Heat-resistant felt material and method for producing heat-resistant felt material

Abstract

The present invention provides a heat-resistant felt material that prevents needle breakage during needling, and has high heat resistance and durability, and a method for producing the heat-resistant felt material. The heat-resistant felt material includes: a base material layer having at least one layer of a base material; and a lamination web layer having at least one layer of a web for lamination, the lamination web layer being entangled and integrated with an adjacent layer of the base material layer on an outer surface of the base material layer by needling, the base material including a base cloth having filaments containing one or more fibers selected from the group consisting of aramid fibers and poly-p-phenylene benzobisoxazole fibers, the base cloth having a density of 0.60 g / cm 3 The following.

Description

TECHNICAL FIELD

[0001] The present application relates to a heat-resistant felt material and a method for producing a heat-resistant felt material. BACKGROUND

[0002] In order to perform press forming or heat-pressing of a laminate, heat-pressing is performed in the process of producing an electrical component having a laminated structure such as a printed circuit board. For example, after laminating a resin-made prepreg and a copper foil or the like, a printed circuit board is produced by heat-pressing using a hot plate. In the heat-pressing, the prepreg is generally temporarily reduced in viscosity by heating and returns to a liquid state, and then gradually hardens. In such heat-pressing, it is required that the distribution of pressure and temperature applied to the laminate be uniform.

[0003] Therefore, in heat-pressing, a heat-pressing cushioning material is generally used as a heat-resistant felt material. The heat-resistant felt material is arranged between a hot plate and a laminate, and the pressure distribution and temperature distribution in heat-pressing can be made uniform by dispersing the pressure and temperature applied from the hot plate in the planar direction. Thus, in order to make the pressure distribution and temperature distribution uniform, the heat-pressing cushioning material as a heat-resistant felt material is required to have basic properties such as appropriate deformation followability, cushioning property, thermal conductivity, dimensional stability, durability, and heat resistance.

[0004] In Patent Literature 1, a heat-pressing cushioning material, that is, a heat-resistant felt material, is disclosed, and as a part of the constituent elements of the heat-pressing cushioning material, a woven fabric layer and a nonwoven fabric layer are listed, and a bulking yarn is used in at least one of the warp yarns or weft yarns of the woven fabric of the woven fabric layer. Also, in this document, it is disclosed that the bulking yarn can include any one or more fibers selected from the group consisting of glass fibers, meta-aramid fibers, para-aramid fibers, and poly-p-phenylene-benzobisoxazole (hereinafter, referred to as PBO) fibers, and the nonwoven fabric of the nonwoven fabric layer can contain any one or more fibers selected from the group consisting of meta-aramid fibers, para-aramid fibers, and PBO fibers.

[0005] Also, in the production of extruded aluminum profiles, when extruded by an extruder, the extruded aluminum profiles are pulled by a tensioner and moved on a dancing pipe while entering a carrying step. After that, the aluminum profiles are gradually cooled while being carried by a cooling belt and a stretcher belt, and after being shaped by being stretched by the stretcher belts at both ends, the aluminum profiles are carried to a sawing table belt.

[0006] Since the temperature of the extruded aluminum profiles is very high, a heat-resistant felt material can be used in the carrying belts such as the roller cover material of the dancing pipe, the cooling belt, the stretcher belt, and the sawing table belt.

[0007] In Patent Literature 2, a cylinder, that is, a roll cover material as a heat-resistant felt material includes a felt material, and as a constituent element of a cylinder including the felt material, a web is laminated on a fiber base material and the fiber base material. Also, in this document, it is disclosed that the fiber used for the base material or the web can be any one or any plurality of fibers selected from the group consisting of polyester fiber, acrylic fiber, meta-type aramid fiber, para-type aramid fiber, and PBO fiber.

[0008] Further, in the process of manufacturing a steel sheet on a continuous galvanizing line (CGL), a steel sheet treated with zinc pot plating is carried by a top roll located on the downstream side of the zinc pot of the CGL. Generally, in order to prevent zinc from adhering to the top roll or to prevent defects from occurring on the steel sheet, the top roll is coated with a roll cover material as a heat-resistant felt material on the top roll.

[0009] In Patent Literature 3, a cylindrical nonwoven fabric roll for ironmaking as a heat-resistant felt material is disclosed, in which a nonwoven fabric made of PBO fiber is used as a surface layer, a nonwoven fabric made of para-type aramid fiber is used as an inner layer, a cylindrical base fabric made of heat-resistant fiber is arranged on the inner side of the inner layer, and entanglement and integration are performed by needle punching.

[0010] Prior Art Documents

[0011] Patent Literature

[0012] Patent Literature 1: Japanese Patent Application Publication No. 2016-10945

[0013] Patent Literature 2: Japanese Patent Application Publication No. 2002-235270

[0014] Patent Literature 3: Japanese Patent Application Publication No. 2000-64014 SUMMARY

[0015] PROBLEMS TO BE SOLVED BY THE INVENTION

[0016] In a heat-resistant felt material used in a step for manufacturing a printed circuit board when used for punch forming or heat press bonding of a target product, a heat-resistant felt material used in a carrying roll cover or a carrying belt of an extruded aluminum profile, or a heat-resistant felt material used in a roll cover of a CGL needs to have higher heat resistance than ever before due to high temperature at the time of use, and further durability is required from the viewpoint of low cost.

[0017] For example, in the step of manufacturing a printed circuit board, a low-loss substrate for high frequencies corresponding to the 5G mobile communication standard or Advanced Driver-Assistance Systems (ADAS) and the like, which has been adopted in recent years, requires a high heat resistance and durability higher than ever before as a heat-pressing buffer material due to the high temperature of 300°C to 400°C or higher at which the material is heat-pressed.

[0018] Also, in the step of manufacturing an extruded aluminum material, the temperature of the aluminum material immediately after extrusion reaches a high temperature of about 450°C to 550°C, and in particular, the roll cover material for a roll sleeve of a dancer pipe is required to have a high heat resistance and durability higher than ever before.

[0019] Further, in the hot-dip galvanizing step in a CGL, the melting temperature of zinc is about 420°C, and since the temperature of a steel sheet subjected to a gold plating process in a zinc pot is very high, the roll cover material for a roll sleeve of a roll that carries the steel sheet is required to have a high heat resistance and durability higher than ever before.

[0020] The heat-pressing buffer material, roll cover material, and carrying belt described in Patent Documents 1 to 3 and the like use a heat-resistant fiber such as an aramid fiber or a PBO fiber to improve the heat resistance by laminating the heat-resistant fiber on a base material (woven fabric, base fabric) and a web (nonwoven fabric) that are constituent elements thereof.

[0021] Of course, the decomposition temperature (melting point) of the aramid fiber and the PBO fiber is about 400°C to 550°C and about 650°C, respectively, and from the viewpoint of heat resistance, these heat-resistant fibers have excellent heat resistance. However, these heat-resistant fibers are materials that also have high tensile strength and tensile modulus, and when these materials are used as a heat-resistant felt material, defects occur in the manufacturing step. In particular, since the tensile strength and tensile modulus of the PBO fiber are much higher than those of the aramid fiber, the mixing ratio of the PBO fiber of the heat-resistant felt material increases, and when it is used as a main component, the above defects become more pronounced.

[0022] Specifically, the heat-resistant felt material is manufactured by laminating a web on a base material and entangling and integrating them by needling, but in this needling process, since the strength of the needle is lower than that of the heat-resistant fiber, needle breakage occurs. In the case where the needling is continued in the state of needle breakage, the entanglement of the base material and the web and the entanglement between the webs are poor in the portion of the needle breakage, and problems such as peeling between the base material and the web and the falling of fibers from the web occur, and the surface smoothness of the heat-resistant felt material is impaired.

[0023] On the other hand, from the viewpoint of durability of the heat-resistant batt, if the weight per unit area and the thickness of the heat-resistant batt are increased, the corresponding durability is improved, but if the weight per unit area and the thickness are increased, the problem of broken needles becomes more apparent, and as a result, there is a problem that the durability of the heat-resistant batt cannot be improved even if the weight per unit area and the thickness are increased.

[0024] Therefore, the present application has been made in view of the above problems, and it is an object of the present application to prevent broken needles from occurring during needle punching of a heat-resistant batt and to provide a novel and improved heat-resistant batt and a method of manufacturing a heat-resistant batt, which have high heat resistance and high durability at the same time.

[0025] Solution to the problem

[0026] As a result of intensive studies to achieve the above object, the present inventors have found that broken needles can be prevented from occurring during needle punching by specifying the density of a base fabric used in a base material of a heat-resistant batt, and thus completed the present application.

[0027] The gist of the present application is as follows.

[0028] [1] A heat-resistant batt,

[0029] comprising:

[0030] a base material layer having at least one base material; and

[0031] a lamination web layer having at least one web for lamination,

[0032] the lamination web layer being entangled with and integrated with (integrated with) an adjacent layer of the base material layer on the outer surface of the base material layer by needle punching,

[0033] the base material includes a base fabric having a yarn containing a fiber selected from one or more of the group consisting of aramid fibers and poly-p-phenylene benzobisoxazole fibers,

[0034] the density of the base fabric is 0.60 g / cm 3 or more.

[0035] [2] The heat-resistant batt according to [1], wherein the density of the base fabric is 0.45 g / cm 3 or more.

[0036] [3] The heat-resistant batt according to [1] or [2], wherein the density of the base fabric is 0.15 g / cm 3 or more.

