JPH0752299A - Laminated sheet for asphalt roofing - Google Patents

Abstract

PURPOSE:To provide a laminated sheet for asphalt roofing having high strength, high elastic modulus and high dimensional stability. CONSTITUTION:A laminated sheet for asphalt roofing comprises an intermediate layer in which fiber made of glass fiber, polyvinyl alcohol fiber, polyester fiber and having a tensile strength of 5g/d or more and 2g/d or more of a stress at the time of 3% orientation, a dry thermal shrinkage factor at l80 deg.C for 10min of 0.5% or less exists in one direction or in the direction and a direction crossing with it, and nonwoven fabrics laminated on both front and rear surfaces of the layer and integrated by needle punching, and heat treated.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a laminated sheet used as a base fabric for asphalt roofing.

[0002]

2. Description of the Related Art In recent years, as a base fabric for asphalt roofing, a heat-pressed non-woven sheet, a needle-punched non-woven sheet and the like have been used. However, when the nonwoven sheet is used as a base fabric for asphalt roofing, the nonwoven sheet is stretched by the processing tension during the asphalt impregnation process and is commercialized while the strain remains. There was a problem that when it was installed, it was heated by sunlight and contracted. Since the roofing material does not exhibit the desired waterproof performance due to shrinkage, efforts have been made to eliminate such shrinkage.
In order to eliminate shrinkage, it is conceivable to eliminate elongation during the asphalt impregnation process or to make the constituent fibers of the non-woven sheet have stress against heat shrinkage.

Various proposals have been made to solve the above problems and improve the strength and elastic modulus, which are the drawbacks of conventional needle punched nonwoven sheets. For example, in Japanese Unexamined Patent Publication No. 51-133583, needle-punching treatment is performed on one side of a fabric web, heat-fixed, and then needle-punching treatment is performed on the other side to suppress damage to the fiber due to needling. In addition, there has been proposed a method for obtaining a non-woven sheet having high strength and high elastic modulus by improving the entanglement property of fibers. In Japanese Patent Publication No. 60-254543, an oil agent is applied in advance to reduce the needle penetration resistance and the punch density is increased before the needle punching treatment to improve the entanglement of the fibers and improve the entanglement. Methods have been proposed for obtaining non-woven sheets having high strength and high modulus. However, all of these methods are intended to improve the entanglement between the fibers, and there is a limit to improving both the strength and the elastic modulus of the fibers, and the former method has a non-woven web. Since the needle punching process is performed twice from both sides, the process is complicated and the product cost is increased. In view of the performance required for the above-mentioned applications, both the strength and the elastic modulus are still insufficient, and a nonwoven sheet having sufficient dimensional stability has not been obtained.

[0004]

SUMMARY OF THE INVENTION It is an object of the present invention to solve the above problems and to provide a laminated sheet for asphalt roofing having high strength, high elastic modulus and dimensional stability. Is.

[0005]

As a result of intensive studies, the present inventors have found that in order to obtain a laminated sheet for asphalt roofing having high strength, high elastic modulus and dimensional stability, one direction or the above The inventors have found that it is possible to suppress the elongation during asphalt processing by inserting fibers having specific physical properties in a direction orthogonal to that, and have reached the present invention.

That is, the present invention comprises a glass fiber, a polyvinyl alcohol fiber, and a polyester fiber, and has a tensile strength of 5 g / d or more and a stress of 2 g at 3% elongation.
/ D or more and fibers having a dry heat shrinkage of 0.5% or less when treated at 180 ° C. for 10 minutes in one direction or in the above-mentioned direction and the direction intersecting with the same, and the above-mentioned intermediate layer. A non-woven fabric laminated on both the front and back sides of a part is integrated by needle punching, and is heat-treated and / or resin-impregnated, and a laminated sheet for asphalt roofing is provided. .

