JP2025023496A - Felt material, carrier material, and method for manufacturing the felt material - Google Patents

Abstract

[Problem] To provide a felt material having high heat resistance and durability, and to provide a new felt material containing a specific fiber that has not been used in a batt fiber layer so far. [Solution] A felt material comprising a base layer and a batt fiber layer, at least one of the batt fiber layers being a heat-resistant batt fiber layer containing at least one type of fiber selected from the group consisting of polyphenylene oxadiazole fiber and polyoxadiazole fiber. [Selected Figure] Figure 1

Description

The present invention relates to a felt material, a conveying material, and a method for manufacturing the felt material.

In the manufacture of aluminum extrusions, the aluminum extrusions are extruded by an extruder, pulled by a puller, and then moved along a run-out tube or placed on a run-out conveyor for the transportation process. The aluminum extrusions are then transported along a cooling belt and stretcher belt, gradually cooled, and then stretched by the stretchers on both ends on the stretcher belt to set the shape, before being transported to the saw table belt.

Because aluminum extrusions reach very high temperatures, heat-resistant felt materials are sometimes used for the roll covers of run-out tubes; pads attached to run-out conveyors; and conveying belts such as cooling belts, stretcher belts, and saw table belts.

In addition, in the production of steel sheets in a continuous hot-dip galvanized steel sheet line (CGL), the steel sheets plated in a zinc pot are transported by a top roll located downstream of the zinc pot in the CGL. The top roll is usually covered with a heat-resistant felt material as a roll cover material to prevent zinc from adhering to the top roll and to prevent scratches on the steel sheets.

Patent Document 1 describes a heat-resistant felt used for covers and conveyor belts of conveyor rolls of aluminum extrusions and roll covers of CGL, which has a base layer having at least one substrate, and discloses that the base layer includes a base fabric having yarns containing at least one type of fiber selected from the group consisting of aromatic polyamide fibers and polyparaphenylene benzobisoxazole fibers (hereinafter also referred to as "PBO fibers").

Patent Document 2 discloses a cylindrical nonwoven fabric roll for steelmaking, in which a surface layer is made of a nonwoven fabric made of polyparaphenylene benzobisoxazole fiber, an inner layer is made of a nonwoven fabric made of para-aramid fiber, and a cylindrical base fabric made of heat-resistant fiber is placed inside the inner layer.

Furthermore, Patent Document 3 describes a heat-resistant felt for high-temperature products, which is made by entangling and integrating a heat-resistant fiber web made by compounding or laminating metal fibers or inorganic fibers, or by compounding or laminating metal fibers or inorganic fibers with heat-resistant organic fibers, through needle punching. It also discloses an embodiment in which a fiber compounded with glass fibers and para-aromatic polyamide fibers is used as the heat-resistant fiber web.

JP 2021-160092 A JP 2000-064014 A Japanese Patent Application Publication No. 8-296160

The materials used for the aluminum extrusion conveyor belts and conveyor roll covers, as well as the materials used for CGL roll covers, require higher heat resistance to accommodate the increasingly high temperatures of the metals being conveyed, and also require greater durability from the standpoint of cost reduction.

In the conveyor belt and roll cover described in Patent Document 1, the heat resistance is improved by using heat-resistant fibers such as aromatic polyamide fibers and PBO fibers in the base material (woven fabric, base fabric) and the web (nonwoven fabric) laminated on the base material, which are the components of the belt and roll cover.
Furthermore, in the cylindrical nonwoven fabric roll for steel making described in Patent Document 2, the heat resistance is improved by using a nonwoven fabric made of PBO fibers for the surface layer, which is a component of the roll.
Furthermore, in the heat-resistant felt for high-temperature products described in Patent Document 3, the heat resistance of the felt is improved by compounding para-aromatic polyamide fibers with glass fibers.

The above-mentioned conventional conveying materials using felt exhibit sufficient heat resistance and durability for conveying objects at temperatures between 200 and 400°C. However, in recent years, there has been a new demand for conveying objects at even higher temperatures. With conventional conveying materials, when such objects at high temperatures are conveyed multiple times, the fiber strength can drop significantly due to thermal degradation (wear progresses more quickly), and the heat resistance and durability are not necessarily sufficient. Furthermore, from the perspective of environmental conservation and the health and safety of workers, the use of inorganic materials such as glass fiber to improve heat resistance and durability should be avoided as much as possible.

The present invention was made in consideration of the above-mentioned conventional circumstances, and aims to provide a felt material with high heat resistance and durability. Another aim of the present invention is to provide a new felt material that contains a specific fiber in the batt fiber layer that has not been used in the same layer until now.

As a result of extensive research into solving the above problems, the inventors discovered that the above problems could be solved by making at least one of the batt fiber layers a heat-resistant batt fiber layer containing specific fibers in a felt material having a base layer and a batt fiber layer, and thus completed the present invention.

