JPS62198446A - Manufacture of laying material having rigidity - Google Patents
Manufacture of laying material having rigidityInfo
- Publication number
- JPS62198446A JPS62198446A JP61039437A JP3943786A JPS62198446A JP S62198446 A JPS62198446 A JP S62198446A JP 61039437 A JP61039437 A JP 61039437A JP 3943786 A JP3943786 A JP 3943786A JP S62198446 A JPS62198446 A JP S62198446A
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven fabric
- resin
- thermoplastic resin
- fiber
- emulsion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000000463 material Substances 0.000 title claims abstract description 37
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 12
- 239000000835 fiber Substances 0.000 claims abstract description 69
- 229920005989 resin Polymers 0.000 claims abstract description 52
- 239000011347 resin Substances 0.000 claims abstract description 52
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 49
- 239000000839 emulsion Substances 0.000 claims abstract description 44
- 239000002245 particle Substances 0.000 claims abstract description 41
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 22
- 239000011230 binding agent Substances 0.000 claims abstract description 15
- 238000002844 melting Methods 0.000 claims abstract description 11
- 230000008018 melting Effects 0.000 claims abstract description 11
- 238000000034 method Methods 0.000 claims abstract description 10
- 229920006248 expandable polystyrene Polymers 0.000 claims abstract description 9
- 239000007787 solid Substances 0.000 claims abstract description 8
- 239000011248 coating agent Substances 0.000 claims abstract description 4
- 238000000576 coating method Methods 0.000 claims abstract description 4
- 239000006260 foam Substances 0.000 claims description 14
- 238000010438 heat treatment Methods 0.000 claims description 8
- 238000001035 drying Methods 0.000 claims description 7
- 238000004080 punching Methods 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 abstract description 11
- 230000000694 effects Effects 0.000 abstract description 4
- 238000005187 foaming Methods 0.000 abstract description 3
- 230000006866 deterioration Effects 0.000 abstract description 2
- 239000004033 plastic Substances 0.000 abstract 1
- 229920003023 plastic Polymers 0.000 abstract 1
- 230000002265 prevention Effects 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 20
- -1 polypropylene Polymers 0.000 description 13
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 10
- 239000004743 Polypropylene Substances 0.000 description 8
- 229920001155 polypropylene Polymers 0.000 description 8
- 230000009477 glass transition Effects 0.000 description 6
- 239000000178 monomer Substances 0.000 description 6
- 229920000728 polyester Polymers 0.000 description 6
- 229920002994 synthetic fiber Polymers 0.000 description 6
- 239000012209 synthetic fiber Substances 0.000 description 6
- 229920001577 copolymer Polymers 0.000 description 5
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 3
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 3
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 3
- 238000005452 bending Methods 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 230000014759 maintenance of location Effects 0.000 description 3
- 230000035699 permeability Effects 0.000 description 3
- 229920002239 polyacrylonitrile Polymers 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 3
- 229920002554 vinyl polymer Polymers 0.000 description 3
- LEJBBGNFPAFPKQ-UHFFFAOYSA-N 2-(2-prop-2-enoyloxyethoxy)ethyl prop-2-enoate Chemical compound C=CC(=O)OCCOCCOC(=O)C=C LEJBBGNFPAFPKQ-UHFFFAOYSA-N 0.000 description 2
- GOXQRTZXKQZDDN-UHFFFAOYSA-N 2-Ethylhexyl acrylate Chemical compound CCCCC(CC)COC(=O)C=C GOXQRTZXKQZDDN-UHFFFAOYSA-N 0.000 description 2
- WDQMWEYDKDCEHT-UHFFFAOYSA-N 2-ethylhexyl 2-methylprop-2-enoate Chemical compound CCCCC(CC)COC(=O)C(C)=C WDQMWEYDKDCEHT-UHFFFAOYSA-N 0.000 description 2
- 229920005789 ACRONAL® acrylic binder Polymers 0.000 description 2
- 229920002126 Acrylic acid copolymer Polymers 0.000 description 2
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 2
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 2
- 239000005977 Ethylene Substances 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 2
- 230000000740 bleeding effect Effects 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 229920001519 homopolymer Polymers 0.000 description 2
- 239000004816 latex Substances 0.000 description 2
- 229920000126 latex Polymers 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 229920006327 polystyrene foam Polymers 0.000 description 2
- PNXMTCDJUBJHQJ-UHFFFAOYSA-N propyl prop-2-enoate Chemical compound CCCOC(=O)C=C PNXMTCDJUBJHQJ-UHFFFAOYSA-N 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 229920003002 synthetic resin Polymers 0.000 description 2
- 239000000057 synthetic resin Substances 0.000 description 2
- 210000002268 wool Anatomy 0.000 description 2
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- JAHNSTQSQJOJLO-UHFFFAOYSA-N 2-(3-fluorophenyl)-1h-imidazole Chemical compound FC1=CC=CC(C=2NC=CN=2)=C1 JAHNSTQSQJOJLO-UHFFFAOYSA-N 0.000 description 1
- HRPVXLWXLXDGHG-UHFFFAOYSA-N Acrylamide Chemical compound NC(=O)C=C HRPVXLWXLXDGHG-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 239000004908 Emulsion polymer Substances 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229920002845 Poly(methacrylic acid) Polymers 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000001273 butane Substances 0.000 description 1
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- SUPCQIBBMFXVTL-UHFFFAOYSA-N ethyl 2-methylprop-2-enoate Chemical compound CCOC(=O)C(C)=C SUPCQIBBMFXVTL-UHFFFAOYSA-N 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 239000001023 inorganic pigment Substances 0.000 description 1
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 description 1
- FQPSGWSUVKBHSU-UHFFFAOYSA-N methacrylamide Chemical compound CC(=C)C(N)=O FQPSGWSUVKBHSU-UHFFFAOYSA-N 0.000 description 1
- 125000005395 methacrylic acid group Chemical group 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 229920002401 polyacrylamide Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000004926 polymethyl methacrylate Substances 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- LYBIZMNPXTXVMV-UHFFFAOYSA-N propan-2-yl prop-2-enoate Chemical compound CC(C)OC(=O)C=C LYBIZMNPXTXVMV-UHFFFAOYSA-N 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000011041 water permeability test Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
Abstract
Description
【発明の詳細な説明】
〔産業上の利用分野〕
本発明は自動車の天井材、ドア） ＩＪム、リヤーシェ
ル、シートバック、トランクまｂｂｓ材等の内装材とし
て有用な深絞成形可能な剛性と遮へい性を兼ね備えた不
織布の製造方法に関するものである。[Detailed Description of the Invention] [Industrial Field of Application] The present invention is a material that has a rigidity that can be deep-drawn and is useful as an interior material for automotive ceiling materials, doors, IJs, rear shells, seat backs, trunk BBS materials, etc. The present invention relates to a method for manufacturing a nonwoven fabric that also has shielding properties.