The present invention will be described in detail below. The intermediate layer portion of the present invention is composed of fibers made of a polyester polymer, a polyvinyl alcohol polymer or glass. As a polyester polymer,
Fiber-forming polyethylene terephthalate, polybutylene terephthalate, or phthalic acid, isophthalic acid, glutaric acid, adipic acid containing these as the main components,
Acid components such as sulfoisophthalic acid, diethylene glycol, propylene glycol, 2,2-bis (4-hydroxyethoxyphenyl) propane, bisphenol A,
Examples thereof include copolyesters in which a diol component such as polyalkylene glycol is copolymerized in a range of up to 15 mol%. However, in the case of these copolymers, it is usually difficult to improve the strength. Since it is necessary to take measures such as increasing the draw ratio, it is preferable to use the former polymer. Examples of the polyvinyl alcohol-based polymer include polyvinyl alcohol having a fiber-forming property, and copolymerized polyvinyl alcohol in which ethylene, vinylpyrrolidone or other vinyl group is copolymerized in an amount of 10 mol% or less, preferably 2 mol% or less. In the present invention, when the polyester-based polymer or polyvinyl alcohol-based polymer is used as the fiber material,
In the polymer, a heat-resistant agent usually used for fibers,
Stabilizers and the like can be added as long as the effects of the present invention are not impaired. Further, the glass may be any glass having ordinary fiber-forming properties.

The fibers constituting the intermediate layer portion of the present invention have a tensile strength of 5 g / d or more, a stress at 3% elongation of 2 g / d or more, and a dry heat shrinkage factor of 0 when treated at 180 ° C. for 10 minutes. .Five
% Or less. The physical properties of the fiber constituting the intermediate layer portion of the present invention are such that the tensile strength is 5 g / d or more, the stress at 3% elongation is 2 g / d or more, and the dry heat shrinkage factor is 0.10 when treated at 180 ° C. for 10 minutes. If it is not more than 5%, the dimension is not stable when the roofing material obtained by using the laminated sheet of the present invention is applied due to thermal environmental factors such as sunlight irradiation.

In the intermediate layer portion of the present invention, the constituent fibers are
It is necessary to exist in one direction or the above-mentioned direction and a direction intersecting with the above-mentioned direction. When the fibers forming the intermediate layer portion are present in one direction, it is preferable that the distance is 3 to 30 mm.

When the fibers constituting the intermediate layer portion are present in one direction and in a direction intersecting with the one direction, the fibers may be arranged or may be knitted with a net, but the dimensional stability of the laminated sheet may be improved. It is preferable to knit a net from the side. The existing state includes an orthogonal shape in which the fibers are orthogonal to and intersecting in one direction, an oblique shape in which the fibers are obliquely intersecting in one direction, a honeycomb state, and the like. It is preferable that they are present at intervals of 3 to 30 mm in the direction. In the case of a honeycomb state, the honeycomb shape formed by the fibers is preferably about 3 to 6 sides.

The fiber constituting the intermediate layer portion of the present invention may be either a multifilament or a monofilament.

The wire diameter of the fibers constituting the intermediate layer portion of the present invention is such that when the tip of the needle punch needle hits the fiber used for the intermediate layer portion, it does not break easily, and it escapes due to the inertia of the needle and the hole in the bed plate escapes. In order to make it enter, it is preferable that the diameter is 0.5 mm or less in terms of circle.

The fibers constituting the intermediate layer portion of the present invention may be those which are firmly solidified with a resin or may be flexible without using a resin, but for the purpose of dimensional stability of the laminated sheet. Is preferably hardened with a resin. The resin as used herein refers to a thermoplastic resin such as polyvinyl acetate or acrylic acid ester, a thermosetting resin such as an epoxy resin, a phenol resin, a urea / formalin resin, or the like. The above resins may be used alone or in combination with other resins, and the kind of the resin is not particularly limited, but a thermosetting resin is used because it is necessary to withstand heat during asphalt processing. Is preferred. However, even if a thermoplastic resin is used, it can be used without any trouble if mechanical conditions such as adjustment of tension during processing are adjusted.

As a method of adhering the resin to the fibers constituting the intermediate layer portion of the present invention, a method of directly adhering the resin to the fibers or a method of adhering the resin after knitting the net is adopted.