That is, the present invention relates to the following.
[1]
A base layer and a batt fiber layer are provided,
At least one of the batt fiber layers is a heat-resistant batt fiber layer containing at least one type of fiber selected from the group consisting of polyphenylene oxadiazole fiber and polyoxadiazole fiber.
[2]
The felt material according to [1], wherein the heat-resistant batt fiber layer is positioned on the outermost side in the stacking direction.
[3]
The felt material according to [1] or [2], wherein the base layer contains at least one type of fiber selected from the group consisting of aramid fiber, polyphenylene oxadiazole fiber, polyoxadiazole fiber, polyparaphenylene benzobisoxazole fiber, and polyimide fiber.
[4]
The felt material according to any one of [1] to [3], having a thickness of 1 mm to 16 mm.
[5]
The felt material according to any one of [1] to [4], wherein at least one of the batt fiber layers has a basis weight of 350 g/m ² to 5500 g/m ² .
[6]
[6] The felt material according to any one of [1] to [5], further comprising an additional batt fiber layer as the batt fiber layer.
[7]
The felt material according to [6], wherein the additional batt fiber layer comprises at least one fiber selected from the group consisting of aramid fiber, carbon fiber, polyparaphenylene benzobisoxazole fiber, polyimide fiber, fluorine fiber, glass fiber, and polyphenylene sulfide fiber.

[8]
The felt material according to any one of [1] to [7], which is in a flat plate shape.
[9]
The felt material according to any one of [1] to [7], which is in the form of a belt.
[10]
The felt material according to any one of [1] to [7], which is cylindrical in shape.
[11]
A carrier material comprising the felt material according to any one of [1] to [10].

[12]
A method for producing a felt material according to any one of [1] to [10], comprising the following steps (a) and (b) in this order:
(a) disposing a fibrous web of batt fibers on at least one surface of the substrate layer;
(b) entangling the fibrous web and the substrate layer to form the batt fiber layer adjacent the substrate layer.

The felt material of the present invention has high heat resistance and durability.

FIG. 1 is a schematic diagram showing one embodiment of a felt material according to the present invention. FIG. 2 is a schematic diagram showing one aspect of a felt material according to an embodiment of the present invention. FIG. 3 is a schematic diagram showing one aspect of a felt material according to an embodiment of the present invention. FIG. 4 is a schematic diagram showing one aspect of a felt material according to an embodiment of the present invention. FIG. 5 is a schematic diagram showing one aspect of a felt material according to an embodiment of the present invention. FIG. 6 is a schematic diagram showing one aspect of a felt material according to an embodiment of the present invention. FIG. 7 is a schematic diagram showing one aspect of a felt material according to an embodiment of the present invention. FIG. 8 is a schematic diagram showing one aspect of a felt material according to an embodiment of the present invention. FIG. 9 is a schematic diagram showing one embodiment of a conveyor belt material used in the manufacture of aluminum extrusion profiles, the conveyor belt material using the felt material according to an embodiment of the present invention. FIG. 10 is a schematic diagram showing one embodiment of a conveyor roll cover material used in the manufacture of aluminum extrusion profiles, the cover material using the felt material according to an embodiment of the present invention. FIG. 11 is a schematic diagram showing one embodiment of a roll cover material for a continuous hot-dip galvanized steel sheet line (CGL) using a felt material according to an embodiment of the present invention. FIG. 12 is a schematic diagram showing a felt material of a comparative example. FIG. 13 is a schematic diagram showing a felt material of a comparative example. FIG. 14 is a schematic diagram showing an outline of a heat abrasion tester used in the heat abrasion tests of the examples.

<Felt material>
The felt material according to an embodiment of the present invention comprises a base layer and a batt fiber layer, and at least one of the batt fiber layers is a heat-resistant batt fiber layer containing at least one type of fiber selected from the group consisting of polyphenylene oxadiazole fiber and polyoxadiazole fiber (hereinafter, these fibers are collectively referred to as "POD fiber").
Hereinafter, preferred embodiments of the felt material according to the present invention will be described with reference to the drawings. In this specification, when an expression "~" is used, it is used as an expression including the numerical values or physical property values before and after it.

The felt material according to an embodiment of the present invention comprises a heat-resistant batt fiber layer 10 and a base material layer 20, as shown, for example, in FIG. 1.

There is no particular limit to the thickness of the felt material according to the embodiment of the present invention, but from the viewpoint of abrasion resistance, it is preferably 1 mm to 16 mm, more preferably 1.5 mm to 16 mm, and even more preferably 2 mm to 16 mm.

In addition, there is no particular limitation on the basis weight of the felt material according to the embodiment of the present invention, but from the viewpoint of abrasion resistance, it is preferably 400 g/m ² to 6500 g/m ² , more preferably 600 g/m ² to 6500 g/m ² , and even more preferably 750 g/m ² to 6500 g/m ² .

[Bat fiber layer]
The batt fiber layer included in the felt material according to the embodiment of the present invention is a layer made of batt fibers. More specifically, the batt fiber layer is a fiber assembly layer formed by entangling batt fibers (preferably short batt fibers) with each other, and in one embodiment, functions as a layer having heat resistance, abrasion resistance, and the like.

(Heat-resistant batt fiber layer)
The felt material according to the embodiment of the present invention includes one or more batt fiber layers, and at least one of the batt fiber layers is a heat-resistant batt fiber layer containing at least one fiber selected from the group consisting of polyphenylene oxadiazole fiber and polyoxadiazole fiber. In other words, at least one of the batt fiber layers included in the felt material according to the embodiment of the present invention is a heat-resistant batt fiber layer containing POD fiber.
This allows the felt material according to the embodiment of the present invention to have high heat resistance and durability.

In this specification, the batt fiber layer containing the POD fiber is simply referred to as a "heat-resistant batt fiber layer," and the other batt fiber layers are referred to as "additional batt fiber layers." The additional batt fiber layers may or may not have heat resistance.
The batt fiber layer may be formed by intertwining two or more layers of the same material. When two or more layers of different materials are intertwined, they constitute two or more independent and different batt fiber layers. Such a layer formed by stacking two or more different batt fiber layers is sometimes collectively referred to as a "laminated batt fiber layer."

