JP3668389B2 - Method for producing sheet-like laminate having porous substance - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a sheet-like laminate having a porous material, more particularly (in the present specification are collectively referred to as "coal dust") granular or powdered charcoal porous such humidity adjusting function and deodorization function with porous material while preventing scattering of the material was sufficiently ensured, moreover the entire sheet-like laminate relates to a method of manufacturing a sheet-like laminate having a porous material having flexibility.
[0002]
[Prior art]
It is known that charcoal such as bamboo charcoal, which is a porous material, has a humidity adjusting function and a deodorizing function. In recent years, it has been known that far-infrared rays and negative ions are generated, and they are attracting attention and are being used in various fields.
Bamboo charcoal, etc. having the above properties are used by putting granular or powdery materials in a breathable bag or kneading them into synthetic fibers to make knitted fabrics, woven fabrics, nonwoven fabrics, etc. It was.
[0003]
[Problems to be solved by the invention]
However, the conventional usage method as described above has the following problems.
(1) Charcoal powder etc. in a breathable bag body is inconvenient to use and handle, such as when the powder powder scatters out of the bag body during use, etc. .
Moreover, the use was limited only by putting charcoal powder etc. in a bag.
(2) The amount of carbon fiber powder kneaded into synthetic fibers, etc. made into knitted fabric, woven fabric, non-woven fabric, etc. cannot be made into a fibrous form if kneaded too much, so the amount used is limited, so humidity The adjustment function and deodorizing function could not be fully exhibited, and far infrared rays and negative ions were not generated.
[0004]
As a method of preventing the scattering of charcoal powder, etc., and being convenient for use and handling, and holding a larger amount of charcoal powder than kneaded into the fiber, the charcoal powder is sandwiched between sheet members, It paid attention to laminating with a binder with a member to make a sheet-like laminated body.
However, when the carbon powder or the like and the sheet member are joined with a binder, the binder covers the surface of the carbon powder and the like, and the humidity adjustment function and the deodorizing function disappear or decrease, and the binder becomes hard when dried. It was also found inconvenient to use and handle as a sheet.
[0005]
Therefore, the present inventors have further studied, and the amount of binder used is kept to the minimum amount necessary for preventing the scattering of charcoal powder, etc., and the carbon fiber powder and the sheet member are laminated with a felt instead of a binder. It has been found that by adopting the needle punch method used at the time, scattering of charcoal powder and the like can be prevented, and the humidity adjusting function and deodorizing function of the charcoal powder can be sufficiently secured.
Moreover, since the needle punch method forms a large number of fine holes in the entire sheet, the layer made of binder and charcoal powder is in a state where the holes are broken, which increases the surface area and flexibility of the same layer. It was found that it contributes to imparting sex.
In addition, during research, it has been found that a porous substance such as barley stone has the same function as a substance having a humidity adjusting function and a deodorizing function in addition to charcoal powder.
The present invention has been completed based on these findings.
[0006]
Accordingly, an object of the present invention is to prevent the scattering of powdery and granular porous materials, and to sufficiently ensure the humidity adjusting function and deodorizing function of the porous materials, and also has a flexible porous material as a whole. It is providing the manufacturing method of a sheet-like laminated body .
[0007]
[Means for Solving the Problems]
The means of the present invention taken to achieve the above object are as follows.
In the first invention,
A granular or / and powdery porous material and a polymer latex or polymer emulsion are mixed to form a paste-like fluid,
Laminate the coating layer and the fluid, press the layered material and heat it at the same time, evaporate the water in the polymer latex or polymer emulsion in the fluid and dry it, and use this as a binder to bind the porous material. A porous material holding layer with breathability,
By forming a large number of fine holes by the needle punch method on one or two or more coating layers laminated on the upper and lower surfaces of the porous material-containing layer, the layers are integrated and flexible. It is characterized by
It is a manufacturing method of the sheet-like laminated body which has a porous substance.
[0008]
As the porous material, for example, bamboo charcoal, charcoal, coconut husk charcoal, porous ceramic, pumice (porous stone), barley stone or silica gel can be used. In addition, the porous material can be used alone, or a plurality of materials can be mixed and used.
Among the porous materials, bamboo charcoal is preferable because it has a strong humidity adjusting function and a deodorizing function and generates far infrared rays and negative ions sufficiently.
[0009]
A material having elasticity is preferable as the material for the binder, and examples thereof include polymer latex (or emulsion) such as natural rubber, synthetic rubber, and plastic. As the polymer latex of plastic, latex such as acrylic resin, urethane resin, vinyl chloride resin that becomes an elastic body after drying is preferable.
However, the latex is not limited to the above.
[0010]
Examples of the material constituting the coating layer include knitted fabric, woven fabric, and non-woven fabric.