[0037] [4] The heat-resistant batt according to any one of [1] to [3], wherein the base material includes at least one cushioning web containing one or more fibers selected from the group consisting of aramid fibers and poly-p-phenylene benzobisoxazole fibers, the fibers being entangled and integrated on at least one face of the base fabric by needling.

[0038] [5] The heat-resistant batt according to [4], wherein the cushioning web contains one or more fibers selected from the group consisting of aramid fibers and poly-p-phenylene benzobisoxazole fibers in a proportion of 50 mass% or more and 100 mass% or less.

[0039] [6] The heat-resistant batt according to any one of [1] to [5], wherein the base fabric has a warp thread count and a weft thread count of 12 threads / inch or more and 57 threads / inch or less, respectively.

[0040] [7] The heat-resistant batt according to any one of [1] to [6], wherein the base fabric has a weight per unit area of 45 g / m 2 or more and 400 g / m 2 or less.

[0041] [8] The heat-resistant batt according to any one of [1] to [7], wherein the base fabric has a thickness of 0.30 mm or more and 0.45 mm or less.

[0042] [9] The heat-resistant batt according to any one of [1] to [8], wherein the laminating web contains one or more fibers selected from the group consisting of aramid fibers and poly-p-phenylene benzobisoxazole fibers in a proportion of 50 mass% or more and 100 mass% or less.

[0043]

[10] The heat-resistant batt according to any one of [1] to [9], wherein the base fabric contains one or more fibers selected from the group consisting of aramid fibers and poly-p-phenylene benzobisoxazole fibers in a proportion of 50 mass% or more and 100 mass% or less.

[0044]

[11] The heat-resistant batt according to any one of [1] to

[10] , wherein the base material layer includes two or more of the base materials.

[0045]

[12] The heat-resistant batt according to any one of [1] to

[11] , wherein the laminating web layer includes two or more of the laminating webs.

[0046]

[13] The heat-resistant batt according to any one of [1] to

[12] , wherein the total weight per unit area of the base fabrics of the base material layer is 90 g / m 2 or more and 1000 g / m2 The following.

[0047]

[14] The heat-resistant batt according to any one of [1] to

[13] , wherein the heat-resistant batt has a weight per unit area of 2000 g / m 2 The following.

[0048]

[15] The heat-resistant batt according to any one of [1] to

[14] , wherein the heat-resistant batt has a weight per unit area of 4000 g / m 2 The following.

[0049]

[16] The heat-resistant batt according to any one of [1] to

[15] , wherein the heat-resistant batt has a flat plate shape.

[0050]

[17] The heat-resistant batt according to any one of [1] to

[15] , wherein the heat-resistant batt has a belt shape.

[0051]

[18] The heat-resistant batt according to any one of [1] to

[15] , wherein the heat-resistant batt has a cylindrical shape.

[0052]

[19] A production method for producing a heat-resistant batt, comprising

[0053] Step (a) of preparing a base material including at least one layer of a base cloth having fibers containing one or more selected from the group consisting of aramid fibers and poly-p-phenylene benzobisoxazole fibers and a density of 0.60 g / cm 3 The following;

[0054] Step (b) of preparing a lamination web; and

[0055] Step (c) of disposing the at least one lamination web obtained in step (b) on at least an outer surface of the base material obtained in step (a) and entangling and integrating by needle punching to obtain a heat-resistant batt.

[0056] Effects of the Invention

[0057] The heat-resistant batt and the production method for the heat-resistant batt having both high heat resistance and high durability can be provided while preventing needle breakage during needle punching of the heat-resistant batt by the above configuration. BRIEF DESCRIPTION OF DRAWINGS

[0058] Figure 1 is a schematic view showing an example of the heat-resistant batt of the first embodiment of the present application.

[0059] Figure 2 is a schematic view showing an example of the heat-resistant batt of the first embodiment of the present application. Figure 1 is a partially enlarged cross-sectional view of the heat-resistant batt shown in

[0060] Figure 3 FIG. 1 is a partial enlarged sectional view showing a modification of the heat-resistant batt material according to the first embodiment of the present application.

[0061] Figure 4 FIG. 2 is a schematic view showing an example of the heat-resistant batt material according to the second embodiment of the present application.

[0062] Figure 5 FIG. 3 is a schematic view showing an example of the heat-resistant batt material according to the third embodiment of the present application.

[0063] Figure 6 FIG. 4 is a schematic view showing an example of the heat-resistant batt material according to the fourth embodiment of the present application.

[0064] Figure 7 FIG. 5 is a schematic view showing an outline of a heating abrasion tester used in the heating abrasion test of the example.

[0065] Explanation of Reference Numerals

[0066] 1, 1A: heat-resistant batt material (heat-pressing cushion material)

[0067] 1B: heat-resistant batt material (carrying roll cover for extruded aluminum section)

[0068] 1C: heat-resistant batt material (carrying belt for extruded aluminum section)

[0069] 1D: heat-resistant batt material (roll cover for CGL)

[0070] 10, 10A, 10B, 10C: base material layer

[0071] 11: base material

[0072] 12: base cloth

[0073] 13: cushioning net

[0074] 14: outer side surface of base material

[0075] 15: inner side surface of base material

[0076] 16, 16A, 16B, 16C: outer side surface of base material layer

[0077] 17, 17A, 17B, 17C: inner side surface of base material layer

[0078] 18: outer side surface of heat-resistant batt material

[0079] 19, 19A, 19B, 19C: inner side surface of heat-resistant batt material

[0080] 20, 20A, 20B, 20C, 20D: laminated net layer

[0081] 21: Mesh for Layering

[0082] 30: Protrusion Detailed Implementation

[0083] Hereinafter, preferred embodiments of the heat-resistant felt material of the present invention will be described with reference to the accompanying drawings.

[0084] 1. First Implementation Method

[0085] First, the heat-resistant felt material of the first embodiment of the present invention will be described. Figure 1 This is a schematic diagram illustrating an example of the heat-resistant felt material according to the first embodiment of the present invention. Figure 2 for Figure 1 A partially enlarged cross-sectional view of the heat-resistant felt material shown. Figure 3 This is a partially enlarged cross-sectional view showing a modified example of the heat-resistant felt material according to the first embodiment of the present invention.

[0086] Furthermore, in this specification and accompanying drawings, components with substantially the same functional configuration are omitted from repeated description by using the same reference numerals. Also, for ease of explanation, components in each figure are appropriately emphasized, and the dimensions shown in the figures do not represent actual dimensions.

[0087] Figure 1 The heat-resistant felt material 1 in the text is a cushioning material for hot pressing and is a laminate with a flat plate shape. For example... Figure 1 As shown, the heat-resistant felt material 1 has a substrate layer 10 and a laminated mesh layer 20 disposed on at least the outer surface 16 of the substrate layer 10. Furthermore, in addition to heat resistance and durability, in order to protect products (such as printed circuit boards) in contact with the heat-resistant felt material 1, the heat-resistant felt material 1 also needs to possess the following required functions: cushioning, surface smoothness, dimensional stability, and thermal conductivity for heating and cooling the aforementioned products through the heat-resistant felt material 1.

[0088] The density of the heat-resistant felt material 1, used as a cushioning material for hot pressing, is not particularly limited; for example, it is 0.2 g / cm³. 3 Above and 0.6 g / cm 3 The preferred value is 0.3 g / cm³. 3 Above and 0.5g / cm 3 The following applies. Furthermore, the thickness of the heat-resistant felt material 1 is not particularly limited; it is 1 mm or more and 10 mm or less, preferably 2 mm or more and 8 mm or less. Also, the dimensions of the heat-resistant felt material 1 are not particularly limited and can be appropriately set according to its application or the heat plate used; for example, the length in the longitudinal and width directions can be 3.6 × 1.3 m respectively.

[0089] In doing so, in addition to the heat resistance and durability required for the heat-resistant felt material 1, the heat-resistant felt material 1 also maintains the cushioning, surface smoothness, dimensional stability, and thermal conductivity of the heat-resistant felt material 1 for protecting products (such as printed circuit boards) that come into contact with the heat-resistant felt material.

[0090] Figure 2 This is a cross-sectional view of part A of the heat-resistant felt material 1 shown in the figure. The following will be based on... Figure 2 The layer structure of heat-resistant felt material 1 is described in detail.

[0091] 1.1. Substrate layer

[0092] like Figure 2 As shown, the substrate layer 10 of the heat-resistant felt material 1 is composed of a substrate 11 formed by multiple layers stacked together. In this embodiment, it is composed of 5 layers stacked together. The substrate 11 has a base fabric 12 and a cushioning mesh 13 disposed at least on the outer surface 14 of the base fabric 12.

[0093] In the heat-resistant felt material 1, the base fabric 12 is a fiber-reinforced substrate that provides tensile strength maintenance, shape stability, and entanglement between the cushioning mesh 13 and the laminating mesh 21 and the base fabric 12. The base fabric 12 can be made of materials such as woven fabric or lattice-like materials. Furthermore, when the base fabric 12 is woven fabric, there are no particular limitations on the weave structure; plain weave, twill weave, satin weave, or a combination of these weaves can be used.

[0094] As a constituent material of the base fabric 12, one or more of the following may be used: meta-aromatic polyamide fibers, para-aromatic polyamide fibers, fully aromatic polyester fibers, PBO fibers and stainless steel fibers. From the viewpoint of heat resistance and durability, aromatic polyamide fibers and PBO fibers are preferred, and PBO fibers are particularly preferred.

