JPS6249398B2 - - Google Patents

Description

[Detailed description of the invention]

This invention relates to asphalt roofing for use in waterproofing high-rise structures, expressways, bridges, subways, public gutters, roofs, etc. In structures such as high-rise buildings, expressways, bridges, subways, and public ditches where the base material expands and contracts rapidly, if cracks occur in the base of these structures, the cracks may extend in the direction of the sheet surface. As the asphalt roofing repeatedly expands and contracts, the displacement causes strain on the waterproof layer, resulting in damage to the asphalt roofing and loss of waterproofing effect. In order to prevent this damage, attempts were made to use thick fabrics such as canvas, glass fiber fabrics, and non-woven fabrics instead of conventional paper as reinforcing materials for asphalt roofing, and JIS standards for waterproof materials were established. The stress at 3% elongation of the ing is 6Kg/cm or more vertically, 4Kg/cm or more horizontally, and the tensile strength is 12Kg/cm vertically.
cm or more, width is 8Kg/cm or more, tensile product (tensile strength x elongation) is 10Kg/cm or more both vertically and horizontally, and elongation at break is 6% or more vertically and 9% or more horizontally. I've reached it. However, it is not possible to obtain an excellent waterproof material by simply satisfying the tensile strength and stress at 3% elongation stipulated in the JIS standard and improving these physical property values for the following reasons. In other words, first, the destruction of the waterproof layer occurs when cracks occur in the base of the structure and the structure repeats expansion and contraction, and the resulting displacement is applied as strain to the waterproof layer. It is impossible to overcome the displacement energy of the structure no matter how much the strength of Changes in the waterproof layer are given as the amount of strain that correlates to the displacement of the underlying layer, and stress only appears as a resistance force for the waterproof material to deform. Therefore, an increase in the initial tensile modulus is due to the concentration of strain due to displacement. Even if it is effective in preventing and dispersing water, it becomes meaningless if the amount of strain exceeds the elongation at break of the waterproof material. Second, asphalt roofing is a composite material of asphalt, which is a waterproof base material, and a roofing base material, which is a reinforcing material, but these are not necessarily uniform in structure, and vary depending on the type of waterproof material. For example, there are asphalt roofings that contain asphalt so that the reinforcing material is homogeneous in the thickness direction, and there are asphalt sheets that are attached to one or both sides of the roofing base material. When considering the role of asphalt roofing as a reinforcing material, it is important to have deformation resistance in order to reinforce asphalt, which has viscoelastic behavior, has poor mechanical performance, and has strong temperature dependence. It is desirable to have a structure in which asphalt is included in a reinforcing material that has a large tensile product and a large tensile product. In addition, considering the situation when the width of the crack that occurs in the base expands and the waterproofing material is displaced and strained, it is important to consider the expansion and contraction of the base in waterproofing materials of the reinforcing material type or the reinforcing material core type. As a result, the displacement and strain caused by the crack width expansion causes shearing force and shear strain on the asphalt layer for bonding and the asphalt layer of the waterproofing material, and tension acts on the reinforcing material.As a result, the asphalt layer for bonding and waterproofing material is displaced. The reinforcing material is not able to effectively exert its reinforcing effect, and the significance of its existence is also small. In order to solve these drawbacks, it is important that the reinforcing material has a tissue structure that can include asphalt, and that has appropriate density, bulk, and fiber alignment. Thirdly, considering the manufacturing process of asphalt roofing, generally asphalt roofing is
The reinforcing material is impregnated with hot asphalt in a high temperature (180-230℃) molten state and squeezed, then asphalt is layered and iron sand etc. , if the tensile modulus (stress at 5% elongation during heating) of the reinforcing material under the above asphalt processing conditions is low,