The coating layer is usually arranged one layer at a time on the upper and lower surfaces of the porous substance-holding layer, but one or more layers are arranged on the above layer for the purpose of improving the added value of the product such as decoration and antibacterial. You can also.
When used in combination with other materials, the coating layer may be only the upper surface or the lower surface.
[0011]
A needle punch method can be used as a means for laminating and integrating a coating layer on the upper and lower surfaces of the porous substance-holding layer. Further, the covering layers can be continuously sewed like quilting, or partly sewed like a futon.
When the needles are used for stacking as described above, a large number of fine holes are formed by the needles in the coating layer and the porous substance-holding layer. Due to the formation of the pores, the surface area of the porous substance holding layer is increased. In addition, the hole portion communicates with the outside air, improving the humidity adjustment function and the deodorizing function.
Moreover, since it becomes easy to bend | fold from the part of a hole and a hole is formed over the whole surface of a porous substance holding layer, it contributes also to the softness | flexibility provision of a laminated body.
[0012]
Examples of the material of the knitted fabric, woven fabric or non-woven fabric include synthetic fibers such as polyester fiber, polypropylene fiber, acrylic fiber, polyethylene fiber, polyamide fiber and acetate fiber, natural fibers such as cotton, wool, hemp and bamboo, and glass fiber. Inorganic fibers such as porous fibers can be used.
As the basis weight, those having a weight of 50 to 1200 g / m ² are preferably used. However, the basis weight is not limited to the above.
[0013]
In the case of a non-woven fabric, the above materials can be used alone, but the respective materials can also be mixed and used. For example, by mixing synthetic fibers with natural fibers or inorganic fibers, the mixed fibers can be strongly bonded to each other due to the heat-fusibility of the synthetic fibers.
As a result, the strength as a non-woven fabric can be increased, and deformation during use, surface rubbing, and generation of pills can be prevented. It is also possible to prevent fluff from standing during washing.
[0014]
In order to impart the above properties to the nonwoven fabric, the synthetic fiber is preferably 5 to 80% by weight, and the other fibers are preferably 95 to 20% by weight.
When the synthetic fiber is less than 5% by weight, the above properties are hardly exhibited, and when it exceeds 80% by weight, it becomes hard and the touch feeling tends to deteriorate.
[0015]
The porous substance-containing layer, for example, a layer formed using bamboo charcoal, is preferably formed using 5 to 80% by weight bamboo charcoal and 95 to 20% by weight binder binding the bamboo charcoal. Within the above range, a desired layer is easily formed, and at the same time, the properties of bamboo charcoal can be sufficiently exhibited.
If the bamboo charcoal is less than 5% by weight, the porous substance-bearing layer cannot sufficiently have a humidity adjusting function and a deodorizing function, and far infrared rays and negative ions cannot be sufficiently generated. If it exceeds 80% by weight, the moldability will be poor and it will be difficult to form a layer.
[0016]
Examples of the material used for the anti-slip treatment include natural rubber, synthetic rubber such as SBR and NBR, plastic such as polyurethane and acrylic resin, and the like. However, it is not limited to the above materials.
[0017]
As a chemical | medical agent which provides antibacterial property, Na-pentachlorophenate, a triphenyl compound, pyrithione zinc, a cyclic nitrogen type compound etc. can be used, for example. However, it is not limited to the said medicine.
[0018]
(Function)
A sheet-like laminate includes a porous material-holding layer and a covering layer having flexibility and air permeability, such as a knitted fabric, a woven fabric, or a non-woven fabric, laminated and integrated on the upper surface and the lower surface of the porous material-containing layer. In the porous material-retaining layer, a porous material such as granular or powdery bamboo charcoal, charcoal, coconut shell charcoal, porous ceramic, pumice (porous stone) or silica gel is bonded with a binder, Breathability is given by the fine hole.
[0019]
Therefore, it is possible to prevent the granular or powdery porous material from separating and scattering during use.
In addition, even if the granular or powdery porous material is formed as a layer, air permeability is provided by a large number of fine holes, so the properties of the porous material are not impaired, and the humidity adjustment function Deodorizing function can be fully demonstrated. Further, those that generate far infrared rays and negative ions can sufficiently generate far infrared rays and negative ions.
[0020]
A porous material holding layer and a covering layer having flexibility and air permeability, such as a knitted fabric, a woven fabric or a nonwoven fabric, laminated on the upper and lower surfaces of the porous material holding layer are integrated by a needle punch method. A lot of fine irregularities are formed on the side of the hole made in the porous material holding layer by the needle barb (which can hook the object in contact when moving with a small barb). Yes.
[0021]
Therefore, the surface area of the porous substance-holding layer is increased due to the above-mentioned numerous fine irregularities, and a large number of porous substances constituting the porous substance-holding layer also appear on the side surface, and the humidity adjusting function and deodorizing function Can be sufficiently exhibited, and far infrared rays and negative ions can be generated more sufficiently.
