectional view of a conventional heat-resistant cushion material C4 for forming presses.
The cushion material C4 shown in FIG. 6 includes a base 11B, a staple fiber felt material layer 11A laminated on the surface of the base 11B and needle punched, and a staple fiber felt laminated on the back surface of the base 11B and needle punched. It is constituted by the material layer 11A.
Thus, in the cushion material C4, the two felt material layers 11A and 11A are laminated. The staple fiber of the felt material layer 11A is made of a meta-aromatic polyamide. For the base body 11B, a woven fabric made of warp yarns 11B1 and weft yarns 11B2 made of heat-resistant fibers is used.

Since the staple fiber of the felt material layer 11A of the cushion material C4 is made of a meta-aromatic polyamide, the heating rate can be easily adjusted. On the other hand, the staple fiber of the meta-aromatic polyamide has a short life span because the cushioning material C4 has a short life because it is difficult to maintain the cushioning property.
Therefore, in order to maintain the cushioning property of the cushion material C4, it is conceivable to increase the basis weight of the staple fiber. However, if the basis weight of the staple fiber is increased, the heat conduction speed becomes slow, so that it is difficult to adjust the temperature rising speed, and the cushion material C4 becomes heavy and the usability during use deteriorates.

In order to eliminate such drawbacks of the cushion material C4, a heat-resistant cushion material C5 for molding press shown in FIG. 7 has been developed. FIG. 7 is a cross-sectional view of another conventional heat-resistant cushioning material C5 for forming presses.
The cushion material C5 shown in FIG. 7 includes a base body 21B, a staple fiber felt material layer 21A laminated on the surface of the base body 21B and needle punched, and a staple fiber felt laminated on the back surface of the base body 21B and needle punched. It is comprised by the material layer 21A. That is, in the cushion material C5, two layers of felt material layers 21A and 21A are laminated.
The staple fiber of the felt material layer 21A is made of a para-aromatic polyamide mainly composed of polyparaphenylene terephthalamide or the like. A woven fabric having warps 21B1 and wefts 21B2 made of heat resistant fibers is used for the base 21B.

  In the felt material layer 21A of the cushion material C5, since the staple fiber is made of para-aromatic polyamide, the cushioning property is excellent. However, since the cushion material C5 has too high thermal conductivity, it is difficult to adjust the temperature rising rate of the cushion material C5. In order to adjust the heating rate, it is necessary to increase the basis weight of the staple fiber, but the cushion material C5 becomes heavy, so that the usability during use is bad.

US Pat. No. 5,945,358 discloses a papermaking felt in which a spunbonded nonwoven fabric is disposed in order to obtain good void volume (void, porosity), running stability, and wear resistance. In this papermaking felt, bat fibers are arranged in the thickness direction of the felt in order to fix the spunbonded nonwoven fabric to the papermaking felt.
However, this papermaking felt is used for running and pressurizing wet paper, but it is not used by heating with a hot platen or the like.
Therefore, the papermaking felt is not required to have characteristics such as heat resistance, adjustment of the heating rate and maintenance of cushioning properties. Therefore, in US Pat. No. 5,945,358, there is no description regarding these characteristics which are the effects of the present invention.

Japanese Patent Laid-Open No. 59-192895 JP 62-156100 A US Pat. No. 5,945,358

  The present invention has been made to solve such a problem, and an object of the present invention is to provide a heat-resistant cushioning material for a molding press that can easily adjust a temperature rising rate and is excellent in maintaining cushioning properties.

In order to achieve the above-mentioned object, the present invention is a heat-resistant cushioning material for a molding press, which is used for manufacturing a laminated product (molded body) with a molding press apparatus and in which a base and a felt material layer are laminated. This cushion material has at least one layer (that is, one layer or two or more layers) of a felt material layer containing heat-resistant staple fibers with respect to one surface and the other surface of the substrate. Inside the cushion material, a plurality of napped fiber bodies made of fine staple fibers penetrate the base body and are formed in the thickness direction of the cushion material to connect all the felt material layers. .
As a result, it is possible to obtain a heat-resistant cushioning material for a molding press having excellent characteristics that has cushioning properties, can easily adjust the temperature rising rate, and can uniformly transmit heat to the entire surface of the laminated product. .

The “felt material layer including heat-resistant staple fibers” is formed by blending heat-resistant staple fibers and other staple fibers, and includes at least 50% by weight or more of heat-resistant staple fibers.
Preferably, the heat-resistant staple fiber constituting the felt material layer includes one or more selected from the group consisting of a meta-aromatic polyamide, a para-aromatic polyamide, and a flame-resistant fiber.
The napped fiber body is formed by entanglement between fibers by needle punching. The napped fiber body has a fineness of 1.0 to 10.0 dtex (decitex) and is made of heat-resistant staple fibers. In this case, the fineness of the napped fiber body is preferably 1.0 to 6.0 dtex (more preferably 1.0 to 3.0 dtex).

The density of the cushioning material is preferably 0.3 g / cm ³ to 0.5 g / cm ³ . Preferably, a surface layer material is laminated on the surface of the cushion material. This surface layer material is bonded to the cushion material by bonding means (for example, resin, prepreg, bonded staple fiber, etc.).

The “napped fiber” refers to a fiber in which the axis of the staple fiber of the napped fiber is oriented in the thickness direction of the cushion material. The “napped fiber body” refers to a bundle of at least three napped fibers.
It is preferable that at least 5 bundles (that is, 5 bundles / cm ² ) are disposed per unit area (1 cm ² ) in a plan view of the cushion material. In addition, the upper limit of the number of bundles of napped fiber bodies in the cushion material is a case where almost all or all of the unit area of the cushion material in a plan view is occupied by bundled napped fiber bodies. The aspect of the napped fiber body as described above can be confirmed by a microscope (see FIG. 4).

  “It is formed in the thickness direction of the cushion material” means that the axis of the staple fiber of the napped fibers is formed so as to face substantially perpendicular to the base material of the cushion material. In the present invention, a cushion in which the axis of staple fibers of napped fibers is oriented within the range of 45 degrees to 135 degrees and within the range of 225 degrees to 315 degrees with respect to the two-dimensional surface formed by the substrate. The material is also included in the configuration “the napped fiber body is formed in the thickness direction of the cushion material”. The “two-dimensional surface formed by the base” is, for example, the X and Z planes formed by the Z direction in which the warp extends and the X direction in which the weft extends, as shown in FIGS. is there.

  The heat-resistant cushion material for molding presses of the present invention is easy to adjust the rate of temperature rise and is excellent in maintaining cushioning properties.

It is sectional drawing which shows an example of the shaping | molding press of a laminated board in the manufacturing apparatus of a double-sided printed wiring board. It is sectional drawing of the heat-resistant cushion material for shaping presses concerning one embodiment of this invention. It is sectional drawing of the heat-resistant cushion material for shaping presses concerning the other embodiment of this invention. It is an expanded sectional view of the heat-resistant cushion material for forming presses shown in FIG. It is a table | surface which shows the various physical properties and performance of the sample of a cushioning material. It is sectional drawing of the conventional heat-resistant cushion material for shaping presses. It is sectional drawing of the conventional heat-resistant cushion material for shaping presses.

The basic structure of the heat-resistant cushioning material for molding presses according to the present invention is a cushioning material used for manufacturing a laminated product with a molding press apparatus, and a substrate and a felt material layer are laminated. In this cushion material, at least one layer (that is, one layer or two layers or more) of a felt material layer containing heat-resistant staple fibers is provided for each of one surface (front surface) and the other surface (back surface) of the substrate. Have. Inside the cushion material, a plurality of napped fiber bodies made of fine staple fibers penetrates the base and is formed in the thickness direction of the cushion material to connect all the felt material layers.
In particular, in this cushion material, the heat-resistant staple fibers constituting the felt material layer are meta-aromatic polyamides (Conex; trade name / manufactured by Teijin Ltd., Nomex; trade name / manufactured by DuPont), para-aromatic It is preferable to include one or more selected from the group consisting of a group polyamide (Kevlar; trade name / manufactured by DuPont, Toaron; trade name / manufactured by Teijin Ltd.) and flame resistant fire fiber.
For example, the felt material layer may be composed of composite staple fibers in which staple fibers of meta-aromatic polyamide and staple fibers of para-aromatic polyamide are mixed.

More specifically, the cushion material is a heat-resistant cushion material for a molding press that is used to manufacture a laminated product with a molding press device and in which a base and a felt material layer are laminated. This cushioning material includes one felt material layer containing meta-aromatic polyamide staple fibers, and another felt material layer containing para-aromatic polyamide staple fibers, and one surface (surface) of the substrate. Each has at least one layer (that is, one layer or two or more layers) with respect to the other surface (back surface).
Inside the cushion material, a plurality of napped fiber bodies made of fine staple fibers penetrate the base and are formed in the thickness direction of the cushion material to connect all the felt material layers.

In these cushion materials, the napped fiber body is preferably a heat-resistant staple fiber having a fineness of 1.0 to 6.0 dtex (decitex) and formed by entanglement between the fibers by needle punching. More preferably, the density of the cushioning material is 0.3 g / cm ³ to 0.5 g / cm ³ .

In the staple fiber having a large fineness, the entanglement between the fibers is weak, so that it is difficult to form a high-density napped fiber body. Therefore, in the present invention, the napped fiber body has heat-resistant staple fibers having a fineness. That is, using a heat-resistant staple fiber having a fineness, a napped fiber body having a high density is formed by entanglement between fibers by needle punching.
And, a large number of napped fiber bodies made of staple fibers having such fineness penetrate through the base inside the cushion material, and are formed in the thickness direction of the cushion material to connect all the felt material layers. Yes. If it carries out like this, many napped fiber bodies will exhibit the effect | action of a spring with respect to the thickness direction of a cushioning material. Therefore, the cushion material is easy to adjust the rate of temperature rise and has excellent cushioning durability.

