WO2023090281A1 - 熱プレス用クッション材 - Google Patents
熱プレス用クッション材 Download PDFInfo
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- WO2023090281A1 WO2023090281A1 PCT/JP2022/042185 JP2022042185W WO2023090281A1 WO 2023090281 A1 WO2023090281 A1 WO 2023090281A1 JP 2022042185 W JP2022042185 W JP 2022042185W WO 2023090281 A1 WO2023090281 A1 WO 2023090281A1
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- WIPO (PCT)
- Prior art keywords
- hot
- yarn
- cushion
- press
- bulky
- Prior art date
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- 239000000463 material Substances 0.000 title claims abstract description 110
- 238000007731 hot pressing Methods 0.000 title abstract description 9
- 239000002759 woven fabric Substances 0.000 claims abstract description 46
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- 239000002861 polymer material Substances 0.000 claims abstract description 30
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
- D02G3/16—Yarns or threads made from mineral substances
- D02G3/18—Yarns or threads made from mineral substances from glass or the like
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D1/00—Woven fabrics designed to make specified articles
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
- D03D15/267—Glass
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
- D03D15/41—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads with specific twist
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
- D03D15/49—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads textured; curled; crimped
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/693—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with natural or synthetic rubber, or derivatives thereof
Definitions
- the present invention relates to a hot-press cushioning material.
- laminate boards When manufacturing copper-clad laminates, flexible printed circuit boards, printed circuit boards such as multilayer boards, IC cards, liquid crystal display boards, ceramic laminates, electronic parts and other precision equipment parts (hereinafter collectively referred to as “laminate boards") is subjected to hot pressing such as press molding or thermocompression bonding.
- FIG. 8 is a diagram for explaining a press device for press molding or thermocompression bonding of a printed circuit board or the like.
- This press device has a pair of heating plates 13, 13 facing each other.
- a pair of heating plates 13, 13 are means for heating and pressurizing a printed circuit board or the like.
- the pressing device sandwiches the material to be pressed 12, which is a laminated plate material, between a pair of hot plates 13, 13, and presses them with constant pressure and heat.
- a flat cushion material 11 is interposed between the hot plate 13 and the material 12 to be pressed in order to uniformize the heat and pressure applied to the material 12 to be pressed over the entire surface.
- a mirror plate 14 made of stainless steel is further interposed between the cushion material 11 and the material 12 to be pressed.
- the general characteristics required of the cushioning material 11 include the cushioning property to absorb unevenness of the hot platen 13 and the material to be pressed 12, and the ability to cover the hot platen 13 so that the temperature and pressure are uniform over the entire press surface. In-plane uniformity for transferring heat and force to the pressing material 12, heat transferability for efficiently transferring heat from the hot plate 13 to the pressed material 12, and heat resistance to withstand the pressing temperature. be done.
- Patent Document 1 a woven fabric using bulky yarn made of glass fiber for at least one of the warp and weft, and a fiber-rubber composite material layer made of rubber impregnated in the woven fabric.
- a cushioning material for In this hot-press cushioning material, voids are provided inside the fiber-rubber composite material layer so as to exhibit good cushioning properties.
- Patent Document 1 by air jet processing, a single yarn is opened or a plied yarn is expanded, and a bulky yarn (bulky yarn) that has a swelling like wool is used for the woven fabric, thereby reducing the voids in the woven fabric. It increases the rate and achieves good cushioning.
- the present inventors made an attempt to increase cushioning properties and durability by using air jet processing to increase the bulkiness of the yarn and increasing the thickness of the bulky yarn.
- the glass fiber is broken due to frequent use of air jet processing, and although the initial cushioning property is high, the characteristics deteriorate significantly as the number of times of use increases, and the durability of the cushioning material for heat press is reduced. I knew it would get worse.
- an object of the present invention is to provide a highly durable cushioning material for heat press that can maintain good cushioning properties even after repeated use.
- a hot-press cushioning material having a cushion part is A woven fabric in which plied yarn is used for at least one of warp and weft; a polymer material attached to the surface of the fibers that make up the woven fabric; including The plied yarn is It is formed by twisting multiple bulky yarns made of glass fiber, It is characterized by
- FIG. 1 shows a hot-press cushioning material according to an embodiment.
