JP2613332B2 - Resin coated film material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin-coated film material used for a PVC resin-coated film material, a rubberized cloth, a chair-covered film material and the like.

[0002]

2. Description of the Related Art In recent years, there has been an increasing demand for a resin-coated film material for furniture such as a chair-covered film material in which a resin such as PVC is coated on one side of a base cloth. Although a large amount of the resin-coated film material used is commercially available, the demand for a resin-coated film material using a base fabric made of synthetic fibers has been increasing, and in particular, dimensional stability, water absorption prevention, etc. Strong demands.

[0003]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems. That is, an object of the present invention is to provide a resin coating film material having excellent dimensional stability, water absorption preventing property, and resin adhesiveness and having a voluminous feel.

[0004]

SUMMARY OF THE INVENTION Namely, the present invention provides "(claim 1) Real twisted, entangled or at least combining a portion is hardened fusible fiber Maruchifirame of its constituent filament false twist state
Natural rubber on at least one surface of a base fabric cement is arranged to warp 及 beauty / or weft, a resin-coated film material having a coating film made of a synthetic rubber or synthetic resin. ".

[0005] Terms and phrases used in the present invention follow the following definitions. Determination of fusion / hardening and determination of the ratio of fused / cured filaments to the number of constituent filaments Here, fusion refers to the state in which individual filaments are melted and integrated with adjacent filaments or not integrated This also means that the filaments are in close contact with each other at the boundary between the filaments and are difficult to separate. Next, as for the method of judging the fusion ratio, 10 fusion yarns obtained by cutting 1 m of a randomly selected fusion yarn at a 10 cm gap are each embedded in paraffin, and a cross section having a thickness of 5 to 10 μm is obtained with a microtome. A total of ten slides are prepared one by one, and the total cross-sectional area and the cross-sectional area of the fused portion are obtained for each sheet, and the ratio of the fused portion determined by the following equation (Equation 1) is used to determine the average value of the ten pieces. .

[0006]

(Equation 1)

A method for determining the proportion of fused / hardened filaments per unit length of a multifilament yarn 20 fusible yarns obtained by cutting 1 m of an arbitrarily selected fused yarn at a gap of 5 cm are embedded in paraffin respectively. 5-1 with a microtome
A total of 20 slides each having a cross section having a thickness of 0 micron were prepared, and the presence or absence of a welded portion was measured for each slide. Then, the ratio of the welded portion to the unit length was calculated by the following equation (Equation 2). Ask for.

[0008]

(Equation 2)

Degree of Deformity The maximum length and the minimum length are obtained from the cross section of the original yarn (before heat treatment or before false twisting), and the degree of deformity is expressed by the following equation (Equation 3).

[0010]

(Equation 3) (A) and (b) show length measurement positions in the cross section shown in FIG. (A) Flat cross-section yarn having parallel and opposite sides (b) Open cross-section yarn having no linear portion (c) Polygon cross-section yarn having three or more sides (d) Radial cross-section yarn

[0011] Strength of elongation and cutting Five arbitrarily collected five fused yarns each having a length of 40 cm were prepared, and a test length of 20 cm and a tensile speed of 20 cm / were measured with an Instron tensile measuring machine.
After setting the minute, chuck fixed length, upper and lower 5cm each, initial load 1 / 30g denier, maximum load 2kg, measure and record the strength from the start until the fused yarn is cut and record the strength (g) at the cutting point Read from the meter. The same measurement is repeated five times and the average value of the five measurements is expressed.

The elongation is recorded simultaneously with the measurement of the elongation / cutting force, and the elongation from the start of the measurement to the cutting point is read from a recorder, and the elongation is expressed by the following equation (Equation 4).

[0013]

(Equation 4) The same measurement is repeated 5 times, and the average value represents elongation.

Cutting elongation of resin-coated film material 3 cm in width and 30 cm in length along warp or weft in woven fabric
Are prepared using an Instron tensile tester, and a test length of 10 cm, a tensile speed of 20 cm / min, a maximum load chuck fixed length, each of upper and lower sides of 5 cm, and an initial load are applied to the extent that the fabric does not sag. The elongation and the load from the start of the first measurement to the cutting of the fabric are recorded, and the elongation at the maximum load is read and expressed by the following equation (Equation 5).