  By the way, when the napped fiber body is formed in the thickness direction of the cushion material without penetrating the base body of the cushion material, the napped fiber body exhibits the action of the spring, but the temperature rising rate of the cushion material The adjustment becomes worse. The reason is that the napped fiber body made of fine staple fibers does not penetrate the cushion material base, and therefore the thermal conductivity in the thickness direction of the cushion material is deteriorated.

Further, when the density of the cushion material is 0.3 g / cm ³ to 0.5 g / cm ³ , the improvement in elasticity of the cushion material accompanying the increase in density and the cushioning property of the napped fiber body act as a synergistic effect. Therefore, cushioning properties are further improved.

A surface layer material is preferably laminated on the surface of the cushion material. If it carries out like this, when carrying out hot press molding of a laminated product (molded object), the surface of a surface layer material will change dependently according to the shape of the uneven surface of a laminated product. As a result, since the surface layer material is in close contact with the laminated product, the cushion material can be easily adhered to the uneven surface of the laminated product. Therefore, the heating plate can transmit the pressing force evenly to the laminated product through the cushion material.
As the surface layer material, a heat-resistant resin having releasability with respect to a cover lay film, a metal foil, or a hot platen is preferable.
As the coverlay film, a polyolefin resin can be used in addition to the polyamide resin and the polystyrene resin which are press molding films. As the coverlay film, Nomex (trade name / manufactured by DuPont) paper or the like made of fibers mainly composed of polymetaphenylene isophthalamide may be employed.
As the metal foil, aluminum alloy foil, stainless steel foil or the like can be used. The heat resistant resins are tetrafluoroethylene / ethylene copolymer (ETFE), tetrafluoroethylene / perfluoroalkyl vinyl ether copolymer (PFA), tetrafluoroethylene / hexafluoropropylene copolymer (FEP), and polytetrafluoro. Selected from the group consisting of ethylene (PTFE).

And in order to laminate | stack (arrange | position) a surface layer material on the surface of a cushion material, resin, a prepreg, or joining fiber is used.
As the resin, an epoxy resin or a polyimide resin can be used, and a heat-welding resin such as a fluorine film can also be used. As the prepreg, a glass epoxy prepreg sheet or the like can be used. As the bonding fiber, unstretched Conex fiber or wholly aromatic polyester fiber (Vectran; trade name) can be used.

Next, an embodiment of the present invention will be described with reference to FIGS.
2 is a cross-sectional view of a heat-resistant cushioning material for molding presses according to one embodiment of the present invention, FIG. 3 is a cross-sectional view of a heat-resistant cushioning material for molding presses according to another embodiment, and FIG. 4 is shown in FIG. It is an expanded sectional view of the heat-resistant cushion material for forming presses.
2 and 4, the first cushion material 10 includes a base body 10B, a first felt material layer 1A laminated on a surface (front surface) on one side (one hot platen 40 side) of the base body 10B, 2nd felt material layer 1B laminated | stacked on the other side surface (back surface) of base | substrate 10B, 3rd felt material layer 1C laminated | stacked on the surface of 1st felt material layer 1A, and 2nd felt material The fourth felt material layer 1D is laminated on the surface of the layer 1B.
The first felt material layer 1A and the second felt material layer 1B are respectively attached to the front surface and the back surface of the base body 10B by needle punching. The third felt material layer 1C is attached to the first felt material layer 1A by needle punching. The fourth felt material layer 1D is attached to the second felt material layer 1B by needle punching.
A plurality of napped fiber bodies 30 made of fine staple fibers penetrate the base body 10B and are formed in the thickness direction of the cushion material 10 to connect all the felt material layers 1A, 1B, 1C, 1D.

In the first cushion material 10 shown in FIG. 2, the first felt material layer 1A, the second felt material layer 1B, the third felt material layer 1C, and the fourth felt material layer 1D are each made of a meta-fragrance. One or both of an aromatic polyamide and a para-aromatic polyamide are included.
For example, the third felt material layer 1C and the fourth felt material layer 1D are made of a felt material of staple fibers (here, meta-aromatic polyamide) having a low thermal conductivity. By doing so, the thermal unevenness in the hot platen 40 is alleviated.
The first felt material layer 1A and the second felt material layer 1B are made of a felt material of staple fiber (here, para-aromatic polyamide) having high thermal conductivity. By doing so, the cushioning property is improved, and therefore, the adjustment of the temperature rising rate and the cushioning property can be set in a well-balanced manner as the cushion material 10 as a whole.

The second cushion material 20 shown in FIG. 3 has a configuration in which the surface layer material 1E is laminated on the surface of the first cushion material 10 (FIG. 2) (here, both one surface and the other surface). ing. That is, the surface layer material 1E is bonded to the surface of the third felt material layer 1C by the joining means P. The surface layer material 1E is also bonded to the surface of the fourth felt material layer 1D by the joining means P.
Also in the second cushion material 20, the first felt material layer 1A, the second felt material layer 1B, the third felt material layer 1C, and the fourth felt material layer 1D are formed of a meta-aromatic polyamide, respectively. One or both of the para-type aromatic polyamides are included.

In the first cushion material 10 and the second cushion material 20, the base body 10B is constituted by a woven fabric formed by weaving warp yarns 10B1 and weft yarns 10B2 made of heat-resistant fibers. The heat-resistant fiber is selected from the group consisting of meta-aromatic polyamide, para-aromatic polyamide, wholly aromatic polyester fiber, polyparaphenylene benzobisoxazole (PBO) fiber, and stainless steel fiber.
The base 10B is desirably a woven fabric made by weaving the warp yarn 10B1 and the weft yarn 10B2 as described above. However, instead of the woven fabric, the warp yarn and the weft yarn may be simply overlapped.

As described above, the base body 10B includes the warp yarn 10B1 and the weft yarn 10B2, and a large number of napped fiber bodies 30 are formed in the thickness direction of the cushion materials 10 and 20 through the base body 10B. Therefore, the warp yarns 10B1 extending in the Z direction, the weft yarns 10B2 extending in the X direction, and the napped fiber bodies 30 extending in the Y direction (thickness direction of the cushion materials 10, 20) are three-dimensionally arranged substantially orthogonal to each other. (Ie, X, Y, Z orthogonal coordinate system). And since the napped fiber body 30 has penetrated the base | substrate 10B, the intermediate part of the napped fiber body 30 is hold | maintained firmly at the base | substrate 10B (FIGS. 2-4).
As a result, a large number of napped fiber bodies 30 exhibit a spring effect in the thickness direction of the cushion materials 10 and 20, so that the cushioning properties of the cushion materials 10 and 20 are improved.

The first felt material layer 1A and the second felt material layer 1B are attached to one surface (front surface) and the other surface (back surface) of the base body 10B by needle punching, respectively. A third felt material layer 1C is attached to the surface of the first felt material layer 1A by needle punching. A fourth felt material layer 1D is attached to the surface of the second felt material layer 1B by needle punching.
The joining means P is respectively arranged on the surface of the third felt material layer 1C and the surface of the fourth felt material layer 1D thus formed. The joining means P is, for example, an unstretched Conex staple fiber and a felt material having a small basis weight.
And if the whole is hot-pressed in a state where the surface layer material 1E is disposed and laminated on the surface of the joining means P, the joining means P melts. As a result, the third felt material layer 1 </ b> C and the surface layer material 1 </ b> E are firmly bonded (adhered) via the molten bonding means P. Further, the fourth felt material layer 1D and the surface layer material 1E are firmly bonded (adhered) via the molten bonding means P.

Here, a method for forming a plurality of napped fiber bodies 30 in the thickness direction of the cushion materials 10 and 20 so that the napped fiber bodies 30 penetrate the base body 10B will be described.
(Procedure 1)
First, a woven fabric is prepared as the base body 10B. A carded staple fiber web is laminated on the front and back surfaces of the woven fabric. Then, needle punching is performed to entangle the staple fiber to the woven fabric (base 10B). Thereby, the 1st felt material layer 1A and the 2nd felt material layer 1B are each laminated | stacked on one surface (front surface) and the other surface (back surface) of a woven fabric (base | substrate 10B).
In this needle punching, needle punching needles (hereinafter referred to as needle needles) having 6 barbs or less per edge are used. The number of times of needle punching is 50 times / cm ² or less. Further, needle punching is performed by setting the first barb of the needle needle (the barb closest to the point) in contact with the woven fabric surface.
By such an entanglement process, the axial direction of the staple fiber becomes parallel to the woven fabric.

(Procedure 2)
The laminating operation is repeated until each of the first felt material 1A and the second felt material 1B reaches a predetermined basis weight. Eventually, when the first felt material 1A and the second felt material 1B reach a predetermined basis weight, the procedure proceeds to a procedure for forming the napped fiber body 30.

(Procedure 3)
In this procedure, a needle needle having a larger number of barbs (stabs) than the needle needle used in the entanglement process (for example, needles of 8 barbs or more per ridge) is used. The plurality of napped fiber bodies 30 are formed in the thickness direction of the cushion materials 10 and 20 by the needle needle.
For example, a needle with 2 ridges and 18 barbs is used, and the number of times of needle punching is 80 times / cm ² or more. The needle needle is set so that the final barb of the needle needle (the barb farthest from the point) passes through the woven fabric.
If needle punching is performed in this state, a plurality of napped fiber bodies 30 penetrates the woven fabric (base 10B) and is formed in the thickness direction of the cushion materials 10 and 20 to connect all the felt material layers. Thus, the cushion materials 10 and 20 having the plurality of napped fiber bodies 30 are completed.