- FIG. 2 shows a normal glass fiber thread.
- FIG. 3 shows a bulky yarn made of glass fiber.
- FIG. 4 is a diagram showing a bulky yarn composite twisted yarn obtained by plying and twisting a plurality of bulky yarns.
- FIG. 5 is a diagram showing a hot-press cushioning material according to another embodiment.
- FIG. 6 is a diagram showing a hot-press cushioning material according to another embodiment.
- FIG. 7 is a graph of Table 1.
- FIG. FIG. 8 is a diagram for explaining a press device for press molding or thermocompression bonding of a printed circuit board or the like.
- FIG. 1 shows a hot press cushion material 10 according to this embodiment.
- the hot press cushion material 10 includes at least a cushion portion 1 .
- the cushion portion 1 is a sheet-like cushion member (cushion sheet) composed of a woven fabric 5 and a polymer material 6 attached to the surface of fibers forming the woven fabric 5 .
- the cushion part 1 includes an air gap 7 inside.
- At least one of the warp yarns 5a and the weft yarns 5b of the woven fabric 5 is a plied yarn.
- a plied yarn is formed by pliing and twisting a plurality of textured yarns made of glass fibers. Such a plied and twisted yarn is hereinafter referred to as a "bulky composite twisted yarn".
- the warp yarns 5a are ordinary glass fiber yarns
- the weft yarns 5b are bulky composite twisted yarns.
- the warp yarns 5a may also be bulky composite twisted yarns like the weft yarns 5b.
- FIG. 2 is a diagram showing a normal glass fiber thread 1a.
- FIG. 3 shows a bulky yarn 1b made of glass fiber.
- FIG. 4 is a diagram showing a bulky yarn composite twisted yarn 1c obtained by plying and twisting a plurality of bulky yarns.
- the glass fiber yarn 1a shown in FIG. 2 is a single yarn, a roving yarn obtained by bundling a plurality of single fibers, or a yarn obtained by twisting a plurality of single yarns or roving yarns.
- the bulky yarn 1b shown in FIG. 3 is a yarn with a large occupied area in which the short fibers constituting the glass yarn are not parallel but are entangled and arranged in a disordered state. is.
- the bulky yarn has bulges like woolen yarn, the woven fabric using the bulky yarn contains many voids inside unlike the ordinary woven fabric. Since the bulky yarn 1b itself contains many voids, it can be appropriately impregnated with the polymer material.
- the bulky yarn 1b is a bulked yarn obtained by bulking a glass fiber yarn.
- a bulky yarn is a textured yarn that is expanded like yarn by opening the yarn or expanding the plied yarn.
- staple yarn As the bulky yarn 1b, staple yarn, sliver yarn, etc. can be used in addition to bulky yarn.
- Staple yarn is obtained by spinning cotton-like short glass fibers into a filament.
- a sliver yarn is a yarn made by twisting untwisted bulky short fibers (sliver).
- the bulky yarn 1b according to the present embodiment is preferably a bundle of 1,000 to 15,000 glass fiber monofilaments. This is for obtaining moderate cushioning properties and sufficient durability.
- the number of single fibers is more preferably 1500 or more, still more preferably 2000 or more. Furthermore, the number of single fibers is more preferably 12,000 or less, and even more preferably 10,000 or less.
- the bulky yarn is a plied yarn, if the twist number is too small, the durability may be deteriorated, and if it is too large, the cushioning property may be deteriorated. 1 to 10 times is preferable, and 0.5 to 5 times is more preferable. It is preferable that the diameter of the single fiber of the glass fiber constituting the bulky yarn is 3 to 11 ⁇ m. This is because if the diameter of the single fiber is less than 3 ⁇ m, the manufacturing process is difficult and the required number of single fibers increases. .
- a general plied yarn means a product in which a plurality of yarns are twisted together, but the bulky yarn composite twisted yarn 1c shown in FIG. In FIG. 4, 3) means those formed by plying and twisting. That is, the bulky yarn conjugate twisted yarn used in the present invention is made by pliing and twisting a plurality of bulky yarns, and is clearly distinguished from, for example, the bulky yarn obtained by further plying and twisting the plied and twisted yarns and finally bulking them.
