JP7552044B2 - Membrane material - Google Patents

Description

The present invention relates to a film material that is optically transparent.

For example, currently, light-transmitting ceiling materials mainly use membrane materials that contain glass fiber fabric, which are lightweight and non-flammable (see, for example, Patent Document 1 below). In ceiling materials that use such light-transmitting membrane materials (light membrane ceiling materials), the light from a light source located inside is diffused and transmitted, making it possible to reduce glare.

JP 2019-214177 A

The light membrane ceiling material described above requires different light transmittances for small spaces that are relatively close to the light source, such as the interior of a house, an office conference room, or a train station waiting room, and large spaces that are relatively far from the light source, such as gymnasiums or commercial facilities. The production of light membrane ceiling materials with different light transmittances requires the use of glass fiber fabrics with different densities and thicknesses, which creates the problem of increased effort and cost.

This problem is not limited to membrane materials used in light membrane ceiling materials as described above, but can also occur in membrane materials used for wall surfaces such as fittings and waist-high walls, lighting furniture such as three-sided mirrors, and indirect lighting that houses lighting fixtures inside, such as footlights and guide lights.

In light of this, the present invention aims to provide a film material that can easily achieve the required light transmittance.

In order to solve the above-mentioned problems, the film material of the present invention is a light-transmitting film material, comprising a light-transmitting base material and a surface material having a triaxial fabric laid on one side of the base material, wherein the surface material has an area ratio of voids of 5% or more and 50% or less, and the base material contains glass cloth or glass nonwoven fabric .

The film material of the present invention allows the light transmittance to be set by the area ratio of the voids in the surface material. Therefore, even if the light transmittance of the base material is the same, the light transmittance can be changed by applying a surface material with a different light transmittance, so the required light transmittance can be easily obtained.

1 is a cross-sectional view showing a schematic configuration of a main embodiment of a membrane material according to the present invention. FIG. 2 is a plan view showing a schematic configuration of a surface material of the membrane material of FIG. 1 .

An embodiment of the membrane material according to the present invention will be described with reference to the drawings, but the present invention is not limited to the embodiment described with reference to the drawings.

<Main embodiment>
A main embodiment of the membrane material according to the present invention will be described with reference to FIGS.

As shown in FIG. 1, a surface material 12 having a triaxial fabric is laid on one surface (the upper surface in FIG. 1) of a light-transmitting substrate 11. An adhesive layer 13 is interposed between the substrate 11 and the surface material 12.

The substrate 11 preferably includes glass fiber glass cloth or glass nonwoven fabric and has a mass of 500 g/m2 or ^less , since this allows for weight reduction. In the case of glass cloth, it is preferably woven with glass fiber warp and weft threads so that the opening ratio is 0.5% to 1.0% and the thickness is 100 μm to 1 mm. On the other hand, in the case of glass nonwoven fabric, it is preferably 50 μm to 150 μm in thickness.

Furthermore, the substrate 11 satisfies the non-combustibility standard. Specifically, for example, in a heat generation test using a cone calorimeter tester in accordance with ISO 5660-1 and in accordance with the fire resistance test method and performance evaluation standard based on Article 2, item 9 of the Building Standards Act and Article 108-2 of the Enforcement Order of the Building Standards Act, the substrate 11 preferably has non-combustibility that satisfies the following conditions: (1) the total heat generation amount (MJ/m ² ) for 20 minutes after the start of heating is 4 MJ/m ² or less, (2) the maximum heat generation rate for 20 minutes after the start of heating does not exceed 200 kW/m ² for 10 seconds or more, and (3) there are no cracks or holes that are harmful to fire prevention and extend through to the back surface for 20 minutes after the start of heating.

As shown in Figures 1 and 2, the surface material 12 includes a triaxial fabric in which glass fiber threads 12a are woven in three axial directions so as to have voids 12b penetrating between one side and the other side, and the area ratio of the voids 12b is adjusted to a range of 5% to 50%.

The triaxial fabric is preferably 100 μm to 1 mm thick and 500 g/m2 ^or less in weight reduction. The surface material 12 is highly rigid because the glass fibers of the threads 12a of the fabric are impregnated with resin and hardened. Examples of the impregnated resin include thermoplastic resin, thermosetting resin, and ultraviolet-curable resin.