[0095] In particular, in this embodiment, the substrate 12 has filaments containing at least one fiber selected from the group consisting of aromatic polyamide fibers and PBO fibers. This improves both the heat resistance of the base fabric 12 and, consequently, the heat resistance of the heat-resistant felt material 1, while also increasing its physical strength. On the other hand, when using a substrate containing filaments containing at least one fiber selected from conventional aromatic polyamide fibers or PBO fibers, needle breakage is prone to occur during the needle punching process, resulting in poor entanglement between the substrate and the web, and between the substrate and the web itself. In such cases, problems such as peeling between the substrate and the web and fiber detachment from the web occur, and the surface smoothness of the heat-resistant felt material is compromised. Therefore, in this embodiment, the problem of needle breakage is suppressed by maintaining the density of the base fabric 12 below a certain level.

[0096] The proportion of PBO fibers in the base fabric 12 is not particularly limited, and the base fabric 12 contains one or more fibers selected from the group consisting of aramid fibers and poly-p-phenylene benzobisoxazole fibers in a composition ratio of preferably 50 mass% or more and 100 mass% or less, more preferably 75 mass% or more and 100 mass% or less. Thereby, the physical strength is improved while improving the heat resistance of the base fabric 12 and further improving the heat resistance of the heat-resistant felt material 1. Also, even in the case where the content of PBO fibers is relatively large, the problem of needle breakage is suppressed by keeping the density of the base fabric 12 below a certain level as described below, and the durability of the heat-resistant felt material 1 can be made excellent.

[0097] Also, the density of the base fabric 12 is 0.60 g / cm 3 or more. Thereby, the needle breakage in the needle punching step in the production of the heat-resistant felt material 1 can be prevented. As a result, the entanglement between the base fabric 12, the cushioning web 13, and the laminating web 21 or the entanglement in the cushioning web 13 and the laminating web 21 can be improved, and as a result, the durability of the heat-resistant felt material 1 can be improved.

[0098] The density of the base fabric 12 can be 0.60 g / cm 3 or more, but in order to further improve the durability of the heat-resistant felt material 1, it is preferably 0.45 g / cm 3 or more. Also, in order to prevent the heat-resistant felt material 1 from being deformed and maintain its shape, the density of the base fabric 12 is preferably 0.15 g / cm 3 or more.

[0099] Also, in the case where the base fabric 12 includes warp yarns and weft yarns, the total number of the warp yarns and the weft yarns of the base fabric 12 is, for example, 12 strands / inch or more and 57 strands / inch or less, preferably 15 strands / inch or more and 57 strands / inch or less, and more preferably 18 strands / inch or more and 57 strands / inch or less. By doing so, the tensile strength of the heat-resistant felt material 1 can be more reliably maintained, its shape can be stabilized, and the entanglement between the cushioning web 13 or the laminating web 21 and the base fabric 12 can be improved.

[0100] Also, the unit area weight of the base fabric 12 is not particularly limited, and is, for example, 45 g / m 2 or more and 400 g / m 2 or more, preferably 75 g / m 2 or more and 400 g / m 2 or more, more preferably 75 g / m 2 or more and 265 g / m 2 or more. By doing so, the tensile strength of the heat-resistant felt material 1 can be more reliably maintained, its shape can be stabilized, and the entanglement between the cushioning web 13 or the laminating web 21 and the base fabric 12 can be improved.

[0101] Further, the thickness of the base fabric 12 is, for example, 0.30 mm or more and 0.70 mm or less, preferably 0.30 mm or more and 0.45 mm or less, and more preferably 0.32 mm or more and 0.45 mm or less. By so doing, the tensile strength of the heat-resistant batt material 1 can be more reliably maintained, the shape thereof can be stabilized, and the entanglement between the cushioning web 13 or the laminating web 21 and the base fabric 12 can be improved.

[0102] The cushioning web 13 is formed by disposing a fiber web composed of, for example, butt fibers as short fibers on the outer surface 14 of the base fabric 12 and entangling the same with the base fabric 12 while being entangled with each other by needle punching.

[0103] The material of the cushioning web 13 is not particularly limited, and a single kind or a combination of two or more of resin materials having heat resistance such as aramid fibers such as meta-aramid fibers, para-aramid fibers, and wholly aromatic polyester fibers, and PBO fibers can be appropriately used.

[0104] Specifically, as the butt fibers, short fibers composed of the above-described materials can be used. That is, from the viewpoint of heat resistance and durability, the cushioning web 13 preferably contains one or more kinds of fibers selected from the group consisting of aramid fibers and PBO fibers. More specifically, a single kind or a combination of two or more of meta-aramid fibers having, as a main component, poly-m-phenylene isophthalamide (Cornex (trade name) manufactured by Teijin) or aramid (Nomex (trade name) manufactured by DuPont), para-aramid fibers having, as a main component, poly-p-phenylene terephthalamide (Kevlar (trade name) manufactured by Teijin DuPont) or twaron (trade name) manufactured by Teijin), Copolyparaphenylene-3,4'-oxydiphenyleneterephthalamide (Technora (trade name) manufactured by Teijin), PPS fibers (Torcon (trade name) manufactured by Teijin), and PBO fibers (Zylon (trade name) manufactured by Toyobo) can be used. In particular, from the viewpoint of heat resistance and durability, PBO fibers are preferred.

[0105] Furthermore, the cushioning net 13 comprises one or more fibers selected from the group consisting of aromatic polyamide fibers and PBO fibers, preferably with a fiber composition ratio of 50% or more and 100% or less by mass, and more preferably 75% or more and 100% or less by mass. This further improves the heat resistance and durability of the heat-resistant felt material 1.

[0106] There is no particular limitation on the length of the short fibers constituting the cushioning net 13; for example, it can be 38 mm or more and 130 mm or less. Furthermore, there is no particular limitation on the fineness of the short fibers constituting the cushioning net 13; for example, it can be 0.8 dtex or more and 11 dtex or less.

[0107] Furthermore, there is no particular limitation on the unit area weight of the cushioning net 13; it can be selected according to the intended use of the heat-resistant felt material, with a value of 50 g / m². 2 Above and 250g / m 2 The following is preferred: 100g / m 2 Above and 200g / m 2 the following.

[0108] and, Figure 2 The heat-resistant felt material 1 shown has a base layer 10 that uses a base fabric 12 and a cushioning mesh 13 disposed on the outer surface 14 of the base fabric 12 as a base material 11. Although the base material 11 is constructed by stacking five layers, the cushioning mesh 13 can also be disposed on the inner surface 15 of the base fabric 12. Furthermore, the cushioning mesh 13 can be disposed only on a portion of the outer surface 14 or the inner surface 15 of the multilayer base material 11, or the cushioning mesh 13 can be omitted, and the base layer 10 can be used only as a laminate of the base fabric 12. This can be appropriately set according to the target design.

[0109] Furthermore, in Figure 2 In the illustrated embodiment, although the substrate layer 10 is described as comprising five substrate layers 11, the present invention is not limited to the illustrated embodiment. The substrate layer may also consist of one substrate layer or two or more substrate layers. When the substrate layer consists of two or more substrate layers, the durability of the heat-resistant felt material becomes excellent. Furthermore, the durability of the heat-resistant felt material using a base fabric comprising multiple PBO fibers can be initially improved by employing a substrate layer comprising a base fabric having a density below the specified density described above. The number of substrate layers in the substrate layer is preferably two or more, more preferably three or more and six or fewer.

[0110] Furthermore, the total unit area weight of the plurality of base fabrics 12 constituting the base layer 10 can be appropriately selected according to the application, without particular limitation, for example, 90 g / m². 2 Above and 1000g / m 2 The preferred value is 300g / m³.2 above and 800 g / m 2 below. Thus, the heat resistance and durability of the heat-resistant batt material 1 are further improved.

[0111] 1.2. Laminated web layer

[0112] The laminated web layer 20 is provided at least on the outer surface 16 of the base material layer 10. The laminated web layer 20 is a fibrous aggregate layer formed by entangling short fibers, and functions as a cushioning material having heat conductivity and cushioning properties in the heat-resistant batt material 1.

[0113] The laminated web layer 20 is formed by laminating one or more layers of the laminated web 21 composed of butt joint fibers as short fibers. Specifically, the laminated web 21 of the laminated web layer 20 is formed by providing a fibrous web composed of butt joint fibers as short fibers on the base material layer 10 and entangling the same with the base material 11 while entangling each other by needle punching.

[0114] The material of the laminated web 21 constituting the laminated web layer 20 is not particularly limited, and a resin material having heat resistance such as an aramid fiber, an all-aramid fiber, a PBO fiber, or the like, alone or in combination of two or more, can be appropriately used. In particular, from the viewpoint of heat resistance and durability, an aramid fiber or a PBO fiber is preferable. Specifically, as the butt joint fibers, short fibers composed of the above-described materials can be used.

[0115] That is, the laminated web 21 constituting the laminated web layer 20 preferably contains one or more fibers selected from the group consisting of an aramid fiber and a PBO fiber. More specifically, a meta-aramid fiber (Kevlar (trade name, manufactured by Teijin) or Twaron (trade name, manufactured by Teijin)) having poly-m-phenylene isophthalamide or the like as a main component, a para-aramid fiber (Kevlar (trade name, manufactured by Teijin) or Twaron (trade name, manufactured by Teijin), Technora (trade name, manufactured by Teijin) having copoly-p-phenylene-3,4'-oxydiphenylene terephthalamide as a main component, PPS fiber (Technora (trade name, manufactured by Teijin)), PBO fiber (Zylon (trade name, manufactured by Toyobo)) or the like, alone or in combination of two or more, can be used.