The polyphenylene oxadiazole and polyoxadiazole constituting the POD fiber are also called polyphenylene-1,3,4-oxadiazole and poly-1,3,4-oxadiazole, respectively.
In addition, polyphenylene oxadiazole has ortho (o-), meta (m-) and para (p-) isomers with respect to the bond of the phenylene moiety. In an embodiment of the present invention, from the viewpoint of heat resistance, it is preferable to use, as the POD fiber, poly(m-phenylene oxadiazole) which is a meta form, poly(p-phenylene oxadiazole) which is a para form, or poly(m-phenylene)(p-phenylene)oxadiazole which is a copolymer of meta and para forms, or a combination thereof, and it is more preferable to use poly(m-phenylene)(p-phenylene)oxadiazole. The same can be said about the structure of the POD fiber and its preferred embodiments mentioned in the following specification.

There are no particular limitations on the proportion of POD fiber in the heat-resistant batt fiber layer, but from the viewpoint of obtaining high heat resistance and durability, the fiber composition proportion is preferably 50% by mass to 100% by mass, more preferably 75% by mass to 100% by mass, even more preferably 90% by mass to 100% by mass, and particularly preferably 100% by mass.
From the viewpoint of environmental conservation and the health and safety of workers, it is preferable that the heat-resistant batt fiber layer does not contain inorganic materials such as glass fibers.

Examples of fibers other than POD fibers that can be contained in the heat-resistant batt fiber layer include aramid fibers, carbon fibers, PBO fibers, polyimide fibers (hereinafter also referred to as "PI fibers"), fluorine fibers, glass fibers, and polyphenylene sulfide fibers.
Aramid fibers have ortho (o-), meta (m-) and para (p-) isomers with respect to the bonds of the phenylene moieties. In an embodiment of the present invention, from the viewpoint of heat resistance, it is more preferable to use, as the aramid fiber, m-aramid fiber which is a meta form, p-aramid fiber which is a para form, or m-p-aramid fiber which is a copolymer of meta and para forms, or a combination thereof. The same can be said about the structure of the aramid fiber and its preferred embodiments mentioned hereinafter in the present specification.

(Additional batt fiber layer)
The felt material according to the embodiments of the present invention may further include an additional batt fiber layer. As mentioned above, "an additional batt fiber layer" in this specification refers to a batt fiber layer that does not include POD fibers.

The additional batt fiber layer may be, for example, a batt fiber layer containing at least one fiber selected from the group consisting of aramid fiber, carbon fiber, polyparaphenylene benzobisoxazole fiber, polyimide fiber, fluorine fiber, glass fiber, and polyphenylene sulfide fiber. Among these, aramid fiber is preferred from the viewpoint of abrasion resistance. Moreover, from the viewpoint of environmental conservation and the health and safety of workers, it is preferred that the additional batt fiber layer does not contain inorganic materials such as glass fiber.
However, from the viewpoint of heat resistance, it is preferable that the felt material according to the embodiment of the present invention includes only a heat-resistant batt fiber layer as the batt fiber layer.

(Specific embodiment of batt fiber layer in felt material)
Specific examples of felt materials according to embodiments of the present invention that include an additional batt fiber layer include those shown in Figures 1, 4, 5, and 8. In the embodiments shown in these figures, the felt material further includes an additional batt fiber layer 10A that does not contain POD fiber, in addition to the heat-resistant batt fiber layer 10.

The felt material according to the embodiment of the present invention may include only one batt fiber layer (i.e., only one heat-resistant batt fiber layer), or may include two or more batt fiber layers. For example, as shown in Figures 2 and 3, the felt material may include only one heat-resistant batt fiber layer 10.
When the felt material according to the embodiment of the present invention includes two or more batt fiber layers, the batt fiber layers may include both the heat-resistant batt fiber layer 10 and the additional batt fiber layer 10A as shown in Figures 1, 4, 5, and 8, or the batt fiber layers may include two or more layers of only the heat-resistant batt fiber layer 10 as shown in Figures 6 and 7.

From the viewpoint of obtaining high heat resistance and durability, it is preferable that at least one of the batt fiber layers of the felt material according to the embodiment of the present invention is a heat-resistant batt fiber layer located on the outermost side in the stacking direction. That is, it is preferable that the felt material according to the embodiment of the present invention is a felt material in which the heat-resistant batt fiber layer is located on the outermost side in the stacking direction.
When the felt material includes two or more batt fiber layers, it is preferable that the layer located at the outermost side in the stacking direction is a heat-resistant batt fiber layer, and that a heat-resistant batt fiber layer or an additional batt fiber layer is located between the heat-resistant batt fiber layer and the substrate.

When the felt material according to the embodiment of the present invention is used as a transport material described below, it is preferable that, from the viewpoint of heat resistance and abrasion resistance, it contains only one heat-resistant batt fiber layer located at the outermost side in the stacking direction, and does not contain any additional batt fiber layers. In this case, as a preferred embodiment, the heat-resistant batt fiber layer is arranged so as to contact the object to be transported, which is in a high-temperature state.

The batt fiber layer is preferably laminated adjacent to at least one side of the base layer, and may be laminated adjacent to both sides of the base layer. For example, a fiber web made of batt fibers can be placed on the base layer and entangled with each other by needle punching to form a batt fiber layer laminated adjacent to the base layer.