Furthermore, the holes formed in the porous substance-holding layer are easily bent at that portion and contribute to imparting flexibility of the laminate. Therefore, when a sheet-like laminated body is used for bedding, it is familiar to the body and the feeling of use is improved, and it is easy to wind and store.
[0022]
In the case where the coating layer is a heat-fusible knitted fabric, woven fabric or non-woven fabric, the fibers constituting the coating layers on the upper and lower surfaces of the sheet-like laminate are strongly bonded to each other by the heat-fusibility. The strength can be increased, and the sheet-like laminate in use can be prevented from being deformed, rubbing on the surface, generation of pills, and the like. It is also possible to prevent fluff from occurring during washing.
[0023]
When the porous material-holding layer contains 5 to 80% by weight of bamboo charcoal and 95 to 20% by weight of the binder that binds the bamboo charcoal, the moldability is good. Therefore, the porous material-holding layer is formed as desired. At the same time, the properties of bamboo charcoal are not impaired, the humidity adjusting function and the deodorizing function can be sufficiently exhibited, and far infrared rays and negative ions can be sufficiently generated.
[0024]
When the anti-slip treatment is applied, the article can be prevented from slipping by placing it on the lower surface of the article used in a slippery state.
For example, if a floor covering made of plastic paint or a floor with plastic tiles is placed on a floor in a room with a rug, cushion, cushion, bedcloth, etc., the rug will slid when used. May fall.
However, by laying a sheet-like laminate on the lower surface of the rugs made of cocoon grass, it is possible to prevent the user from falling down so that the rugs do not slip.
[0025]
When the coating layer has antibacterial properties, generation of wrinkles and bacteria can be prevented.
[0026]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described in more detail with reference to the drawings.
FIG. 1 is a perspective view of a sheet-like laminate according to the present invention,
FIG. 2 is a partial sectional view of a sheet-like laminate according to the present invention,
FIG. 3 is an enlarged explanatory view of the air holes formed in the sheet-like laminate.
In the figure, S is a sheet-like laminate. The sheet-like laminate S is composed of a porous material holding layer 1, a non-woven fabric 2 that is laminated and integrated on the upper surface of the porous material holding layer 1, and a coating layer that is laminated and integrated on the lower surface. A non-woven fabric 3 and a rubber layer 4 laminated and integrated on the lower surface of the non-woven fabric 3 are provided. The rubber layer 4 is formed by spraying a rubber liquid on the nonwoven fabric 3.
In the present embodiment, the nonwoven fabric 3 has the rubber layer 4, but the rubber layer 4 is not necessary when anti-slip is unnecessary.
[0027]
In the porous substance-holding layer 1, 70% by weight of granular or powdery bamboo charcoal (diameter: 0.8 to 2 mm) 11 is partially bonded with a binder 12 made of 30% by weight of an acrylic resin, and is air permeable. Have The unit weight of the porous substance-holding layer 1 is 300 g / m ² .
[0028]
The nonwoven fabric 2 has a basis weight of 140 g / m ² and is constituted by entanglement of 40% by weight of natural fibers and 60% by weight of polyester fibers.
The nonwoven fabric 3 has a basis weight of 250 g / m ² and is constituted by bonding 70% by weight of polyester fibers with 30% by weight of silicone resin.
The rubber layer 4 is a vulcanized NBR layer and has anti-slip properties.
In addition, the said nonwoven fabric 2, the nonwoven fabric 3, and the rubber layer 4 are antimicrobial-treated with Na-pentachlorophenate.
[0029]
The sheet-like laminate S is composed of a porous material-holding layer 1, a nonwoven fabric 2 and a nonwoven fabric 3 including a rubber layer 4 that are integrally fixed together by a needle punch method. Fine holes 5 are formed. On the side surface of the hole 5, there are many scratched irregularities 51 formed by needle barbs.
[0030]
Here, the manufacturing method of the sheet-like laminated body S is demonstrated with reference to FIG. 1 thru | or FIG.
Granular or powdery bamboo charcoal (diameter 0.8-2 mm) 11 is mixed in an acrylic resin latex to form a paste-like fluid. This fluid is adjusted so that bamboo charcoal is 70% by weight and acrylic resin is 30% by weight when the acrylic resin latex is dried to be a solid.
[0031]
The fluid is laminated on the upper surface of the nonwoven fabric 3. As described above, the laminating amount of the fluid is set so that the unit weight of the porous material holding layer 1 is 300 g / m ² when the acrylic resin latex is dried to be a solid. .
Further, the nonwoven fabric 2 is laminated on the upper surface of the laminated fluid.
The non-woven fabric 2 and the non-woven fabric 3 are previously coated with Na-pentachlorophenate to give antibacterial properties.