- the total number of single fibers in the bulky composite twisted yarn is preferably 3,000 to 100,000 in order to obtain good cushioning properties and sufficient durability.
- the number of single fibers is more preferably 4500 or more, still more preferably 6000 or more.
- the number of single fibers is more preferably 80,000 or less, and even more preferably 60,000 or less.
- the number of twists of the bulky yarn composite twisted yarn can be, for example, 1 to 4 twists per inch of length of the bulky yarn.
- the number of single fibers of the warp yarn 5a or the weft yarn 5b of the woven fabric 5 should be increased. sexuality declines. Therefore, in order to obtain good cushioning properties and sufficient durability, the present inventors have found that at least one of the warp yarns 5a and the weft yarns 5b of the woven fabric 5 is not only bulky yarns, but also a plurality of bulky yarns. was further plied and twisted to obtain a bulky yarn composite twisted yarn 1c.
- the cushion part 1 is a sheet-like object. If the thickness of the cushion portion 1 is too small, the cushioning property may be deteriorated, and if the thickness is too large, the heat transfer property may be deteriorated. Therefore, the appropriate thickness of the cushion part 1 is preferably set within a range of 0.5 to 5.0 mm, for example, although it depends on the application. Also, when two or more layers of the cushion part 1 are laminated and used, the total thickness is preferably in the range of 0.5 to 5.0 mm.
- the hot-press cushioning material 10 exhibits good cushioning properties.
- the hot-press cushioning material 10 according to the present embodiment is woven with bulky composite twisted yarns and takes the shape of a woven fabric. It becomes a thing.
- the hot-press cushioning material 10 according to the present embodiment takes the shape of a woven fabric, the thickness can be made smaller than that of a nonwoven fabric, and the heat transfer property can also be excellent.
- polymer material 6 Although there are no particular restrictions on the polymer material 6, synthetic rubber or synthetic resin can be used.
- specific examples of the polymer material 6 include synthetic rubbers such as fluororubber, EPM, EPDM, hydrogenated nitrile rubber, silicone rubber, acrylic rubber, and butyl rubber, and synthetic resins such as fluororesin and polyimide. Examples include resins, polyamide resins, polyetheretherketone resins, and the like.
- the polymer material preferably has a thermal decomposition temperature (5% weight loss temperature) exceeding the pressing temperature and a glass transition temperature. From this point of view, particularly preferred polymer materials are fluororubbers and polyimide resins.
- the polymer material protects the glass fibers and binds the points of contact of the fibers (including the points of contact between the warp and weft, as well as the points of contact between the filament fibers that make up the bulky yarn). Therefore, the hot-press cushioning material 10 using the polymer material 6 can reduce breakage of the glass fibers when repeatedly used for hot-pressing, can suppress so-called settling of the woven fabric 5, and has good cushioning properties. can be maintained.
- t1 be the thickness of the hot-press cushion material 10 when it is compressed at a temperature of 230° C. and a pressure of 0.01 kgf/cm 2
- the cushioning property Fn of the hot press cushion material 10 can be expressed by (t 1 ⁇ t 2 ) ⁇ 1000/t 2 .
- the thicknesses t 1 and t 2 when the hot-press cushioning material 10 is compressed under the above-described press test conditions are determined by an Instron universal material testing machine (manufactured by Instron) and an Autograph precision universal testing machine (Inc. Shimadzu) can be measured by a tester having a compression function.
- the cushioning property Fn measured in this way is preferably 400 or more. With such a range, sufficient cushioning properties can be imparted to the hot-press cushioning material 10 .
- a more preferable range of the Fn value is 420 or more, and a further preferable range is 450 or more.
- a polymer material 6 is adhered to the surface of the fibers forming the woven fabric 5 of the cushion portion 1 in order to prevent the woven fabric 5 from settling and to maintain good properties of the hot-press cushioning material 10 .