[0116] As described above, the laminating web 21 preferably contains one or more kinds of fibers selected from the group consisting of aramid fibers and PBO fibers. That is, preferably, at least one of the laminating webs 21 constituting the laminated web layer 20 contains one or more kinds of fibers selected from the group consisting of aramid fibers and PBO fibers. Thereby, the heat resistance of the laminated web layer 20 is improved, and further, the heat resistance of the felt material 1 is improved. Further, the aramid fibers or the PBO fibers have excellent physical strength such as tensile strength and tensile modulus, and contribute to the shape stability of the laminated web layer 20 and the heat-resistant felt material 1, and further, the durability of the heat-resistant felt material 1 is improved.

[0117] The laminated web layer 20 is preferably such that at least one of the laminating webs 21 constituting the laminated web layer 20 contains one or more kinds of fibers selected from the group consisting of aramid fibers and PBO fibers, and more preferably, all of the laminating webs 21 constituting the laminated web layer 20 contain one or more kinds of fibers selected from the group consisting of aramid fibers and PBO fibers. Thereby, the heat resistance and the durability of the heat-resistant felt material 1 are further improved.

[0118] Further, each of the laminating webs 21 constituting the laminated web layer 20 contains one or more kinds of fibers selected from the group consisting of aramid fibers and PBO fibers, the proportion of which in the fiber composition is preferably 50% by mass or more and 100% by mass or less, and more preferably 75% by mass or more and 100% by mass or less. Thereby, the heat resistance and the durability of the heat-resistant felt material 1 are further improved.

[0119] Further, the laminated web layer 20 contains one or more kinds of fibers selected from the group consisting of aramid fibers and PBO fibers, the proportion of which in the fiber composition is preferably 50% by mass or more and 100% by mass or less, and more preferably 75% by mass or more and 100% by mass or less. Thereby, the heat resistance and the durability of the heat-resistant felt material 1 are further improved.

[0120] The fiber length of the staple fibers constituting the laminated web layer 20 is not particularly limited, and for example, can be 38 mm or more and 130 mm or less. Further, the fineness of the staple fibers constituting the laminated web layer 20 is not particularly limited, and for example, can be 0.8 dtex or more and 11 dtex or less.

[0121] Further, the unit area weight of the laminating web 21 of the laminated web layer 20 is not particularly limited, and can be selected according to the use of the heat-resistant felt material, and is 50 g / m 2 or more and 250 g / m 2 , preferably 100 g / m 2 or more and 200 g / m 2 or less.

[0122] Further, the laminated web layer 20 can include one or more layers of the laminating web 21, but can be selected according to the use of the heat-resistant batt material, for example, in the case where the heat-resistant batt material 1 is used as a cushioning material for hot pressing, it is preferable to include two or more layers, more preferably three or more layers and 15 or less layers. Thereby, the durability of the heat-resistant batt material 1 is further improved.

[0123] Further, the total weight per unit area of the laminated web layer 20 is not particularly limited, and can be selected according to the use of the heat-resistant batt material, for example, in the case where the heat-resistant batt material 1 is used as a cushioning material for hot pressing, it is preferable to be 200 g / m 2 or more and 3000 g / m 2 or less. Thereby, the heat-resistant batt material 1 as a hot pressing cushioning material can have appropriate thermal conductivity and cushioning properties. 2 or more and 2500 g / m 2 or less. Thereby, the heat-resistant batt material 1 as a hot pressing cushioning material can have appropriate thermal conductivity and cushioning properties.

[0124] Further, according to the present embodiment, the base cloth 12 of the base material layer 10 includes one or more fibers selected from the group consisting of aramid fibers and PBO fibers, so that the heat-resistant batt material 1 has excellent heat resistance. Further, the density of the base cloth 12 is 0.60 g / cm 3 or less. Thereby, in the needle punching step in the production process of the heat-resistant batt material 1, needle breakage can be prevented. As a result, the entanglement between the base material 12, the cushioning web 13, and the laminating web 21 or the entanglement in the cushioning web 13 and the laminating web 21 can be improved, the tensile strength of the obtained heat-resistant batt material 1 is maintained, and the shape stability is improved. As a result, the durability of the heat-resistant batt material 1 is improved.

[0125] Further, in the case where aramid fibers and PBO fibers are used as the material used in the base material 11 or the laminated web layer 20 as a constituent element of the heat-resistant batt material 1, since the tensile strength or tensile modulus of the aramid fibers and PBO fibers is higher than that of other materials, the effects of preventing needle breakage in the process of producing the heat-resistant batt material 1, maintaining the tensile strength, stabilizing the shape, and improving the entanglement between the cushioning web 13 or the laminating web 21 and the base cloth 12 are more effective.

[0126] Further, according to the present embodiment, the heat resistance and the durability of the heat-resistant batt material 1 are both excellent.

[0127] In particular, even when aromatic polyamide fibers and / or PBO fibers are used in the substrate 12 and the weight per unit area is large, the heat-resistant felt material 1 of this embodiment can suppress needle breakage during the preparation of the heat-resistant felt material 1. This improves the entanglement between the substrate 12, the cushioning mesh 13, and the laminating mesh 21, or the entanglement between the cushioning mesh 13 and the laminating mesh 21, resulting in maintaining the tensile strength of the obtained heat-resistant felt material 1 and improving its shape stability. Therefore, when aromatic polyamide fibers or PBO fibers are used in the substrate as usual, the weight per unit area of ​​the heat-resistant felt material cannot be increased; in this embodiment, the problem of difficulty in improving the durability of the heat-resistant felt material is solved.

[0128] From the perspective of durability and heat resistance, the preferred unit area weight of heat-resistant felt material 1 is 2000 g / m². 2 The above, more preferably 4000g / m 2 above.

[0129] Furthermore, in the above Figure 1 and Figure 2 In the heat-resistant felt material 1 shown, a laminated mesh layer 20 is disposed on the outer surface 16 of the substrate layer 10; however, the present invention is not limited to the illustrated arrangement. For example, in Figure 3 In the heat-resistant felt material 1A shown, laminated mesh layers 20 and 20A are disposed on the outer surface 16 and inner surface 17 of the substrate layer 10, with the substrate layer 10 positioned approximately at the center of the depth direction of the heat-resistant felt material 1A. As described above, since the cross-sectional structure of the heat-resistant felt material 1A is symmetrical in the depth direction, bending and warping of the heat-resistant felt material 1A are suppressed. The laminated mesh layer 20A may have the same structure as the laminated mesh layer 20. However, the laminated mesh layer 20A may be the same as or different from the laminated mesh layer 20. Furthermore, the laminated mesh layer 20A may not contain aromatic polyamide fibers and PBO fibers.

[0130] 2. Second Implementation Method

[0131] Next, the heat-resistant felt material of the second embodiment of the present invention will be described. Figure 4 This is a schematic diagram illustrating an example of the heat-resistant felt material according to the second embodiment of the present invention. Hereinafter, the differences from the first embodiment described above will be highlighted, and identical items will be omitted.

[0132] Figure 4 The heat-resistant felt material 1B shown is a material for transport roller sleeves used in the manufacture of extruded aluminum profiles. The heat-resistant felt material 1B is cylindrical in shape. Figure 4 As shown, the heat-resistant felt material 1B has a substrate layer 10A and a laminated mesh layer 20B disposed on the outer surface 16A of the substrate layer 10A.

[0133] The base material layer 10A is in a cylindrical shape. Also, the laminated mesh layer 20B is in a cylindrical shape to cover the outer surface 16A, i.e., the outer periphery, of the base material layer 10A. The structure of the base material layer 10A can be the same as that of the base material layer 10 of the above-described first embodiment, and the structure of the laminated mesh layer 20B can also be the same as that of the laminated mesh layer 20 of the above-described first embodiment. Thus, the heat-resistant felt material IB can have both excellent heat resistance and durability.

[0134] Also, the unit area weight of the laminated mesh layer 20B can be the same as that of the heat-resistant felt material 1 of the first embodiment, but in the case where the heat-resistant felt material IB is used as a carrier roll cover used in the production process of extruded aluminum profiles, the unit area weight of the laminated mesh layer 20B is preferably 1500 g / m 2 or more and 5000 g / m 2 or more. Thus, in the heat-resistant felt material IB, appropriate thermal conductivity and cushioning as a carrier roll cover can be obtained. 2 or more and 4500 g / m 2 or more. Thus, in the heat-resistant felt material IB, appropriate thermal conductivity and cushioning as a carrier roll cover can be obtained.

[0135] The density of the heat-resistant felt material IB as a carrier roll cover material used in the production process of extruded aluminum profiles is not particularly limited, and is, for example, 0.3 g / cm 3 or more and 0.7 g / cm 3 or more, preferably 0.4 g / cm 3 or more and 0.6 g / cm 3 or more. Also, the thickness of the heat-resistant felt material IB is not particularly limited, and is, for example, 3 mm or more and 17 mm or less, preferably 4 mm or more and 15 mm or less. Further, the size of the heat-resistant felt material IB is not particularly limited, and can be appropriately set according to its use or the roll used, and is, for example, an inner diameter of 30 mm or more and 150 mm or less, preferably 40 mm or more and 130 mm or less, and a face length (length in the width direction) of 50 mm or more and 1400 mm or less, preferably 100 mm or more and 1200 mm or less.

