WO2002070805A1

WO2002070805A1 - Polyester nonwoven fabric, nonwoven fabric product thereof and various products using the nonwoven fabrics reinforcing material

Info

Publication number: WO2002070805A1
Application number: PCT/JP2002/002019
Authority: WO
Inventors: Kenji Abe; Mitsuo Itou; Nobuhiro Matsunaga; Katsuyoshi Niikura; Yoshihiro Enomoto
Original assignee: Mitsubishi Burlington Co.,Ltd.; Unitika Fibers Ltd.
Priority date: 2001-03-06
Filing date: 2002-03-05
Publication date: 2002-09-12
Also published as: JP3927910B2; JPWO2002070805A1

Abstract

A nonwoven fabric mainly comprising polyester short fibers and polyester binder short fibers, and is provided with such physical properties that a shrinkage percentage at a 150 °C x 15-min heat treating is up to 2% in both longitudinal and lateral directions and a tensile strength is at least 15 N/5cm in both longitudinal and lateral directions. Such a high-strength, low-shrinking polyester nonwoven fabric used does not adversely affect human bodies by scattering broken fibers at handling unlike glass fiber cloth, nor pose an environmental problem that might be caused by debris left after burning carpets. Especially, when this nonwoven fabric is embedded in the backing layers of various carpets, it bonds strongly to a resin component constituting the backing layer to deliver a reinforcing effect stronger than glass fiber cloth.

Description

Description Polyester non-woven fabric, its non-woven fabric products and the non-woven fabric used as reinforcement

Technical field

The present invention provides a polyester-based nonwoven fabric that can be substituted for a glass fiber fabric or the like, and a resin composition, which is directly obtained from the nonwoven fabric, on a backside of a filler, a blind curtain, a mouthpiece, or a facing material. Various types of resin such as tile carpets, mats, artificial turf, salted pip sheets, salted pilings, cushion floors and other resin laminated products, rugs used indoors and outdoors, wall coverings and ceiling materials, etc. Regarding sheet products. Background art

For this kind of rug, as disclosed in, for example, Japanese Patent No. 2696657, etc., a glass fiber cloth is embedded inside the backing layer to reinforce and provide dimensional stability. However, it is known that fine broken fibers are scattered during handling, which has an adverse effect on the human body, and when they are incinerated, the glass fiber fabric remains without being incinerated. Therefore, it was an environmental problem.

Further, as disclosed in, for example, Japanese Patent Application Laid-Open No. 9-3147777, a polyester long-fiber nonwoven fabric is used as a base sheet for a wall covering material. This polyester long-fiber non-woven fabric is made of polyester long-fiber, whose main material is polyester long-fiber, and the contact points of the fibers are bonded with an adhesive made of thermosetting resin, and the dry heat shrinkage is 1% or less. is there. The present invention solves the above-mentioned conventional problems, has no environmental problems, and is capable of exhibiting a reinforcing effect superior to glass fiber cloth. And to provide various sheet products using the nonwoven fabric as a reinforcing material. Disclosure of the invention

The polyester-based nonwoven fabric according to the present invention is a high-strength, low-heat-shrinkable polyester-based nonwoven fabric that can replace conventional glass fiber cloth.

An object of the present invention is to provide a main component of the present invention, which is a polyester short fiber and a polyester binder short fiber, each of which has a shrinkage rate of 15% or less at 15 OX 15 minutes heat treatment of 2% or less. This is effectively solved by a polyester-based nonwoven fabric characterized by having a tensile strength of 15 NZ 5 cm or more in both the transverse direction and the transverse direction.

The polyester-based nonwoven fabric according to the present invention can be used as a heat-resistant filter itself, or molded and used as a non-woven fabric product such as a blind curtain or a lactate, a tile, a pet, a mat, It can reinforce flat materials such as artificial turf, indoor and outdoor rugs, wall coverings and ceiling materials.

These flat members have a surface material such as a pile fabric, a 21 dollar punch fabric, a decorative sheet, a decorative resin plate, etc. on the surface thereof, and the nonwoven fabric according to the present invention is coated on the back surface with a hot melt adhesive or the like. A backing layer composed of a resin such as polyvinyl chloride, polypropylene, styrene-butene copolymer (SBR) latex, or the like is laminated on the backside of the adhesive, or a backing layer is formed inside the backing layer. Embedding the non-woven fabric related to the above can be used for any purpose.