During the above-mentioned asphalt processing, the reinforcing material is stretched in the length direction, resulting in width addition, and processing distortion occurs in the product. Furthermore, commercialized asphalt roofing is waterproofed using either a hot method or a cold method, but if asphalt roofing has a low stress at 5% elongation when heated and has some processing strain,
When carried out using the hot method, the strain is released and shrinkage occurs, resulting in poor dimensional stability.When carried out using the cold method, the above distortion is gradually released, causing joint defects due to shrinkage of the waterproof layer. . The present inventor has conducted extensive research into what kind of characteristic values are required for asphalt roofing with excellent performance, and what kind of structure of reinforcing material is required to provide such characteristic values. The nonwoven fabric for the reinforcing material is a nonwoven fabric with an orthogonal arrangement structure, that is, a large number of polyester filaments are arranged in the length direction and the width direction in a substantially stretched state, and the polyester filaments in the length direction and the width direction are The inventors have discovered that it is optimal to fold the sheets in the length direction and width direction and stack them one on top of the other, and have thus arrived at the present invention. That is, the present invention provides asphalt roofing using a nonwoven fabric made of polyester filaments as a reinforcing material, in which the nonwoven fabric arranges a large number of polyester filaments in a substantially stretched state in the length direction and the width direction. Polyester filaments in the length direction and width direction are folded in the length direction and width direction, respectively, to form an orthogonal array structure by stacking them and bonding them with a thermosetting adhesive. Length L is 50cm or more,
In addition, the deviation l in the length direction of the folding point is set to 1/5 or less of the above folding length L, and the folding length D of the polyester filament in the width direction is set to 50
cm or more, and the deviation d of the folding point in the width direction is set to 1/4 or less of the folding length D, the thickness of the nonwoven fabric is 0.3 to 1.3 mm, and the apparent density is 0.10 to 0.37. This is an asphalt roofing system characterized by: In the present invention, the orthogonally textured nonwoven fabric can be manufactured, for example, as follows. In FIG. 1, reference numerals 1 and 2 each indicate a large number of polyester filaments arranged in a comb shape. It is stretched to a predetermined stretching ratio by hanging it in the form of a belt around the feed roller and draw roller of the book, and is sprayed by an air jet device having a thin slit toward a deflecting rocking plate with a variable inclination angle provided below. As the deflection oscillation plate swings, the flying direction of the particles is periodically changed, and the particles are collected on the collection conveyor 3 below. At this time, one polyester filament 1 is
The polyester filament 2 is deposited while being oscillated in the length direction (direction of arrow M) and stacked on the collecting conveyor 3, while the other polyester filament 2 is deposited while being oscillated in the width direction (direction of arrow C) and stacked on the collection conveyor 3. It is laminated onto the longitudinal polyester filaments 1 already superimposed on the collection conveyor 3. The above polyester filaments 1 and 2 maintain the relationship Vf = 2NL, where the running speed is Vf, the amplitude of swinging (turning length) on the collection conveyor 3 is L, and the period of swinging is N. By doing so, it is collected on the collection conveyor 3 in a substantially stretched state. For example, Vf=750m/min, L=
When 60 cm is required, by setting N=Vf/2L=625 cycles/min, the polyester filaments 1 and 2 can be overlapped in a substantially linearly stretched state. When the oscillation period N of the deflection oscillation plate is larger than the above value, the deposition amplitude of the polyester filaments 1 and 2 is reduced and automatically corrected to an amplitude that satisfies the above equation. Note that the amplitude L in the above equation is illustrated using D for the polyester filament 2 in the width direction. The above-mentioned polyester filaments 1 and 2 collide with a deflection rocking plate that is fixed to the horizontal shaft directly below the air jet device and rotates back and forth. The polyester filaments 1 and 2 are deposited between the direction deflected by the swing angle θ, but if the distance between the swing center of the deflection swing plate and the collection conveyor 3 is H, then the folded length L of the polyester filaments 1 and 2 is is expressed as L=Htanθ. The above swing angle θ is preferably 35 degrees or less,