The nonwoven fabric used in the present invention is made of thermoplastic synthetic fiber. For example, an acid component such as phthalic acid, isophthalic acid, glutaric acid, adipic acid, sulfoisophthalic acid, etc., such as those described above for the polyester-based polymer such as polyethylene terephthalate / polybutylene terephthalate or the intermediate layer portion, diethylene glycol,
Propylene glycol, 2,2-bis (4-hydroxyethoxyphenyl) propane, bisphenol A, a copolymer obtained by copolymerizing a diol component such as polyalkylene glycol up to 15 mol%, polyethylene, polypropylene, etc. Polyolefin polymer, nylon 6
-A polyamide-based polymer such as nylon 66 is used, and fibers made of these polymers alone, or bonded type composite fibers or core-sheath type composite fibers in which two or more kinds of polymers are combined are also used. it can.

The nonwoven fabric used in the present invention is a long fiber nonwoven fabric,
Although any short fiber non-woven fabric may be used, when asphalt roofing using the laminated sheet of the present invention requires high strength, it is preferable to use long fiber non-woven fabric.

The basis weight of the nonwoven fabric used in the present invention is not particularly limited and may be appropriately selected depending on the application, but is preferably 30 to 200 g / m ² for the purpose of the present invention.

The single yarn denier of the fibers constituting the nonwoven fabric used in the present invention is preferably in the range of 1 to 20 denier, and when it exceeds 20 denier, it is entangled with the fibers constituting the intermediate layer portion by needle punching treatment, Also, the entanglement between the front and back nonwoven fabrics of the fiber becomes insufficient. Further, when the thickness is less than 1 denier, when the laminated sheet is subjected to heat pressure contact, heat is transmitted to the center of the fibers constituting the intermediate layer portion and the fibers constituting the non-woven fabric, and the laminated sheet becomes plastic, so that only a sheet having no sense of volume is obtained. Sometimes I can't.

In the laminated sheet of the present invention, the intermediate layer portion and the non-woven fabric laminated on both front and back surfaces thereof are integrated by needle punching, and heat-treated and / or resin-impregnated. .

The needle punching treatment preferably has a needle density of 20 to 100 times / cm ² . When the needle density exceeds 100 times / cm ² , the entanglement of the fibers forming the intermediate layer portion is improved, but the surface of the laminated sheet becomes uneven due to the collision of the fibers with the needles, or the needle friction or needles It causes breakage. If the needle density is less than 20 times / cm ² , the entanglement between the fibers and the non-woven fabric may deteriorate, and delamination may occur between the intermediate layer portion and the non-woven fabric layer.

As the heat treatment, after laminating the intermediate layer portion and the non-woven fabric laminated on both front and back surfaces thereof, the non-woven fabric itself is hot-pressed by using a hot-pressing roll, or the non-woven fabric itself is hot-dried. A method of shrinking and joining with the intermediate layer portion is used.

Regarding the resin impregnation treatment, after laminating the intermediate layer portion and the non-woven fabric laminated on both front and back surfaces thereof, a resin layer is formed by using a general resin such as an acrylate ester, an epoxy resin or a phenol resin. After dipping the laminated sheet in, squeeze with a squeezing means such as mangle rolls,
A method of drying with a band dryer, a method of applying resin foam foamed with a foaming machine to a laminated sheet and then drying with a hot air dryer, and the like are used. The heat treatment and the resin impregnation treatment can further improve the bondability between the intermediate layer portion and the nonwoven fabric laminated on both front and back surfaces thereof.

[0023]

In the laminated sheet of the present invention, nonwoven fabrics are arranged on both sides, fibers having high strength and high elasticity are interposed in the intermediate layer portion, the intermediate layer portion and the nonwoven fabric are laminated, needle punched, and heated. Since it is treated and / or impregnated with resin, it becomes a laminated sheet having high strength and high elasticity, which cannot be obtained by the conventional needle punched nonwoven fabric, and can be a sheet capable of withstanding heat during asphalt processing.