従来、上記内装材としてはフェノール・アルデヒド縮合
樹脂に繊維を充填したレジンフェルト、発泡合成樹脂、
ポリプロピレン複合体、ポリプロピレン製ダンボール等
の１００℃以上の温度に耐えうる素材が用いられている
。これら素材において、レジンフェルトは剛性、耐熱保
型性、寸法安定性、遮へい性に優れるが、成形作業性、
耐衝撃性、および軽さに乏しい欠点がある。また、ポリ
プロピレン製ダンボールは剛性、軽量性に優れるが、そ
の反面、深絞成型に乏しいし、コルゲート部材を用いる
ため強度に方向性がある。更に発泡合成樹脂、例えばポ
リスチレンは軽さに優れるが成型作業性や耐屈曲性が乏
しい欠点があり、また、成型後の外＃！（はだざわり）
に難点がある。内装材としての要求性能、即ち、剛性と
適度の柔軟性、軽量性、寸法安定性、耐熱保型性、成形
性の全てを満足する素材は得られていない。Conventionally, the above-mentioned interior materials include resin felt made of phenol-aldehyde condensation resin filled with fibers, foamed synthetic resin,
Materials that can withstand temperatures of 100°C or higher are used, such as polypropylene composites and polypropylene cardboard. Among these materials, resin felt has excellent rigidity, heat-resistant shape retention, dimensional stability, and shielding properties, but it has poor molding workability.
It has the disadvantage of poor impact resistance and lightness. Furthermore, polypropylene cardboard has excellent rigidity and light weight, but on the other hand, it is poor in deep drawing, and because it uses a corrugated member, its strength is directional. Furthermore, foamed synthetic resins, such as polystyrene, have excellent lightness, but have the disadvantage of poor moldability and bending resistance, and also have the disadvantage of poor external strength after molding. (Hadazawari)
There is a problem with this. No material has been obtained that satisfies all of the performance requirements for interior materials, namely, rigidity, appropriate flexibility, lightness, dimensional stability, heat-resistant shape retention, and moldability.
一方、ポリエチレンやポリプロピレン、低融点（１４０
℃）ポリエステル等の繊維を繊維バインダーとし、これ
と合成繊維よりなる繊維マットをニードリングしてウェ
ブの上下層の繊維を仮り止めした後、加熱して上記繊維
バインダーを溶融させ、池の合成繊維の結合を行って弾
力に富む不、ａ布を製造する方法は公知である。この不
織布は軽量性、柔軟性に富むが成形性、剛性に欠けるた
め平担な場所で使用される内装材としては有用であるが
、複雑な形状の場所に適用される内装材としては有用で
ない。On the other hand, polyethylene, polypropylene, low melting point (140
°C) Using fibers such as polyester as a fiber binder, a fiber mat made of synthetic fibers is needled to temporarily bind the fibers in the upper and lower layers of the web, and then heated to melt the fiber binder and create synthetic fibers. A method of producing a highly elastic nonwoven fabric by bonding is known. Although this nonwoven fabric is lightweight and flexible, it lacks moldability and rigidity, so it is useful as an interior material for flat areas, but it is not useful as an interior material for areas with complex shapes. .
また、ニードルパンチ布に軟化点が１００〜１３０℃の
熱可塑性樹脂の水性エマルジョンを塗布または含浸させ
た後、加熱乾燥して水分を除去して成形可能な不織布を
得、これを更に加熱、プレス成形して得られた自動車の
内装材は公知である。この内装材は形状が複雑な場所に
敷設できる利点を有する。この不織布の繊維の固定はニ
ードルパンチングによる繊維同志の絡合とエマルジョン
樹脂の繊維への付着によるものであるが、エマルジョン
が塗布、含浸される不織布の見掛密度が０．０８〜０．
１３ ？／ｄｌと嵩高いためエマルジョン樹脂による充
填効果が悪い欠点がある。又、充填効果が不十分な為、
遮へい性に劣る欠点がある。In addition, after applying or impregnating a needle-punched cloth with an aqueous emulsion of a thermoplastic resin with a softening point of 100 to 130°C, heat and dry it to remove moisture to obtain a moldable nonwoven fabric, which is further heated and pressed. Automotive interior materials obtained by molding are known. This interior material has the advantage that it can be installed in places with complex shapes. The fixation of the fibers of this nonwoven fabric is due to the entanglement of the fibers by needle punching and the adhesion of the emulsion resin to the fibers, but the apparent density of the nonwoven fabric to which the emulsion is applied and impregnated is 0.08 to 0.
13? /dl, which has the disadvantage that the filling effect with emulsion resin is poor. Also, because the filling effect is insufficient,
It has the disadvantage of poor shielding properties.