Hereinafter, the polyester-based nonwoven fabric of the present invention will be described in more detail. First, the polyester short fiber as a main component is a low heat shrinkable polyester short fiber having a heat shrinkage rate of 3% or less, preferably 1.5% or less when subjected to a heat treatment of 15 OX for 15 minutes, which is sufficiently heat-set in the drawing step. Can be The fineness is suitably from 1 to 70 dtex, but from the viewpoint of rigidity, it is preferably from 20 to 70 dtex. On the other hand, as the polyester-based binder short fibers, those having a fineness of 2 to 30 dte X, a melting point as high as possible, and a low heat shrinkage which is heat-set to some extent in the stretching process are preferable.

The mixing ratio of the main polyester short fiber and the polyester binder short fiber is suitably about 910 to 190. A mixed web composed of both short fibers uniformly mixed in this range is subjected to a heat fusion treatment with a hot embossing roll, a hot flat roll, or the like.In this case, the heat fusion temperature should be set as high as possible. It is preferable from the viewpoint of reducing the heat shrinkage and increasing the rigidity of the nonwoven fabric, and is usually 15 or more, preferably 180 or more, more preferably 200 or more.

As the polyester binder short fiber, a fiber containing a low melting point copolymer polyester as a binder component is used. Such a low-melting-point copolymerized polyester includes, in units of ethylene terephthalate, phthalic enzyme, isophthalic acid, adipic acid, diethylene glycol, 1,4-butanediol, 1,6-hexanediol, and ω-force. One or more selected from components such as prolactone are copolymerized and have a melting point of 160 or more. In particular, a fiber containing a polyethylene terephthalate / isophthalate copolymer having a melting point of 200 ° C. or more as a binder component is preferable from the viewpoint of low cost and high adhesive strength.

By using a binder component having a high melting point, preferably as high as 160 or more, it is possible to set the heat fusion treatment temperature at the time of nonwoven fabric production higher. The heat shrinkage of the obtained nonwoven fabric can be reduced, and a nonwoven fabric having excellent rigidity can be obtained.

Examples of the fiber form of the polyester-based binder short fibers include core-sheath type and sea-island type composite fibers in which a low-melting copolyester forms part or all of the surface of a single fiber in a round cross section or an irregular cross section. . Of these, core-sheath composite fibers having the above-mentioned low-melting-point copolymerized polyester as a sheath component and ordinary polyethylene terephthalate as a core component are more preferred. In this case, it is preferable that the melting point or the softening point is as high as possible, and in this case as well, the heat setting is performed at as high a temperature as possible in the stretching step so that the heat shrinkage ratio is as small as possible. The basis weight of the polyester nonwoven fabric is 35 to 300 g Zm ² , and the thickness is

It is desirable that the thickness be 1 mm or less from the viewpoint of the reinforcing effect and the effect of providing dimensional stability.

If the basis weight of the nonwoven fabric is less than 35 g / m ² , the effect of dimensional stability may be insufficient. Further, those having a basis weight of more than 300 g Zm ² may be inappropriate in terms of cost and excessive weight.

The thickness of the nonwoven fabric is preferably 1 mm or less. If the thickness is large, there are voids in the non-woven fabric, leaving room for expansion and contraction and low rigidity. Therefore, it is better to control the thickness with a hot emboss roller or flat roller.

As described above, the nonwoven fabric having the above configuration can be used as a heat-resistant filter itself, or molded and used as a nonwoven product such as a blind curtain or a roll curtain. It is a reinforcing material that can reinforce flat members such as rugs, wall coverings, and ceiling materials used indoors and outdoors, such as artificial grass.

In the rug of the present invention in which a backing layer made of a resin composition is laminated on the back surface, the shrinkage rate in the backing layer during the heat treatment of 150 × 15 minutes is reduced in the direction of the heat (the progress of the nonwoven fabric during the formation of the nonwoven fabric). Direction) and horizontal direction High-strength, low-shrinkage polyester non-woven fabric that replaces conventional glass fiber fabrics that has a tensile strength of 2% or less for both directions and a tensile strength of 15 NZ5cm or more for both the horizontal direction and the horizontal direction. Is done.

The surface of this rug has surface covering materials such as pile fabric, needle-punched fabric, decorative sheet, and decorative resin plate, and its back surface has polyvinyl chloride, polypropylene, styrene-butadiene copolymer latex, etc. A backing layer made of a resin composition is laminated.