[0136] Also, in the above description, although it has been described that the heat-resistant felt material IB has the laminated mesh layer 20B disposed only on the outer surface 16A of the base material layer 10A, it is not limited to the above-described manner, and the heat-resistant felt material IB can have a laminated mesh layer (not shown) disposed on the inner surface 17A of the base material layer 10A, as with the layer structure shown in the above-described Figure 3 embodiment. Also in this case, the structure of the laminated mesh layer disposed on the inner surface 17A of the base material layer 10A can be the same as that of the laminated mesh layer 20A of the above-described first embodiment.

[0137] However, in order to improve the durability of the surface in contact with the roll (the inner surface 19A of the heat-resistant felt material 1B) during use and prevent fiber shedding or dimensional change on the surface in contact with the roll (the inner surface 19A of the heat-resistant felt material 1B) during loading of the roll, the laminated web layer is preferably not disposed on the inner surface 17A of the base material layer 10A.

[0138] 3. Third Embodiment

[0139] Next, the heat-resistant felt material of the third embodiment of the present application will be described. Figure 5 A schematic view showing an example of the heat-resistant felt material of the third embodiment of the present application is shown in FIG. 3. Hereinafter, differences from the first embodiment described above will be mainly described, and the same matters will be omitted.

[0140] Figure 5 The heat-resistant felt material 1C is a carrying tape used in the production of extruded aluminum profiles. The heat-resistant felt material 1C is a tape in a ring shape. That is, the overall shape of the heat-resistant felt material 1C is in a tape shape. As shown in FIG. 3, the heat-resistant felt material 1C has a base material layer 10B and a laminated web layer 20C disposed on the outer surface 16B of the base material layer 10B. Figure 5

[0141] The base material layer 10B is in a tape shape. Also, the laminated web layer 20C is in a tape shape to cover the outer surface 16B, that is, the outer periphery, of the base material layer 10B. The base material layer 10B can have the same structure as the base material layer 10 of the first embodiment described above, and the laminated web layer 20C can have the same structure as the laminated web layer 20 of the first embodiment described above. Thus, the heat-resistant felt material 1C can have both excellent heat resistance and durability.

[0142] Also, the unit area weight of the laminated web layer 20C can be the same as that of the heat-resistant felt material 1 of the first embodiment, but in the case where the heat-resistant felt material is used as a carrying tape used in the production of extruded aluminum profiles, the unit area weight of the laminated web layer 20C is preferably 1500 g / m 2 or more and 5000 g / m 2 or more and 4500 g / m 2 or more and 5000 g / m 2 or more. In the heat-resistant felt material 1C, appropriate thermal conductivity and cushioning as a carrying tape can be obtained.

[0143] The density of the heat-resistant felt material 1C as a carrying tape used in the production of extruded aluminum profiles is not particularly limited, and is, for example, 0.3 g / cm 3 or more and 0.7 g / cm 3 or more and 0.6 g / cm 3 or more and 0.6 g / cm​3 The thickness of the heat-resistant felt material 1C is not particularly limited, and is, for example, 3 mm or more and 16 mm or less, and preferably 4 mm or more and 14 mm or less. Further, the size of the heat-resistant felt material 1C is not particularly limited, and can be appropriately set according to its use, such as the arrangement position, and is, for example, 0.5 m or more and 12 m or less in the length, and preferably 1 m or more and 10 m or less, and can be 40 mm or more and 1400 mm or less in the width, and preferably 60 mm or more and 1200 mm or less.

[0144] Further, in the above description, although it has been described that the heat-resistant felt material 1C has the laminated web layer 20C arranged only on the outer surface 16B of the base material layer 10B, it is not limited to the above-described manner, and the heat-resistant felt material 1C can have a laminated web layer (not shown) arranged on the inner surface 17B of the base material layer 10B, as in the layer structure shown in Figure 3 Further, in the above description, although it has been described that the heat-resistant felt material 1C has the laminated web layer 20C arranged only on the outer surface 16B of the base material layer 10B, it is not limited to the above-described manner, and the heat-resistant felt material 1C can have a laminated web layer (not shown) arranged on the inner surface 17B of the base material layer 10B, as in the layer structure shown in

[0145] However, in order to improve the durability of the surface in contact with the roll (the inner surface 19B of the heat-resistant felt material 1C) during use and prevent fiber peeling or dimensional change on the surface in contact with the roll (the inner surface 19B of the heat-resistant felt material 1C) during the loading of the roll, it is preferable that no laminated web layer be arranged on the inner surface 17B of the base material layer 10B.

[0146] 4. 4th Embodiment

[0147] Next, the heat-resistant felt material of the 4th embodiment of the present application will be described. Figure 6 is a schematic view showing an example of the heat-resistant felt material of the 4th embodiment of the present application. Hereinafter, the differences from the above-described 1st embodiment will be mainly described, and the same matters will be omitted.

[0148] Figure 6 The heat-resistant felt material 1D shown in FIG. 10 is a roll cover material for a continuous hot-dip galvanized steel sheet production line (CGL). The overall shape of the heat-resistant felt material 1D is a cylindrical shape. As shown in FIG. 10, the heat-resistant felt material 1D has a base material layer 10C, and a laminated web layer 20D and a tab 30 arranged on the outer surface 16C of the base material layer 10C. Figure 6

[0149] ​The base material layer 10C is in a cylindrical shape. Also, the laminated web layer 20D is in a cylindrical shape to cover the outer surface 16C, i.e., the outer circumference, of the base material layer 10C. Also, in the base material layer 10C, the end portion in the direction perpendicular to the circumferential direction thereof, i.e., the axial direction, is protruded from the laminated web layer 20D and extended to form the tab 30. In the tab 30, the heat-resistant felt material ID is bound and fixed to the roll.

[0150] The structure of the base material layer 10C can be the same as that of the base material layer 10 of the above-described first embodiment, and the structure of the laminated web layer 20D can also be the same as that of the laminated web layer 20 of the above-described first embodiment. Thereby, the heat-resistant felt material ID can have both excellent heat resistance and durability.

[0151] Also, the unit area weight of the laminated web layer 20D can be the same as that of the heat-resistant felt material 1 of the first embodiment, but in the case where the heat-resistant felt material ID is used as the roll cover material of the CGL, the unit area weight of the laminated web layer 20D is preferably 3000 g / m 2 or more and 6500 g / m 2 or more and 6500 g / m 2 or more and 6500 g / m 2 or more and 6500 g / m. Thereby, in the heat-resistant felt material ID, appropriate thermal conductivity and cushioning as the roll cover material of the CGL can be obtained.

[0152] The density of the heat-resistant felt material ID as the roll cover material of the CGL is not particularly limited, and is, for example, 0.3 g / cm 3 or more and 0.7 g / cm 3 or more and 0.7 g / cm 3 or more and 0.7 g / cm 3 or more and 0.7 g / cm. Also, the thickness of the heat-resistant felt material ID is not particularly limited, and is, for example, 4 mm or more and 16 mm or less, preferably 5 mm or more and 15 mm or less. Further, the size of the heat-resistant felt material ID is not particularly limited, and can be appropriately set according to the use thereof or the roll used, and is, for example, the inner diameter is 90 mm or more and 2500 mm or less, preferably 500 mm or more and 2000 mm or less, and the face length (length in the width direction) can be 1000 mm or more and 3000 mm or less, preferably 1500 mm or more and 2500 mm or less.

[0153] Also, in the above description, although it has been described that the heat-resistant felt material ID has the laminated web layer 20D disposed only on the outer surface 16C of the base material layer 10C, it is not limited to the above-described manner, and the heat-resistant felt material ID can have the laminated web layer 20D disposed on the inner surface 16B of the base material layer 10C as well as on the outer surface 16C thereof. Figure 3The layer structure is the same as shown, and the heat-resistant batt material 1D can also have a lamination web layer (not shown) disposed on the inner surface 17C of the base material layer 10C. In this case as well, the structure of the lamination web layer disposed on the inner surface 17C of the base material layer 10C can be the same as the structure of the lamination web layer 20A of the first embodiment described above.

[0154] However, in order to improve the durability of the surface (inner surface 19C of the heat-resistant batt material 1D) that comes into contact with the roll during use and prevent fiber shedding or dimensional changes on the surface (inner surface 19C of the heat-resistant batt material 1D) that comes into contact with the roll during roll loading, it is preferable that no lamination web layer be disposed on the inner surface 17C of the base material layer 10A.

[0155] 5. Method for producing a heat-resistant batt material

[0156] Next, the method for producing a heat-resistant batt material according to the preferred embodiment of the present application, i.e., the method for producing the heat-resistant batt material 1 described above, will be described as an example.

[0157] The method for producing a heat-resistant batt material according to the present application includes: step (a) of preparing a base material including at least one layer of a base cloth having filaments containing one or more fibers selected from the group consisting of aramid fibers and PBO fibers and having a density of 0.60 g / cm 3 The following; step (b) of preparing a lamination web; step (c) of disposing at least one layer of the lamination web obtained in step (b) on at least an outer surface of the base material layer obtained in step (a) and entangling and integrating by needling to obtain a heat-resistant batt material.