[0015]

(Equation 5) The same measurement is repeated 5 times, and the average value represents elongation.

According to the present invention, as described above, in a synthetic fiber multifilament yarn, the yarn is subjected to a fusion treatment in a real twisted or false twisted state, and several of the constituent filaments are fused and fused.
It has been found that the tape base material made of the yarn has a high degree of convergence just by being cured, and that the shape retention (three-dimensional structure) in the cross-sectional direction and the fabric standing in the width direction are remarkably improved. Is based on

Therefore, in the present invention, it is considered that the ratio of the fused and hardened filaments in the synthetic fiber multifilaments is important. However, actually, several (2 to 15) constituent filaments are fused and hardened, and such a portion exists over 70% or more of the unit length of the multifilament yarn. If so, it has been found that the desired purpose is achieved. In this case, in terms of the number of constituent filaments, it is preferable that filaments corresponding to 3 to 50% of the number of the filaments are fused and hardened.

The fused or cured filament or filaments are present at a relatively outer periphery of the multifilament yarn, and are preferably present in a state of being wound around the multifilament yarn.

The above-mentioned fused / cured multifilament yarn can be in the form of flat yarn (so-called raw yarn) or false twisted crimped yarn. Hereinafter, examples of the manufacturing method in each case will be described.

(A) In the case of a flat yarn A multifilament yarn (usually total denier: 40 to 250 de, filament denier: 0.5 to 10 de) in a stretched state is subjected to a real twist or false twist using a twisting machine. While applying or after applying the alternately twisted yarn, the yarn is fused by a heater. In this case, the number of twists is adopted from the range of 3 to 70 as the twist coefficient (A) represented by the following equation (Equation 6) according to the denier of the yarn.

[0021]

(Equation 6) In order to fuse and solidify a part or all of the filaments, a heater temperature of 200 to 300 ° C. (when the heater length is 30 to 250 cm) may be employed.

(B) In the case of false twisted crimped yarn In this case, there are a single yarn and a false twisted double-layer crimped yarn having a core-sheath structure.

In the case of a single yarn, the number of constituent filaments of a synthetic fiber multifilament yarn in a drawn state (a drawn yarn state or a drawn state in IN-DRAW processing of POY) is subjected to a normal false twist crimping step. The processing conditions, particularly the heater temperature, are adjusted so that the book is fused. Specifically, usually, a synthetic fiber multifilament yarn having a cutting strength of 2.0 to 9.0 g / de and an elongation of 20 to 70% has a false twist coefficient (α) of 0.8 to 1.2, Heater temperature 2
What is necessary is just to process in 30-300 degreeC and the heater length of 30-250 cm.

The false twist coefficient (α) is

[0025]

(Equation 7) Where T is the number of false twists (times / m), and de is the denier of the original yarn.

An appropriate condition is selected from the range of the processing conditions as described above, and the processed yarn strength is set to 1.0 to 7.0 g / de,
It is preferable to keep the elongation of the processed yarn within the range of 6 to 36%. Examples of the form of the processed yarn include those including a non-fused untwisted yarn (that is, an SZ alternating twisted yarn) to substantially untwisted yarns. It is advantageous from the aspect of sex. The synthetic multifilament yarn used as a raw yarn usually has a total denier of 40 to 250 de and a filament denier of 0.5 to 1.
What is necessary is just the thing of 0de. When a part or the whole of such a filament yarn is replaced with a modified cross-section filament, in particular, a modified cross-section filament having a degree of irregularity of 1.1 to 15, the porosity of the obtained processed yarn increases and the resin impregnation property increases. Has the advantage of further improving the effect of fixing the form of the yarn.