本発明者は後者の成形可能な不織布のかかる寸法安定性
、剛性に乏しい欠点を適宜の軽量性、耐熱保型性、通気
性を低下させないで改良した不織布の製造方法として、
先に熱可塑性樹脂製バインダー繊維が１５〜５０重量％
と、該熱可塑性樹脂の融点よりも４０℃以上高い融点を
有する合成繊維もしくは天然繊維８５〜５０重通％とよ
りなる繊維マットをニードリングした後、該マットを前
記熱可塑性樹脂製バインダー繊維は溶融するが合成繊維
または天然繊維は溶融しない温度で加熱して熱可塑性樹
脂製バインダー繊維を溶融させ、次いで該熱可塑性樹脂
製バインダー繊維が溶融状態を保つ間に該繊維マットを
圧縮して該マットの見掛密度を０．１５〜０．５０ ｆ
／ｌ−ｆｆ！に調整し、この圧縮された繊維マットに更
に成形可能な温度礒囲が８０〜１８０℃の熱可塑性樹脂
の水性エマルジョンを該繊維マットの繊維取量に対し、
エマルジョンの樹脂固型分が１５〜３ｏｏ！１１−１よ
％となる様に塗布または含浸させたのち、６０〜２５０
℃に加熱乾燥して水分を除去して不織布を得ることを特
徴とする成形可能な不織布の製造方法を提供した（特開
昭５８−８７３５３号）。The present inventor has developed a method for producing a nonwoven fabric that improves the poor dimensional stability and rigidity of the latter moldable nonwoven fabric without reducing its lightness, heat-resistant shape retention, and air permeability.
15 to 50% by weight of thermoplastic resin binder fiber first
After needling a fiber mat made of 85 to 50% by weight of synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the thermoplastic resin, the mat is combined with the thermoplastic resin binder fibers. The thermoplastic resin binder fibers are melted by heating at a temperature that melts the synthetic fibers or natural fibers, and then the fiber mat is compressed while the thermoplastic resin binder fibers remain in a molten state. The apparent density of 0.15 to 0.50 f
/l-ff! An aqueous emulsion of a thermoplastic resin having a temperature range of 80 to 180°C that can be further molded into this compressed fiber mat is added to the fiber content of the fiber mat.
The resin solid content of the emulsion is 15~3oo! After coating or impregnating it to 11-1%, 60-250%
A method for manufacturing a moldable nonwoven fabric is provided, which is characterized in that the nonwoven fabric is obtained by heating and drying at a temperature of 0.degree.
この方法は、熱可塑性樹脂製繊維バインダーと樹脂エマ
ルジョンの併用によ抄不織布の剛性を向上させるととも
に、繊維同志を接着させて寸法安定性を向上させ、また
、エマルジョンを塗布または含浸させる前に繊維マット
を圧縮して空気の一部を追い出し、エマルジョン樹脂の
マット中への充填率を多くすることを可能ならしめて不
織布の剛性向上を計っている点に太きｔ特徴がある。This method uses a combination of a thermoplastic resin fiber binder and a resin emulsion to improve the rigidity of the paper-made nonwoven fabric, as well as bonding the fibers together to improve dimensional stability. The feature of the thick t is that the mat is compressed to expel some of the air, making it possible to increase the filling rate of the emulsion resin into the mat, thereby improving the rigidity of the nonwoven fabric.
しかし、この成形可能な不織布は、成型性、寸法安定性
、通気性（吸音性）に浸れ、剛性の向上も達成出来たが
、通気比を持たせた湯水の遮へい性に劣る。さらに、用
途により、より高い剛性、非透水性を要求されるものが
ある。However, although this moldable nonwoven fabric has excellent moldability, dimensional stability, air permeability (sound absorption), and improved rigidity, it is inferior in hot water shielding ability with a high air permeability ratio. Furthermore, depending on the application, higher rigidity and water impermeability are required.
非透水性、剛性に優れる素材として、樹脂バッキングさ
れた不織布の裏面に発泡体シートを接着したカーペット
を我々は先に提案した。（実願昭５７−１７０６５６号
、同５７−１９５７３１号参照）
しかし、この方法ではバッキング層形成工程と発泡体シ
ートの接着工程が必要であるとともに、発泡体シートの
折曲による破壊を防止するために、更にこの発泡体シー
トに非発泡シートを積層する必要がある。さらに、樹脂
層が直接表層となる為、外観上の問題がある。We previously proposed a carpet made of resin-backed nonwoven fabric with a foam sheet adhered to the back side as a material with excellent water impermeability and rigidity. (Refer to U.S. Patent Application No. 57-170656 and 57-195731.) However, this method requires a backing layer formation step and a foam sheet bonding step, and also requires a step to prevent the foam sheet from breaking due to bending. Furthermore, it is necessary to further laminate a non-foamed sheet to this foamed sheet. Furthermore, since the resin layer directly forms the surface layer, there are problems in terms of appearance.
本発明は、先に提案した敷設材の性能向上、つまり遮へ
い性の改良、剛性の向上、外観性の改善を行うことを目
的でなされたものであ抄、バッキング材として発泡性ポ
リスチレン樹脂粒子等の発泡性樹脂粒子と樹脂水性エマ
ルジョンと不織布を組合せることによ抄かかる線層を解
決したものである。The present invention was made for the purpose of improving the performance of the laying material proposed earlier, that is, improving shielding properties, improving rigidity, and improving appearance. By combining expandable resin particles, an aqueous resin emulsion, and a nonwoven fabric, the problem of the linear layer required for papermaking is solved.
即ち、本発明は、上層用不織布と下層用不織布間に発泡
性熱可塑性樹脂粒子を挾んで積層体となし、ニードルパ
ンチを行なって上下層を絡合せ、ついでこのニードルパ
ンチ不織布積層体に樹脂水性エマルジョンを塗布含浸し
、次いで塗布面を加熱して前記発泡性熱可塑性樹脂粒子
の発泡を行うとともに樹脂水性エマルジョンを乾燥させ
ることを特徴とする剛性を有する敷設材の製造方法を提
供するものである。That is, in the present invention, foamable thermoplastic resin particles are sandwiched between an upper layer nonwoven fabric and a lower layer nonwoven fabric to form a laminate, the upper and lower layers are entangled by needle punching, and then an aqueous resin is applied to the needle punched nonwoven fabric laminate. Provided is a method for producing a rigid laying material, which comprises coating and impregnating an emulsion, then heating the coated surface to foam the expandable thermoplastic resin particles, and drying the aqueous resin emulsion. .