Examples of the thermoplastic resins include polyester resins such as polyethylene terephthalate (PET) resin, polybutylene terephthalate (PBT) resin, polytrimethylene terephthalate (PTT) resin, polyethylene naphthalate (PEN) resin, and liquid crystal polyester resin; polyolefin resins such as polyethylene (PE) resin, polypropylene (PP) resin, and polybutylene resin; styrene-based resins; polyoxymethylene (POM) resin, polyamide (PA) resin, polycarbonate (PC) resin, polymethylene methacrylate (PMMA) resin, polyvinyl chloride (PVC) resin, polyphenylene sulfide (PPS) resin, polyphenylene ether (PPE) resin, modified PPE resin, thermoplastic polyimide (PI) resin, and polyamide-imide (PAI). Resins, polyetherimide (PEI) resins, polysulfone (PSU) resins, modified PSU resins, polyethersulfone (PES) resins, polyketone (PK) resins, polyetherketone (PEK) resins, polyetheretherketone (PEEK) resins, polyetherketoneketone (PEKK) resins, polyarylate (PAR) resins, polyethernitrile (PEN) resins, thermoplastic phenolic resins, phenoxy resins, fluorine-based resins such as polytetrafluoroethylene resins, and further, thermoplastic elastomers such as polystyrene resins, polyolefin resins, polyurethane resins, polyester resins, polyamide resins, polybutadiene resins, polyisoprene resins, and fluorine-based resins, as well as copolymers, modified products, and resins made by blending two or more of these resins.

Examples of the thermosetting resin include phenolic resin (PF), epoxy resin (EP), melamine resin (MF), urea resin (UF), unsaturated polyester resin (UP), alkyd resin, polyurethane (PUR), thermosetting polyimide (PI), etc.

Examples of the UV-curable resin include acrylic and epoxy resins.

The adhesive layer 13 bonds the substrate 11 and the surface material 12, and examples of the adhesive include a hot melt adhesive with 100% solids, a moisture-curing adhesive with 100% solids (e.g. polyurethane (PUR) resin), a high-viscosity rubber adhesive, and a high-viscosity urethane resin adhesive. Examples of hot melt adhesives include ethylene-vinyl acetate copolymer resin (EVA resin), polyamide resin, etc.

When the above-mentioned adhesive is applied to the adhesive layer 13, it is highly preferable because it prevents the adhesive from penetrating into the pores of the substrate 11 or the surface material 12, or into the voids 12b of the surface material 12, thereby preventing a decrease in the adhesive strength between the substrate 11 and the surface material 12. In addition, it is preferable to apply a high-viscosity rubber-based adhesive or a high-viscosity urethane resin-based adhesive with a viscosity of 40 Pa·s or more, more preferably 50 Pa·s or more.

A method for manufacturing the membrane material 10 according to this embodiment will now be described.
First, the above-mentioned resin (e.g., a thermosetting resin) is dissolved or dispersed in a solvent such as water to prepare an impregnation liquid, and the surface material 12 is immersed in the impregnation liquid to impregnate the resin between the glass fibers of the yarns 12a of the fabric of the surface material 12.

Examples of the resin impregnation method include immersing the sheet-like surface material 12 directly in the impregnation liquid in a container, or running a web-like surface material between a pair of rolls to which the impregnation liquid is applied to impregnate the surface material with the impregnation liquid, and then cutting the web.

Next, a mesh-like (or sheet-like) adhesive layer (e.g., hot melt adhesive) 13 is laminated on one side of the base material 11, and then a surface material 12 impregnated with resin is laminated. This is then heated (e.g., at about 100°C for about 30 seconds) to harden the resin and melt the adhesive. As a result, the surface material 12 hardens and the base material 11 and the surface material 12 are bonded together by the adhesive layer 13, and the membrane material 10 can be obtained.

In the membrane material 10 according to this embodiment, the surface material 12 includes a triaxial fabric having voids 12b formed by weaving glass fiber threads 12a in three axial directions, and is laid on a substrate 11 including a glass cloth or glass nonwoven fabric containing glass fibers, so that the light transmittance can be set by the area ratio of the voids 12b in the surface material 12.

That is, if the light transmittance of the base material 11 is Pb, the light transmittance of the surface material 12 is Ps, and the light transmittance of the adhesive layer 13 is Pg, the light transmittance Pf of the film material 10 can be expressed by the following formula (1).

Pf=Pb×Ps×Pg (1)

Here, the light transmittance Pg of the adhesive layer 13 can be practically ignored, so the above formula (1) essentially consists of only the first and second terms.