- the adhesion amount of the polymer material 6 when the ignition loss test was conducted, the LOI (Loss on Ignition) of the bulky yarn composite twisted yarn to which the polymer material 6 was adhered, taken out from the hot-press cushioning material 10, was It is preferable to make it 5 to 30% by mass. Note that the ignition loss is more preferably 8% by mass or more. Further, the ignition loss is more preferably 25% by mass or less.
- the bulky composite twisted yarn taken out from the hot-press cushion material 10 is heated to a high temperature to volatilize a part of the components of the polymer material 6, and then the weight change of the bulky composite twisted yarn is measured. It is a test to
- a 50 mm square sample is taken from the hot press cushion material, and 10 bulky composite twisted yarns are extracted from the sample. That is, 10 bulky composite twisted yarns having a length of 50 mm are prepared. After these samples are sufficiently dried, they are weighed in a crucible. The weight at this time is represented by ma.
- the crucible containing the sample is placed in a muffle furnace and heated at approximately 650°C for approximately one hour, after which the crucible containing the sample is weighed.
- the weight at this time is represented by mb.
- LOI (ma-mb) / (ma-mc) x 100
- the hot-press cushion material 10 may include at least the cushion portion 1 , and may include only the cushion portion 1 .
- the cushion part 1 of the hot-press cushion material 10 may have a single layer or a plurality of layers.
- FIG. 5 is a diagram showing a hot-press cushioning material 10a according to another embodiment.
- the surface layer portion 2 is laminated on the surface of the cushion portion 1 with the adhesive layer portion 3 interposed therebetween.
- the surface layer portion 2 is provided mainly for imparting releasability to the hot-press cushioning material.
- a synthetic resin film, a base material made of a woven fabric coated with a releasing resin on the surface side, or the like can be used.
- the thickness of the surface layer portion 2 is preferably 0.1 to 0.5 mm, for example.
- the adhesive layer portion 3 the same polymer material as that of the cushion portion 1 is preferably used.
- FIG. 6 is a diagram showing a hot-press cushion material 10b according to another embodiment.
- a hot-press cushion material 10b two layers of cushion portions 1 are laminated with an adhesive sheet portion 4 interposed therebetween.
- Surface layer portions 2 are laminated on the upper and lower surfaces of each cushion portion 1 with adhesive layer portions 3 interposed therebetween. Since the cushion part 1 is constructed by impregnating a polymer material into a glass fiber woven fabric, there is a limit to its thickness. , there is an advantage that the total thickness of the cushion portion 1 can be further increased.
- the bonding between the cushion portions 1 can be performed only with an adhesive, but in this case, the gaps between the textures of the cushion portions 1 may be filled with the adhesive, resulting in a decrease in cushioning properties. Therefore, it is preferable to use the adhesive sheet portion 4 .
- the adhesive sheet portion 4 is, for example, a sheet-like adhesive layer in which an adhesive is applied to a plain weave fabric composed of ordinary glass fiber yarns 1a. As for this adhesive, it is preferable to use a polymer material as in the case of the cushion part 1 . In order to prevent fibers from fraying from the side surfaces and fluff from falling off, the side surfaces of the produced hot-press cushioning material may be coated with a heat-resistant resin.
- a woven fabric is prepared in which at least one of the warp and the weft is a bulky composite twisted yarn.
- the bulky yarn composite twisted yarn is formed by plying and twisting a plurality of bulky yarns made of glass fibers (glass bulky yarns).
- the weaving method of the woven fabric is not limited, and for example, plain weave, twill weave, and other known weaves can be employed.
- a polymer material (fluororubber, polyimide resin, etc.) is attached to at least the surface of the fibers that make up the woven fabric.
- the woven fabric is constructed by immersing the woven fabric in an unvulcanized fluororubber solution obtained by dissolving unvulcanized fluororubber at a predetermined concentration and then sufficiently drying the woven fabric.
- the cushion part (cushion sheet) 1 can be produced by attaching fluororubber to the surface of the fiber.
- polyimide resin varnish of a predetermined concentration is applied to the woven fabric and dried sufficiently to adhere the polyimide resin to the surface of the fibers that make up the woven fabric, resulting in a cushion.