If it exceeds 35 degrees, the mechanical load will be excessive. Also,
The above-mentioned distance H is preferably 1 m or less; if it exceeds 1 m, the polyester filaments 1 and 2 collide with the deflection rocking plate and deflect, and therefore the desired folded length L cannot be obtained. In order to set the width, area weight, tensile strength, and other physical properties of the nonwoven fabric to the desired size, as shown in Fig. A plurality of supply units 4M and 4C in the width direction and in the width direction are respectively arranged in parallel. Unit 4M in length direction
Of course, the webs deposited on the collection conveyor 3 are arranged so that there are no gaps and the weight distribution is even, but also the webs deposited on the collection conveyor 3 are arranged so that the webs are evenly distributed.
It is preferable to arrange the M and 4M in a staggered manner so as not to interfere with each other. In order to maintain an even distribution of fabric weight in the length direction, the number of laminated layers is 10 or more.
That is, it is necessary to set the longitudinal deviation l of the turning point 1a to 1/5 or less of the turning length L. Therefore, if the speed of collection conveyor 3 is Vc,
It is necessary to satisfy L≧5Vc/N. For example, when Vc = 34 m/min and N = 625 cycles/min, if L≧27.2 cm, L/l≦1/5 is satisfied and the basis weight distribution becomes uniform. Also, L=50cm,
If Vc = 34 m/min, N = 625 cycles/min, the longitudinal deviation l of the turning point 1a is l =
Vc/N is 5.4 cm, and the number of stacked sheets at this time is 18.5. On the other hand, for the supply unit 4C in the width direction, overlapping conditions are set taking into consideration not only the uniformity of the web but also the uniformity of physical properties such as tensile strength in the width direction. That is, since the folding length D on the collecting conveyor 3 is normally at a maximum of 1 m, the supply units 4C in the width direction are arranged at a pitch of 1/4 or less of the folding length D. In other words, the deviation d in the width direction of the folding point 2a of the polyester filament 2 in the width direction is set to be D/4 or less. Therefore, the above polyester filament 2 in the width direction
are deposited on the collecting conveyor 3 that moves at a constant speed Vc, so it is desirable to set the number of stacked sheets to 10 or more in order to make the deposition distribution uniform in the length direction. That is, when the band width of the polyester filament 2 in the width direction is W, it is preferable to satisfy W≧5Vc/N. For example, Vc/34m/
min, N = 625 cycles/min, W is 27.2
Set to cm or more. And W=40cm, N=625
When using cycles/min, set Vc to 50m/min or less. In this invention, the polyester filaments 1 and 2 are made of polyesters such as polyethylene terephthalate, polybutylene terephthalate, polyoxybenzoate, polycyclohexane dimethylene terephthalate, and polyethylene naphthalate, as well as isophthalate as an acid component in the polyester consisting of the above repeating units. Acid, adipic acid, sebadic acid, decane 1,10-dicarboxylic acid, hexahydroterephthalic acid, etc., and glycol component such as neopentyl glycol, diethylene glycol, 2,2-bis(4-hydroxyphenyl)
It consists of a copolymerized polyester obtained by copolymerizing propane, 2,2-bis(4-hydroxyethoxyphenyl)propane, etc., preferably at a content of 20 mol% or less, and a mixture thereof. The preferred thickness is 5 to 15 deniers; if the thickness is less than 5 deniers, it is too thin and the tear strength when made into a non-woven fabric is insufficient; on the other hand, if it exceeds 15 deniers,
If it is too thick, the number of bonding points will decrease when it is made into a nonwoven fabric, resulting in a decrease in stress and tensile strength at 5% elongation. The nonwoven fabric made of the polyester filaments 1 and 2 described above is generally preliminarily bonded, then further impregnated with a thermosetting adhesive liquid, dried, and then permanently bonded by heat setting under tension. For the above-mentioned preliminary adhesion, additional components such as isophthalic acid and adipic acid are added to fibers having a softening point or melting point lower than those of the above-mentioned polyester filaments 1 and 2, such as undrawn polyethylene terephthalate filaments or polyethylene terephthalate, during the above-mentioned web formation. It is preferable that filaments made of copolymerized polyester are mixed and bonded under heat. That is, polyester filament 1,