When the fineness of the staple fiber is less than 1.0 dtex, the staple fiber is likely to become a hair ball by needle punching, and the napped fiber body 30 is difficult to form. On the other hand, when the fineness of the staple fiber exceeds 6.0 dtex, the entanglement between the staple fibers is weak, so that it is difficult to form the napped fiber body 30 with high density, and the cushioning property of the cushion material is weakened.
Therefore, in the cushion materials 10 and 20 of the present invention, the fineness of the staple fiber of the napped fiber body 30 is preferably in the range of 1.0 to 6.0 dtex. By doing so, the staple fibers are unlikely to become pills by needle punching, so that the napped fiber body 30 can be easily formed. Further, since the entanglement between the staple fibers becomes strong, the napped fiber body 30 having a high density is easily formed, and the cushioning properties of the cushion materials 10 and 20 are enhanced.
In the present invention, it is most preferable to use a heat-resistant staple fiber having a fineness of 1.0 to 3.0 dtex.

  The cushion materials 10 and 20 having the above-described configuration are applied to, for example, the laminated plate forming press apparatus 1 in the double-sided printed wiring board manufacturing apparatus shown in FIG. In this FIG. 1, the case where the laminated board used as the board | substrate of a double-sided printed wiring board is a laminated product is shown.

Hereinafter, the heat-resistant cushion material for molding presses of the present invention will be described in more detail with reference to examples. In addition, the following example does not limit this invention at all.
In the examples and comparative examples, the following configurations were all used in common.
(1) Cushion material base:
For the base material of the cushion material, a woven fabric woven from a spun yarn of a meta-aromatic polyamide was used. The fiber of this woven fabric is Cornex (trade name / manufactured by Teijin Limited).
(2) Needle punching conditions:
(A) Entanglement conditions;
A needle of 6 barbs per ridge was used, the number of times of needle punching was 50 times / cm ^2, and the first barb of the needle needle was set at a position in contact with the woven fabric surface.
(B) Napped fiber body formation conditions;
In the examples, 18 barbs per two ridges were used after the entanglement treatment, the number of needle punching was 80 times / cm ^2, and the final barb of the needles was set at a position penetrating the woven fabric.
In the comparative example, in order to prevent the napped fiber body from being formed, 18 barbs per two ridges are used after the entanglement treatment, the needle punching frequency is set to 80 times / cm ^2, and the first barb of the needle needle is woven. It set to the position which contacts the cloth surface.

(1) About the staple fiber which comprises a felt material, in Examples 1-9 and Comparative Examples 1-5, the following were used.
(A) As staple fibers of meta-aromatic polyamide, Cornex (trade name / manufactured by Teijin Ltd.) 2 dtex 50 mm cut short fibers were used.
(B) Polyparaphenylene terephthalamide (Kevlar; trade name / manufactured by DuPont) 2 dtex 50 mm cut short fiber was used as the staple fiber of the para-aromatic polyamide.

(2) About the staple fiber which comprises a felt material, in Examples 10-12 and Comparative Examples 6 and 7, the following were used.
(A) As staple fiber of meta-aromatic polyamide, Cornex (trade name / manufactured by Teijin Ltd.) 6 dtex, 50 mm cut length short fiber was used.
(B) Polyparaphenylene terephthalamide (Kevlar; trade name / manufactured by DuPont) 5 dtex short fiber having a cut length of 50 mm was used as the staple fiber of para-aromatic polyamide.

Example 1
Polyparaphenylene terephthalamide staple fibers were laminated as carding webs on the front and back surfaces of the woven fabric, respectively. Then, needle cushioning was performed to form the first felt material layer 1A and the second felt material layer 1B, respectively, and the cushioning material according to Example 1 was produced.

(Example 2)
Conex staple fibers were laminated as carding webs on the front and back surfaces of the woven fabric, respectively. And the needle material was punched and the 1st felt material layer 1A and the 2nd felt material layer 1B were formed, respectively, and the cushioning material concerning Example 2 was produced.

(Example 3)
Polyparaphenylene terephthalamide staple fiber on the surface of the woven fabric (the surface on the one side of the heating platen 40), Conex staple fiber on the back side of the woven fabric (the surface on the side opposite to the one of the heating platen 40), Each was laminated as a web. Then, the first felt material layer 1A and the second felt material layer 1B were formed by needle punching, and the cushion material according to Example 3 was produced.

Example 4
A web obtained by blending 50% by weight of staple fibers of polyparaphenylene terephthalamide and 50% by weight of carbon fibers is laminated as a web on the surface of the woven fabric (the surface on the one heating platen 40 side). On the back of the woven fabric (the surface opposite to one of the heating plates 40), 50% by weight of Conex staple fibers and 50% by weight of carbon fibers are mixed and laminated as a web.
And the needle material was punched and the 1st felt material layer 1A and the 2nd felt material layer 1B were formed, respectively, and the cushioning material concerning Example 4 was produced.

(Example 5)
Conex staple fibers on the surface of the woven fabric (one side of the heating platen 40), and polyparaphenylene terephthalamide staple fibers on the back side of the woven fabric (the side opposite to the one of the heating plates 40), Each was laminated as a web. Then, needle cushioning was performed to form the first felt material layer 1A and the second felt material layer 1B, and the cushioning material according to Example 5 was produced.

(Example 6)
Polyparaphenylene terephthalamide staple fibers were laminated as carding webs on the front and back surfaces of the woven fabric, respectively. Then, needle punching was performed to form a first felt material layer 1A and a second felt material layer 1B, respectively, and a cushion material according to Example 6 was produced. In Example 6, compared with Example 1, the basis weight of staple fibers was increased.

(Example 7)
Conex staple fibers were further laminated as webs on the surface of the cushion material produced in Example 1. Then, needle punching was performed to form a third felt material layer 1C and a fourth felt material layer 1D, and a cushion material according to Example 7 was produced.

(Example 8)
Further, a staple fiber of polyparaphenylene terephthalamide was laminated as a web on the surface of the cushion material manufactured in Example 2. Then, needle punching was performed to form a third felt material layer 1C and a fourth felt material layer 1D, respectively, and a cushion material according to Example 8 was produced.

Example 9
An ETFE film was further bonded to the surface of the cushion material produced in Example 7 via a glass epoxy prepreg sheet to produce a cushion material according to Example 9.

(Example 10)
Polyparaphenylene terephthalamide staple fiber on the surface of the woven fabric (the surface on the one side of the heating platen 40), Conex staple fiber on the back side of the woven fabric (the surface on the side opposite to the one of the heating platen 40), Each was laminated as a web. Then, needle punching was performed to form the first felt material layer 1 </ b> A and the second felt material layer 1 </ b> B, and the cushion material according to Example 10 was produced.

(Example 11)
On the surface of the woven fabric (the surface on the one heating platen 40 side), a mixture of 50% by weight of staple fibers of polyparaphenylene terephthalamide and 50% by weight of carbon fibers was laminated as a web. On the back of the woven fabric (the surface opposite to one of the heating plates 40), 50% by weight of Conex staple fibers and 50% by weight of carbon fibers were mixed and laminated as a web.
Then, needle punching was performed to form a first felt material layer 1A and a second felt material layer 1B, respectively, and a cushion material according to Example 11 was produced.

(Example 12)
An ETFE film was further bonded to the surface of the cushion material produced in Example 10 via a glass epoxy prepreg sheet to produce a cushion material according to Example 12.

(Comparative Example 1)
Polyparaphenylene terephthalamide staple fibers were laminated as carding webs on the front and back surfaces of the woven fabric, respectively. Then, the first felt material layer 1A and the second felt material layer 1B were formed by needle punching, and the cushion material according to Comparative Example 1 was produced.

(Comparative Example 2)
Conex staple fibers were laminated as carding webs on the front and back surfaces of the woven fabric, respectively. Then, needle punching was performed to form a first felt material layer 1A and a second felt material layer 1B, respectively, and a cushion material according to Comparative Example 2 was produced.

(Comparative Example 3)
Polyparaphenylene terephthalamide staple fiber on the surface of the woven fabric (the surface on the one side of the heating platen 40), Conex staple fiber on the back side of the woven fabric (the surface on the side opposite to the one of the heating platen 40), Each was laminated as a web. Then, needle cushioning was performed to form a first felt material layer 1A and a second felt material layer 1B, respectively, and a cushion material according to Comparative Example 3 was produced.

(Comparative Example 4)
On the surface of the woven fabric (the surface on the one heating platen 40 side), a mixture of 50% by weight of staple fibers of polyparaphenylene terephthalamide and 50% by weight of carbon fibers was laminated as a web. On the back of the woven fabric (the surface opposite to one of the heating plates 40), 50% by weight of Conex staple fibers and 50% by weight of carbon fibers were mixed and laminated as a web.
Then, needle cushioning was performed to form the first felt material layer 1 </ b> A and the second felt material layer 1 </ b> B, and the cushion material according to Comparative Example 4 was produced.

(Comparative Example 5)
An ETFE film was further bonded to the surface of the cushion material produced in Comparative Example 3 via a glass epoxy prepreg sheet to produce a cushion material according to Comparative Example 5.

(Comparative Example 6)
Polyparaphenylene terephthalamide staple fiber on the surface of the woven fabric (the surface on the one side of the heating platen 40), Conex staple fiber on the back side of the woven fabric (the surface on the side opposite to the one of the heating platen 40), Each was laminated as a web. And the needle punching was performed, the 1st felt material layer 1A and the 2nd felt material layer 1B were formed, respectively, and the cushioning material concerning the comparative example 6 was produced.

(Comparative Example 7)
An ETFE film was further bonded to the surface of the cushion material produced in Comparative Example 6 via a glass epoxy prepreg sheet to produce a cushion material according to Comparative Example 7.