The backing layer is not particularly limited, but styrene-butadiene copolymer latex as disclosed in JP-A-2000-239398 is used because of environmental problems and problems in handling. It is preferable to use a resin rubber as a hardening agent and a resin composition containing a polyisocyanate compound having a reactive isocyanate group as a curing agent. In addition, from the viewpoint of obtaining good walking properties, it is preferable to mix a heat-expandable microcapsule with the resin composition to be the backing layer, and to use a heat-expanded porous body as the backing layer.

As the polyester fiber nonwoven fabric to be embedded in the backing layer of the rug according to the present invention, the shrinkage ratio at the time of heat treatment at 150 ° C for 15 minutes must be 2% or less in both the vertical direction and the horizontal direction. Is less than 1%. When the above shrinkage exceeds 2%, shrinkage occurs due to heating in the process of forming the backing layer, resulting in insufficient dimensional stability.

In addition, the tensile strength of the polyester-based nonwoven fabric must be 15 N / 5 cm or more in both the vertical and horizontal directions, and if it is less than 15 N / 5 cm, the reinforcing effect will be insufficient. Although the lower limit (15N / 5 cm) of the tensile strength of the polyester-based nonwoven fabric used in the present invention is lower than the tensile strength of the usual glass fiber cloth which has been conventionally used, the lower limit of the resin is once embedded in the backing layer. When integrated with the composition, the polyester nonwoven exhibits a higher reinforcing effect than glass fiber fabric. This consists of the resin composition and the reinforcing material that make up the backing layer. It is considered that this is based on the difference in bonding strength between the resin composition and the polyester fiber non-woven fabric used in the present invention. BEST MODE FOR CARRYING OUT THE INVENTION

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the best mode for carrying out the present invention will be specifically described based on examples.In these examples, the heat shrinkage ratio, tensile strength, and melting point of binder fibers of a nonwoven fabric are determined by the following method. It was measured.

[Thermal shrinkage of non-woven fabric]

A non-woven fabric cut out to a size of 20 cm square is left in an oven set at 150 for 15 minutes and then taken out. Was calculated.

[Tensile strength of non-woven fabric]

Orientec samples of 5 cm wide x 10 cm long in the evening direction and the horizontal direction, with the direction of travel during production of the nonwoven fabric as the vertical direction and the direction perpendicular to the direction of travel as the horizontal direction. The measurement was carried out using a Tensilon RTC-1310 manufactured by Sharp at a grip interval of 5 cm and a tensile speed of 10 cmZ. '.,

[Melting point of binder short fiber]

The melting point of a polymer having a crystalline melting point is measured at a rate of temperature rise of 20 ° CZ using a differential scanning calorimeter DSC-2 manufactured by PerkinElmer Co., Ltd. (DSC method), and the DSC method is used. Amorphous polymers without a crystalline melting point were measured visually using a microscope with a hot stage. The melting point is a value measured by the DSC method unless otherwise specified.

(Example 1)

Ordinary polyethylene terephthalate used for fibers (melting point: 255 ° C) On the core, polyethylene terephthalate Z isophthalate copolymerized polyester (melting point 200) on the sheath, compounding ratio (mass ratio) 1: 1, spinning temperature 28 O, total discharge 61 The composite spinning was performed at a take-off speed of 100 Om / min for 5 minutes to obtain an undrawn yarn. The obtained undrawn yarn is bundled into a tow of 110,000 dtex, drawn at a draw ratio of 3.5, at a drawing temperature of 70, and given a crimp using a push-in type crimper. It was cut to 76 mm to obtain a core-sheath composite short binder fiber having a single fiber fineness of 6.6 dte X. 30% of this binder staple fiber and 70% of polyester staple fiber which has a single fiber fineness of 40 dtex, a fiber length of 76 mm, a melting point of 255, and a heat shrinkage of 1.8% (17 O, dry heat for 15 minutes). The mixed web is passed through a carding machine to form a mixed web, and then the mixed web is heat-sealed by a 190 flat mouth heat-sealing machine to reduce the heat shrinkage rate in the direction of the fabric (non-woven fabric production line). A heat-fused nonwoven fabric having a strength of 95 NZ5 cm, a heat shrinkage in the transverse direction of 0.2%, a strength of 76 NZ5 cm, a basis weight of 100 gZm ² and a thickness of 0.9 mm was obtained.