[0024]

EXAMPLES The present invention will be specifically described below with reference to examples. In addition, the measurement and evaluation of various characteristics in the examples,
It carried out by the following method. Cutting strength (g / d) of intermediate layer fiber: JIS L-10
According to the method described in No. 69, using a constant-speed elongation type tensile tester (Tensilon manufactured by Orienteik Co., Ltd.), measurement was performed at a tensile speed of 20 cm / min for 10 points of the sample, and the obtained load value at the time of cutting was a positive amount of fiber It was divided by the fineness (d), and the average value was taken as the breaking strength (g / d) of the fiber. Stress (g / d) at 3% elongation of intermediate layer fiber: JIS
According to the method described in L-1069, the load value at a tensile rate of 20 cm / min at 3% elongation was measured for each of the 10 points of the sample, and each load value was divided by the true fiber fineness (d) of the fiber, and the average value was obtained. Was the stress (g / d) when the fiber was stretched by 3%. Tensile strength of laminated sheet (kg / 5cm width): JIS L
According to the strip method described in 1096, using a constant-speed extension type tensile tester (Tensilon manufactured by Orienteik Co., Ltd.), measurement is made for 10 points of a sample having a width of 5 cm and a length of 20 cm at a gripping interval of 10 cm and a pulling speed of 10 cm / min. Then, the average value of the obtained tensile strength is calculated as the tensile strength (kg
/ 5 cm width). Stress at 3% elongation of laminated sheet (kg / 5 cm width): J
According to the strip method described in IS L-1096, the load value at the time of 3% elongation was measured for each of the 10 points of the sample at a tensile speed of 10 cm / min, and each load value was divided by the sample width of 5 cm, and the average value was calculated. Stress at 3% elongation (kg / 5cm
Width). Dimensional stability after asphalt impregnation (%): 80% asphalt roofing with asphalt impregnated laminated sheet
The dimensional change after leaving for 1 week in a hot air high temperature dryer at ℃ was measured, and the result was taken as the dimensional stability (%) after impregnating with asphalt.

Example 1 Polyethylene terephthalate having a melting point of 260 ° C. and an intrinsic viscosity (measured at 20 ° C. using a mixed solvent of phenol / ethane tetrachloride in a weight ratio of 20 ° C.) was made into a spinneret having a pore diameter of 0.35 mm and a pore number of 160. It was discharged from the spinneret at a melting temperature of 285 ° C., drawn and drawn by an air sacker at a spinning speed of 4500 m / min, and the fibers after the collection were collected on a wire netting net to form a web. The web was weakly pressure-bonded with a heat pressure-bonding roll to obtain a nonwoven fabric. The basis weight of the obtained non-woven fabric was 40 g / m ² . Next, wire diameter 0.5mm, tensile strength 5.5g / d, 3%
A glass fiber having a tensile stress of 4 g / d and a dry heat shrinkage rate of 0% when treated at 180 ° C. for 10 minutes is 10 mm
Intermediate layers are arranged at intervals, and the non-woven fabric is laminated on both front and back surfaces of the intermediate layer, and needles (PPD-
No. 1 40) was used for needle punching at a needle density of 45 times / cm ² and then pressure-contacted with a heating roller at a temperature of 230 ° C. to obtain a laminated sheet. Table 1 shows the physical properties of the obtained laminated sheet of Example 1.

Example 2 The laminated sheet obtained in Example 1 was impregnated with a mixed resin of urea melamine resin and acrylic ester resin to prepare a laminated sheet with resin. The physical properties of the resulting laminated sheet of Example 2 are shown in Table 1.

Example 3 In Example 1, instead of using the intermediate layer portion made of glass fiber, the wire diameter was 0.7 mm, the tensile strength was 6 g / d, the stress at 3% elongation was 3 g / d, and at 180 ° C. A laminated sheet was obtained in the same manner as in Example 1 except that polyvinyl alcohol fibers having a dry heat shrinkage of 0.2% after 10 minutes of treatment were arranged at 10 mm intervals in the longitudinal direction to form an intermediate layer portion. The obtained laminated sheet was made into a laminated sheet with a resin in the same process as in Example 2. The physical properties of the resulting laminated sheet of Example 3 are shown in Table 1.