About the sample of the cushion material produced in each of these Examples and Comparative Examples, the test was performed using a test apparatus having the same structure as the molding press apparatus 1 shown in FIG. Thereby, the performance of each cushion material was measured.
Regarding the sample of the cushion material, a series of procedures of “maintaining a temperature of 190 ° C. and a pressure of 40 kg / cm ² for 60 minutes, and then cooling with water for 15 minutes and releasing pressure for 15 minutes” is one cycle. And about this sample, after repeating this series of procedures 300 cycles and pressurizing a sample 300 times, the measurement of the item shown below was implemented.

(1) Measurement of heating rate (° C./min):
The time until the sample of the cushioning material was changed from 90 ° C. to 140 ° C. was measured, and a temperature increase rate (° C./min) was obtained.
As the evaluation of the rate of temperature rise, the rate of temperature rise of the sample exceeded 1.8 ° C./min, and “2.2” or less than 2.2 ° C./min exceeded “1.5 ° C./min. / Min or less, and exceeding 2.2 ° C./min and not exceeding 2.5 ° C./min are indicated by “◯” and the others are indicated by “x” (FIG. 5).

(2) Measurement of cushion displacement (μm):
The thickness of the cushion material sample was measured when the cushion material sample was molded and pressed at 0.2 kg and at 50 kg when heated to 180 ° C. Then, the difference between the thickness at the time of molding press at 50 kg and the thickness at the time of molding press at 0.2 kg was determined, and this difference was defined as the cushion displacement (μm).
As the evaluation of the cushion displacement amount, the cushion displacement amount of the sample was set to “◎” when the cushion displacement amount was 500 μm or more, “◯” when 400 μm or more and less than 500 μm, and “X” when less than 400 μm (FIG. 5).

FIG. 5 is a table showing various physical properties of the cushion material samples prepared in Examples and Comparative Examples, and the performance of the cushion material samples measured by the above test apparatus.
As can be seen from FIG. 5, the sample according to the example of the present invention is better in both the evaluation of the temperature rising rate and the evaluation of the cushion displacement amount than the sample according to the comparative example. Therefore, it was confirmed that the cushioning material according to the present invention is easy to adjust the temperature rising rate and is excellent in maintaining the cushioning property.
Moreover, regarding the density of the cushioning material in various examples of the present invention, the minimum value (0.30 g / cm ³ ) is obtained in Example 11, and the maximum value (0.49 g / cm ³ ) is obtained in Example 9. . Therefore, it can be seen that the density of the cushioning material of the present invention is preferably 0.3 g / cm ³ to 0.5 g / cm ³ .

Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications and additions are possible within the scope of the gist of the present invention.
In the drawings, the same reference numerals denote the same or corresponding parts.

  The heat-resistant cushion material for molding presses of the present invention can be applied to manufacturing processes for printed wiring boards, printed wiring boards, flat panel displays, semiconductor packages, and the like.

  The present invention relates to a heat-resistant cushioning material for molding press (hereinafter sometimes referred to as a cushioning material), and particularly relates to a heat-resistant cushioning material having an excellent temperature rise rate and high cushioning properties.

A product having a laminated structure (laminated product) is, for example, sandwiched between a plurality of hot plates and manufactured by hot pressing with these hot plates. An example of a laminated product manufactured by this method is as follows. In addition to the examples shown below, there are a wide variety of laminated products.
(1) Laminate board to be a printed wiring board substrate:
As this laminated board, there are a paper phenol laminated board made of kraft paper and phenol resin, and a glass epoxy laminated board made of glass fiber woven fabric and epoxy resin.
(2) Printed wiring board:
As this printed wiring board, a single-sided printed wiring board with a conductor pattern formed on one side of the board, a double-sided printed wiring board with a conductor pattern formed on both sides of the board, and a conductor pattern formed not only on the outside surface but also on the inside Multi-layer printed wiring boards.
(3) Flat panel display: Liquid crystal display, electroluminescence, etc.
(4) Semiconductor package: There is a chip size package (CSP) that is almost the same size as the chip.

  In the process of manufacturing these various laminated products (molded bodies) with a molding press apparatus, a cushion material is interposed between the hot platen and the laminated product. This cushion material has a cushioning property so that the hot platen and the laminated product do not directly contact each other, and also exhibits a function of uniformly transferring the heat generated by the hot plate to the entire surface of the laminated product.

A specific use example of this cushion material will be described with reference to FIG. FIG. 1 is a cross-sectional view illustrating an example of a laminated plate forming press in a double-sided printed wiring board manufacturing apparatus.
In the molding press apparatus 1 shown in FIG. 1, a pair of hot plates 40 arranged opposite to each other, a pair of cushion materials C arranged on the inner side of the pair of hot plates 40, and arranged on the inner side of the cushion materials C A pair of mirror plates 50, copper foil 60, and prepreg 70 are used.
Finally, a double-sided printed wiring board is formed by the prepreg 70 and the copper foil 60. The prepreg 70 is configured by stacking a plurality of plate materials in which a glass cloth is impregnated with an epoxy resin to form a semi-cured state.

The laminated plate is formed by applying heat and pressure with the hot plates 40, 40, but the molding conditions at this time differ depending on the composition of the epoxy resin raw material. Therefore, it is necessary to match the heat transfer amount (temperature increase rate: ° C./min) of the cushion material C used in the molding press process with the molding conditions.
If the heat transfer amount of the cushion material C does not match the molding conditions of the epoxy resin, there is a possibility that a physical property difference may occur in the laminated product. For example, a physical property difference is generated between a laminated product located in the immediate vicinity of the hot plates 40 and 40 and a laminated product located in the center between the hot plates 40 and 40 and away from the hot platen 40. Further, even in one laminated product, there may be a difference in physical properties between the central portion and the peripheral portion.

The reason for this is that in the manufacturing process in which the viscosity of the resin in the prepreg 70 is once lowered by the hot press and the resin is returned to a liquid state, and then the curing of the resin proceeds gradually. This is because the timing for increasing the pressure is shifted.
That is, the timing of the molding press by temperature and pressure for moving the resin to bond the prepregs 70, to bond the prepreg 70 and the copper foil 60, and to remove and subdivide the air contained in the resin. This is because it exceeds the allowable range.
For example, if pressure is applied to the prepreg 70 when the viscosity of the resin becomes too low, the resin flows more than necessary, and the thickness of the central portion of the laminated plate increases and the thickness of the peripheral portion decreases. As a result, there arises a disadvantage that the thickness of the finally manufactured laminated product becomes non-uniform.
On the other hand, if the pressure is applied to the prepreg 70 when the viscosity of the resin becomes too high, the resin does not flow sufficiently and the air contained in the resin does not disappear, which causes a problem in the insulation of the laminated product. Therefore, the cushion material C is required to have an excellent temperature rising rate.

Conventionally, craft paper or the like has been often used as a cushioning material in molding presses. However, in recent years, since the laminated product to be manufactured has been increased in size and precision, a cushioning material having further excellent characteristics has been demanded.
Examples of such cushion materials include those containing inorganic fibers and a heat-resistant aromatic polymer pulp (Japanese Patent Laid-Open No. 59-197295), and those containing aromatic polyamide fibers (Japanese Patent Laid-Open No. Sho). 62-156100). However, each cushion material has a short life because it is difficult to maintain the cushioning property.

For example, as such a cushion material, there is a heat-resistant cushion material C4 for forming press as shown in FIG. FIG. 6 is a cross-sectional view of a conventional heat-resistant cushion material C4 for forming presses.
The cushion material C4 shown in FIG. 6 includes a base 11B, a staple fiber felt material layer 11A laminated on the surface of the base 11B and needle punched, and a staple fiber felt laminated on the back surface of the base 11B and needle punched. It is constituted by the material layer 11A.
Thus, in the cushion material C4, the two felt material layers 11A and 11A are laminated. The staple fiber of the felt material layer 11A is made of a meta-aromatic polyamide. For the base body 11B, a woven fabric made of warp yarns 11B1 and weft yarns 11B2 made of heat-resistant fibers is used.

Since the staple fiber of the felt material layer 11A of the cushion material C4 is made of a meta-aromatic polyamide, the heating rate can be easily adjusted. On the other hand, the staple fiber of the meta-aromatic polyamide has a short life span because the cushioning material C4 has a short life because it is difficult to maintain the cushioning property.
Therefore, in order to maintain the cushioning property of the cushion material C4, it is conceivable to increase the basis weight of the staple fiber. However, if the basis weight of the staple fiber is increased, the heat conduction speed becomes slow, so that it is difficult to adjust the temperature rising speed, and the cushion material C4 becomes heavy and the usability during use deteriorates.

In order to eliminate such drawbacks of the cushion material C4, a heat-resistant cushion material C5 for molding press shown in FIG. 7 has been developed. FIG. 7 is a cross-sectional view of another conventional heat-resistant cushioning material C5 for forming presses.
The cushion material C5 shown in FIG. 7 includes a base body 21B, a staple fiber felt material layer 21A laminated on the surface of the base body 21B and needle punched, and a staple fiber felt laminated on the back surface of the base body 21B and needle punched. It is comprised by the material layer 21A. That is, in the cushion material C5, two layers of felt material layers 21A and 21A are laminated.
The staple fiber of the felt material layer 21A is made of a para-aromatic polyamide mainly composed of polyparaphenylene terephthalamide or the like. A woven fabric having warps 21B1 and wefts 21B2 made of heat resistant fibers is used for the base 21B.