- a part (cushion sheet) 1 can be produced.
- the coating amount of the polymer material is preferably 20-300 g/m 2 , for example.
- the adhesion amount of the polymer material can be adjusted by squeezing with a resin roll, rubber roll, metal roll, or the like.
- the amount of the polymer material adhered to the bulky yarn composite twisted yarn, which is taken out from the hot-press cushioning material and attached to the polymer material has an ignition loss of 5 to 30 masses. %.
- the woven fabric thus obtained in which the polymer material is attached to the surface of the fibers, is in a state in which the fibers are fixed and covered, so that the shape and voids of the woven fabric can be maintained even when used at high temperatures. can do Therefore, even when used repeatedly, good cushioning properties can be ensured.
- the hot-press cushioning material has a surface layer portion (surface layer sheet) 2
- a polyimide resin that will become the surface layer portion 2 is applied to one side of the sheet that will become the base material, and after drying,
- a surface layer sheet obtained by applying a fluororubber or a polyimide resin to be the adhesive layer portion 3 to the other surface to be the adhesive surface and drying it can be used.
- the hot-press cushioning material has an adhesive sheet portion (adhesive sheet) 4, for example, the adhesive sheet 4 obtained by applying fluororubber or polyimide resin to both sides of the base sheet and drying it is used. can be done.
- the adhesive sheet portion 4 may be a film having no substrate.
- the hot press cushion material has a structure in which a plurality of sheet-like materials are laminated, the cushion part 1 and other sheet-like materials are laminated (for example, a surface layer part (surface layer sheet) 2, a cushion part (cushion sheet) 1 , an adhesive sheet portion 4, a cushion portion (cushion sheet) 1, and a surface layer portion (surface layer sheet) 2), and integrated by heat pressing.
- the cushion part 1 and other sheet-like materials are laminated (for example, a surface layer part (surface layer sheet) 2, a cushion part (cushion sheet) 1 , an adhesive sheet portion 4, a cushion portion (cushion sheet) 1, and a surface layer portion (surface layer sheet) 2), and integrated by heat pressing.
- the hot-press cushioning material according to the present invention can be used in the same manner as in the conventional method shown in FIG. That is, by performing hot pressing in a state in which the hot-press cushion material 10 of the present embodiment is interposed between the hot plate 13 and the material 12 to be pressed, heat and pressure applied to the material 12 to be pressed can be made uniform over the entire surface.
- Examples 1 to 2 and Comparative Examples 1 to 4 include a surface layer sheet and an adhesive sheet
- Comparative Example 5 does not include a surface layer sheet and an adhesive sheet, and is composed only of a cushion sheet.
- Example 1 4 glass yarns (E glass fiber, single fiber diameter 6 ⁇ m, total number of single fibers 800, count 67.5 tex) are plied and twisted to prepare 3 bulky yarns, and the 3 bulky yarns are plied and twisted.
- a bulky composite twisted yarn (total number of single fibers: 9600) was prepared.
- a double woven bulky glass cloth using the bulky composite twisted yarn as the weft yarn of a woven fabric was prepared as a woven fabric material. The glass cloth was impregnated with fluororubber to form a cushion base material. Two layers of this cushion base material were prepared. Also, an adhesive sheet was prepared by coating both sides of a plain-woven glass cloth with fluororubber.
- two layers of surface layer sheets were prepared by applying polyimide resin on one side of a plain woven glass cloth and fluororubber for bonding on the other side. These materials were laminated in the order of surface layer sheet, cushion base material, adhesive sheet, cushion base material, and surface layer sheet from the top, and integrated by hot pressing to obtain a sample of the hot-press cushioning material.
- Example 2 The same procedure as in Example 1 except that glass yarn (E glass fiber, single fiber diameter 9 ⁇ m, total number of single fibers 400, count 67.5 tex) was used and a bulky yarn composite twisted yarn (total number of single fibers 4800) was used. A hot-press cushioning material was produced by the method, and a sample was obtained.