（不織布）
本発明における敷物原反としての不織布としては、羊毛
、ナイロン、ポリアクリロニトリル、ポリアセテート、
ポリプロピレン等の天然及び樹脂繊維を素材として得た
ニードルパンチカーペットが用いられる。(Nonwoven Fabric) Examples of the nonwoven fabric used as the rug material in the present invention include wool, nylon, polyacrylonitrile, polyacetate,
Needle punch carpets made from natural and resin fibers such as polypropylene are used.
このニードルパンチカーペットは合成繊維および／また
は天然繊維よ妙なる繊維マットをニードリングして得た
ウェブであり、このものは公知の不織布の製造方法で製
造される。即ち、１．２〜３００デニール、繊維長２５
〜１５０■の繊維を十分に混合、開繊されたものをウェ
ブ形成装置に供給し、該混合繊維より形成されたカード
を目的とするｆＩＪ！！維目付量になる様に積み重ねて
得たウェブ（Ｎ１．ｍマットおよび／またはこのウェブ
）を垂直方向にニードリングして繊維同志をからみ合わ
せることによ抄仮止めしたものである。This needle-punched carpet is a web obtained by needling a fiber mat of synthetic fibers and/or natural fibers, and is manufactured by a known method for manufacturing nonwoven fabrics. That is, 1.2 to 300 denier, fiber length 25
~150 μ of fibers are sufficiently mixed and opened, and then supplied to a web forming device, and a card formed from the mixed fibers is produced. ! The webs (N1.m mats and/or this web) obtained by stacking the fibers to a fiber density are vertically needled to entangle the fibers to temporarily bind the sheets.
この峨惟の一部（マット重量の１５〜５０重量％の繊維
）を、融点が８０〜２００℃と低い樹脂繊維バインダー
におきかえると得られる敷設材の強度はより向上する。If a part of this fiber (15 to 50% by weight of fibers based on the weight of the mat) is replaced with a resin fiber binder having a low melting point of 80 to 200°C, the strength of the resulting laying material will be further improved.
かかる繊維バインダーとしては、ポリエチレン、ポリプ
ロピレン、線状ポリエステル、低分子量共縮合ポリアミ
ド等の樹脂の短慣維（長さ１５〜４０ ｇ！Ｒ）のもの
が用いられる。As such a fiber binder, short fibers (length: 15 to 40 g!R) of resin such as polyethylene, polypropylene, linear polyester, and low molecular weight co-condensed polyamide are used.
繊維マットを構成する合成繊維の原料としてはポリエチ
レンテレフタレート、ポリアミド等、前記熱可塑性樹脂
製繊維バインダーの融点よりも４０℃以上、好ましくは
７０℃以上高い融点（具体的には２００〜２８０℃）を
有する熱可塑性樹脂が用いられる。また、天然繊維とし
ては木綿、麻、羊毛等が用いられる。The raw materials for the synthetic fibers constituting the fiber mat include polyethylene terephthalate, polyamide, etc., which have a melting point higher than the melting point of the thermoplastic resin fiber binder by 40°C or more, preferably 70°C or more (specifically 200 to 280°C). A thermoplastic resin having a Further, as natural fibers, cotton, linen, wool, etc. are used.
このＬ理工織布と下層不織布との間に後述する発泡性樹
脂粒子を挟み、ニードリングすることにより、上下層の
繊維がからみあい、発泡性樹脂粒子は安定に固定される
。By sandwiching the below-described foamable resin particles between the L-woven fabric and the lower nonwoven fabric and needling, the fibers of the upper and lower layers are entangled, and the foamable resin particles are stably fixed.
（発泡性熱可塑性樹脂粒子）
発泡性熱可塑性樹脂粒子としては、発泡性ポリスチレン
、発泡性α〜メチレン・スチレン共重合体、発泡性ポリ
エチレン、発泡性ポリプロピレン等の粒径が０．１〜３
ｍ程度のものが用いられる。(Expansible thermoplastic resin particles) Examples of the expandable thermoplastic resin particles include expandable polystyrene, expandable α-methylene-styrene copolymer, expandable polyethylene, expandable polypropylene, etc. with a particle size of 0.1 to 3.
A diameter of about m is used.
これらの中でも、粒径が１．５■以下の発泡性ポリスチ
レン粒子が安価であり、好ましい。Among these, expandable polystyrene particles having a particle size of 1.5 square meters or less are preferred because they are inexpensive.
この発泡性樹脂粒子（１）は、第１図に示すように不織
布（Ｌ２’）間に出来るかぎ９層状となすように並べる
とよい。The expandable resin particles (1) are preferably arranged in nine layers between the nonwoven fabrics (L2') as shown in FIG.
（樹脂水性エマルジョン）
バッキング材として、繊維マットの係止、発泡体粒子の
接着機能をなす樹脂水性エマルジョンとしては、ガラス
転移点が一６５℃〜＋１５０℃の樹脂の水性エマルジョ
ン、例えばポリ酢酸ビニル、塩化ビニル・塩化ビニリデ
ン共重合体、スチレン・ブタジェン共１合体ゴム、スチ
レン−メタクリル酸メチル共重合体、スチレン−アクリ
ル酸ｎ −ブチル共歌合体、エチレン・酢酸ビニル共重
合体、スチレン会アクリル酸ｎ−ブチル番アクリル酸共
重合体、塩化ビニリデン・アクリロニトリル・アクリル
酸共重合体等のラテックス、水性エマルジョンの単独並
びに混合体が用いられる。(Aqueous Resin Emulsion) As a backing material, an aqueous resin emulsion that functions to anchor the fiber mat and adhere the foam particles is an aqueous emulsion of a resin with a glass transition point of 165°C to +150°C, such as polyvinyl acetate, Vinyl chloride/vinylidene chloride copolymer, styrene/butadiene copolymer rubber, styrene/methyl methacrylate copolymer, styrene/n-butyl acrylate copolymer, ethylene/vinyl acetate copolymer, styrene/acrylic acid n - Butyl No. Latex such as acrylic acid copolymer, vinylidene chloride/acrylonitrile/acrylic acid copolymer, or aqueous emulsion may be used alone or as a mixture.