2, when being supplied to the air jet device, the above-mentioned low melting point or low softening point adhesive filament is mixed with polyester filaments 1 and 2 in the form of a sash, and is conveyed together with the polyester filaments 1 and 2 to a collection conveyor 3 made of net. After being deposited on top, other nets are stacked on top of each other, sandwiched together like a sandwich, and pressed onto a heat cylinder to be heat-welded. The preferred mixing ratio of the adhesive filament is 5 to 20% of the total amount.
% (weight ratio), particularly preferably 10 to 15%.
If the blending ratio of the adhesive filament is less than 5%, it will be too small and the abrasion resistance of the nonwoven fabric will be low, the fluff will increase, and the handling during processing will deteriorate.
On the other hand, if it exceeds 20%, the physical properties such as tensile strength and handleability will deteriorate due to insufficient content of the polyester filaments 1 and 2 in the length and width directions. On the other hand, the thermosetting adhesive for actually bonding the above-mentioned nonwoven fabrics is a reaction product of an amino compound such as urea, cyclic urea, or melamine with formaldehyde, and the preferable solid content is 10 to 15%. (weight ratio). If the above solid content is less than 10%,
When impregnating molten asphalt, the stress at 5% elongation during heating is insufficient. On the other hand, the effect does not improve even if it exceeds 15%. In addition to the above-mentioned thermosetting adhesive, polyvinyl alcohol, reactive acrylic adhesive, self-crosslinking acrylic adhesive, etc. may be used in combination, and in this case, the toughness, abrasion resistance,
Anti-fuzz properties etc. are improved. The thickness of the nonwoven fabric used in this invention is 0.3
~1.3 mm, and the apparent density is 0.10-0.37.
If the thickness and apparent density of the nonwoven fabric are out of the above range, there are disadvantages such as poor asphalt impregnation and encapsulation, asphalt oozing during construction, and deterioration of product properties. occurs. The nonwoven fabric obtained in this way is
It has high tensile modulus, elasticity, and tensile product, and has excellent asphalt impregnation and encapsulation properties, and the directional distribution ratio of various physical properties of the nonwoven fabric and product can be arbitrarily adjusted according to the arrangement distribution ratio of the fibers that make up the nonwoven fabric. It has excellent physical properties as a waterproof reinforcing fabric. The asphalt roofing of the present invention is produced by applying the above-mentioned nonwoven fabric according to a conventional method (see JIS-A-6022).
It is impregnated with molten asphalt (JIS-K-2207 (petroleum asphalt) grade 3 or 4 compliant asphalt for waterproofing work) heated to 160-230°C, cooled, and then mineral powder such as iron sand. Manufactured by spraying. In that case, the above-mentioned nonwoven fabric has a stress at 5% elongation in the longitudinal direction at 200°C.
5.5Kg/5cm or more, and the heat shrinkage rate is preferably 1.5% or less in both the length and width directions, and the stress at 5% elongation is less than 5.5Kg/5cm, and the heat shrinkage rate is 1.5%. If it exceeds this, the workability and dimensional stability of the roofing will deteriorate. For this purpose as well, it is necessary to use a nonwoven fabric with an orthogonal structure made of polyester filaments 1 and 2 with excellent heat resistance, and to bond this with a thermosetting adhesive. Further, the above nonwoven fabric has at least
Weight per unit area of 140g/ ^m2 , stress at 5% elongation at room temperature is 30Kg/5cm or more in the length direction, 15Kg/5 in the width direction
cm or more, tensile strength is 45Kg/5cm or more in the length direction,
24Kg/5cm or more in the width direction, elongation at break of 20% or more in both the length and width directions, and a tensile product of 18 in the length direction.
Kg/cm/cm or more, and 12Kg/cm/cm or more in the width direction, so after impregnating with asphalt, that is, the physical properties of the asphalt roofing are as shown in Table 1 below.