[0158] 5.1. Step (a)

[0159] In the present embodiment, first, the base material 11 is prepared before the step of obtaining the heat-resistant batt material described above. In the base material 11, at least one layer of the base cloth 12 described above is prepared, and a plurality of layers of the base cloth 12 are laminated as needed, and the base material layer 10 is further prepared by entangling and integrating by needling. At this time, the cushioning web 13 can be disposed on one of the outer surface 14 or the inner surface 15 of part or all of the base material 11 that constitutes the base material layer 10. Also, in the base material 10, the cushioning web 13 can be omitted, and only the base cloth 12 can be used. Finally, the prepared base material 11 is laminated as the base material layer 10.

[0160] 5.2. Step (b)

[0161] In the next step, the above-mentioned lamination web 21 constituting the lamination web layer 20 is prepared on at least the outer surface 16 of the base material layer 10. The lamination web 21 preferably contains one or more fibers selected from the group consisting of aramid fibers and PBO fibers. These fibers have excellent heat resistance and physical strength, and contribute to improvement in the heat resistance and durability of the heat-resistant blanket material 1 obtained. On the other hand, in the case where the base material layer is entangled by conventional needle punching for its physical strength, these fibers easily cause needle breakage. Thus, in the conventional method, the base material layer and the lamination web layer cannot be sufficiently integrated, and the physical strength of these fibers cannot sufficiently contribute to improvement in the durability of the heat-resistant blanket material. However, in the present embodiment, by using the above-mentioned base material 11, needle breakage can be suppressed and the base material layer 10 and the lamination web layer 20 can be sufficiently entangled and integrated. Thus, the physical strength of these fibers can effectively contribute to improvement in the durability of the heat-resistant blanket material 1.

[0162] 5.3. Step (c)

[0163] Also, in the next step, at least one layer of the lamination web 13 is arranged on at least the outer surface 14 of the base material layer 10, and as necessary, a plurality of layers of the lamination web 13 are laminated, and entangled and integrated by needle punching.

[0164] Also, in the needle punching, the heat-resistant blanket material 1 can be made into a flat shape, a belt shape, and a cylindrical shape by batch-wise needle punching of a sheet in which one or more layers of the base material 11 and the lamination web are overlapped, and the base material 11 entangles and integrates the cushioning web 13 and the base fabric 12. Also, the base material 11 and the lamination web 21 are prepared in a long-size roll, and the heat-resistant blanket material 1 can be made into a seamless belt shape and a cylindrical shape by continuous winding of a plurality of layers of needle punching to a prescribed length.

[0165] Also, the needle punching is performed while winding one or more layers of the base material 11 on a roller having a prescribed diameter of a needle-through hole, and the heat-resistant blanket material 1 can be made into a seamless cylindrical shape by performing the needle punching while winding one or more layers of the lamination web 21 thereon.

[0166] The heat-resistant blanket material 1 can be obtained by the above steps. Also, the obtained heat-resistant blanket material 1 can be appropriately cut according to the use.

[0167] The same applies to the other heat-resistant blanket materials 1B to 1D. Also, for the heat-resistant blanket material 1 as a heat-pressing cushioning material, a release material can be arranged, bonded, or heat-pressed on the outer surface 18 or the inner surface 19 thereof.

[0168] Example

[0169] Hereinafter, the present application will be more specifically described by examples, but the present application is not limited to these examples.

[0170] 1. Preparation of heat-resistant batt

[0171] (1) Preparation of base material layer

[0172] For the base material layer of each of the examples and comparative examples, the following materials were used.

[0173] Example 1, 7 and 13

[0174] A woven fabric composed of PBO fibers (filament fineness: 2 / 20S (two twisted filaments of the 20th interval), filament density: 18 filaments / inch (warp) • 15 filaments / inch (weft), weave: 1 / 1 plain weave, weight per unit area: 75 g / m 2 and base fabric density: 0.234 g / cm 3 ) was prepared. Furthermore, a buffer net composed of PBO fibers (filament fineness: 1.7 dtex, fiber length: 44 mm and weight per unit area: 120 g / m 2 ) was prepared, disposed on the front surface of the base fabric, integrated with the base fabric by needle punching, a base material was prepared, and a base material layer composed of 6 layers of the base material was prepared by repeating this 6 times (weight per unit area of the base material layer: 1170 g / m 2 ).

[0175] Example 19

[0176] A woven fabric composed of PBO fibers (filament fineness: 2 / 20S (two twisted filaments of the 20th interval), filament density: 18 filaments / inch (warp) • 15 filaments / inch (weft), weave: 1 / 1 plain weave, weight per unit area: 75 g / m 2 and base fabric density: 0.234 g / cm 3 ) was prepared. Furthermore, a buffer net composed of PBO fibers (filament fineness: 1.7 dtex, fiber length: 44 mm and weight per unit area: 120 g / m 2 ) was prepared, disposed on the front surface of the base fabric, integrated with the base fabric by needle punching, a base material was prepared, and a base material layer composed of 3 layers of the base material was prepared by repeating this 3 times (weight per unit area of the base material layer: 585 g / m 2 ).

[0177] Example 2, 8 and 14

[0178] A woven fabric composed of PBO fibers (filament fineness: 2 / 20S (two twisted filaments of the 20th interval), filament density: 24 filaments / inch (warp) • 21 filaments / inch (weft), weave: 1 / 1 plain weave, weight per unit area: 100 g / m 2 and base fabric density: 0.294 g / cm3 Furthermore, a cushioning mesh composed of PBO fibers (filament fineness of 1.7 dtex, fiber length of 44 mm, and weight per unit area of ​​120 g / m²) is prepared. 2 The substrate is prepared by needle punching on the front surface of the base fabric and then integrated with it. This process is repeated three times to prepare a substrate layer consisting of five layers (the substrate layer has a unit area weight of 1100 g / m²). 2 ).

[0179] Example 20

[0180] A fabric composed of PBO fibers for both warp and weft (filament fineness 2 / 20S (two twisted yarns at the 20th pitch), yarn density 24 yarns / inch (warp) · 21 yarns / inch (weft), 1 / 1 plain weave, and a unit area weight of 100g / m²) was prepared. 2 The density of the base fabric is 0.294 g / cm³. 3 Furthermore, a cushioning mesh composed of PBO fibers (filament fineness of 1.7 dtex, fiber length of 44 mm, and weight per unit area of ​​120 g / m²) is prepared. 2 The substrate is prepared by needle punching on the front surface of the base fabric and then integrated with it. This process is repeated twice to prepare a substrate layer consisting of two layers (the substrate layer has a unit area weight of 440 g / m²). 2 ).

[0181] Examples 3, 9 and 15

[0182] A fabric composed of PBO fibers for both warp and weft (filament fineness 2 / 20S (two twisted yarns at the 20th pitch), yarn density: 35 yarns / inch (warp) · 30 yarns / inch (weft), 1 / 1 plain weave, with a unit area weight of 155g / m²) was prepared. 2 The density of the base fabric is 0.408 g / cm³. 3 Furthermore, a cushioning mesh composed of PBO fibers (filament fineness of 1.7 dtex, fiber length of 44 mm, and weight per unit area of ​​120 g / m²) is prepared. 2 The substrate is prepared by needle punching on the front surface of the base fabric and then integrated with the base fabric. This process is repeated four times to prepare a substrate layer consisting of four layers (the substrate layer has a unit area weight of 1100 g / m²). 2 ).

[0183] Example 21

[0184] A woven fabric composed of PBO fibers (filament fineness: 2 / 20S (two twisted filaments at the 20th interval), filament density: 35 threads / inch (warp) x 30 threads / inch (weft), weave: 1 / 1 plain weave, weight per unit area: 155 g / m 2 and base fabric density: 0.408 g / cm 3 ). Also, a buffer net composed of PBO fibers (filament fineness: 1.7 dtex, fiber length: 44 mm, and weight per unit area: 120 g / m 2 ) was prepared, disposed on the front surface of the base fabric, integrated with the base fabric by needling, and a base material was prepared. By repeating this twice, a base material layer composed of two layers of base material was prepared (base material layer weight per unit area: 550 g / m 2 ).

[0185] Examples 4, 10, and 16

[0186] A woven fabric composed of PBO fibers (filament fineness: 2 / 20S (two twisted filaments at the 20th interval), filament density: 46 threads / inch (warp) x 40 threads / inch (weft), weave: 1 / 1 plain weave, weight per unit area: 210 g / m 2 and base fabric density: 0.500 g / cm 3 ). Also, a buffer net composed of PBO fibers (filament fineness: 1.7 dtex, fiber length: 44 mm, and weight per unit area: 120 g / m 2 ) was prepared, disposed on the front surface of the base fabric, integrated with the base fabric by needling, and a base material was prepared. By repeating this three times, a base material layer composed of three layers of base material was prepared (base material layer weight per unit area: 990 g / m 2 ).

[0187] Example 22

[0188] A woven fabric composed of PBO fibers (filament fineness: 2 / 20S (two twisted filaments at the 20th interval), filament density: 46 threads / inch (warp) x 40 threads / inch (weft), weave: 1 / 1 plain weave, weight per unit area: 210 g / m 2 and base fabric density: 0.500 g / cm 3 ). Also, a buffer net composed of PBO fibers (filament fineness: 1.7 dtex, fiber length: 44 mm, and weight per unit area: 120 g / m 2 ) was prepared, disposed on the front surface of the base fabric, integrated with the base fabric by needling, and a base material was prepared. By repeating this twice, a base material layer composed of two layers of base material was prepared (base material layer weight per unit area: 660 g / m 2 ).