  In the felt material layer 21A of the cushion material C5, since the staple fiber is made of para-aromatic polyamide, the cushioning property is excellent. However, since the cushion material C5 has too high thermal conductivity, it is difficult to adjust the temperature rising rate of the cushion material C5. In order to adjust the heating rate, it is necessary to increase the basis weight of the staple fiber, but the cushion material C5 becomes heavy, so that the usability during use is bad.

US Pat. No. 5,945,358 discloses a papermaking felt in which a spunbonded nonwoven fabric is disposed in order to obtain good void volume (void, porosity), running stability, and wear resistance. In this papermaking felt, bat fibers are arranged in the thickness direction of the felt in order to fix the spunbonded nonwoven fabric to the papermaking felt.
However, this papermaking felt is used for running and pressurizing wet paper, but it is not used by heating with a hot platen or the like.
Therefore, the papermaking felt is not required to have characteristics such as heat resistance, adjustment of the heating rate and maintenance of cushioning properties. Therefore, in US Pat. No. 5,945,358, there is no description regarding these characteristics which are the effects of the present invention.

Japanese Patent Laid-Open No. 59-192895 JP 62-156100 A US Pat. No. 5,945,358

  The present invention has been made to solve such a problem, and an object of the present invention is to provide a heat-resistant cushioning material for a molding press that can easily adjust a temperature rising rate and is excellent in maintaining cushioning properties.

In order to achieve the above-mentioned object, the heat-resistant cushioning material for molding press according to the present invention is used for producing a laminated product with a molding press apparatus, and the heat-resistant cushioning material for molding press in which a base and a felt material layer are laminated. Because
The cushion material has the felt material layer containing heat-resistant staple fibers, one layer or two layers for each of the one surface and the other surface of the base,
The felt material layer is composed of a composite staple fiber in which a staple fiber of a meta-aromatic polyamide and a staple fiber of a para-aromatic polyamide are mixed.
By performing needle punching by setting the needle needle so that the final barb of the needle needle (the barb farthest from the point) is in a position that penetrates the base body,
Inside the cushion material, a plurality of napped fiber bodies made of staple fibers having a fineness of 1.0 to 10.0 dtex penetrates the base body, and is formed in the thickness direction of the cushion material. When the felt material layers of the first layer are connected to each other, and the two layers of the felt material layers are laminated, the plurality of napped fiber bodies are connected to the first felt material layer. By connecting the respective layers, the plurality of napped fiber bodies exert a spring action in the thickness direction of the cushion material.
The heat-resistant cushioning material for molding presses of the present invention is a heat-resistant cushioning material for molding presses that is used to produce a laminated product (molded body) with a molding press device, and in which a base and a felt material layer are laminated. . This cushion material has at least one layer (that is, one layer or two or more layers) of a felt material layer containing heat-resistant staple fibers with respect to one surface and the other surface of the substrate. Inside the cushion material, a plurality of napped fiber bodies made of fine staple fibers penetrate the base body and are formed in the thickness direction of the cushion material to connect all the felt material layers. .
As a result, it is possible to obtain a heat-resistant cushioning material for a molding press having excellent characteristics that has cushioning properties, can easily adjust the temperature rising rate, and can uniformly transmit heat to the entire surface of the laminated product. .

The “felt material layer including heat-resistant staple fibers” is formed by blending heat-resistant staple fibers and other staple fibers, and includes at least 50% by weight or more of heat-resistant staple fibers.
Preferably, the heat-resistant staple fiber constituting the felt material layer includes one or more selected from the group consisting of a meta-aromatic polyamide, a para-aromatic polyamide, and a flame-resistant fiber.
The napped fiber body is formed by entanglement between fibers by needle punching. The napped fiber body has a fineness of 1.0 to 10.0 dtex (decitex) and is made of heat-resistant staple fibers. In this case, the fineness of the napped fiber body is preferably 1.0 to 6.0 dtex (more preferably 1.0 to 3.0 dtex).

The density of the cushioning material is preferably 0.3 g / cm ³ to 0.5 g / cm ³ . Preferably, a surface layer material is laminated on the surface of the cushion material. This surface layer material is bonded to the cushion material by bonding means (for example, resin, prepreg, bonded staple fiber, etc.).

The “napped fiber” refers to a fiber in which the axis of the staple fiber of the napped fiber is oriented in the thickness direction of the cushion material. The “napped fiber body” refers to a bundle of at least three napped fibers.
It is preferable that at least 5 bundles (that is, 5 bundles / cm ² ) are disposed per unit area (1 cm ² ) in a plan view of the cushion material. In addition, the upper limit of the number of bundles of napped fiber bodies in the cushion material is a case where almost all or all of the unit area of the cushion material in a plan view is occupied by bundled napped fiber bodies. The aspect of the napped fiber body as described above can be confirmed by a microscope (see FIG. 4).

  “It is formed in the thickness direction of the cushion material” means that the axis of the staple fiber of the napped fibers is formed so as to face substantially perpendicular to the base material of the cushion material. In the present invention, a cushion in which the axis of staple fibers of napped fibers is oriented within the range of 45 degrees to 135 degrees and within the range of 225 degrees to 315 degrees with respect to the two-dimensional surface formed by the substrate. The material is also included in the configuration “the napped fiber body is formed in the thickness direction of the cushion material”. The “two-dimensional surface formed by the base” is, for example, the X and Z planes formed by the Z direction in which the warp extends and the X direction in which the weft extends, as shown in FIGS. is there.

In the heat-resistant cushion material for molding press of the present invention, a plurality of napped fiber bodies made of staple fibers penetrates the base body, and is formed in the thickness direction of the cushion material to connect the felt material layers. Since the spring effect is exhibited, the cushioning property of the cushioning material is improved .

It is sectional drawing which shows an example of the shaping | molding press of a laminated board in the manufacturing apparatus of a double-sided printed wiring board. It is sectional drawing of the heat-resistant cushion material for shaping presses concerning one embodiment of this invention. It is sectional drawing of the heat-resistant cushion material for shaping presses concerning the other embodiment of this invention. It is an expanded sectional view of the heat-resistant cushion material for forming presses shown in FIG. It is a table | surface which shows the various physical properties and performance of the sample of a cushioning material. It is sectional drawing of the conventional heat-resistant cushion material for shaping presses. It is sectional drawing of the conventional heat-resistant cushion material for shaping presses.

The basic structure of the heat-resistant cushioning material for molding presses according to the present invention is a cushioning material used for manufacturing a laminated product with a molding press apparatus, and a substrate and a felt material layer are laminated. In this cushion material, at least one layer (that is, one layer or two layers or more) of a felt material layer containing heat-resistant staple fibers is provided for each of one surface (front surface) and the other surface (back surface) of the substrate. Have. Inside the cushion material, a plurality of napped fiber bodies made of fine staple fibers penetrates the base and is formed in the thickness direction of the cushion material to connect all the felt material layers.
In particular, in this cushion material, the heat-resistant staple fibers constituting the felt material layer are meta-aromatic polyamides (Conex; trade name / manufactured by Teijin Ltd., Nomex; trade name / manufactured by DuPont), para-aromatic It is preferable to include one or more selected from the group consisting of a group polyamide (Kevlar; trade name / manufactured by DuPont, Toaron; trade name / manufactured by Teijin Ltd.) and flame resistant fire fiber.
For example, the felt material layer may be composed of composite staple fibers in which staple fibers of meta-aromatic polyamide and staple fibers of para-aromatic polyamide are mixed.

More specifically, the cushion material is a heat-resistant cushion material for a molding press that is used to manufacture a laminated product with a molding press device and in which a base and a felt material layer are laminated. This cushioning material includes one felt material layer containing meta-aromatic polyamide staple fibers, and another felt material layer containing para-aromatic polyamide staple fibers, and one surface (surface) of the substrate. Each has at least one layer (that is, one layer or two or more layers) with respect to the other surface (back surface).
Inside the cushion material, a plurality of napped fiber bodies made of fine staple fibers penetrate the base and are formed in the thickness direction of the cushion material to connect all the felt material layers.

In these cushion materials, the napped fiber body is preferably a heat-resistant staple fiber having a fineness of 1.0 to 6.0 dtex (decitex) and formed by entanglement between the fibers by needle punching. More preferably, the density of the cushioning material is 0.3 g / cm ³ to 0.5 g / cm ³ .

In the staple fiber having a large fineness, the entanglement between the fibers is weak, so that it is difficult to form a high-density napped fiber body. Therefore, in the present invention, the napped fiber body has heat-resistant staple fibers having a fineness. That is, using a heat-resistant staple fiber having a fineness, a napped fiber body having a high density is formed by entanglement between fibers by needle punching.
And, a large number of napped fiber bodies made of staple fibers having such fineness penetrate through the base inside the cushion material, and are formed in the thickness direction of the cushion material to connect all the felt material layers. Yes. If it carries out like this, many napped fiber bodies will exhibit the effect | action of a spring with respect to the thickness direction of a cushioning material. Therefore, the cushion material is easy to adjust the rate of temperature rise and has excellent cushioning durability.

  By the way, when the napped fiber body is formed in the thickness direction of the cushion material without penetrating the base body of the cushion material, the napped fiber body exhibits the action of the spring, but the temperature rising rate of the cushion material The adjustment becomes worse. The reason is that the napped fiber body made of fine staple fibers does not penetrate the cushion material base, and therefore the thermal conductivity in the thickness direction of the cushion material is deteriorated.

Further, when the density of the cushion material is 0.3 g / cm ³ to 0.5 g / cm ³ , the improvement in elasticity of the cushion material accompanying the increase in density and the cushioning property of the napped fiber body act as a synergistic effect. Therefore, cushioning properties are further improved.