[Table] These physical properties not only satisfy the above-mentioned JIS standards, but especially the elongation at break must be 15% or more in both the length direction (vertical) and width direction (horizontal), and meet the JIS standards. It is extremely large compared to 6% or more in the vertical direction and 9% or more in the horizontal direction, and the tensile product is 18 or more in the length direction (vertical) and 12 or more in the width direction (horizontal), which is 10 or more vertically and 10 It is extremely large compared to the above. Therefore, it can be used to waterproof structures such as the above-mentioned high-rise buildings where the underlying structure undergoes large expansion and contraction movements, and even if cracks occur in the underlying structure, it will not be damaged and will achieve the purpose of waterproofing. can do. Next, the effects of this invention will be specifically explained using experimental examples. Experimental example 1 Intrinsic viscosity (phenol/tetrachloroethane=
6/4 weight ratio, measured at 30°C) 0.63 polyethylene terephthalate was discharged at a rate of 1.25 g from a rectangular nozzle with 300 orifices with a diameter of 0.3 mm and a length of 0.6 mm.
hole・min, extruded into a webbing shape at a temperature of 290℃, 5 feed rollers with a surface length of 500mm, a surface speed of 150m/min (the latter three of the 5 are heated to 90℃), and a surface speed of 750m/min. A belt was placed on a draw roller and stretched five times to obtain 15 denier polyester filaments 1 and 2. On the other hand, polyethylene terephthalate/isophthalate (molar ratio 9/1, melting point 230°C) with an intrinsic viscosity of 0.63 was discharged at a rate of 1.25 g/hole・min from a rectangular nozzle with 30 orifices with a diameter of 0.3 mm and a length of 0.6 mm. It is taken up by three take-up rollers with a surface speed of 750 m/min.
An adhesive filament was obtained. The above polyester filament 1 (or 2) and the adhesive filament are layered and mixed on a guide roller with a surface length of 500 mm in a blind state to form a nonwoven fabric web with an orthogonal arrangement structure and a random structure as shown in Table 2. In order to produce the nonwoven webs of Examples 1 and 2 with orthogonal arrangement structures, the filaments 1 and 2 are arranged in the length direction (vertical) and width direction (horizontal), respectively. 750m/
lead to a take-off roller with a surface speed of min, then
Supplied to a 570mm slit air jet device,
The jet is applied to the deflection rocking plate below it, at 8.25m/min.
The deposition amplitudes L and D are 70 cm on a wire mesh collection conveyor running at a speed of , and the oscillation period N is 535.7 cycles/
It was deposited and collected while rocking at a speed of 100 min to obtain orthogonally arranged webs. On the other hand, when obtaining a nonwoven web with a random structure, the entire amount of filaments constituting the web is supplied to the unit for forming the longitudinal component, and the oscillation cycle is repeated 100 times.
Deposition was carried out in a random manner at a rate of cycles/min to obtain a web with a random structure. Next, the obtained web is sandwiched between two upper and lower net conveyors,
Preliminarily bonded by pressing onto a heating roll at 150℃ for 20 seconds at a pressure of 0.2Kg/cm ² , cooled with cold air, then taken out from the net conveyor and coated with urea-formalin resin 70% by weight.
and 30% by weight of PVA with a solid content of 15% by weight, and squeezed to give a solid content of 10 to 15%.
Thereafter, it was dried with a drum dryer, and then bonded by heat setting at 210° C. for 3 minutes using a clip tenter under 5% tension. The obtained nonwoven fabric
According to the method shown in JIS-A-6022, molten asphalt (JIS-A-6011) at 210°C was impregnated (asphalt applied amount: 850 g/m ² ), and iron sand was sprinkled on it. Asphalt roofing of Example 1 was obtained. Table 2 shows the manufacturing conditions of these asphalt roofing base fabrics and the physical properties of the nonwoven fabrics.
Table 3 shows the physical properties of the asphalt roofing product. In addition, in Table 3, ◎
The marks are visually judged to be excellent, ◯ are almost good, △ are slightly poor, and × are poor.