[0189] Examples 5, 11, 17, and 23

[0190] A woven fabric composed of PBO fibers (filament fineness: 2 / 20S (two twisted filaments of the 20th interval), filament density: 57 filaments / inch (warp) x 50 filaments / inch (weft), weave: 1 / 1 plain weave, weight per unit area: 265 g / m 2 , and base fabric density: 0.589 g / cm 3 ) was prepared. Furthermore, a buffer net composed of PBO fibers (filament fineness: 1.7 dtex, fiber length: 44 mm, and weight per unit area: 120 g / m 2 ) was prepared, disposed on the front surface of the base fabric, integrated with the base fabric by needling, a base material was prepared, and a base material layer composed of two layers of the base material was prepared by repeating this two times (base material layer weight per unit area: 770 g / m 2 ).

[0191] Examples 6, 12, and 18

[0192] A woven fabric composed of para-type aramid fibers (filament fineness: 1670 dtex of a multifilament (1000 single filaments of 1.7 dtex bundled into a bundle), filament density: 36 filaments / inch (warp) x 36 filaments / inch (weft), weave: 1 / 1 plain weave, weight per unit area: 400 g / m 2 , and base fabric density: 0.597 g / cm 3 ) was prepared. Furthermore, a buffer net composed of PBO fibers (filament fineness: 1.7 dtex, fiber length: 44 mm, and weight per unit area: 120 g / m 2 ) was prepared, disposed on the front surface of the base fabric, integrated with the base fabric by needling, a base material was prepared, and a base material layer composed of two layers of the base material was prepared by repeating this two times (base material layer weight per unit area: 1040 g / m 2 ).

[0193] Example 24

[0194] A woven fabric composed of para-type aramid fibers (filament fineness: 1670 dtex of a multifilament (1000 single filaments of 1.7 dtex bundled into a bundle), filament density: 18 filaments / inch (warp) x 12 filaments / inch (weft), weave: 1 / 1 plain weave, weight per unit area: 400 g / m 2 , and base fabric density: 0.597 g / cm 3 ) was prepared. Furthermore, a buffer net composed of PBO fibers (filament fineness: 1.7 dtex, fiber length: 44 mm, and weight per unit area: 120 g / m 2) was prepared. The base material layer (520 g / m2) was prepared by repeating this process twice. 2

[0195] Comparative Examples 1, 3 and 5

[0196] A woven fabric composed of PBO fibers (filament fineness: 2 / 20S (two twisted filaments at the 20th interval), filament density: 68 threads / inch (warp) • 60 threads / inch (weft), weave: twill weave, weight per unit area: 320 g / m 2 , base fabric density: 0.667 g / cm 3 , and product model: DA4220W (manufactured by Toyobo Co., Ltd.)) was prepared. Further, a buffer net composed of PBO fibers (filament fineness: 1.7 dtex, fiber length: 44 mm, and weight per unit area: 120 g / m 2 ) was prepared, disposed on the front surface of the base fabric, integrated with the base fabric by needling, and the base material was prepared. By repeating this process twice, a base material layer composed of two layers of base material (base material layer weight per unit area: 880 g / m 2 ) was prepared.

[0197] Comparative Example 7

[0198] A woven fabric composed of PBO fibers (filament fineness: 2 / 20S (two twisted filaments at the 20th interval), filament density: 68 threads / inch (warp) • 60 threads / inch (weft), weave: twill weave, weight per unit area: 320 g / m 2 , base fabric density: 0.667 g / cm 3 , and product model: DA4220W (manufactured by Toyobo Co., Ltd.)) was prepared. Further, a buffer net composed of PBO fibers (filament fineness: 1.7 dtex, fiber length: 44 mm, and weight per unit area: 120 g / m 2 ) was prepared, disposed on the front surface of the base fabric, integrated with the base fabric by needling, and the base material was prepared. By repeating this process twice, a base material layer composed of two layers of base material (base material layer weight per unit area: 880 g / m 2 ) was prepared.

[0199] Comparative Examples 2, 4 and 6

[0200] A woven fabric composed of PBO fibers (filament fineness: 555 dtex (a bundle composed of 332 single filaments of 1.7 dtex), filament density: 35 threads / inch (warp) • 35 threads / inch (weft), weave: 1 / 1 plain weave, weight per unit area: 160 g / m 2 , base fabric density: 0.696 g / cm 3 ​and a product model is LZY0535W (manufactured by Toyobo Co., Ltd.). Further, a buffer net composed of PBO fiber (a filament fineness of 1.7 dtex, a fiber length of 44 mm, and a unit area weight of 120 g / m 2 ) is prepared, disposed on the front surface of the base cloth, integrated with the base cloth by needling, and a base material is prepared. By repeating this four times, a base material layer composed of four layers of base material (a base material layer unit area weight of 1120 g / m 2 ) is prepared.

[0201] Comparative Example 8

[0202] A woven cloth composed of PBO fiber (a filament fineness of 555 dtex (a bundle of 332 filaments of 1.7 dtex, bundled), a filament density of 35 threads / inch (warp) x 35 threads / inch (weft), a weave of 1 / 1 plain weave, and a unit area weight of 160 g / m 2 , a base cloth density of 0.696 g / cm 3 , and a product model of LZY0535W (manufactured by Toyobo Co., Ltd.) is prepared. Further, a buffer net composed of PBO fiber (a filament fineness of 1.7 dtex, a fiber length of 44 mm, and a unit area weight of 120 g / m 2 ) is prepared, disposed on the front surface of the base cloth, integrated with the base cloth by needling, and a base material is prepared. By repeating this two times, a base material layer composed of two layers of base material (a base material layer unit area weight of 560 g / m 2 ) is prepared.

[0203] (2) Formation of Laminated Net Layer

[0204] Examples 1 to 5 and Comparative Examples 1 and 2

[0205] As the butt joint fiber of the laminated net layer, short fibers of PBO (a fineness of 1.7 dtex and a fiber length of 44 mm) are prepared, and a laminated net having a unit area weight of 120 g / m 2 per layer is obtained. In each of the examples and comparative examples, the number of laminated nets is adjusted as shown in Table 1 so that the unit area weight of each final product is about 6800 g / m 2 , needling is repeated, and a laminated net layer is formed on the front surface of the base material layer.

[0206] Example 6

[0207] As the butt joint fiber of the laminated net layer, short fibers of para-aramid (a fineness of 2.5 dtex and a fiber length of 51 mm) are prepared, and a laminated net having a unit area weight of 120 g / m 2The layering web was prepared using PBO short fibers (1.7 dtex in fineness and 44 mm in fiber length) as the interfacing fibers of the layering web, and a layering web having a weight per unit area of 120 g / m 2 The needle punching was repeated to form the layering web layer on the front surface of the base material layer.

[0208] Examples 7 to 11 and Comparative Examples 3 and 4

[0209] The layering web was prepared using PBO short fibers (1.7 dtex in fineness and 44 mm in fiber length) as the interfacing fibers of the layering web, and a layering web having a weight per unit area of 120 g / m 2 The layering web was prepared using PBO short fibers (1.7 dtex in fineness and 44 mm in fiber length) as the interfacing fibers of the layering web, and a layering web having a weight per unit area of 120 g / m 2 The needle punching was repeated to form the layering web layer on the front surface of the base material layer.

[0210] Example 12

[0211] The layering web was prepared using PBO short fibers (1.7 dtex in fineness and 44 mm in fiber length) as the interfacing fibers of the layering web, and a layering web having a weight per unit area of 120 g / m 2 The layering web was prepared using PBO short fibers (1.7 dtex in fineness and 44 mm in fiber length) as the interfacing fibers of the layering web, and a layering web having a weight per unit area of 120 g / m 2 The needle punching was repeated to form the layering web layer on the front surface of the base material layer.

[0212] Examples 13 to 17 and Comparative Examples 5 and 6

[0213] The layering web was prepared using PBO short fibers (1.7 dtex in fineness and 44 mm in fiber length) as the interfacing fibers of the layering web, and a layering web having a weight per unit area of 120 g / m 2 The layering web was prepared using PBO short fibers (1.7 dtex in fineness and 44 mm in fiber length) as the interfacing fibers of the layering web, and a layering web having a weight per unit area of 120 g / m 2 The needle punching was repeated to form the layering web layer on the front surface of the base material layer.

[0214] Example 18

[0215] The layering web was prepared using PBO short fibers (1.7 dtex in fineness and 44 mm in fiber length) as the interfacing fibers of the layering web, and a layering web having a weight per unit area of 120 g / m 2The lamination mesh is used for layering. In each embodiment and comparative example, the number of layers of the lamination mesh is adjusted as shown in Table 3 so that the unit area weight of each final product is approximately 2000 g / m². 2 Repeated needle punching was performed to form a multilayer mesh on the front surface of the substrate layer.

[0216] Examples 19-23 and Comparative Examples 7 and 8

[0217] As the connecting fibers for the lamination of the lamination mesh, short PBO fibers (fineness of 1.7 dtex and fiber length of 44 mm) were prepared, resulting in a unit area weight of 120 g / m² per layer. 2 The lamination mesh is used for layering. In each embodiment and comparative example, the number of layers of the lamination mesh is adjusted as shown in Table 3 so that the unit area weight of each final product is approximately 1000 g / m². 2 Repeated needle punching was performed to form a multilayer mesh on the front surface of the substrate layer.