A surface layer material is preferably laminated on the surface of the cushion material. If it carries out like this, when carrying out hot press molding of a laminated product (molded object), the surface of a surface layer material will change dependently according to the shape of the uneven surface of a laminated product. As a result, since the surface layer material is in close contact with the laminated product, the cushion material can be easily adhered to the uneven surface of the laminated product. Therefore, the heating plate can transmit the pressing force evenly to the laminated product through the cushion material.
As the surface layer material, a heat-resistant resin having releasability with respect to a cover lay film, a metal foil, or a hot platen is preferable.
As the coverlay film, a polyolefin resin can be used in addition to the polyamide resin and the polystyrene resin which are press molding films. As the coverlay film, Nomex (trade name / manufactured by DuPont) paper or the like made of fibers mainly composed of polymetaphenylene isophthalamide may be employed.
As the metal foil, aluminum alloy foil, stainless steel foil or the like can be used. The heat resistant resins are tetrafluoroethylene / ethylene copolymer (ETFE), tetrafluoroethylene / perfluoroalkyl vinyl ether copolymer (PFA), tetrafluoroethylene / hexafluoropropylene copolymer (FEP), and polytetrafluoro. Selected from the group consisting of ethylene (PTFE).

And in order to laminate | stack (arrange | position) a surface layer material on the surface of a cushion material, resin, a prepreg, or joining fiber is used.
As the resin, an epoxy resin or a polyimide resin can be used, and a heat-welding resin such as a fluorine film can also be used. As the prepreg, a glass epoxy prepreg sheet or the like can be used. As the bonding fiber, unstretched Conex fiber or wholly aromatic polyester fiber (Vectran; trade name) can be used.
The heat-resistant cushioning material for molding presses of the present invention is used to produce a laminated product with the molding press apparatus 1, and the heat-resistant cushioning material for molding presses in which a base 10B and felt material layers 1A, 1B, 1C, 1D are laminated. 10 and 20, the cushion materials 10 and 20 are configured so that the felt material layers 1 </ b> A, 1 </ b> B, 1 </ b> C, and 1 </ b> D including heat-resistant staple fibers are respectively applied to one surface and the other surface of the base body 10 </ b> B. Needle punching is performed by setting the needle needle so that the final barb (the barb farthest from the point) of the needle needle is located at a position penetrating the base body 10B. Accordingly, a plurality of napped fiber bodies 30 made of staple fibers having a fineness of 1.0 to 10.0 dtex are provided in the cushion members 10 and 20 in front. It penetrates the base 10B and is formed in the thickness direction of the cushion materials 10 and 20 to connect the felt material layers.
The heat-resistant staple fibers constituting the felt material layers 1A, 1B, 1C, 1D are preferably selected from the group consisting of meta-aromatic polyamides, para-aromatic polyamides, and flame-resistant fibers.
The felt material layers 1A, 1B, 1C, 1D are preferably composed of composite staple fibers in which the meta-aromatic polyamide staple fibers and the para-aromatic polyamide staple fibers are mixed. .
The heat-resistant cushioning material for molding presses of the present invention is used to produce a laminated product with the molding press apparatus 1, and the heat-resistant cushioning material for molding presses in which a base 10B and felt material layers 1A, 1B, 1C, 1D are laminated. 10. This cushioning material 10, 20 comprises one felt material layer containing meta-aromatic polyamide staple fibers and another felt material layer containing para-aromatic polyamide staple fibers. At least one layer is provided for each of the one surface and the other surface of the base body 10B, and the final barb of the needle needle (the barb farthest from the point) is a position that penetrates the base body 10B. As described above, by setting the needle needle and performing needle punching, 1.0 to 10. a plurality of napped fibrous body 30 made of dtex fineness of staple fibers of the substrate 10B and the through, yet have been formed in the thickness direction of the cushion members 10 and 20 connecting the felt material layer.
The napped fiber body 30 is a heat-resistant staple fiber having a fineness of 1.0 to 6.0 dtex, and is preferably formed by entanglement between fibers by needle punching.
The cushion materials 10 and 20 preferably have a density of 0.3 g / cm ³ to 0.5 g / cm ³ .
A surface layer material 1E is preferably laminated on the surface of the cushion material 20.
The surface layer material 1E is preferably a cover lay film, a metal foil, or a heat resistant resin having releasability.
The heat-resistant cushioning material for molding presses of the present invention is used for manufacturing a laminated product with the molding press apparatus 1, and is heat-resistant for molding presses in which a base body 10B and felt material layers 1A, 1B, 1C, 1D are laminated. Cushioning materials 10 and 20, which are made of the felt material layers 1A, 1B, 1C, and 1D containing heat-resistant staple fibers on one side and the other side of the base 10B. The cushion materials 10 and 20 have a fineness of 1.0 to 10.0 dtex so that each of the cushion materials 10 and 20 exhibits a spring action in the thickness direction. A plurality of napped fiber bodies 30 made of staple fibers are formed in the thickness direction of the cushion materials 10 and 20 so as to penetrate the base body 10B. The material layers are connected.
The heat-resistant cushioning material for molding presses of the present invention is used for manufacturing a laminated product with the molding press apparatus 1, and is heat-resistant for molding presses in which a base body 10B and felt material layers 1A, 1B, 1C, 1D are laminated. Cushion materials 10 and 20, each of which includes one felt material layer containing meta-aromatic polyamide staple fibers and another felt material layer containing para-aromatic polyamide staple fibers; In the cushion material 10, so as to exert a spring action in the thickness direction of the cushion materials 10, 20. 20, a plurality of napped fiber bodies 30 made of staple fibers having a fineness of 1.0 to 10.0 dtex penetrate the base body 10B. And it is formed in the thickness direction of the said cushion materials 10 and 20, and connects the said felt material layer.
Thereby, the heat-resistant cushion material for molding presses of the present invention is easy to adjust the temperature rising rate and is excellent in maintaining cushioning properties.

Next, an embodiment of the present invention will be described with reference to FIGS.
2 is a cross-sectional view of a heat-resistant cushioning material for molding presses according to one embodiment of the present invention, FIG. 3 is a cross-sectional view of a heat-resistant cushioning material for molding presses according to another embodiment, and FIG. 4 is shown in FIG. It is an expanded sectional view of the heat-resistant cushion material for forming presses.
2 and 4, the first cushion material 10 is a first felt material layer laminated on a base 10B and a surface (front surface) on one side (one hot platen 40 side) of the base 10B. 1st felt material layer 1A, 2nd felt material layer 1B which is the 1st felt material layer laminated | stacked on the other side surface (back surface) of base | substrate 10B, and the surface of 1st felt material layer 1A the third and the felt material layer 1C, a fourth felt material layer is a second layer of felt material layer laminated on a surface of the second felt material layer 1B is a second layer of felt material layer laminated on 1D.
The first felt material layer 1A and the second felt material layer 1B are respectively attached to the front surface and the back surface of the base body 10B by needle punching. The third felt material layer 1C is attached to the first felt material layer 1A by needle punching. The fourth felt material layer 1D is attached to the second felt material layer 1B by needle punching.
A plurality of napped fiber bodies 30 made of fine staple fibers penetrate the base body 10B and are formed in the thickness direction of the cushion material 10 to connect all the felt material layers 1A, 1B, 1C, 1D.

In the first cushion material 10 shown in FIG. 2, the first felt material layer 1A, the second felt material layer 1B, the third felt material layer 1C, and the fourth felt material layer 1D are each made of a meta-fragrance. One or both of an aromatic polyamide and a para-aromatic polyamide are included.
For example, the third felt material layer 1C and the fourth felt material layer 1D are made of a felt material of staple fibers (here, meta-aromatic polyamide) having a low thermal conductivity. By doing so, the thermal unevenness in the hot platen 40 is alleviated.
The first felt material layer 1A and the second felt material layer 1B are made of a felt material of staple fiber (here, para-aromatic polyamide) having high thermal conductivity. By doing so, the cushioning property is improved, and therefore, the adjustment of the temperature rising rate and the cushioning property can be set in a well-balanced manner as the cushion material 10 as a whole.

The second cushion material 20 shown in FIG. 3 has a configuration in which the surface layer material 1E is laminated on the surface of the first cushion material 10 (FIG. 2) (here, both one surface and the other surface). ing. That is, the surface layer material 1E is bonded to the surface of the third felt material layer 1C by the joining means P. The surface layer material 1E is also bonded to the surface of the fourth felt material layer 1D by the joining means P.
Also in the second cushion material 20, the first felt material layer 1A, the second felt material layer 1B, the third felt material layer 1C, and the fourth felt material layer 1D are formed of a meta-aromatic polyamide, respectively. One or both of the para-type aromatic polyamides are included.

In the first cushion material 10 and the second cushion material 20, the base body 10B is constituted by a woven fabric formed by weaving warp yarns 10B1 and weft yarns 10B2 made of heat-resistant fibers. The heat-resistant fiber is selected from the group consisting of meta-aromatic polyamide, para-aromatic polyamide, wholly aromatic polyester fiber, polyparaphenylene benzobisoxazole (PBO) fiber, and stainless steel fiber.
The base 10B is desirably a woven fabric made by weaving the warp yarn 10B1 and the weft yarn 10B2 as described above. However, instead of the woven fabric, the warp yarn and the weft yarn may be simply overlapped.

As described above, the base body 10B includes the warp yarn 10B1 and the weft yarn 10B2, and a large number of napped fiber bodies 30 are formed in the thickness direction of the cushion materials 10 and 20 through the base body 10B. Therefore, the warp yarns 10B1 extending in the Z direction, the weft yarns 10B2 extending in the X direction, and the napped fiber bodies 30 extending in the Y direction (thickness direction of the cushion materials 10, 20) are three-dimensionally arranged substantially orthogonal to each other. (Ie, X, Y, Z orthogonal coordinate system). And since the napped fiber body 30 has penetrated the base | substrate 10B, the intermediate part of the napped fiber body 30 is hold | maintained firmly at the base | substrate 10B (FIGS. 2-4).
As a result, a large number of napped fiber bodies 30 exhibit a spring effect in the thickness direction of the cushion materials 10 and 20, so that the cushioning properties of the cushion materials 10 and 20 are improved.