敷設材の不戦布層の柔軟性の面からはガラス転移点が２
０℃以下の樹脂水性エマルジョンやラテックスが好まし
く、逆に敷設材の不織布層に剛性や成形性を付与するに
はガラス転移点が８０℃以上の樹脂水性エマルジョンが
好ましい。In terms of flexibility of the non-woven fabric layer of the laying material, the glass transition point is 2.
An aqueous resin emulsion or latex having a temperature of 0° C. or lower is preferable, and an aqueous resin emulsion having a glass transition point of 80° C. or higher is preferable in order to impart rigidity and moldability to the nonwoven fabric layer of the laying material.
ガラス転移点が８０℃以上の水性エマルジョンとしては
、（ａ）、ポリメタクリル酸ｎ−プロピル（Ｔｇ８１℃
）、ポリスチレン（１００℃）、ポリアクリロニトリル
（１００℃）、ポリメタクリル酸メチル（１０５℃）、
ポリメタクリル酸（１３０℃）、ポリイタコン酸（１３
０℃）、ポリアクリルアミド（１５３℃）等のホモ重合
体の水性エマルジョンの他、（ｂ）、これら重合体の原
料であるビニル単骨体５０〜１００重欣％、好ましくは
６５〜９５重量％と、他のビニル単量体、例えばアクリ
ル酸２−エチルヘキシル（Ｔｇ−８５℃）、アクリル酸
ｎ・ブチル（−５４℃）、アクリル酸エテル（−２２℃
）、アクリル酸イソプロピル（−５℃）、メタクリル酸
２−エチルヘキシル（−５℃）、アクリル酸ｎ・プロピ
ル（８℃）、メタクリル酸Ｈｅブチル（２０℃）、酢酸
ビニル（３０℃）、メタクリル酸エチル（６５℃）、塩
化ビニル（７９℃）等もしくは塩化ビニリデン（−１８
℃）５０重量％以下、好ましくは３５〜５重量％との共
重合体の水性エマルジョン〔この（６）項において、（
）内に示されるＴｇは、これらビニル単量体もしくは塩
化ビニリデンのホモ重合体のガラス転移点である）、（
ｃ）−’ｒｇが＋８０〜１５５℃の樹脂水性エマルジョ
ン５０〜９７重量％、好ましくは５５〜９５重量％と、
Ｔｇが一８５℃〜＋８０℃未満の樹脂水性エマルジョン
５０〜３重量％、好ましくは４５〜５重量％との混合物
等があげられる。As the aqueous emulsion having a glass transition point of 80°C or higher, (a) polyn-propyl methacrylate (Tg81°C
), polystyrene (100°C), polyacrylonitrile (100°C), polymethyl methacrylate (105°C),
Polymethacrylic acid (130°C), polyitaconic acid (13
0°C), an aqueous emulsion of a homopolymer such as polyacrylamide (153°C), and (b) 50 to 100% by weight, preferably 65 to 95% by weight of vinyl monomers, which are the raw materials for these polymers. and other vinyl monomers, such as 2-ethylhexyl acrylate (Tg -85°C), n-butyl acrylate (-54°C), ethyl acrylate (-22°C)
), isopropyl acrylate (-5°C), 2-ethylhexyl methacrylate (-5°C), n-propyl acrylate (8°C), He-butyl methacrylate (20°C), vinyl acetate (30°C), methacrylic acid Ethyl (65℃), vinyl chloride (79℃), etc. or vinylidene chloride (-18℃), etc.
°C) 50% by weight or less, preferably 35 to 5% by weight [in this item (6),
) is the glass transition point of these vinyl monomers or homopolymers of vinylidene chloride), (
c) 50-97% by weight, preferably 55-95% by weight of an aqueous resin emulsion with -'rg of +80-155°C;
Examples include a mixture with 50 to 3% by weight, preferably 45 to 5% by weight of an aqueous resin emulsion having a Tg of 185°C to less than +80°C.
水性エマルジョンの樹脂固形分濃度は通常２０〜６０重
量％であり、分散している樹脂粒子の径は１０μ（ミク
ロン）以下、好ましくは０．０５〜１．０μである。The resin solid content concentration of the aqueous emulsion is usually 20 to 60% by weight, and the diameter of the dispersed resin particles is 10 microns or less, preferably 0.05 to 1.0 microns.
ガラス転移点が２０℃以下の樹脂水性エマルジョンとし
ては、例えば、
（１）、アクリル酸２−エチルヘキシル、アクリル酸ｎ
−ブチル、アクリル酸エチル、アクリル酸インプロピル
、メタクリル酸２−エチルヘキシル、アクリル酸ｎ−プ
ロピル、メタクリルＷ！ｉｎ・ブチル、塩化ビニリデン
、エチレン、ブタジェンより選ばれた単量体
２０〜ｉｏｏ重量％
（ｉｉ）、酢酸ビニル、メタクリル酸エチル、塩化ビニ
ル、メタクリル酸ｎ −７’ロビル、スチレン、アクリ
ロニトリル、メタクリル酸メチル、アクリル酸、イタコ
ン酸、アクリルアミド、メタクリルアミドより選ばれた
単量体
８０重量％以下
（ｉｉＤ−ジアセトンアクリルアミド、無水マレイン酸
、ジエチレングリコールジアクリレートより選ばれた単
量体 Ｏ〜５重駄％の乳化重合物があげられる
。Examples of aqueous resin emulsions with a glass transition point of 20°C or lower include (1), 2-ethylhexyl acrylate, and n-acrylic acid.