(Preferred range of dimensions, etc.)
There are no particular limitations on the fiber length of the batt fibers constituting the batt fiber layer, but from the viewpoint of abrasion resistance, it is preferably 20 mm to 120 mm, more preferably 30 mm to 120 mm, and even more preferably 40 mm to 120 mm.

There are no particular limitations on the fineness of the batt fibers that make up the batt fiber layer, but from the standpoint of abrasion resistance, it is preferably 1 dtex to 10 dtex, more preferably 2 dtex to 8 dtex, and even more preferably 3 dtex to 6 dtex.

There is no particular limitation on the basis weight of the batt fiber layer, but from the viewpoint of abrasion resistance, the basis weight of at least one of the batt fiber layers is preferably 350 g/m ² to 5,500 g/m ² , more preferably 540 g/m ² to 5,500 g/m ² , and even more preferably 680 g/m ² to 5,500 g/m ² .
When the felt material according to the embodiment of the present invention includes two or more batt fiber layers, it is preferable that all of the layers satisfy the above-mentioned basis weight.

There is no particular limitation on the thickness of the batt fiber layer, but from the viewpoint of abrasion resistance, the thickness is preferably 1 mm to 16 mm, more preferably 1.5 mm to 16 mm, and even more preferably 2 mm to 16 mm.
When the felt material according to the embodiment of the present invention includes two or more batt fiber layers, it is preferable that each of them satisfies the above thickness.

(Laminated batt fiber layer)
When the felt material according to the embodiment of the present invention includes a laminated batt fiber layer, the heat-resistant batt fiber layer may be disposed so as to be included in the laminated batt fiber layer, or may be disposed outside the laminated batt fiber layer. In either case where the heat-resistant batt fiber layer is disposed so as to be included in the laminated batt fiber layer, or where the heat-resistant batt fiber layer is disposed outside the laminated batt fiber layer, it is preferable that the felt material includes the heat-resistant batt fiber layer so as to be located at the outermost position in the stacking direction.
For example, a layer structure of a laminated batt fiber layer including a heat-resistant batt fiber layer and an additional batt fiber layer can be such that the heat-resistant batt fiber layer is positioned at the outermost side in the stacking direction of the felt material, and the heat-resistant batt fiber layer or the additional batt fiber layer is positioned adjacent to it.

Similarly, when the laminated batt fiber layer is configured to include a heat-resistant batt fiber layer and an additional batt fiber layer, the fiber that configures the additional batt fiber layer may be, for example, at least one type of fiber selected from the group consisting of aramid fiber, carbon fiber, polyparaphenylene benzobisoxazole fiber, polyimide fiber, fluorine fiber, glass fiber, and polyphenylene sulfide fiber. Of these, aramid fiber is preferred from the viewpoint of abrasion resistance.

[Base layer]
The felt material according to the embodiment of the present invention comprises one or more substrate layers.
The fibers constituting the base material layer are not particularly limited, but from the viewpoint of strength and heat resistance, it is preferable that the fiber be at least one type of fiber selected from the group consisting of aramid fiber, polyphenylene oxadiazole fiber, polyoxadiazole fiber, polyparaphenylene benzobisoxazole fiber, and polyimide fiber, more preferably aramid fiber, polyphenylene oxadiazole fiber, polyoxadiazole fiber, or a combination thereof, and even more preferably aramid fiber.

The felt material according to the embodiment of the present invention may include only one base layer, or may include two or more base layers. From the viewpoint of dimensional stability and strength, it is preferable that the felt material includes two or more base layers.
When the felt material according to an embodiment of the present invention includes two or more substrate layers, all of the substrate layers may be adjacent to each other, or a layer other than the substrate layer may be included between the substrate layers, and further, a pair of substrate layers may be adjacent to each other and another pair of substrate layers may include a layer other than the substrate layer between them.

In addition, even if two or more layers made of the same material are adjacent to each other, they form two or more base layers that are independent and different from each other.

The base layer can be made of, for example, a woven fabric, a nonwoven fabric, or a lattice material. The woven fabric, the nonwoven fabric, and the lattice material may be formed using spun yarn or filament yarn obtained from fibers. When the base layer is a woven fabric, the weave of the woven fabric is not particularly limited, and any of plain weave, twill weave, satin weave, and multi-layer weave using these can be used.
When the felt material according to the embodiment of the present invention comprises two or more substrate layers, each layer may be made of the above-mentioned woven fabric, nonwoven fabric or lattice material.

There is no particular restriction on the thickness of the substrate layer, but from the viewpoint of strength, it is preferably 0.1 mm to 3 mm, more preferably 0.15 mm to 2 mm, and even more preferably 0.2 mm to 1 mm.
When the felt material according to the embodiment of the present invention includes two or more base layers, it is preferable that each of the base layers satisfies the above thickness.

There is no particular restriction on the basis weight of the base layer, but from the viewpoint of smoothness, it is preferably 50 g/m ² to 500 g/m ² , more preferably 60 g/m ² to 300 g/m ² , and even more preferably 70 g/m ² to 200 g/m ² .
When the felt material according to the embodiment of the present invention includes two or more base layers, it is preferable that each of the base layers satisfies the above-mentioned basis weight.

From the standpoint of dimensional stability and strength, it is preferable that the felt material according to the embodiment of the present invention includes two or more substrate layers each consisting of one layer.

[Other layers]
In addition to the substrate layer and the batt fiber layer, the felt material according to the embodiment of the present invention may include other layers, such as film layers, paper layers, sheets, foams, and the like.
The felt material according to the embodiment of the present invention preferably comprises only a base layer and a batt fiber layer, and more preferably comprises only a base layer and a heat resistant batt fiber layer.