The first felt material layer 1A and the second felt material layer 1B are attached to one surface (front surface) and the other surface (back surface) of the base body 10B by needle punching, respectively. A third felt material layer 1C is attached to the surface of the first felt material layer 1A by needle punching. A fourth felt material layer 1D is attached to the surface of the second felt material layer 1B by needle punching.
The joining means P is respectively arranged on the surface of the third felt material layer 1C and the surface of the fourth felt material layer 1D thus formed. The joining means P is, for example, an unstretched Conex staple fiber and a felt material having a small basis weight.
And if the whole is hot-pressed in a state where the surface layer material 1E is disposed and laminated on the surface of the joining means P, the joining means P melts. As a result, the third felt material layer 1 </ b> C and the surface layer material 1 </ b> E are firmly bonded (adhered) via the molten bonding means P. Further, the fourth felt material layer 1D and the surface layer material 1E are firmly bonded (adhered) via the molten bonding means P.

Here, a method for forming a plurality of napped fiber bodies 30 in the thickness direction of the cushion materials 10 and 20 so that the napped fiber bodies 30 penetrate the base body 10B will be described.
(Procedure 1)
First, a woven fabric is prepared as the base body 10B. A carded staple fiber web is laminated on the front and back surfaces of the woven fabric. Then, needle punching is performed to entangle the staple fiber to the woven fabric (base 10B). Thereby, the 1st felt material layer 1A and the 2nd felt material layer 1B are each laminated | stacked on one surface (front surface) and the other surface (back surface) of a woven fabric (base | substrate 10B).
In this needle punching, needle punching needles (hereinafter referred to as needle needles) having 6 barbs or less per edge are used. The number of times of needle punching is 50 times / cm ² or less. Further, needle punching is performed by setting the first barb of the needle needle (the barb closest to the point) in contact with the woven fabric surface.
By such an entanglement process, the axial direction of the staple fiber becomes parallel to the woven fabric.

(Procedure 2)
The laminating operation is repeated until each of the first felt material 1A and the second felt material 1B reaches a predetermined basis weight. Eventually, when the first felt material 1A and the second felt material 1B reach a predetermined basis weight, the procedure proceeds to a procedure for forming the napped fiber body 30.

(Procedure 3)
In this procedure, a needle needle having a larger number of barbs (stabs) than the needle needle used in the entanglement process (for example, needles of 8 barbs or more per ridge) is used. The plurality of napped fiber bodies 30 are formed in the thickness direction of the cushion materials 10 and 20 by the needle needle.
For example, a needle with 2 ridges and 18 barbs is used, and the number of times of needle punching is 80 times / cm ² or more. The needle needle is set so that the final barb of the needle needle (the barb farthest from the point) passes through the woven fabric.
If needle punching is performed in this state, a plurality of napped fiber bodies 30 penetrates the woven fabric (base 10B) and is formed in the thickness direction of the cushion materials 10 and 20 to connect all the felt material layers. Thus, the cushion materials 10 and 20 having the plurality of napped fiber bodies 30 are completed.

When the fineness of the staple fiber is less than 1.0 dtex, the staple fiber is likely to become a hair ball by needle punching, and the napped fiber body 30 is difficult to form. On the other hand, when the fineness of the staple fiber exceeds 6.0 dtex, the entanglement between the staple fibers is weak, so that it is difficult to form the napped fiber body 30 with high density, and the cushioning property of the cushion material is weakened.
Therefore, in the cushion materials 10 and 20 of the present invention, the fineness of the staple fiber of the napped fiber body 30 is preferably in the range of 1.0 to 6.0 dtex. By doing so, the staple fibers are unlikely to become pills by needle punching, so that the napped fiber body 30 can be easily formed. Further, since the entanglement between the staple fibers becomes strong, the napped fiber body 30 having a high density is easily formed, and the cushioning properties of the cushion materials 10 and 20 are enhanced.
In the present invention, it is most preferable to use a heat-resistant staple fiber having a fineness of 1.0 to 3.0 dtex.

As described above, in the present invention, a plurality of napped fiber bodies 30 penetrates the base body 10B in the cushion materials 10 and 20, and is formed in the thickness direction of the cushion materials 10 and 20, and the base material 10B has 1 The first felt material layer (that is, the first felt material layer 1A and the second felt material layer 1B) is connected to form a cushion material having a three-layer specification. In the case where two layers of felt material layers are laminated on the base body 10B (that is, in the case of a cushion material having a five-layer specification), the plurality of napped fiber bodies 30 are the first felt material layer (that is, the first felt material layer). The second felt material layer (that is, the third felt material layer 1C and the fourth felt material layer 1D) is connected to the layer 1A and the second felt material layer 1B), respectively. As a result, the plurality of napped fiber bodies 30 exert an action of a spring in the thickness direction of the cushion materials 10 and 20.
The cushion materials 10 and 20 having the above-described configuration are applied to, for example, the laminated plate forming press apparatus 1 in the double-sided printed wiring board manufacturing apparatus shown in FIG. In this FIG. 1, the case where the laminated board used as the board | substrate of a double-sided printed wiring board is a laminated product is shown.

Hereinafter, the heat-resistant cushion material for molding presses of the present invention will be described in more detail with reference to examples. In addition, the following example does not limit this invention at all.
In the examples and comparative examples, the following configurations were all used in common.
(1) Cushion material base:
For the base material of the cushion material, a woven fabric woven from a spun yarn of a meta-aromatic polyamide was used. The fiber of this woven fabric is Cornex (trade name / manufactured by Teijin Limited).
(2) Needle punching conditions:
(A) Entanglement conditions;
A needle of 6 barbs per ridge was used, the number of times of needle punching was 50 times / cm ^2, and the first barb of the needle needle was set at a position in contact with the woven fabric surface.
(B) Napped fiber body formation conditions;
In the examples, 18 barbs per two ridges were used after the entanglement treatment, the number of needle punching was 80 times / cm ^2, and the final barb of the needles was set at a position penetrating the woven fabric.
In the comparative example, in order to prevent the napped fiber body from being formed, 18 barbs per two ridges are used after the entanglement treatment, the needle punching frequency is set to 80 times / cm ^2, and the first barb of the needle needle is woven. It set to the position which contacts the cloth surface.

(1) About the staple fiber which comprises a felt material, in Examples 1-9 and Comparative Examples 1-5, the following were used.
(A) As staple fibers of meta-aromatic polyamide, Cornex (trade name / manufactured by Teijin Ltd.) 2 dtex 50 mm cut short fibers were used.
(B) Polyparaphenylene terephthalamide (Kevlar; trade name / manufactured by DuPont) 2 dtex 50 mm cut short fiber was used as the staple fiber of the para-aromatic polyamide.

(2) About the staple fiber which comprises a felt material, in Examples 10-12 and Comparative Examples 6 and 7, the following were used.
(A) As staple fiber of meta-aromatic polyamide, Cornex (trade name / manufactured by Teijin Ltd.) 6 dtex, 50 mm cut length short fiber was used.
(B) Polyparaphenylene terephthalamide (Kevlar; trade name / manufactured by DuPont) 5 dtex short fiber having a cut length of 50 mm was used as the staple fiber of para-aromatic polyamide.

Example 1
Polyparaphenylene terephthalamide staple fibers were laminated as carding webs on the front and back surfaces of the woven fabric, respectively. Then, needle cushioning was performed to form the first felt material layer 1A and the second felt material layer 1B, respectively, and the cushioning material according to Example 1 was produced.

(Example 2)
Conex staple fibers were laminated as carding webs on the front and back surfaces of the woven fabric, respectively. And the needle material was punched and the 1st felt material layer 1A and the 2nd felt material layer 1B were formed, respectively, and the cushioning material concerning Example 2 was produced.

(Example 3)
Polyparaphenylene terephthalamide staple fiber on the surface of the woven fabric (the surface on the one side of the heating platen 40), Conex staple fiber on the back side of the woven fabric (the surface on the side opposite to the one of the heating platen 40), Each was laminated as a web. Then, the first felt material layer 1A and the second felt material layer 1B were formed by needle punching, and the cushion material according to Example 3 was produced.

Example 4
A web obtained by blending 50% by weight of staple fibers of polyparaphenylene terephthalamide and 50% by weight of carbon fibers is laminated as a web on the surface of the woven fabric (the surface on the one heating platen 40 side). On the back of the woven fabric (the surface opposite to one of the heating plates 40), 50% by weight of Conex staple fibers and 50% by weight of carbon fibers are mixed and laminated as a web.
And the needle material was punched and the 1st felt material layer 1A and the 2nd felt material layer 1B were formed, respectively, and the cushioning material concerning Example 4 was produced.

(Example 5)
Conex staple fibers on the surface of the woven fabric (one side of the heating platen 40), and polyparaphenylene terephthalamide staple fibers on the back side of the woven fabric (the side opposite to the one of the heating plates 40), Each was laminated as a web. Then, needle cushioning was performed to form the first felt material layer 1A and the second felt material layer 1B, and the cushioning material according to Example 5 was produced.

(Example 6)
Polyparaphenylene terephthalamide staple fibers were laminated as carding webs on the front and back surfaces of the woven fabric, respectively. Then, needle punching was performed to form a first felt material layer 1A and a second felt material layer 1B, respectively, and a cushion material according to Example 6 was produced. In Example 6, compared with Example 1, the basis weight of staple fibers was increased.