The heat-sealed nonwoven fabric was cut into a square of 50 cm and used for reinforcement. On both sides of the reinforcing material, a resin composition having the following compounding ratio was laminated to a thickness of 1 mm each. The resin composition was solidified by passing the mixture for minutes. The length and width of the obtained backing material and the tensile strength in the evening and transverse directions were measured, and the length of the evening back was 50 cm, the length of the weft was 50 cm, and the evening The tensile strength in the direction was 200 N / 5 cm or more, and the tensile strength in the horizontal direction was 200 N / 5 cm or more.

[Blending ratio (parts by mass)]

100 parts of polyvinyl chloride resin

Plasticizer (DOP) 85 parts

Stabilizer 1 part Filler (calcium carbonate) 400 parts

1 part of pigment (carbon black)

1 part of hygroscopic agent (CaO)

(Comparative Example 1)

As a binder fiber, normal polyethylene terephthalate is disposed on the core, and a copolymerized polyester having a melting point of 105 ton by visual method is disposed on the sheath, and stretched at a stretching temperature of 50. Using <4080> and setting the thermal fusion temperature to 19 Ot: Example 1 except that the thermal fusion temperature was changed to 130 because the nonwoven fabric wraps around the roller of the flat roller thermocompression bonding machine. The length of the backing material and the length of the weft and the tensile strength in the evening and weft directions were measured.The length of the weft was 49.2 cm, and the length of the weft was 49.4 cm, the tensile strength in the vertical direction was 200 N or more, 5 cm, and the tensile strength in the horizontal direction was 180 NZ, 5 cm. The heat-sealed nonwoven fabric itself had a shrinkage rate of 4.2% in the transverse direction, a transverse shrinkage rate of 2.7%, and a tensile strength in the vertical direction of 9% during a heat treatment of 150 × 15 minutes. The tensile strength in the horizontal direction was 1 N / 5 cm, and the tensile strength in the horizontal direction was 74 NZ 5 cm.

(Examples 2, 3 and Comparative Example 2)

In Example 1, the total discharge amount when producing the binder short fiber was changed to obtain a binder short fiber having a short fiber fineness of 22 dteX. Using this bus Indah short fibers, 50% mixing ratio of polyester staple fibers consisting mainly, the basis weight of the thermally fused nonwoven fabric and 3 5 g / m ^2, by changing the heat-sealing temperature by Flat Roller thermal compression machine Table 1 shows the results obtained in the same manner as in Example 1 except for the above.

【table 1】 Non-woven cloth Backing material

Strength (N / 5cm)

Heat fusion Heat shrinkage (%) Thickness Strength (N / 5cm) Temperature (° c) (mm)

Vertical 3 = 1 Vertical 3 = 1 Vertical

Example 2 200 43 35 0.3 0.1 0.5 155 141 Example 3 180 26 22 1.4 1.7 0.8 136 113 Comparative Example 2 160 14 12 2.2 3.0 1.2 94 87

The nonwoven fabrics obtained in Examples 2 and 3 have a low heat shrinkage and a high strength, and a good backing material using the nonwoven fabric itself as a reinforcing material can be obtained. However, the non-woven fabric of Comparative Example 2 had a high heat shrinkage, and as a backing material, irregularities appeared on the surface, and its reinforcing effect was lower than in Examples 2 and 3.

(Example 4)

As a binder fiber, ordinary polyethylene terephthalate is disposed in the core, a copolyester having a melting point of 160 is disposed in the sheath as a binder component, and a unit manufactured by Unitika Fiber Co., Ltd. is manufactured by drawing at a drawing temperature of 12. The same procedure as in Example 1 was carried out except that Cassven® was used and the heat-sealing temperature was changed to 180 "C. When the tensile strength in the horizontal and horizontal directions was measured, the vertical length was 50 cm, the horizontal length was 50 cm, the tensile strength in the vertical direction was 20 ON or more / 5 cm, and the horizontal tensile strength. The heat-sealed nonwoven fabric itself had a 0.1% shrinkage ratio in the vertical direction and a 0.1% shrinkage ratio in the horizontal direction when heat-treated at 150 ° C for 15 minutes. The tensile strength in the vertical direction was 92 N / 5 cm, and the tensile strength in the horizontal direction was 70/5 cm.