-Butyl, ethyl acrylate, inpropyl acrylate, 2-ethylhexyl methacrylate, n-propyl acrylate, methacrylic W! 20 to 10% by weight of a monomer selected from in-butyl, vinylidene chloride, ethylene, butadiene (ii) vinyl acetate, ethyl methacrylate, vinyl chloride, n-7' lobil methacrylate, styrene, acrylonitrile, methacrylic acid 80% by weight or less of a monomer selected from methyl, acrylic acid, itaconic acid, acrylamide, and methacrylamide (ii) a monomer selected from D-diacetone acrylamide, maleic anhydride, and diethylene glycol diacrylate O to 5% by weight Examples include emulsion polymers.
このエマルジョン中に、得られる不織布に重看感を付与
するため、炭酸カルシウム、酸化鉄、フェライト、硫酸
パリクム等の無機充填剤や顔料を配合することも可能で
ある。Inorganic fillers and pigments such as calcium carbonate, iron oxide, ferrite, and paricum sulfate can also be blended into this emulsion in order to impart a sense of dignity to the resulting nonwoven fabric.
不織布間に発泡性樹脂粒子を挟み、ニードリングされた
積層体（３）への水性樹脂エマルジョンの塗布は、スプ
レー、浸漬、はけ、フオーム瀘工機、ロール等を用いて
行われる。バッキング材の塗布量は、３０〜１，０００
ｆ／ ｒｒ？ （固型分）、好ましくは８０〜ａｏｏ
ｒ／−である。The aqueous resin emulsion is applied to the needled laminate (3) with foamable resin particles sandwiched between nonwoven fabrics using a spray, dipping, brush, foam filter, roll, or the like. The amount of backing material applied is 30 to 1,000
f/rr? (solid content), preferably 80 to aoo
It is r/-.
一般に、樹脂水性エマルジョンの総＠量は、不織布の重
量の２０〜１００重量％（固形分広量）となるように用
いる。Generally, the total amount of the aqueous resin emulsion is 20 to 100% by weight (broad solid content) of the weight of the nonwoven fabric.
一般に繊維マットへのエマルジョンの含浸を完全とする
ため塗布されたエマルジョンは絞りロールにより圧搾さ
れる。Generally, the applied emulsion is squeezed using squeezing rolls to completely impregnate the fiber mat with the emulsion.
エマルジョンの塗布は繊維マットの片側面よ妙、または
両（ロ）面より行うことができる。The emulsion can be applied from one side or both sides of the fiber mat.
エマルジョンが塗布、含浸された繊維マットは水分を除
去するため６０〜２５０℃に加熱され、不織布が製造さ
れる。この加熱乾燥工程の際、発泡性熱可塑性横脂粒子
は一部は発泡体粒子状態で繊維マット内に存在し、一部
は互の融着により発泡体シートを形成し、敷設材に成形
性と剛性と遮へい性を付与する。The fiber mat coated and impregnated with the emulsion is heated to 60 to 250°C to remove moisture, and a nonwoven fabric is produced. During this heat-drying process, some of the expandable thermoplastic side fat particles exist in the fiber mat in the form of foam particles, and some of them fuse with each other to form a foam sheet, making the laying material moldable. and provides rigidity and shielding properties.
塗布されたエマルジョンの加熱乾燥、および発泡性樹脂
粒子の発泡は任意の方法で行なうことができる。例えば
加熱シリンダー、赤外線加熱機、熱風乾燥機、サクショ
ンドライヤー等を用いることができるが、熱風乾燥機を
使用するのが好ましい。また、乾燥は８０−１８０℃で
行なうことができるが、繊維劣化防止の面および発泡を
十分に行わしめるために１００〜１４０℃の熱風で行な
うことが好ましい。Heat drying of the applied emulsion and foaming of the expandable resin particles can be carried out by any method. For example, a heating cylinder, an infrared heater, a hot air dryer, a suction dryer, etc. can be used, but it is preferable to use a hot air dryer. Although drying can be carried out at 80 to 180°C, it is preferable to dry with hot air at 100 to 140°C in order to prevent fiber deterioration and to ensure sufficient foaming.
この加熱により発泡性樹脂粒子は約５〜５０倍発泡し、
粒径が０．５〜４．５■の発泡体粒子もしくは互の融着
により発泡体シートとなり、樹脂エマルジョンがバッキ
ングされた繊維マット中に装着される。This heating causes the expandable resin particles to expand approximately 5 to 50 times,
Foam particles having a particle size of 0.5 to 4.5 square meters or are fused together to form a foam sheet, which is mounted in a fiber mat backed with a resin emulsion.
また、不織布として繊維バインダーを含有する繊維マッ
トを用いたときは、エマルジョン加熱乾燥時にこの繊維
バインダーが溶融され、繊維マット中の繊維同志の絡み
合いがより強固となる。Furthermore, when a fiber mat containing a fiber binder is used as the nonwoven fabric, the fiber binder is melted during heating and drying of the emulsion, and the intertwining of the fibers in the fiber mat becomes stronger.
（効果）
本発明の敷設材はかかる発泡体の存在ゆえに剛性及び遮
へい性が大幅に向上した敷設材となっている。(Effects) The laying material of the present invention has significantly improved rigidity and shielding properties due to the presence of the foam.
また、との敷設材を発泡体が溶融する温度に加熱し、敷
設材をプレス成形すれば所望の形状に敷設材を賦型でき
る。Further, by heating the laying material to a temperature at which the foam melts and press-molding the laying material, the laying material can be shaped into a desired shape.
以下、実施例により本発明を更に詳細に説明する。Hereinafter, the present invention will be explained in more detail with reference to Examples.
ポリエステル繊維及びボリグロピレン繊維３５０ｆ ／
ｍ”よ！７なるプレーンタイプ・ニードルパンチカー
ペット（ポリエステル繊維８０％）を用いた。Polyester fiber and polyglopylene fiber 350f/
A plain type needle-punched carpet (80% polyester fiber) named "m"yo!7 was used.