【table】

【table】

【table】

[Table] As is clear from Tables 2 and 3 above,
Comparative example 1 using a nonwoven fabric with a random structure as a reinforcing material
Although the basis weight was increased compared to Examples 1 and 2, the nonwoven fabric (reinforcing material) was heated to 5% at 200°C.
The stress during elongation is small, the thermal shrinkage rate at 200°C is large, and the dimensional stability during and after asphalt processing is poor compared to Examples 1 and 2 with orthogonal arrangement structures.
And the stress at 3% elongation does not meet the JIS standard. On the other hand, Examples 1 and 2 of the orthogonal arrangement structure are JIS
It not only satisfies the standards, but also has extremely good dimensional stability during and after asphalt processing, and also satisfies the requirements in Table 1. Experimental Example 2 Next, asphalt roofings of Examples 3 to 5 and Comparative Examples 2 and 3 were manufactured using nonwoven fabrics having substantially the same orthogonal arrangement structure as those of Examples 1 and 2, but using different amounts of adhesive. The manufacturing conditions and physical properties of the nonwoven fabric are shown in Table 4, and the product physical properties are shown in Table 5.

【table】

[Table] As shown in Table 4, Comparative Examples 2 and 3, which have a small amount of thermosetting resin applied, have a higher stress at 5% elongation than Examples 3 to 5, which have a larger amount of thermosetting resin applied. The tensile strength is slightly low, the stress at 5% elongation at 200°C is extremely low, and the heat shrinkage rate at 200°C is high. In particular, since the stress at 5% elongation at 200℃ is low, the dimensional stability during and after asphalt processing is low, and as shown in Table 5, the stress at 3% elongation is low.
Does not meet JIS standards. On the other hand, Example 3~
No. 5 has extremely good dimensional stability during and after asphalt processing, and the product physical properties satisfy the requirements of the JIS standard and Table 1. Experimental Example 3 Asphalt roofings of Examples 6 to 8 and Comparative Examples 4 and 5 were produced in the same manner as in Example 1 except that the folding widths L and D of the polyester filaments 1 and 2 were changed. The manufacturing conditions and physical properties of the nonwoven fabric are shown in Table 6, and the physical properties of the product are shown in Table 7.

【table】

【table】

[Table] Examples 6, 7, and 8, in which the folding widths L and D were set to 50 cm or more, all satisfied the requirements in Table 1 above and had extremely good dimensional stability during and after asphalt processing. . On the other hand, comparative example 4 in which the folding widths D and L were each set to 30 cm.
are the stress at 5% elongation, tensile strength and
The stress at 5% elongation at 200°C is too small, the stress at 3% elongation and tensile strength of the product physical properties do not meet JIS standards, and the dimensional stability during and after asphalt processing is poor. In addition, the folding width is 30cm,
In Comparative Example 5 with a 25% amount of thermosetting resin, the physical properties of the nonwoven fabric were improved due to the increased amount of thermosetting resin compared to Comparative Example 4, even though the product physical properties met the JIS standard. , The stress at 5% elongation at 200°C in the physical properties of the nonwoven fabric was too small, so the dimensional stability during asphalt processing was comparable to Comparative Example 4, and the dimensional stability of the product after processing was slightly higher than that of Comparative Example 4. It's only good.

[Brief explanation of the drawing]

FIG. 1 is a perspective view for explaining the method of manufacturing a nonwoven fabric for reinforcing material used in the present invention, and FIG. 2 is a plan view for explaining another example of the manufacturing method. 1: Polyester filaments in the length direction arranged in a sash pattern, 2: Polyester filaments in the width direction arranged in a sash pattern, 1a, 2a:
Turning point, L, D: turning length, l, d: deviation.

Claims (1)

[Scope of Claims] 1. In asphalt roofing using a nonwoven fabric made of polyester filaments as a reinforcing material, the nonwoven fabric arranges a large number of polyester filaments in a substantially stretched state in the length direction and the width direction, and The polyester filaments in the length direction and the width direction are folded in the length direction and the width direction, respectively, to form an orthogonal array structure by stacking them and bonding them with a thermosetting adhesive. The folding length L is set to 50 cm or more, the deviation l in the length direction of the folding point is set to 1/5 or less of the above folding length L, and the folding length D of the polyester filament in the width direction is set to 50 cm or more. , and the deviation d of the turning point in the width direction is the turning length D.
Asphalt roofing, each set to 1/4 or less, wherein the thickness of the above nonwoven fabric is 0.3 to 1.3 mm, and the apparent density is 0.10 to 0.37. 2 The stress in the length direction at 5% elongation of the nonwoven fabric is 30Kg/5
cm or more, width direction 15Kg/5cm or more, length direction 45Kg/5cm or more, width direction 24Kg/5cm or more, breaking elongation 20% or more in both length and width directions, non-woven fabric heat at 200℃ Claim 1, wherein the shrinkage rate is 1.5% or less in both the length direction and the width direction.
Asphalt roofing as described in section. 3. The thermosetting adhesive according to claim 1 or 2, wherein the thermosetting adhesive is mainly composed of a reaction product of formaldehyde and at least one amino compound selected from urea, cyclic urea, and melamine. Asphalt roofing.