[shape]
The felt material according to the embodiment of the present invention may be in various shapes depending on its use, for example, in the shape of a flat plate, a belt or a cylinder.

[Application]
The felt material according to the embodiment of the present invention has high heat resistance and durability, and is therefore suitable for use as a transport material for transporting objects in a high-temperature state, such as metals (aluminum, iron, etc.), glass, ceramics, etc., at temperatures of 200°C to 500°C.
Further, examples of such applications include a conveyor roll cover material used in the production of aluminum extrusion profiles, and a roll cover material for continuous hot-dip galvanized steel sheet lines (CGL).

<Transportation materials>
A carrier material according to an embodiment of the present invention includes the felt material described above.
Hereinafter, preferred embodiments of the carrier according to the present invention will be described with reference to the drawings.

Figure 9 is a schematic diagram showing an example of a felt material 100 according to an embodiment of the present invention used as a conveyor belt material during the manufacture of aluminum extrusion profiles. In this example, the felt material 100 is in the form of an endless belt. In the example shown in Figure 9, the felt material 100 has a base layer 120 and a laminated batt fiber layer 110. The laminated batt fiber layer 110 is a layer in which a heat-resistant batt fiber layer and an additional batt fiber layer are laminated together so that the heat-resistant batt fiber layer is located at the outermost side in the stacking direction.

Figure 10 is a schematic diagram showing an example of a felt material 200 according to an embodiment of the present invention used as a conveying roll cover material during the manufacture of aluminum extrusion profiles. In this example, the felt material 200 has a cylindrical shape. In the example shown in Figure 10, the felt material 200 has a base layer 220 and a laminated batt fiber layer 210. The laminated batt fiber layer 210 is a layer in which a heat-resistant batt fiber layer and an additional batt fiber layer are laminated so that the heat-resistant batt fiber layer is located at the outermost side in the stacking direction.

Figure 11 is a schematic diagram showing an example of a felt material 300 according to an embodiment of the present invention used as a roll cover material for a continuous hot-dip galvanized steel line (CGL). In this example, the felt material 300 has a cylindrical shape. In the example shown in Figure 11, the felt material 300 has a base layer 320 and a laminated batt fiber layer 310. The laminated batt fiber layer 310 is a layer in which a heat-resistant batt fiber layer and an additional batt fiber layer are laminated so that the heat-resistant batt fiber layer is located at the outermost side in the stacking direction.

The heat resistance and durability that the transport material should have is usually sufficient to transport objects at temperatures between 200 and 400°C. However, in recent years, there has been a demand for transporting objects at higher temperatures, for example, transport materials capable of transporting objects at temperatures between 400 and 550°C. This has led to increased demand for transport materials with higher heat resistance and durability.

The carrier material according to the embodiment of the present invention is equipped with the above-mentioned felt material, and therefore has higher heat resistance and durability than conventional products, and can fully meet such requirements.

<Method of manufacturing felt material>
A method for producing a felt material according to an embodiment of the present invention preferably includes the following steps (a) and (b) in this order:
(a) disposing a fibrous web of batt fibers on at least one surface of a substrate layer;
(b) entangling the fibrous web and the substrate layer with each other to form a batt fiber layer adjacent to the substrate layer.

In the method for producing a felt material according to an embodiment of the present invention, at least one of the batt fiber layers is a heat-resistant batt fiber layer containing at least one type of fiber selected from the group consisting of polyphenylene oxadiazole fiber and polyoxadiazole fiber.

The details and preferred aspects of the base layer, batt fiber, fiber web, and batt fiber layer used in the manufacturing method of the felt material according to the embodiment of the present invention are the same as those described above.

The method for producing a felt material according to an embodiment of the present invention may be modified as appropriate depending on the specific form of the felt material to be produced.
For example, when the batt fiber layer is composed of multiple layers, i.e., when two or more layers made of the same material are entangled to form one batt fiber layer, or when two or more layers made of different materials are entangled to form separate batt fiber layers, the batt fiber layer may be formed by using a fiber web in step (b) in which multiple fiber webs are entangled in advance. Alternatively, after entangling the fiber web and the base layer in step (b), the batt fiber layer may be formed by entangling another fiber web made of the same or different material with the fiber web.

The present invention will be explained in more detail below with reference to examples, but the present invention is not limited to these examples.

[Example 1] Base layer: aramid fiber / Additional batt fiber layer: aramid fiber (base layer side) / Heat-resistant batt fiber layer: POD fiber (outermost in the lamination direction)
(Formation of Base Layer)
A spun yarn of aramid fiber (product name: Conex; meta-aramid fiber manufactured by Teijin Limited) was woven into a plain weave to form a base layer. The thickness of the base layer was 0.5 mm and the basis weight was 160 g/ ^m2 .

(Formation of heat-resistant batt fiber layer and additional batt fiber layer and preparation of felt material)
A fiber web (fiber length: 51 mm; fineness: 2.5 dtex) made of aramid fiber (trade name: Kevlar (registered trademark); para-aramid fiber manufactured by DuPont-Toray Co., Ltd.) was laminated on one side of the substrate layer prepared above, and needle punched. Furthermore, a fiber web (fiber length: 64 mm; fineness: 4.4 dtex) made of poly(m-phenylene)(p-phenylene)oxadiazole fiber (POD fiber) (trade name: PODRUN; manufactured by Jiangsu Pod New Material Co., Ltd.) was laminated on the fiber web, and needle punched to prepare a felt material according to Example 1. The felt material according to Example 1 is shown diagrammatically in FIG. 1.