例２ 下層用不織布
１５デニール、繊維要約１００ｓａ＋＋のポリエステル
繊維及びポリプロピレン（融点１６４℃）繊維をランダ
ムに積み重ねた繊維マット（５００ｆ／？？／）を、１
５−１８−３２−３ＲＢの針を用いて１平方インチ当り
５０本の割合でニードリングして、厚さ約３ｗ＋のニー
ドルパンチカーペット（ポリエステル繊維が８０％）を
得た。Example 2 A fiber mat (500 f/??/) made by randomly stacking polyester fibers and polypropylene (melting point 164°C) fibers with a nonwoven fabric of 15 denier and a fiber summary of 100 sa++ for the lower layer was made into one
Needling was performed using 5-18-32-3RB needles at a rate of 50 needles per square inch to obtain a needle-punched carpet (80% polyester fiber) approximately 3W+ thick.
以下の実施例、比較例に用いた敷物原反の不織布はこれ
らのニードルパンチカーペットである。These needle-punched carpets were used as nonwoven fabrics for rugs in the Examples and Comparative Examples below.
実施例１
前記上層用不織布と下層用不織布間に、平均粒径が０．
３３ ｍの発泡性ポリスチレン粒子（ブタン５．５重量
％含有）を１７１１１１Ｆ／−の割合で挾持させて積層
体とし、次いで上層用不織布側からニードリングを行な
い上下層の不織布繊維のからみ合せを行った。Example 1 Between the nonwoven fabric for the upper layer and the nonwoven fabric for the lower layer, an average particle size of 0.
33 m of expandable polystyrene particles (containing 5.5% by weight of butane) were sandwiched at a ratio of 171111F/- to form a laminate, and then needling was performed from the upper layer nonwoven fabric side to entangle the upper and lower layer nonwoven fabric fibers. Ta.
次に、この積層体の全面に、バッキング材として三菱油
化バーデイツシエ■製アクリル系水性エマルジョン１ア
クロナール ＹＪ−１６５０Ｄ”（商品名、樹脂固型分
５０％、粒径０．２ ミクロン、造膜温度７℃）を２５
０ ？ ／ ｍ’ （固を分）となるｉ４布し、次いで
ニップロールを用いてエマルジョンをニードルパンチカ
ーペットに含浸させた。Next, as a backing material, acrylic water-based emulsion 1 Acronal YJ-1650D" manufactured by Mitsubishi Yuka Verdice Co., Ltd. (trade name, resin solid content 50%, particle size 0.2 microns, film forming temperature 7℃) to 25
0? / m' (hardness), and then the emulsion was impregnated into the needle punch carpet using a nip roll.
そして、エマルジョンを含浸させたニードルパンチカー
ペットを１３０℃の熱風で１５分間加熱して水分を除去
するとともに発泡性ポリスチレン粒子を発泡させ、嵩密
度が約０．１８ ｆ ／ｄ、粒径が１．５ｗ以下のポリ
スチレン発泡体粒子の層を挾持させ九敷設材を製造した
。Then, the needle punch carpet impregnated with the emulsion was heated with hot air at 130°C for 15 minutes to remove moisture and expand the expandable polystyrene particles, so that the bulk density was about 0.18 f /d and the particle size was 1. Nine pavers were made by sandwiching layers of polystyrene foam particles of 5w or less.
さらに、この敷設材を１４０℃に加熱してバッキング層
の樹脂膜及びポリスチンン発泡体を軟化させ、次いで冷
却プレス金車を用いて２０Ａｙ／ｄの圧力を１分間かけ
て成型し、自動車室内床用カーペットを製造した。Furthermore, this laying material was heated to 140°C to soften the resin film and polystine foam of the backing layer, and then molded using a cooling press wheel for 1 minute at a pressure of 20 Ay/d to form the interior floor of an automobile. Manufactured carpets.
比較例１
実施例１において、上下ｆｉ５不哉不問布間泡性ポリス
チレン粒子をサンドイッチしない（用いない）他は同様
にして敷設材（仕上の肉厚は６ ｍ ）を得、さらに成
形して自動車室内床用カーペットを得た。Comparative Example 1 A laying material (finished wall thickness: 6 m) was obtained in the same manner as in Example 1, except that the foamed polystyrene particles were not sandwiched between the upper and lower fi5-independent fabrics, and were further molded to form automobiles. Obtained indoor floor carpet.
実権例２
樹脂水性エマルジョンとして、アクロナールＹＪ−１６
５０Ｄの代りに１三菱油化バーディッシエ■製アクリル
酸エステルΦスチレン共爪合体エマルジョン−７クロナ
ール Ｙ、Ｔ−７０８２Ｄ”（商品名、樹脂のＴｇ約１
２０℃、固型分５０％、樹脂粒径約０．３ ミクロン）
を用いる他は同様にして表１に示す物性の敷設材を得た
。Actual Example 2 Acronal YJ-16 as a resin aqueous emulsion
50D instead of 1 Acrylic ester Φ styrene co-claw coalescing emulsion made by Mitsubishi Yuka Verdissier - 7 Chronal Y, T-7082D" (product name, resin Tg approx. 1
(20℃, solid content 50%, resin particle size approximately 0.3 microns)
A laying material having the physical properties shown in Table 1 was obtained in the same manner except that the following was used.
また、この敷設材を１４０℃に加熱してバッキング！苔
の樹脂膜およびポリスチレン発泡体を軟化させ、次いで
冷却プレス金型を用いて１０ ｋｇ／ｃｄの圧力を１分
間かけて成形し、自動車室内床用カーペットを製造した
。Also, heat this laying material to 140℃ and back it! The moss resin film and polystyrene foam were softened and then molded using a cooling press mold under a pressure of 10 kg/cd for 1 minute to produce a carpet for the interior floor of an automobile.
比較例２
実施例２において発泡性ポリスチレン粒子を用いない外
は同様にして表１に示す物性の敷設材を得た。Comparative Example 2 A laying material having the physical properties shown in Table 1 was obtained in the same manner as in Example 2, except that the expandable polystyrene particles were not used.