[0032]
The layer laminated on the three layers is pressed and heated at the same time, and the moisture of the acrylic resin latex in the fluid is evaporated and dried. When the acrylic resin is dried, it becomes a binder 12 and the bamboo charcoal 11 is partially bonded to form a porous substance-holding layer 1 having air permeability.
After pressing and heating as described above, the rubber layer 4 made of NBR is sprayed on the lower surface of the nonwoven fabric 3 to impart anti-slip properties. The rubber layer 4 can also be formed by adhering a rubber sheet. In order to further increase the slip resistance, an uneven pattern can be provided on the lower surface of the rubber layer 4.
In addition, Na-pentachlorophenate can be applied to the lower surface of the rubber layer 4 in advance in order to impart antibacterial properties.
[0033]
Then, the needle laminated on the four layers by needle punching is pierced with the needle from the nonwoven fabric 2 toward the rubber layer 4, and the whole is integrated and at the same time a large number of holes 5 having air permeability. Form. The side surface of the hole 5 is formed with a large number of irregularities 51 that are scratched by a needle barb, and the four layers are integrated.
[0034]
(Work)
The operation of the embodiment of the present invention will be described with reference to FIGS.
In the porous substance-holding layer 1 constituting the sheet-like laminate S, the granular or powdery bamboo charcoal 11 is bound by the binder 12, and the bamboo charcoal 11 is detached from the porous substance-holding layer 1 during use. Can be prevented.
Therefore, it is possible to prevent the bamboo charcoal 11 from being scattered around and the use place and the like from becoming dirty.
[0035]
Further, since the granular or powdery bamboo charcoal 11 is partially bonded by the binder 12, a part of the bamboo charcoal 11 is exposed and communicates with the outside of the sheet-like laminate 1. In addition, the porous material holding layer 1, the nonwoven fabric 2, the nonwoven fabric 3, and the rubber layer 4 are formed with holes 5, and on the side surfaces thereof, a number of irregularities 51 such as scratches are formed. Due to the unevenness 51, the surface of the bamboo charcoal 11 is largely exposed, and the surface of the bamboo charcoal 11 communicates with the outside through the holes 5.
Accordingly, the surface area of the bamboo charcoal 11 in contact with the outside air is large, the properties of the bamboo charcoal 11 are not impaired, the humidity adjusting function and the deodorizing function can be fully exhibited, and far infrared rays and negative ions are sufficiently generated. Can be made.
[0036]
The nonwoven fabric 3 uses 70% by weight of heat-fusible polyester fibers, and the nonwoven fabric 2 uses 60% by weight of heat-fusible polyester fibers.
Therefore, the fibers constituting each nonwoven fabric are strongly bonded to each other to increase the strength of the sheet-like laminate S. Therefore, it is possible to prevent the sheet-like laminate S from being deformed, the surface from being worn away, and the generation of pills. It is also possible to prevent fluff from occurring during washing.
[0037]
Since the rubber layer 4 made of NBR is formed on the lower surface of the nonwoven fabric 3, the sheet-like laminate 1 has anti-slip properties.
Moreover, since Na-pentachlorophenate is apply | coated to the surface of the nonwoven fabric 2, the nonwoven fabric 3, and the rubber layer 4, it also has antimicrobial property.
[0038]
Note that the terms and expressions used in the present specification are merely explanatory and are not restrictive, and do not exclude terms and expressions equivalent to the above terms and expressions. The present invention is not limited to the illustrated embodiments, and various modifications can be made within the scope of the claims.
[0039]
【The invention's effect】
According to the present invention, a sheet having a porous material that prevents the powdery or granular porous material from scattering and sufficiently secures the humidity adjusting function and the deodorizing function of the porous material and that has flexibility as a whole. The manufacturing method of a laminated body can be provided.
[Brief description of the drawings]
FIG. 1 is a perspective view of a sheet-like laminate according to the present invention.
FIG. 2 is a partial cross-sectional view of a sheet-like laminate according to the present invention.
FIG. 3 is an enlarged explanatory view of a vent hole formed in a sheet-like laminate.
[Explanation of symbols]
S sheet-like laminated body 1 porous substance holding layer 11 bamboo charcoal 12 binder 2 non-woven fabric 3 non-woven fabric 4 rubber layer 5 vent hole 51 unevenness

Claims (1)

A granular or / and powdery porous material and a polymer latex or polymer emulsion are mixed to form a paste-like fluid,
  Laminate the coating layer and the fluid, press and heat the laminated material at the same time, evaporate the moisture of the polymer latex or polymer emulsion in the fluid and dry it, and bind the porous material using this as a binder A porous material holding layer with breathability,
  By forming a large number of fine holes by needle punching on one or two or more coating layers laminated on the upper and lower surfaces of the porous material retaining layer, the layers are integrated and flexible. It is characterized by
  A method for producing a sheet-like laminate having a porous material.

Images