The felt material according to Example 1 includes a laminated batt fiber layer consisting of a heat-resistant batt fiber layer (a layer of POD fiber) and an additional batt fiber layer (a layer of aramid fiber). Of the two layers constituting the laminated batt fiber layer, the additional batt fiber layer is located on the substrate layer side, and the heat-resistant batt fiber layer is located on the outermost side in the lamination direction of the felt material. The heat-resistant batt fiber layer has a thickness of 3 mm and a basis weight of 1200 g/ ^m2 , and the additional batt fiber layer has a thickness of 9 mm and a basis weight of 3600 g/ ^m2 .

[Example 2] Base material layer: aramid fiber/heat-resistant batt fiber layer: POD fiber A felt material according to Example 2 was produced in the same manner as in Example 1, except that a fiber web made of POD fiber was used instead of the fiber web made of aramid fiber in forming the batt fiber layer. The felt material according to Example 2 is shown diagrammatically in FIG.

The heat-resistant batt fiber layer of the felt material according to Example 2 was formed by needle punching the same fiber web (POD fiber). In the production of the felt material, the fiber web (POD fiber) on the base layer side and the base layer were entangled with each other, and then the same fiber web (POD fiber) was entangled with the fiber web to form one heat-resistant batt fiber layer. The thickness of the heat-resistant batt fiber layer was 12 mm, and the basis weight was 4800 g/ ^m2 .

[Example 3] Base layer: aramid fiber / Additional batt fiber layer: carbon fiber and aramid fiber (base layer side) / Heat-resistant batt fiber layer: POD fiber (outermost in the stacking direction)
A felt material according to Example 3 was produced in the same manner as in Example 1, except that in forming the additional batt fiber layer, a fiber web containing 70 mass % of a fiber web (fiber length: 51 mm; fineness: 2.2 dtex) made of carbon fiber (trade name: Pyromex (registered trademark); manufactured by Teijin Ltd.) and 30 mass % of a fiber web made of aramid fiber was used instead of the fiber web made of aramid fiber. The felt material according to Example 3 is shown diagrammatically in FIG. 1.

The felt material according to Example 3 includes a laminated batt fiber layer consisting of a heat-resistant batt fiber layer (a layer of POD fiber) and an additional batt fiber layer (a layer of carbon fiber). Of the two layers constituting the laminated batt fiber layer, the additional batt fiber layer is located on the substrate layer side, and the heat-resistant batt fiber layer is located on the outermost side in the lamination direction of the felt material. The heat-resistant batt fiber layer has a thickness of 3 mm and a basis weight of 1200 g/ ^m2 , and the additional batt fiber layer has a thickness of 9 mm and a basis weight of 3600 g/ ^m2 .

[Example 4] Base layer: POD fiber / Additional batt fiber layer: Aramid fiber (base layer side) / Heat-resistant batt fiber layer: POD fiber (outermost in the lamination direction)
A felt material according to Example 4 was produced in the same manner as in Example 1, except that a spun yarn made of POD fiber was used instead of a spun yarn made of aramid fiber in forming the base layer. The felt material according to Example 4 is shown diagrammatically in FIG.

The felt material according to Example 4 includes a laminated batt fiber layer consisting of a heat-resistant batt fiber layer (a layer of POD fiber) and an additional batt fiber layer (a layer of aramid fiber). Of the two layers constituting the laminated batt fiber layer, the additional batt fiber layer is located on the substrate layer side, and the heat-resistant batt fiber layer is located on the outermost side in the lamination direction of the felt material. The heat-resistant batt fiber layer has a thickness of 3 mm and a basis weight of 1200 g/ ^m2 , and the additional batt fiber layer has a thickness of 9 mm and a basis weight of 3600 g/ ^m2 .

[Example 5] Base layer: aramid fiber / Additional batt fiber layer: aramid fiber (base layer side) / Heat-resistant batt fiber layer: POD fiber (outermost in the lamination direction)
A felt material according to Example 5 was produced in the same manner as in Example 1, except that in forming the heat-resistant batt fiber layer and the additional batt fiber layer, the amounts of the fiber web made of POD fiber and the fiber web made of aramid fiber used were half those of Example 1. The felt material according to Example 5 is shown diagrammatically in FIG.

The felt material according to Example 5 includes a laminated batt fiber layer consisting of a heat-resistant batt fiber layer (a layer of POD fiber) and an additional batt fiber layer (a layer of aramid fiber). Of the two layers constituting the laminated batt fiber layer, the additional batt fiber layer is located on the substrate layer side, and the heat-resistant batt fiber layer is located on the outermost side in the lamination direction of the felt material. The heat-resistant batt fiber layer has a thickness of 1.5 mm and a basis weight of 600 g/ ^m2 , and the additional batt fiber layer has a thickness of 4.5 mm and a basis weight of 1800 g/ ^m2 .

[Comparative Example 1] Base layer: aramid fiber / Additional batt fiber layer: aramid fiber (base layer side) / Additional batt fiber layer: PI fiber (outermost in the lamination direction)
A felt material according to Comparative Example 1 was produced in the same manner as in Example 1, except that a fiber web (fiber length: 64 mm; fineness: 6.7 dtex) made of PI fiber (trade name: YILUN; manufactured by Changchun Hippolyking Co., Ltd.) was used instead of the fiber web made of POD fiber to form the additional batt fiber layer. The felt material according to Comparative Example 1 is shown diagrammatically in FIG.