Example 4 Instead of using the intermediate layer part made of glass fiber in Example 1, the wire diameter is 0.5 mm, the tensile strength is 6.2 g / d, 3%.
An intermediate layer part is a net formed by knitting polyester fiber having a stress of 3.5 g / d during elongation and a dry heat shrinkage rate of 0.4% when treated at 180 ° C. for 10 minutes at intervals of 10 mm in both warp and weft directions. A laminated sheet was obtained in the same manner as in Example 1 except for the above. The obtained laminated sheet was made into a laminated sheet with a resin in the same process as in Example 2. Example 4 obtained
Table 1 shows the physical properties of the laminated sheet.

Example 5 In Example 1, the intermediate layer portion had a wire diameter of 0.5 mm, a tensile strength of 5.5 g / d, a stress at 3% elongation of 4 g / d, and a 180% stress.
A laminated sheet was obtained in the same manner as in Example 1 except that a net in which glass fibers having a dry heat shrinkage of 0% at 10 ° C. for 10 minutes were knitted at intervals of 10 mm in both warp and weft directions was used. . The obtained laminated sheet was made into a laminated sheet with a resin in the same process as in Example 2. The physical properties of the obtained laminated sheet of Example 5 are shown in Table 1.

Comparative Example 1 A laminated sheet was obtained in the same manner as in Example 1 except that the intermediate layer portion was not used. The physical properties of the resulting laminated sheet of Comparative Example 1 are shown in Table 1.

Comparative Example 2 The laminated sheet obtained in Comparative Example 1 was subjected to the same steps as in Example 2 to prepare a laminated sheet with a resin. The physical properties of the resulting laminated sheet of Comparative Example 2 are shown in Table 1.

Evaluation after Asphalt Impregnation Using the laminated sheets obtained in Examples 1 to 5 and Comparative Examples 1 and 2, asphalt impregnation was performed at an asphalt temperature of 180 ° C. and a tension of 0.7 kg / cm during processing. Created asphalt roofing. The dimensional stability of the obtained asphalt roofing was evaluated, and the results are shown in Table 1.

[0033]

[Table 1]

As is clear from the table shown in Table 1,
The laminated sheets obtained in Examples 1 to 5 satisfying the constitutional requirements of the present invention have high strength and high elastic modulus fibers arranged in the intermediate layer portion, so that tensile strength and stress at 3% elongation are Both were excellent. On the contrary, the laminated sheets of Comparative Examples 1 and 2 had low tensile strength and low stress at 3% elongation, as is clear from Table 1. As for the dimensional stability of asphalt roofing impregnated with asphalt, as apparent from Table 1, Examples 1 to 5
Since the asphalt roofing obtained in (1) had fibers having specific physical properties arranged in the intermediate layer, the vertical and horizontal expansion and contraction were small and the dimensional stability was excellent. On the other hand, Comparative Example 1
The asphalt roofing obtained in ~ 2 had insufficient dimensional stability.

[0035]

EFFECT OF THE INVENTION The laminated sheet for asphalt roofing of the present invention comprises a fiber having an intermediate layer portion having a high strength and a high elastic modulus, a nonwoven fabric is placed on both front and back surfaces of the intermediate layer portion, and needle punching is performed, and Since it is subjected to heat treatment and / or resin impregnation, it has a high strength and a high elastic modulus which cannot be obtained by the conventional needle punched nonwoven fabric, and it is possible to withstand the heat during asphalt processing. Therefore, when an asphalt roofing is produced using the laminated sheet for asphalt roofing of the present invention, an asphalt roofing having extremely small internal strain and excellent dimensional stability can be obtained.

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Claims (1)

[Claims] 1. A glass fiber, a polyvinyl alcohol fiber, or a polyester fiber, having a tensile strength of 5 g /
d or more, stress at 3% elongation is 2 g / d or more, and 180
Fibers having a dry heat shrinkage of 0.5% or less when treated at 10 ° C. for 10 minutes are laminated on one side or in the above-mentioned direction and in a direction intersecting with the middle-layer part and both sides of the middle-layer part. A laminated sheet for asphalt roofing, characterized in that it is integrated with the formed nonwoven fabric by needle punching, and is heat-treated and / or resin-impregnated.