- glass yarn E glass fiber, single fiber diameter 9 ⁇ m, total number of single fibers 400, count 67.5 tex
- a bulky yarn composite twisted yarn total number of single fibers 4800
- a double woven bulky glass cloth was prepared as a woven fabric material by using bulky yarn (total number of single fibers: 3200) obtained by twisting four of the same glass yarns as in Example 1 and bulky processing them as wefts of the woven fabric. That is, the bulky yarn used is not a bulky yarn composite twisted yarn.
- the glass cloth was impregnated with fluororubber to form a cushion base material. Six layers of this cushion base material were prepared. Further, five layers of adhesive sheets similar to those in Example 1 were prepared. Furthermore, two layers of surface layer sheets similar to those in Example 1 were prepared.
- These materials are, from the top, the surface layer sheet, the cushion base material, the adhesive sheet, the cushion base material, the adhesive sheet, the cushion base material, the adhesive sheet, the cushion base material, the adhesive sheet, the cushion base material, the adhesive sheet, the cushion base material, the adhesive sheet, the cushion base material, the adhesive sheet, the cushion base material, the adhesive sheet, the cushion base material, and the surface layer.
- the sheets were laminated in order and integrated by hot pressing to obtain a sample of a cushioning material for hot pressing.
- Example 2 A double weave bulky glass cloth using bulky glass yarn (E glass fiber, single fiber diameter 9 ⁇ m, total number of single fibers 7800, count 1390 tex) as the weft of the woven fabric was prepared as a woven fabric material. . That is, the bulky yarn used is not plied and twisted, and is not made into a bulky yarn composite twisted yarn. Using this double-weave bulky glass cloth, a sample of a hot-press cushioning material having the same structure as in Example 1 was obtained.
- E glass fiber single fiber diameter 9 ⁇ m, total number of single fibers 7800, count 1390 tex
- Example 3 Four yarns were prepared by pliing and twisting two of the same glass yarns as in Example 1, and bulky yarn was prepared by bulking the yarn obtained by pliing and twisting the four yarns (total number of single fibers: 6400). bottom. That is, instead of forming a bulky yarn composite twisted yarn by pliing and twisting bulky yarns, bulky processing is applied to the plied and twisted yarns to form bulky yarns. A double woven bulky glass cloth using the bulky yarn as the weft yarn of the woven fabric was prepared as a woven fabric material. Using this double-weave bulky glass cloth, a sample of a hot-press cushioning material having the same structure as in Example 1 was obtained.
- Comparative Example 4 A nonwoven fabric made of polymetaphenylene isophthalamide having a basis weight of 450 g/m 2 was used as a cushion base material. Using the three-layer cushion base material, the same adhesive sheet as used in two-layer Example 1, and the same surface layer sheet as used in two-layer Example 1, the surface layer sheet, the cushion base material, and the An adhesive sheet, a cushion base material, an adhesive sheet, a cushion base material, and a surface layer sheet were laminated in this order and integrated by hot pressing to obtain a sample of a hot-press cushioning material.
- FIG. 7 is a graph of Table 1.
- the cushioning property was evaluated as good when the Fn value was 400 or more, and the durability was evaluated as good when the Fn value was 400 or more after 10 presses.