なお、カーペットの評価は次の方法による。In addition, the evaluation of the carpet is based on the following method.
三点曲げ強度；
試料片（ｄｘｓｏｍ、ｔｊｔ５０ｍ＋）をスパン１００
■にて支持し、試料の中心点の置所にインストロン型試
験機を用いて５０ｆｉ／分の側合で試料片に垂直に変形
荷重を負荷した際の最大屈曲抵抗値を測定した。Three-point bending strength; sample piece (dxsom, tjt50m+) span 100
The maximum bending resistance value was measured when a deformation load was applied perpendicularly to the sample piece at a side alignment of 50 fi/min using an Instron type testing machine at the center point of the sample.
非透水性： ＪＩＳ Ａ−６９１０の透水試験に準する。Impermeable: Conforms to JIS A-6910 water permeability test.
水頭２５０柵とし、１２時間後に判定する。A water head of 250 is used as a fence, and judgment is made after 12 hours.
×：水が裏面を貫通して残存していないもの。×: Water did not penetrate through the back surface and remain.
Δ：裏面に水のにじみが認められるもの。Δ: Water bleeding is observed on the back side.
Ｏ：裏面に水のにじみが認められないもの。O: No water bleeding was observed on the back side.
表１Table 1
第１図は本発明の実施により得られた敷設材の断面図で
ある。
図中、１は発泡性ポリスチレン粒子、２は上層用不織布
、２′は下層用不織布である。
特許出願人 三菱油化バーデイツシエ未式会社代理人
弁理士 古 川 秀 利
代理人 弁理士 長 谷 正 久
第１図FIG. 1 is a sectional view of a laying material obtained by implementing the present invention. In the figure, 1 is expandable polystyrene particles, 2 is a nonwoven fabric for the upper layer, and 2' is a nonwoven fabric for the lower layer. Patent Applicant: Mitsubishi Yuka Verdatesier Private Company Agent
Patent Attorney Hidetoshi Furukawa Agent Patent Attorney Masahisa Hase Figure 1
Claims (1)
樹脂粒子を挾んで積層体となし、ニードルパンチを行な
って上下層を絡合せした後、ついでこのニードルパンチ
不織布積層体に樹脂水性エマルジョンを塗布含浸し、次
いで塗布面を加熱して前記発泡性熱可塑性樹脂粒子の発
泡を行うとともに樹脂水性エマルジョンを乾燥させるこ
とを特徴とする剛性を有する敷設材の製造方法。 ２）、不織布が、融点が８０〜１８０℃の樹脂繊維バイ
ンダー１５〜５０重量％と、該繊維バインダーよりも４
０℃以上高い融点を有する樹脂繊維もしくは天然繊維８
５〜５０重量％よりなるニードルパンチ不織布であるこ
とを特徴とする特許請求の範囲第１項記載の製造方法。 ３）、発泡性熱可塑性樹脂粒子が、粒径１．５ｍｍ以下
の発泡性ポリスチレン粒子であることを特徴とする特許
請求の範囲第１項記載の製造方法。 ４）、発泡性熱可塑性樹脂粒子が不織布１００重量部に
対し１０〜２００重量部の割合で用いられることを特徴
とする特許請求の範囲第１項記載の製造方法。 ５）、不織布に対し、水性エマルジョンの樹脂が固型分
量で３０〜１０００ｇ／ｍ＾２の割合で塗布されること
を特徴とする特許請求の範囲第１項記載の製造方法。[Scope of Claims] 1) A laminate is formed by sandwiching foamable thermoplastic resin particles between an upper layer nonwoven fabric and a lower layer nonwoven fabric, and the upper and lower layers are intertwined by needle punching, and then the needle punched nonwoven fabric A method for manufacturing a rigid laying material, which comprises coating and impregnating a laminate with an aqueous resin emulsion, then heating the applied surface to foam the expandable thermoplastic resin particles, and drying the aqueous resin emulsion. 2) The nonwoven fabric contains 15 to 50% by weight of a resin fiber binder having a melting point of 80 to 180°C and a
Resin fiber or natural fiber with a melting point higher than 0°C8
The manufacturing method according to claim 1, wherein the needle-punched nonwoven fabric comprises 5 to 50% by weight. 3) The manufacturing method according to claim 1, wherein the expandable thermoplastic resin particles are expandable polystyrene particles having a particle size of 1.5 mm or less. 4) The manufacturing method according to claim 1, wherein the expandable thermoplastic resin particles are used in a ratio of 10 to 200 parts by weight per 100 parts by weight of the nonwoven fabric. 5) The manufacturing method according to claim 1, wherein the aqueous emulsion resin is applied to the nonwoven fabric at a solid content of 30 to 1000 g/m^2.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP61039437A JPS62198446A (en) | 1986-02-25 | 1986-02-25 | Manufacture of laying material having rigidity |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP61039437A JPS62198446A (en) | 1986-02-25 | 1986-02-25 | Manufacture of laying material having rigidity |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS62198446A true JPS62198446A (en) | 1987-09-02 |
| JPH0228457B2 JPH0228457B2 (en) | 1990-06-25 |
Family
ID=12552978
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP61039437A Granted JPS62198446A (en) | 1986-02-25 | 1986-02-25 | Manufacture of laying material having rigidity |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS62198446A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2383053A (en) * | 2001-12-11 | 2003-06-18 | Snecma Propulsion Solide | Method of forming a fibre reinforced composite material |
-
1986
- 1986-02-25 JP JP61039437A patent/JPS62198446A/en active Granted
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2383053A (en) * | 2001-12-11 | 2003-06-18 | Snecma Propulsion Solide | Method of forming a fibre reinforced composite material |
| GB2383053B (en) * | 2001-12-11 | 2005-07-13 | Snecma Propulsion Solide | Making a needled fiber preform for fabricating a composite material part |
| US7052632B2 (en) | 2001-12-11 | 2006-05-30 | Snecma Propulsion Solide | Making a needled fiber preform for fabricating a composite material part |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0228457B2 (en) | 1990-06-25 |
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