Therefore, even if the light transmittance Pb of the base material 11 is the same, the light transmittance Pf of the film material 10 can be set to a value as needed by applying a surface material 12 with a different light transmittance Ps.

Specifically, for example, when the width W of the glass fiber threads 12a is 4 mm and the weave angle θ is 60°, the area ratio of the voids 12b in the surface material 12 can be approximately 30%. In this case, if the width W of the threads 12a is reduced or the weave angle θ is increased, the area ratio of the voids 12b in the surface material 12 can be increased. On the other hand, if the width W of the threads 12a is increased or the weave angle θ is reduced, the area ratio of the voids 12b in the surface material 12 can be reduced.

In this way, the surface area ratio of the voids 12b is adjusted to be in the range of 5% to 50%, i.e., by laying the surface material 12 with the adjusted light transmittance Ps on the base material 11 with light transmittance Pb, it is possible to easily make the membrane material 10 have the light transmittance Pf required.

Specifically, for example, when used as a light membrane ceiling material in a large space where the distance to the light source is relatively far, such as a commercial facility or gymnasium, the light transmittance Pf of the film material 10 is set to 50% or more and 90% or less. When used as a light membrane ceiling material in a small space where the distance to the light source is relatively close, such as the interior of a house, an office conference room, or a waiting room in a train station, the light transmittance Pf of the film material 10 is set to 30% or more and 70% or less. When used for purposes that do not require a relatively large amount of light, such as indirect lighting for footlights and guide lights, the light transmittance Ps of the film material 10 is set to 10% or more and 50% or less. In this way, the surface material 12 with the adjusted area ratio of the void portion 12b is laid on the base material 11 with light transmittance Pb.

In other words, a series of surface materials 12 are prepared by stocking a number of different surface area ratios of voids 12b in the range of 5% to 50%. In other words, a series of surface materials 12 with different light transmittances Ps are prepared, and by combining them with a substrate 11 with a single light transmittance Pb, a combination series is created that allows a film material 10 with the desired light transmittance Pf to be obtained.

Therefore, with the membrane material 10 according to this embodiment, the required light transmittance Pf can be easily obtained.

In addition, since it is necessary to keep the light transmittance Pb of the base material 11 as high as possible, the density and thickness of the base material 11 become relatively small, and the rigidity of the base material 11 becomes low. However, the rigidity of the surface material 12 is increased by impregnating the glass fibers of the woven threads 12a of the surface material 12 with resin and hardening the resin, so that the surface material 12 can be used as a core material and has sufficient rigidity.

If the surface material is made of a biaxial (warp and weft) fabric, the directionality is vertical and horizontal, so when the resin is impregnated and cured, it tends to bend vertically or horizontally. In contrast, the membrane material 10 according to this embodiment has a surface material 12 made of a triaxial (axial, right-up bias yarn, left-up bias yarn) fabric, so the directionality is diagonal, and it can maintain its rigidity when the resin is impregnated and cured.

Other Embodiments
In the above-mentioned embodiment, the description was centered on the case where the present invention is applied to a light-transmitting membrane ceiling material, but the present invention is not limited thereto. As another embodiment, the present invention can be applied in the same manner as the above-mentioned embodiment, if the present invention is used as a light-transmitting membrane material, such as a membrane material used for wall surfaces such as fittings and waist-high walls, lighting furniture such as a three-way mirror, or indirect lighting such as footlights and guide lights that house lighting fixtures inside.

The film material of the present invention can be easily obtained with the required light transmittance, and therefore can be used in an extremely beneficial manner in industry.

10 Membrane material 11 Base material 12 Surface material 12a Yarn 12b Cavity 13 Adhesive layer

Claims (5)

A light-transmitting film material,
A substrate having optical transparency;
A surface material having a triaxial woven fabric laid on one surface of the base material;
Equipped with
The surface material has an area ratio of voids of 5% or more and 50% or less,
The substrate includes a glass cloth or a glass nonwoven fabric.
A membrane material characterized by: 2. The membrane of claim 1, wherein the fibers of the triaxial fabric are hardened with a resin . 3. The membrane material according to claim 1, wherein the triaxial fabric contains glass fibers . The membrane material according to any one of claims 1 to 3 , characterized in that an adhesive layer is interposed between the base material and the surface material. The film material according to claim 4, characterized in that the adhesive layer contains at least one of a hot melt adhesive with a solid content of 100%, a moisture-curing adhesive with a solid content of 100%, a high-viscosity rubber-based adhesive, and a high-viscosity urethane resin-based adhesive .

Images