In the case of a core-sheath false-twisted double-layered crimped yarn; this processed yarn is typically manufactured in JP-B-61-19733.
Gazette, JP-A-61-19737 or JP-A-61-3
It can be obtained by a method described in, for example, US Pat. The methods described in these publications are based on a pre-entanglement of two or more types of undrawn filament yarns having different elongations and then subjecting them to simultaneous drawing false twisting to provide a core-sheath structure, that is, a filament yarn having a low elongation. Is a core portion, and a high elongation yarn is wound around the core portion in an alternately twisted state as a sheath portion. In this case, pre-entanglement is not always necessary for the purpose of the present invention, but may be adopted as necessary. The processing method may be in accordance with the method described in the publication, but in that case, the heater temperature needs to be set higher. Preferred ranges of the total denier and the number of filaments of the core yarn and the sheath yarn are as follows.

[0028]

[Table 1]

[0029] In such a two-layer structure yarn, fusion bonding
The cured filament is preferably present in the sheath. Especially in the sheath portion, the sheath portion surrounds the core yarn in an alternately twisted state, so if this state is utilized, the fused / cured filament is located on the outer periphery of the multifilament yarn, and furthermore, It is possible to have a structure wound around. Such a two-layer yarn has an additional effect. That is, the characteristic that a part of the filament group constituting the sheath yarn is raised as a loop, slack, or fluff from the surface of the multifilament promotes the holding effect of the resin or the like, that is, the inclusion effect. That is,
When the fused / cured filament yarn is arranged as warp yarn and / or weft yarn, the above-mentioned loops or slacks protrude into the weave space, thereby improving the resin application rate and the retention.

The above-mentioned fused / cured flat yarn and false-twisted crimped yarn both have an elongation breaking strength of 200 to 1000 g and an elongation breaking strength of 1.0 to 5 g / denier. 0.0 g / d and the elongation are preferably in the range of 5 to 36%. When used in place of the conventional Suf Moss spun yarn, the yarn diameter may be 0.05 mm or more (130 denier or more).

The fused / cured false-twisted two-layer structure yarn of the present invention is not limited to the above-mentioned yarn.
It may be obtained using another method.

Next, the fused and cured multifilament yarn is subjected to weaving in order to obtain a resin-coated film material. In this case, the warp and / or warp yarns are used according to the use and purpose of the resin-coated film material. Or arrange on the weft. The warp and weft densities at this time are
Depending on the denier of the fused and cured multifilament yarn, when the denier of the yarn is 40 to 250 de, the former may be selected from the range of 23 to 90 yarns / inch, and the latter may be selected from the range of 14 to 70 yarns / inch. The warp and the weft do not necessarily have to have the same denier, but the sum of the warp diameter and the weft diameter is preferably 0.1 mm or more.

When such a resin-coated film material is applied to the resin-coated film material, a thermoplastic synthetic fiber such as natural rubber, synthetic rubber, polyester, acrylic, etc. , PVC, especially those films.

[0034]

According to the present invention, without relying on confounding,
A resin-coated film material that is woven in a glue-free and untwisted state, and that has significantly improved shape retention in the cross-sectional direction (three-dimensional structure) and fabric standing in the width direction. A resin-coated film material having significantly improved properties is provided.

In the field of thick resin-coated film materials,
The present invention has a great significance in view of the fact that only rayon soup yarns have been used so far. In other words, simply selecting a denier synthetic fiber multifilament yarn corresponding to a spun yarn of rayon sull eliminates the equivalent characteristics and the temperature / humidity dependency which has been regarded as a defect of rayon. To further describe this point, a spun yarn using rayon swoof has been used as a base material of a conventional thick resin-coated film material. In the case of a spun yarn, the short fibers are formed into the yarn while being spun by spinning, so that the roundness resulting from the real twist form makes it difficult to flatten the yarn. In addition, rayon swoof has an elongation at break of at most about 15% and low tear strength. In an environment of high humidity and high temperature and high humidity and humidity, the fiber absorbs moisture, resulting in deterioration of physical properties and adhesion performance. In addition, there is a disadvantage that the water permeates into the fibers and the deterioration in performance becomes larger, for example, when a large amount of water is temporarily attached such as rainwater or dew condensation. In the present invention, a thick resin-coated film material is provided by using a polyester multifilament having almost no humidity dependence.