[0218] Example 24

[0219] As the connecting fibers for the lamination of the lamination web, short fibers of para-type aromatic polyamide (fineness of 2.5 dtex and fiber length of 51 mm) were prepared, resulting in a unit area weight of 120 g / m² per layer. 2 The lamination mesh is used for layering. In each embodiment and comparative example, the number of layers of the lamination mesh is adjusted as shown in Table 4 so that the unit area weight of each final product is approximately 1000 g / m². 2 Repeated needle punching was performed to form a multilayer mesh on the front surface of the substrate layer.

[0220] 2. Evaluation

[0221] (1) Broken needle

[0222] In each embodiment and comparative example, the needle breakage status of the needles used for acupuncture during the preparation process was confirmed. The results are shown in Tables 1 to 4.

[0223] Table 1

[0224]

[0225]

[0226] Table 2

[0227]

[0228]

[0229] Table 3

[0230]

[0231]

[0232] Table 4

[0233]

[0234]

[0235] As shown in Tables 1 to 4, the heat-resistant batts of Examples 1 to 24 did not have needle breakage during needle punching in the process of producing the heat-resistant batt, or even if needle breakage occurred, the needle breakage was significantly prevented compared to the Comparative Examples. Therefore, since the production can be performed without needle breakage while maintaining the heat resistance required as a heat-resistant batt material, durability can also be improved. Furthermore, even if the product unit area weight is large, the occurrence of such needle breakage was sufficiently suppressed. Furthermore, the place where needle breakage occurred formed a muscle-like fine line along the needle punching direction on the surface of the heat-resistant batt material.

[0236] (2) Heat abrasion test (thickness retention rate)

[0237] For Examples 4 to 6 and Comparative Examples 1 and 2 in which needle breakage occurred, a heat abrasion test was performed by a heat friction tester as shown in Figure 7 , and the thickness retention rate of the test piece of the non-needle broken part and the needle broken part was evaluated.

[0238] In a heat friction tester 100 as shown in Figure 7 , a friction element 120 is fixed on the upper surface of a sample stage 110. The friction element 120 is configured to be able to be heated to an arbitrary temperature by a heater 111 provided inside the sample stage 110. For this heatable friction element 120, a heat-resistant batt material 1 as a test piece is supported by a support portion 130 so as to be in contact with the friction element 120 from the front side surface 18 on the side of the lamination web layer 20. Furthermore, in the heat-resistant batt material 1, a weight 140 is disposed on the side opposite to the friction element 120, whereby a prescribed load (stress) is generated between the front side surface 18 and the friction element 120. In this state, the front side surface 18 of the heat-resistant batt material 1 is abraded by sliding the heat-resistant batt material 1 with respect to the friction element 120 in the direction of the face of the front side surface 18, that is, in the direction of the arrow in the drawing. The test conditions are as follows.

[0239] Test conditions

[0240] Friction element temperature: 450°C (heated by a heater)

[0241] Number of test piece reciprocations: 3000 reciprocations (50 reciprocations / min)

[0242] Test piece sliding distance: 100 mm

[0243] Load: 1720 g

[0244] Test piece size: 50 mm (direction perpendicular to needle punching direction) x 300 mm (needle punching direction)

[0245] The test piece of each example and comparative example was sampled so that the broken needle portion occurring during needle punching was located at a position 15 mm from the end of the test piece on one side (in the needle punching direction), and the portion was used as an evaluation portion for the thickness retention rate of the broken needle portion, while the test piece was sampled at a position 15 mm from the end of the test piece on the other side (in the needle punching direction) (a position 35 mm from the one end), so that the broken needle portion was not present, and the portion was used as an evaluation portion for the thickness retention rate of the non-broken needle portion.

[0246] The results are shown in Table 5. Also, the thickness retention rate in the table was calculated according to the following formula.

[0247] Thickness retention rate = 100 - [(thickness before abrasion) - (thickness after abrasion)] / (thickness before abrasion) x 100

[0248] Table 5

[0249]

[0250] As shown in Table 5, it was found that the thickness retention rate of the broken needle portion of Examples 4 to 6 was greater than that of the broken needle portion of Comparative Examples 1 and 2, and the durability was improved.

[0251] Also, although the broken needle portion of the examples was broken like that of the comparative examples, the thickness of the broken needle portion of the examples was thinner than that of the comparative examples. It is considered that the broken needle of the comparative examples easily occurs at the beginning of needle punching, and, on the contrary, the broken needle of the examples occurs at the end of needle punching (high unit area weight product), and since the broken needle of needle punching is suppressed to the end, the entanglement and integration between the base material layer and the lamination web layer are further developed. That is, in the product of the examples, even if the broken needle occurs, the needle punching effect until the end of needle punching (high unit area weight product) can be obtained.

[0252] While the preferred embodiments of the present application have been described in detail with reference to the accompanying drawings, the application is not limited to any of the examples. It will be apparent to those having ordinary skill in the art to which the present application pertains that various changes and modifications can be made within the scope of the technical idea recited in the claims, and it is understood that such changes and modifications belong to the technical scope of the present application.

Claims

1. A heat-resistant felt material, characterized in that, include: A substrate layer having at least one substrate layer; and A laminated mesh layer, having at least one layer of laminated mesh. The laminated mesh layer is entangled with adjacent layers of the substrate layer on the outer surface of the substrate layer by needle punching, thus becoming an integral part of the substrate layer. The substrate includes a base fabric having filaments containing one or more fibers selected from the group consisting of aromatic polyamide fibers and poly(p-phenylene benzoxazole) fibers. The substrate includes at least one layer of cushioning mesh containing one or more fibers selected from the group consisting of aromatic polyamide fibers and poly(p-phenylene benzoxazole) fibers. The fibers are entangled and integrally formed on at least one surface of the base fabric by needle punching. The area weight of the cushioning mesh is 50 g / m². 2 Above and 250g / m 2 the following, The density of the base fabric is 0.60 g / cm³. 3 the following.

2. The heat-resistant felt material according to claim 1, characterized in that, The density of the base fabric is 0.45 g / cm³. 3 the following.

3. The heat-resistant felt material according to claim 1, characterized in that, The density of the base fabric is 0.15 g / cm³. 3 above.

4. The heat-resistant felt material according to claim 1, characterized in that, The buffer mesh comprises one or more fibers selected from the group consisting of aromatic polyamide fibers and poly(p-phenylenebenzoxazole) fibers, with a fiber composition ratio of 50% or more and 100% or less by weight.

5. The heat-resistant felt material according to claim 1, characterized in that, The base fabric has a warp count of 12 threads / inch and a weft count of 57 threads / inch.

6. The heat-resistant felt material according to claim 1, characterized in that, The base fabric has a unit area weight of 45g / m². 2 Above and 400g / m 2 the following.

7. The heat-resistant felt material according to claim 1, characterized in that, The thickness of the base fabric is 0.30 mm or more and 0.45 mm or less.

8. The heat-resistant felt material according to claim 1, characterized in that, The lamination web comprises one or more fibers selected from the group consisting of aromatic polyamide fibers and poly(p-phenylenebenzoxazole) fibers, with a fiber composition ratio of 50% or more and 100% or less by weight.

9. The heat-resistant felt material according to claim 1, characterized in that, The base fabric comprises one or more fibers selected from the group consisting of aromatic polyamide fibers and poly(p-phenylenebenzoxazole) fibers, with a fiber composition ratio of more than 50% by weight and less than 100% by weight.

10. The heat-resistant felt material according to claim 1, characterized in that, The substrate layer comprises two or more of the substrate layers.

11. The heat-resistant felt material according to claim 1, characterized in that, This includes two or more layers of the aforementioned laminated mesh.

12. The heat-resistant felt material according to claim 1, characterized in that, The total unit area weight of the base fabric of the substrate layer is 90g / m². 2 Up to 1000g / m 2 .

13. The heat-resistant felt material according to claim 1, characterized in that, The heat-resistant felt material has a unit area weight of 2000 g / m². 2 above.

14. The heat-resistant felt material according to claim 1, characterized in that, The heat-resistant felt material has a unit area weight of 4000 g / m². 2 above.

15. The heat-resistant felt material according to claim 1, characterized in that, The heat-resistant felt material is in the shape of a flat plate.

16. The heat-resistant felt material according to claim 1, characterized in that, The heat-resistant felt material is in the shape of a strip.

17. The heat-resistant felt material according to claim 1, characterized in that, The heat-resistant felt material is cylindrical in shape.

18. A method for preparing heat-resistant felt materials, characterized in that, include: Step (a) involves preparing a substrate comprising at least one layer of a base fabric, said base fabric having fibers containing one or more fibers selected from the group consisting of aromatic polyamide fibers and poly(p-phenylenebenzoxazole) fibers and having a density of 0.60 g / cm³. 3 The substrate comprises at least one layer of cushioning mesh, the cushioning mesh containing one or more fibers selected from the group consisting of aromatic polyamide fibers and poly(p-phenylenebenzoxazole) fibers, the fibers being entangled and integrally formed on at least one surface of the base fabric by needle punching, and the area weight of the cushioning mesh being 50 g / m². 2 Above and 250g / m 2 the following; Step (b): Prepare the mesh for lamination; as well as Step (c) involves placing at least one layer of the laminated mesh obtained in step (b) onto at least the outer surface of the substrate obtained in step (a), and then binding and integrating it by needle punching to obtain a heat-resistant felt material.

Images