The felt material according to Comparative Example 1 includes a laminated batt fiber layer consisting of an additional batt fiber layer (PI fiber layer) and another additional batt fiber layer (aramid fiber layer). Of the two layers constituting the laminated batt fiber layer, the aramid fiber layer is located on the substrate layer side, and the PI fiber layer is located on the outermost side in the lamination direction of the felt material. The additional batt fiber layer (PI fiber layer) had a thickness of 3 mm and a basis weight of 1200 g/ ^m2 , and the other additional batt fiber layer (aramid fiber layer) had a thickness of 9 mm and a basis weight of 3600 g/ ^m2 .

[Comparative Example 2] Base layer: aramid fiber / Additional batt fiber layer: aramid fiber (base layer side) / Additional batt fiber layer: aramid fiber (outermost in the stacking direction)
A felt material according to Comparative Example 2 was produced in the same manner as in Example 1, except that in forming the additional batt fiber layer, a fiber web (fiber length: 51 mm; fineness: 3.8 dtex) made of aramid fiber (trade name: Technora (registered trademark); para-aramid fiber manufactured by Teijin Limited) was used instead of the fiber web made of POD fiber. The felt material according to Comparative Example 2 is shown diagrammatically in FIG. 12.

The felt material according to Comparative Example 2 includes a laminated batt fiber layer including an additional batt fiber layer (aramid fiber layer) and another additional batt fiber layer (aramid fiber layer). The two additional batt fiber layers are made of different aramid fibers, and therefore each constitutes an independent additional batt fiber layer. Of the two layers constituting the laminated batt fiber layer, the layer of aramid fiber (Kevlar (registered trademark)) is located on the substrate layer side, and the layer of aramid fiber (Technora (registered trademark)) is located on the outermost side in the lamination direction of the felt material. The additional batt fiber layer (aramid fiber (Technora) layer) had a thickness of 3 mm and a basis weight of 1200 g/ ^m2 , and the other additional batt fiber layer (aramid fiber (Kevlar) layer) had a thickness of 9 mm and a basis weight of 3600 g/ ^m2 .

[Comparative Example 3] Base layer: aramid fiber / Additional batt fiber layer: aramid fiber (base layer side) / Additional batt fiber layer: aramid fiber (outermost in the stacking direction)
A felt material according to Comparative Example 3 was produced in the same manner as in Example 1, except that in forming the additional batt fiber layer, a fiber web (fiber length: 51 mm; fineness: 2.5 dtex) made of aramid fiber (trade name: Twaron (registered trademark); para-aramid fiber manufactured by Teijin Limited) was used instead of the fiber web made of POD fiber. The felt material according to Comparative Example 3 is shown diagrammatically in FIG. 12.

The felt material according to Comparative Example 3 includes a laminated batt fiber layer including an additional batt fiber layer (aramid fiber layer) and another additional batt fiber layer (aramid fiber layer). The two additional batt fiber layers are made of different aramid fibers, and therefore each constitutes an independent additional batt fiber layer. Of the two layers constituting the laminated batt fiber layer, the layer of aramid fiber (Kevlar (registered trademark)) is located on the substrate layer side, and the layer of aramid fiber (Twaron (registered trademark)) is located on the outermost side in the lamination direction of the felt material. The additional batt fiber layer (aramid fiber (Twaron) layer) had a thickness of 3 mm and a basis weight of 1200 g/ ^m2 , and the other additional batt fiber layer (aramid fiber (Kevlar) layer) had a thickness of 9 mm and a basis weight of 3600 g/ ^m2 .

[Comparative Example 4] Base material layer: aramid fiber/additional batt fiber layer: aramid fiber A felt material according to Comparative Example 4 was produced in the same manner as in Example 1, except that in forming the additional batt fiber layer, a fiber web (fiber length: 51 mm; fineness: 2.5 dtex) made of aramid fiber (product name: Kevlar (registered trademark); para-aramid fiber made by Toray DuPont Co., Ltd.) was used instead of the fiber web made of POD fiber. The felt material according to Comparative Example 4 is shown diagrammatically in FIG. 13.

The additional batt fiber layer of the felt material according to Comparative Example 4 was formed by needle punching the same fiber web (aramid fiber). In the preparation of the felt material, the fiber web (aramid fiber) on the base layer side and the base layer were entangled with each other, and then the same fiber web (aramid fiber) was entangled with the fiber web to form one additional batt fiber layer. The additional batt fiber layer had a thickness of 12 mm and a basis weight of 4800 g/ ^m2 .

[Comparative Example 5] Base layer: aramid fiber / Additional batt fiber layer: aramid fiber (base layer side) / Additional batt fiber layer: PBO fiber (outermost in the lamination direction)
A felt material according to Comparative Example 5 was produced in the same manner as in Example 1, except that a fiber web (fiber length: 44 mm; fineness: 1.7 dtex) made of PBO fiber (trade name: ZYLON (registered trademark); manufactured by Toyobo Co., Ltd.) was used instead of the fiber web made of POD fiber to form the additional batt fiber layer. The felt material according to Comparative Example 5 is shown diagrammatically in FIG. 12.