(Example 7)
Conex staple fibers were further laminated as webs on the surface of the cushion material produced in Example 1. Then, needle punching was performed to form a third felt material layer 1C and a fourth felt material layer 1D, and a cushion material according to Example 7 was produced.

(Example 8)
Further, a staple fiber of polyparaphenylene terephthalamide was laminated as a web on the surface of the cushion material manufactured in Example 2. Then, needle punching was performed to form a third felt material layer 1C and a fourth felt material layer 1D, respectively, and a cushion material according to Example 8 was produced.

Example 9
An ETFE film was further bonded to the surface of the cushion material produced in Example 7 via a glass epoxy prepreg sheet to produce a cushion material according to Example 9.

(Example 10)
Polyparaphenylene terephthalamide staple fiber on the surface of the woven fabric (the surface on the one side of the heating platen 40), Conex staple fiber on the back side of the woven fabric (the surface on the side opposite to the one of the heating platen 40), Each was laminated as a web. Then, needle punching was performed to form the first felt material layer 1 </ b> A and the second felt material layer 1 </ b> B, and the cushion material according to Example 10 was produced.

(Example 11)
On the surface of the woven fabric (the surface on the one heating platen 40 side), a mixture of 50% by weight of staple fibers of polyparaphenylene terephthalamide and 50% by weight of carbon fibers was laminated as a web. On the back of the woven fabric (the surface opposite to one of the heating plates 40), 50% by weight of Conex staple fibers and 50% by weight of carbon fibers were mixed and laminated as a web.
Then, needle punching was performed to form a first felt material layer 1A and a second felt material layer 1B, respectively, and a cushion material according to Example 11 was produced.

(Example 12)
An ETFE film was further bonded to the surface of the cushion material produced in Example 10 via a glass epoxy prepreg sheet to produce a cushion material according to Example 12.

(Comparative Example 1)
Polyparaphenylene terephthalamide staple fibers were laminated as carding webs on the front and back surfaces of the woven fabric, respectively. Then, the first felt material layer 1A and the second felt material layer 1B were formed by needle punching, and the cushion material according to Comparative Example 1 was produced.

(Comparative Example 2)
Conex staple fibers were laminated as carding webs on the front and back surfaces of the woven fabric, respectively. Then, needle punching was performed to form a first felt material layer 1A and a second felt material layer 1B, respectively, and a cushion material according to Comparative Example 2 was produced.

(Comparative Example 3)
Polyparaphenylene terephthalamide staple fiber on the surface of the woven fabric (the surface on the one side of the heating platen 40), Conex staple fiber on the back side of the woven fabric (the surface on the side opposite to the one of the heating platen 40), Each was laminated as a web. Then, needle cushioning was performed to form a first felt material layer 1A and a second felt material layer 1B, respectively, and a cushion material according to Comparative Example 3 was produced.

(Comparative Example 4)
On the surface of the woven fabric (the surface on the one heating platen 40 side), a mixture of 50% by weight of staple fibers of polyparaphenylene terephthalamide and 50% by weight of carbon fibers was laminated as a web. On the back of the woven fabric (the surface opposite to one of the heating plates 40), 50% by weight of Conex staple fibers and 50% by weight of carbon fibers were mixed and laminated as a web.
Then, needle cushioning was performed to form the first felt material layer 1 </ b> A and the second felt material layer 1 </ b> B, and the cushion material according to Comparative Example 4 was produced.

(Comparative Example 5)
An ETFE film was further bonded to the surface of the cushion material produced in Comparative Example 3 via a glass epoxy prepreg sheet to produce a cushion material according to Comparative Example 5.

(Comparative Example 6)
Polyparaphenylene terephthalamide staple fiber on the surface of the woven fabric (the surface on the one side of the heating platen 40), Conex staple fiber on the back side of the woven fabric (the surface on the side opposite to the one of the heating platen 40), Each was laminated as a web. And the needle punching was performed, the 1st felt material layer 1A and the 2nd felt material layer 1B were formed, respectively, and the cushioning material concerning the comparative example 6 was produced.

(Comparative Example 7)
An ETFE film was further bonded to the surface of the cushion material produced in Comparative Example 6 via a glass epoxy prepreg sheet to produce a cushion material according to Comparative Example 7.

About the sample of the cushion material produced in each of these Examples and Comparative Examples, the test was performed using a test apparatus having the same structure as the molding press apparatus 1 shown in FIG. Thereby, the performance of each cushion material was measured.
Regarding the sample of the cushion material, a series of procedures of “maintaining a temperature of 190 ° C. and a pressure of 40 kg / cm ² for 60 minutes, and then cooling with water for 15 minutes and releasing pressure for 15 minutes” is one cycle. And about this sample, after repeating this series of procedures 300 cycles and pressurizing a sample 300 times, the measurement of the item shown below was implemented.

(1) Measurement of heating rate (° C./min):
The time until the sample of the cushioning material was changed from 90 ° C. to 140 ° C. was measured, and a temperature increase rate (° C./min) was obtained.
As the evaluation of the rate of temperature rise, the rate of temperature rise of the sample exceeded 1.8 ° C./min, and “2.2” or less than 2.2 ° C./min exceeded “1.5 ° C./min. / Min or less, and exceeding 2.2 ° C./min and not exceeding 2.5 ° C./min are indicated by “◯” and the others are indicated by “x” (FIG. 5).

(2) Measurement of cushion displacement (μm):
The thickness of the cushion material sample was measured when the cushion material sample was molded and pressed at 0.2 kg and at 50 kg when heated to 180 ° C. Then, the difference between the thickness at the time of molding press at 50 kg and the thickness at the time of molding press at 0.2 kg was determined, and this difference was defined as the cushion displacement (μm).
As the evaluation of the cushion displacement amount, the cushion displacement amount of the sample was set to “◎” when the cushion displacement amount was 500 μm or more, “◯” when 400 μm or more and less than 500 μm, and “X” when less than 400 μm (FIG. 5).

FIG. 5 is a table showing various physical properties of the cushion material samples prepared in Examples and Comparative Examples, and the performance of the cushion material samples measured by the above test apparatus.
As can be seen from FIG. 5, the sample according to the example of the present invention is better in both the evaluation of the temperature rising rate and the evaluation of the cushion displacement amount than the sample according to the comparative example. Therefore, it was confirmed that the cushioning material according to the present invention is easy to adjust the temperature rising rate and is excellent in maintaining the cushioning property.
Moreover, regarding the density of the cushioning material in various examples of the present invention, the minimum value (0.30 g / cm ³ ) is obtained in Example 11, and the maximum value (0.49 g / cm ³ ) is obtained in Example 9. . Therefore, it can be seen that the density of the cushioning material of the present invention is preferably 0.3 g / cm ³ to 0.5 g / cm ³ .

Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications and additions are possible within the scope of the gist of the present invention.
In the drawings, the same reference numerals denote the same or corresponding parts.

  The heat-resistant cushion material for molding presses of the present invention can be applied to manufacturing processes for printed wiring boards, printed wiring boards, flat panel displays, semiconductor packages, and the like.

Claims (8)

Heat-resistant cushioning material (10, 20) for molding press, which is used to manufacture a laminated product with a molding press device (1), and in which a base (10B) and a felt material layer (1A, 1B, 1C, 1D) are laminated Because
The cushion material (10, 20) includes at least the felt material layer (1A, 1B, 1C, 1D) containing heat-resistant staple fibers with respect to one surface and the other surface of the base body (10B). One layer at a time,
Inside the cushion material (10, 20), a plurality of napped fiber bodies (30) made of fine staple fibers penetrate the base body (10B), and the thickness of the cushion material (10, 20). A heat-resistant cushioning material for a molding press, characterized by being formed in a direction and connecting all the felt material layers. The heat-resistant cushion material (10, 20) for molding press according to claim 1,
The heat-resistant staple fiber constituting the felt material layer (1A, 1B, 1C, 1D) is one or more selected from the group consisting of a meta-aromatic polyamide, a para-aromatic polyamide, and a flame-resistant fire fiber. Contains seeds. A heat-resistant cushion material (10, 20) for molding press according to claim 2,
The felt material layers (1A, 1B, 1C, 1D) are composed of composite staple fibers in which the meta-aromatic polyamide staple fibers and the para-aromatic polyamide staple fibers are mixed. Heat-resistant cushioning material (10, 20) for molding press, which is used to manufacture a laminated product with a molding press device (1), and in which a base (10B) and a felt material layer (1A, 1B, 1C, 1D) are laminated Because
The cushion material (10, 20) includes one felt material layer containing meta-aromatic polyamide staple fibers and another felt material layer containing para-aromatic polyamide staple fibers. Each having at least one layer for one side and the other side of
Inside the cushion material (10, 20), a plurality of napped fiber bodies (30) made of fine staple fibers penetrate the base body (10B), and the thickness of the cushion material (10, 20). A heat-resistant cushioning material for a molding press, characterized by being formed in a direction and connecting all the felt material layers. The heat-resistant cushion material (10, 20) for molding press according to any one of claims 1 to 4,
The napped fiber body (30) is a heat-resistant staple fiber having a fineness of 1.0 to 6.0 dtex, and is formed by entanglement between fibers by needle punching. The heat-resistant cushion material (10, 20) for molding press according to any one of claims 1 to 4, wherein the density of the cushion material (10, 20) is 0.3 g / cm ³ to 0.5 g / cm ³ .   The heat-resistant cushion material (20) for molding presses according to any one of claims 1 to 4, wherein a surface layer material (1E) is laminated on a surface of the cushion material (20).   It is a heat-resistant cushion material (20) for shaping presses of Claim 7, Comprising: The said surface layer material (1E) is a heat resistant resin which has a cover-lay film, metal foil, or mold release property.

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