- the ignition loss is 5 to 30% by mass.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Woven Fabrics (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
- Laminated Bodies (AREA)
Abstract
Description
クッション部を有する熱プレス用クッション材であって、
前記クッション部は、
経糸又は緯糸の少なくとも一方に合撚糸が用いられた織布と、
前記織布を構成する繊維の表面に付着させたポリマー材料と、
を含み、
前記合撚糸は、
ガラス繊維からなる複数の嵩高糸を合撚して形成されている、
ことを特徴とする。
図1は、本実施形態に係る熱プレス用クッション材10を示す。図1に示すように、熱プレス用クッション材10は、少なくともクッション部1を備える。クッション部1は、織布5と、織布5を構成する繊維の表面に付着させたポリマー材料6とで構成される、シート状のクッション部材(クッションシート)である。クッション部1は、内部に空隙7を含む。
熱プレス用クッション材10を、230℃の温度、0.01kgf/cm2の加圧力で圧縮したときの厚みをt1とし、230℃の温度、40kgf/cm2の加圧力で圧縮したときの厚みをt2とするとき、熱プレス用クッション材10のクッション性Fnは、(t1-t2)×1000/t2で表すことができる。
織布5のヘタリを抑止して、熱プレス用クッション材10が良好な特性を維持するために、クッション部1の織布5を構成する繊維の表面には、ポリマー材料6を付着させている。ポリマー材料6の付着量は、強熱減量試験を行った際、熱プレス用クッション材10から取り出した、ポリマー材料6が付着した嵩高糸複合撚糸の強熱減量(LOI:Loss on Ignition)が、5~30質量%となるようにすることが好ましい。なお、強熱減量は、8質量%以上とすることがより好ましい。また、強熱減量は、25質量%以下とすることがより好ましい。強熱減量試験とは、熱プレス用クッション材10から取り出した嵩高糸複合撚糸を高温に加熱して、ポリマー材料6の成分の一部を揮発させた後の嵩高糸複合撚糸の重量変化を測定する試験である。
LOI=(ma-mb)/(ma-mc)×100
熱プレス用クッション材10は、少なくともクッション部1を備えておればよく、クッション部1のみであってもよい。熱プレス用クッション材10のクッション部1は、1層でもよいし、複数層でもよい。
まず、経糸又は緯糸の少なくとも一方が、嵩高糸複合撚糸である織布を用意する。嵩高糸複合撚糸は、ガラス繊維からなる嵩高糸(ガラスバルキーヤーン)を複数合撚して形成される。織布の織り方には、限定はなく、例えば、平織り、綾織、その他の公知の織りを採用できる。
ガラスヤーン(Eガラス繊維、単繊維径6μm、単繊維総本数800本、番手67.5tex)を4本合撚しバルキー加工した嵩高糸を3本用意し、その3本の嵩高糸を合撚した嵩高糸複合撚糸(単繊維総本数9600本)を用意した。その嵩高糸複合撚糸を織布の緯糸に用いた2重織りバルキーガラスクロスを、織布材料として用意した。そのガラスクロスにフッ素ゴムを含浸し、クッション基材とした。このクッション基材を2層分用意した。また、平織りガラスクロスの両面にフッ素ゴムをコーティングした接着シートを用意した。さらに、平織りガラスクロスの片面にポリイミド樹脂、反対面に接着用のフッ素ゴムをそれぞれ塗布した表層シートを2層分用意した。これらの材料を、上から表層シート、クッション基材、接着シート、クッション基材、表層シートの順に積層し、熱プレスにより一体化させて、熱プレス用クッション材のサンプルを得た。
ガラスヤーン(Eガラス繊維、単繊維径9μm、単繊維総本数400本、番手67.5tex)を用い、嵩高糸複合撚糸(単繊維総本数4800本)とした以外は、実施例1と同様の方法により熱プレス用クッション材を作製し、サンプルを得た。
実施例1と同じガラスヤーンを4本合撚しバルキー加工した嵩高糸(単繊維総本数3200本)を織布の緯糸として用いた、2重織りバルキーガラスクロスを、織布材料として用意した。すなわち、用いた嵩高糸は嵩高糸複合撚糸としていない。そのガラスクロスにフッ素ゴムを含浸し、クッション基材とした。このクッション基材を6層分用意した。また、実施例1と同様の接着シートを5層分用意した。さらに、実施例1と同様の表層シートを2層分用意した。これらの材料を、上から表層シート、クッション基材、接着シート、クッション基材、接着シート、クッション基材、接着シート、クッション基材、接着シート、クッション基材、接着シート、クッション基材、表層シートの順に積層し、熱プレスにより一体化させて、熱プレス用クッション材のサンプルを得た。