The felt material according to Comparative Example 5 includes a laminated batt fiber layer consisting of an additional batt fiber layer (a layer of PBO fiber) and another additional batt fiber layer (a layer of aramid fiber). Of the two layers constituting the laminated batt fiber layer, the layer of aramid fiber (Kevlar (registered trademark)) is located on the substrate layer side, and the layer of PBO fiber (Zylon (registered trademark)) is located on the outermost side in the lamination direction of the felt material. The additional batt fiber layer (layer of PBO fiber) had a thickness of 3 mm and a basis weight of 1200 g/ ^m2 , and the other additional batt fiber layer (layer of aramid fiber (Kevlar)) had a thickness of 9 mm and a basis weight of 3600 g/ ^m2 .

<Evaluation of heat wear loss>
The felt materials obtained in Examples 1 to 5 and Comparative Examples 1 to 5 were evaluated for heat abrasion loss by the following method.
In this specification, the "vertical" direction of the felt material and the "vertical" direction in the heat abrasion test refer to a direction parallel to the direction in which the base layer and the like are moved to attach the heat-resistant batt fiber layer by needle punching when producing the felt materials of the Examples and Comparative Examples. Also, the "horizontal" direction of the felt material and the "horizontal" direction in the heat abrasion test refer to a direction perpendicular to the "vertical" direction and on the same plane.

Felt material (40 cm length x 20 cm width) was heated (exposed to dry heat) under the following conditions. The unheated felt material and the heated felt material were each cut into pieces measuring 35 cm length x 5 cm width to obtain test pieces.

[Felt material heating (dry heat exposure) conditions]
・Heating temperature: 300℃
Heating time: 20 hours Heating equipment: Asahi Scientific Co., Ltd. High Temp Oven H-80

[Heat wear tester]
In the heat abrasion tester 500 shown in FIG. 14, an abrasion element 520 is fixed on the upper surface of a sample stage 510. The abrasion element 520 is configured to be able to be heated to an arbitrary temperature by a heater 511 provided in the sample stage 510. The heatable abrasion element 520 is supported by a support part 530 so that the outer surface of the heat-resistant batt fiber layer 10 located at the outermost position in the stacking direction of the felt material 1 as a test piece is in contact with the abrasion element 520. Furthermore, a weight 540 is placed on the felt material 1 on the opposite side to the abrasion element 520, so that a predetermined load (stress) is generated between the outer surface of the heat-resistant batt fiber layer 10 and the abrasion element 520. In this state, the felt material 1 is slid horizontally against the abrasion element 520, i.e., in the direction of the arrow in the figure, to abrade the outer surface of the heat-resistant batt fiber layer 10 of the felt material 1.

The obtained test pieces were subjected to a heat abrasion test using the above-mentioned tester under the following conditions, and the heat abrasion loss (mm) was determined as shown below. The results are shown in Tables 1 and 2.
Heat wear loss = thickness before wear - thickness after wear

[Heat wear test conditions]
Test (wearing element) temperature: 400°C (heated by heater)
Number of times the wear piece is moved: 3,000 times (50 times/min)
Test piece sliding distance: 100 mm
Load capacity: 1720g

As shown in Table 1, the felt materials according to Examples 1 to 5 exhibited high heat resistance and durability. The felt materials having such high heat resistance and durability can be suitably used as, for example, a carrier material.
In contrast, as shown in Table 2, the felt materials of Comparative Examples 1 to 5 were inferior in heat resistance and durability.

The felt material of the present invention has high heat resistance and durability, so it can be used as a conveying material for conveying objects in a high-temperature state, such as a conveying belt material or conveying roll cover material during the production of aluminum extrusion profiles, or a roll cover material for a hot-dip galvanized steel sheet line (CGL).

REFERENCE SIGNS LIST 1, 100, 200, 300 Felt material 10 Heat-resistant batt fiber layer 10A Additional batt fiber layer 20 Base material layer 110, 210, 310 Laminated batt fiber layer 120, 220, 320 Base material layer 500 Heat abrasion tester 510 Sample stage 511 Heater 520 Abrasion element 530 Support 540 Weight

Claims (12)

A base layer and a batt fiber layer are provided,
At least one of the batt fiber layers is a heat-resistant batt fiber layer containing at least one type of fiber selected from the group consisting of polyphenylene oxadiazole fiber and polyoxadiazole fiber. The felt material according to claim 1, wherein the heat-resistant batt fiber layer is located on the outermost side in the stacking direction. The felt material according to claim 1, wherein the base layer contains at least one type of fiber selected from the group consisting of aramid fibers, polyphenylene oxadiazole fibers, polyoxadiazole fibers, polyparaphenylene benzobisoxazole fibers, and polyimide fibers. The felt material according to claim 1, having a thickness of 1 mm to 16 mm. The felt material according to claim 1, wherein at least one of the batt fiber layers has a basis weight of 350 g/m ² to 5500 g/m ² . The felt material of claim 1, further comprising an additional batt fiber layer as the batt fiber layer. The felt material of claim 6, wherein the additional batt fiber layer includes at least one fiber selected from the group consisting of aramid fiber, carbon fiber, polyparaphenylene benzobisoxazole fiber, polyimide fiber, fluorine fiber, glass fiber, and polyphenylene sulfide fiber. The felt material according to claim 1, which is flat. The felt material according to claim 1, which is in the form of a belt. The felt material according to claim 1, which is cylindrical in shape. A conveying material comprising the felt material according to any one of claims 1 to 10. A method for producing a felt material according to any one of claims 1 to 10, comprising the following steps (a) and (b) in this order:
(a) disposing a fibrous web of batt fibers on at least one surface of the substrate layer;
(b) entangling the fibrous web and the substrate layer to form the batt fiber layer adjacent the substrate layer.

Images