(Comparative Example 3) As a reinforcing fiber fabric, the basis weight is 35 gZm ² , the thickness is 0.26 mm, the shrinkage is 0% during heat treatment at 15 OX 15 minutes in the evening direction and the weft direction, the tensile strength is 103ΝΖ5 cm in the evening direction, and Tensile strength in the U direction The same procedure as in Example 1 was carried out except that a commercially available nonwoven glass fiber nonwoven fabric of 57 N / 5 cm was used, and the length of the backing material in the vertical and horizontal directions, and the tensile strength in the vertical and horizontal directions According to the measurement, both the length of the evening and the length of the horizontal were 50 cm, and the dimensional stability was excellent, but the tensile strength in the vertical direction was 180NZ5 cm, and the tensile strength in the horizontal direction was It was 136 N / 5 cm, which was inferior to Examples 1 and 2 in terms of reinforcing effect.

(Example 5)

As in Example 1, the binder short fiber used in Example 1 was 60% and the polyester short fiber was 40%, and the heat shrinkage in the vertical direction (the direction of progress of the nonwoven fabric production line) was 0.2% and the strength was 78N, as in Example 1. A heat-fused nonwoven fabric having a heat shrinkage in the horizontal direction of / 5 cm, a horizontal direction of 0.4%, a strength of 65 N 5 cm, a basis weight of 50 g / m ² and a thickness of 5 mm was obtained. The beige-dyed polyester staple fiber basis weight 1 50 g / m ² of needle-punched nonwoven fabric using (3. 3 dte xx 5 lmm) and face material, polyester thermal bonding nonwoven as an adhesive (manufactured by Toyobo Co., Ltd. It was laminated and integrated with the heat-sealed nonwoven fabric of the present invention obtained earlier using “Dynac G 0000.” This member has good flatness and dimensional stability and can be used well as a wall covering material. there were.

As can be understood from the above description, the polyester-based nonwoven fabric according to the present invention is a fabric that satisfies high strength and low heat shrinkage for reinforcement and dimensional stability, and is fine when handled like glass fiber fabric. The broken fibers do not scatter and have an adverse effect on the human body, and do not remain in the environment even if incinerated after the product life has expired. In addition, it has a strong bonding force with the resin composition and adhesive that make up the backing layer, and has a strong reinforcing effect on the glass fiber cloth. There is also an excellent advantage of exhibiting.

Further, since the polyester-based nonwoven fabric of the present invention has the above-mentioned excellent advantages, a tile carpet, a mat, an artificial grass, a PVC sheet, a PVC tile, and a backing layer made of a resin composition are laminated on the back surface of a surface material. It can be suitably used as a resin laminate product such as a cushion floor, a rug used indoors and outdoors, a reinforcing material for reinforcing a wall covering material or a ceiling material, or as a filter, a blind curtain, a roll curtain and the like.

Claims

The scope of the claims

1. Consisting of polyester short fiber and polyester binder short fiber, the shrinkage rate during heat treatment of 15 O ^ X 15 minutes is less than 2% in both the horizontal and horizontal directions, and the tensile strength is in the vertical direction. A polyester nonwoven fabric having a width of at least 15ΝΖ5 cm in both horizontal and vertical directions.

2. The monofilament fineness of the main polyester short fiber is 20 to 70 dtex, and the single fiber fineness of the polyester binder short fiber is 2 to 30 dtex according to claim 1. Polyester nonwoven fabric.

3. The polyester-based nonwoven fabric according to claim 1 or 2, wherein the melting point of the polyester-based binder short fibers is at least 160 ^ and less than the melting point of the main polyester short fibers.

4. The polyester nonwoven fabric according to any one of claims 1 to 3, wherein the basis weight is 35 to 300 g Zm ² and the thickness is 1 mm or less.

5. The polyester nonwoven fabric according to any one of claims 1 to 4, wherein the polyester binder short fibers have a composite structure such as a core-sheath type or a sea-island type.

6. The polyester-based nonwoven fabric according to any one of claims 1 to 5, wherein the mixing ratio of the main polyester short fiber and the polyester binder short fiber is 90/90 to 90/90. .

7. A filter comprising the nonwoven fabric according to any one of claims 1 to 6.

8. A non-woven fabric according to any one of claims 1 to 6, wherein the non-woven fabric is a nonwoven fabric.

9. A reinforcing material comprising the nonwoven fabric according to any one of claims 1 to 6.

10. A rug, characterized in that the reinforcing material according to claim 9 is embedded in a backing layer made of a resin composition laminated on the back surface of the facing material.

11. The resin composition according to claim 10, wherein the resin composition is a mixture of a styrene-butadiene copolymer latex as a base rubber, and a polyisocyanate compound having a reactive isocyanate group as a curing agent. The rug described in the section.

12. The rug according to claim 10 or 11, wherein the backing layer is made porous by heat expansion of the heat-expandable microcapsules.