ガラスヤーン(Eガラス繊維、単繊維径9μm、単繊維総本数7800本、番手1390tex)をバルキー加工した嵩高糸を織布の緯糸として用いた2重織りバルキーガラスクロスを、織布材料として用意した。すなわち、用いた嵩高糸は合撚しておらず、さらに嵩高糸複合撚糸としていない。この2重織りバルキーガラスクロスを用いて、実施例1と同様の構成とした熱プレス用クッション材のサンプルを得た。
実施例1と同じガラスヤーンを2本合撚した糸を4本用意し、その4本の糸を合撚して得られた糸(単繊維総本数6400本)にバルキー加工した嵩高糸を用意した。すなわち、嵩高糸を合撚した嵩高糸複合撚糸とするのではなく、合撚した糸にバルキー加工を施し、嵩高糸とした。その嵩高糸を、織布の緯糸に用いた2重織りバルキーガラスクロスを、織布材料として用意した。この2重織りバルキーガラスクロスを用いて、実施例1と同様の構成とした熱プレス用クッション材のサンプルを得た。
クッション基材として、目付重量が450g/m2のポリメタフェニレンイソフタラミド製不織布を用いた。3層のクッション基材と、2層の実施例1で用いたものと同じ接着シートと、2層の実施例1で用いたものと同じ表層シートを用い、上から表層シート、クッション基材、接着シート、クッション基材、接着シート、クッション基材、表層シートの順に積層し、熱プレスにより一体化させて、熱プレス用クッション材のサンプルを得た。
目付重量が190g/m2のクラフト紙を20枚重ねて、熱プレス用クッション材のサンプルを得た。
[プレス耐久性試験条件]
加圧力 :40kgf/cm2
加圧時間:75分
温度 :230℃
加熱時間:60分(30分間で25℃から所定温度まで昇温し、その状態を30分間保持)
冷却時間:15分
サンプルサイズ:280mm角
プレス機:150tテストプレス機(関西ロール株式会社製)
各種サンプルについて、プレス前、並びに、1回、10回、50回、100回、及び200回のプレス後それぞれでのクッション性を評価した。なお、比較例5のサンプルについては、プレスの繰り返しに耐えられる熱プレス用クッション材ではないため、プレスは1回のみとした。各種サンプルに、下記の加圧試験を行った。そして、0.01kgf/cm2の加圧力で圧縮したときの厚みt1と、40kgf/cm2の加圧力で圧縮したときの厚みt2との差(μm)により圧縮クッション性Fnを求めた。その結果を表1に示す。図7は、表1をグラフ化したものである。
加圧力 :40kgf/cm2
温度 :230℃
予熱 :0.05kgf/cm2の加圧条件で2分間
加圧速度:1mm/min
サンプルサイズ :25mmφ
サンプル採取位置:耐久性試験用サンプルの、端から5cm以上離れた位置から1か所
試験装置:インストロン万能材料試験機 5565型(インストロン ジャパン カンパニィリミテッド製)
1a ガラス繊維糸
1b 嵩高糸
1c 嵩高糸複合撚糸
2 表層部
3 接着層部
4 接着シート部
5 織布
5a 経糸
5b 緯糸
6 ポリマー材料
7 空隙
10 熱プレス用クッション材
11 クッション材
12 被プレス材
13 熱盤
14 鏡面板
Claims (5)
- クッション部を有する熱プレス用クッション材であって、
前記クッション部は、
経糸又は緯糸の少なくとも一方に合撚糸が用いられた織布と、
前記織布を構成する繊維の表面に付着させたポリマー材料と、
を含み、
前記合撚糸は、
ガラス繊維からなる複数の嵩高糸を合撚して形成されている、
熱プレス用クッション材。 - 前記ガラス繊維の単繊維の直径は、3~11μmである、
請求項1に記載の熱プレス用クッション材。 - 前記合撚糸を構成する単繊維の総本数は、3000本~100000本である、
請求項1又は請求項2に記載の熱プレス用クッション材。 - 230℃、0.01kgf/cm2の条件で前記熱プレス用クッション材を圧縮したときの厚さをt1、230℃、40kgf/cm2の条件で前記熱プレス用クッション材を圧縮したときの厚さをt2で表すと、下記(1)式から求められるFnは、400以上である、
請求項1から請求項3の何れか一つに記載の熱プレス用クッション材。
Fn=(t1-t2)×1000/t2・・・(1) - 前記熱プレス用クッション材から取り出した前記ポリマー材料が付着した前記合撚糸の強熱減量は、5~30%である、
請求項1から請求項4の何れか一つに記載の熱プレス用クッション材。
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