From the above, the present invention provides the following (a)
To (s). (A) A resin-coated film material in which 3 to 50% of the constituent filaments are fused and cured. (B) A resin-coated film material in which the fused and cured filaments exist over a length of 70% or more of the unit length of the multifilament yarn. (C) A resin-coated film material in which a fused and cured filament is present relatively at the outer periphery of the multifilament yarn. (D) A resin-coated film material in which a fused and cured filament is wound around a multifilament yarn. (E) A resin-coated film material in which the multifilament yarn is a flat yarn. (F) A resin-coated film material in which the multifilament yarn is a false twist crimped yarn. (G) A resin-coated film material in which the multifilament yarn is a single yarn of a false twist crimped yarn. (H) A resin-coated film material in which the multifilament yarn is a core-sheath false-twisted double-layer structure crimped yarn. (I) A resin-coated film material in which at least a part of the constituent filaments of the sheath is fused. (J) A resin-coated film material containing a modified filament in at least a part of the constituent filaments. (K) A resin coating film material in which the degree of irregularity of the irregularly shaped filament is 1.1 to 15. (L) A resin-coated film material having an elongation-cutting strength of a synthetic fiber multifilament yarn of 200 to 600 g. (M) A resin-coated film material having an elongation breaking strength of a synthetic fiber multifilament yarn of 1.0 to 4.0 g / de. (N) The elongation of the synthetic fiber multifilament yarn is 5 to 30.
% Resin-coated film material. (O) The diameter of the synthetic multifilament yarn is 0.05
Resin-coated film material of not less than mm. (P) A resin-coated film material in which the sum of the diameters of the warp and the weft is 0.1 mm or more. (Q) A resin-coated film material obtained by impregnating a synthetic resin multifilament yarn with a hydrophobic resin. (R) A resin-coated film material in which a thermoplastic resin film is fused and adhered in a laminated state. (S) A resin-coated film material having a cut elongation of 25% or less in a direction in which the fused and cured synthetic fiber multifilament yarns are arranged.

[0037]

Example 1 Polyester multifilament yarn having an elongation and breaking elongation of 130% (48 filaments of 200 denier; undrawn yarn having a round cross section) and a polyester multifilament yarn having an elongation and cutting elongation of 300% (90 denier 24 filaments; triangular cross section) , Irregularity: 1.2, undrawn yarn), interlaced, and then stretched false twist fusion. At that time, the false twist temperature was 235 ° C., the false twist stretching ratio was 1.72 times, the peripheral speed of the triaxial friction disk as the false twist tool was 700 m / min, and the processing speed was 350 m / min. Was obtained. The extension cut elongation of this fused yarn is 18%,
The yarn strength is 3.0 g / d, the yarn diameter is 0.12 mm (measurement
EIKO, INDUSTRIAL CO. LTD, DIAL THICKNESS. GAUGE
, Measured 20 times with a 10 cm gap using a so-called peacock,
(Expressed as the average value). This fused yarn is used for warp and weft, and has a warp density of 45 threads / inch and a weft density of 35 threads /
A 100-micron-thick vinyl chloride film was melt-extruded using a calender and laminated on the front side of the substrate using the obtained greige fabric as a substrate. At that time, the total thickness of the film and the base material was as thick as 0.30 mm. The adhesive strength of the obtained resin-coated film material is 1.5 kg /
The film was as high as cm and had no water absorption.

[0038]

[Reference Example] A laminate prepared by melt-extruding a 100-micron PVC film by a calender on a base material using a woven cloth having a weft density of 45 × 35 / inch using 177 denier (# 30) rayon spun yarn. 0.26 thick
mm, it can be seen that the thickness of the fused yarn of the present invention is too large.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a flat cross-section yarn. (B) A cross-sectional view of an open cross-section yarn.

Continued on the front page (51) Int.Cl. ⁶ Identification number Agency reference number FI Technical display location D02G 1/02 D02G 1/02 A 3/40 3/40 D06M 15/693 D06M 15/693

Claims (1)

(57) [Claims] 1. A real twisted, on at least one surface of the base fabric at least some of its constituent filament entanglement or false twist state synthetic fiber multifilaments that are cured fused are disposed in the warp 及 beauty / or weft A resin coating material having a coating film made of natural rubber, synthetic rubber or synthetic resin.