Felt material, conveying material, and method for manufacturing felt material

Abstract

The present invention provides a felt material having high heat resistance and durability, as well as a novel felt material containing specific fibers in the same layer that were not previously used in a flocked fiber layer. A felt material includes a substrate layer and flocked fiber layers, at least one of the flocked fiber layers being a heat resistant flocked fiber layer comprising at least one fiber selected from the group consisting of polyphenylene oxadiazole fibers and polyoxadiazole fibers.

Description

Technical Field

[0001] The invention relates to a felt material, a conveying material and a method for manufacturing the felt material. Background Art

[0002] In the manufacturing of aluminum extrusion profiles, after being extruded by an extruder, the aluminum extrusion profile is pulled by a tractor and moved on a run-out tube or placed on a run-out conveyor to enter the conveying step. Then, the aluminum profile is gradually cooled while being conveyed by a cooling belt and a stretching belt, and is stretched and shaped by the stretchers at both ends of the stretching belt before being conveyed to the saw table belt.

[0003] Since the temperature of aluminum extrusion profiles is very high, heat-resistant felt materials are sometimes used for the roll-cover material of the output tube, the pad installed on the output conveyor, and the conveyor belts such as cooling belts, stretching belts and saw table belts.

[0004] In the production of steel sheets on a continuous hot-dip galvanizing line (CGL), the steel sheets electroplated in the zinc pot are conveyed by a top roller located downstream of the zinc pot of the CGL. In general, in order to prevent zinc from adhering to the top roller or to prevent defects from being generated on the steel sheet, the top roller is covered with a heat-resistant felt material as a roller covering material.

[0005] Patent document 1 describes a heat-resistant felt comprising a substrate layer having at least one substrate, which is used for a conveyor roller covering of an aluminum extruded profile or a conveyor belt, or a roller covering of a CGL, and discloses that the substrate layer comprises a base cloth having yarns comprising at least one fiber selected from aromatic polyamide fibers and polyparaphenylene benzobisoxazole fibers (hereinafter also referred to as "PBO fibers").

[0006] Patent document 2 discloses a cylindrical nonwoven fabric roller for ironmaking, which has a nonwoven fabric formed of polyparaphenylene benzobisoxazole fibers as a surface layer, a nonwoven fabric formed of para-aramid fibers as an inner layer, and a cylindrical base fabric formed of heat-resistant fibers arranged inside the inner layer.

[0007] In addition, Patent Document 3 describes a heat-resistant felt for high-temperature products in which a heat-resistant fiber web formed by compounding or laminating metal fibers or inorganic fibers, or compounding or laminating metal fibers or inorganic fibers with heat-resistant organic fibers is integrally entangled by needle punching. In addition, as the above-mentioned heat-resistant fiber web, a method of using a fiber composited with glass fiber and para-aramid fiber is disclosed.

[0008] Prior art literature

[0009] Patent Literature

[0010] Patent Document 1 Japanese Patent Application Publication No. 2021-160092

[0011] Patent Document 2: Japanese Patent Application Laid-Open No. 2000-064014

[0012] Patent Document 3: Japanese Patent Application Laid-Open No. 8-296160 Summary of the invention

[0013] Problem that the invention aims to solve

[0014] Conveyor materials used in conveyor belts or conveyor roller covers of aluminum extruded profiles and conveyor materials used in roller covers of CGLs require higher heat resistance due to further increases in the temperature of the metals being conveyed, and further durability is required from the perspective of cost reduction.

[0015] In the conveyor belt or roller cover described in Patent Document 1, heat resistance is improved by using heat-resistant fibers such as aromatic polyamide fibers or PBO fibers for the substrate (woven fabric, base fabric) or the web (nonwoven fabric) laminated on the substrate as its constituent elements.

[0016] In addition, in the cylindrical nonwoven fabric roller for iron and steel production described in Patent Document 2, heat resistance is improved by using a nonwoven fabric formed of PBO fibers as a surface layer as a component thereof.

[0017] Furthermore, in the heat-resistant felt for high-temperature products described in Patent Document 3, the heat resistance of the felt is improved by compounding glass fibers with para-aramid fibers.

[0018] The conveying material using the above-mentioned conventional felt material shows heat resistance and durability sufficient for conveying objects at a temperature of 200 to 400°C. However, in recent years, there has been a new demand for conveying objects at a higher temperature. In the conventional conveying materials, if the object in the high temperature state is conveyed multiple times, the fiber strength is sometimes significantly reduced due to thermal degradation (wear progresses faster), and the heat resistance and durability may not be sufficient. In addition, from the perspective of environmental protection and the health and safety of operators, in order to improve heat resistance and durability, the use of inorganic materials such as glass fibers should be avoided as much as possible.

[0019] The present invention is accomplished in view of the above-mentioned prior art, and its object is to provide a felt material having high heat resistance and durability. In addition, another object of the present invention is to provide a novel felt material, which contains specific fibers that have not been used in a flocking fiber layer (batt fiber layer) in the same layer.

[0020] Solutions to the problem

[0021] The inventors of the present invention have repeatedly conducted in-depth research to solve the above-mentioned problems, and found that in a felt material including a base material layer and a flocking fiber layer, the above-mentioned problems can be solved by making at least one layer of the flocking fiber layer a heat-resistant flocking fiber layer containing specific fibers, thereby completing the present invention.

[0022] That is, the present invention relates to the following contents.

[0023] [1] A felt material comprising a base material layer and a flocking fiber layer,

[0024] At least one of the flocked fiber layers is a heat-resistant flocked fiber layer including at least one fiber selected from the group consisting of polyphenylene oxadiazole fibers and polyoxadiazole fibers.

[0025] [2] The felt material according to [1], wherein the heat-resistant flocking fiber layer is located on the outermost side in the stacking direction.

[0026] [3] The felt material according to [1] or [2], wherein the base layer comprises at least one fiber selected from the group consisting of aramid fiber, polyphenylene oxadiazole fiber, polyoxadiazole fiber, polyparaphenylene benzobisoxazole fiber and polyimide fiber.

[0027] [4] The felt material according to any one of [1] to [3], wherein the thickness of the felt material is 1 mm to 16 mm.

[0028] [5] The felt material according to any one of [1] to [4], wherein the weight per unit area of ​​at least one layer of the flocked fiber layer is 350 g / m 2 ~5500g / m 2 .

[0029] [6] The felt material according to any one of [1] to [5], further comprising an additional flocking fiber layer as the flocking fiber layer.

[0030] [7] The felt material according to [6], wherein the additional flocking fiber layer contains at least one fiber selected from the group consisting of aromatic polyamide fibers, carbon fibers, polyparaphenylene benzobisoxazole fibers, polyimide fibers, fluorine fibers, glass fibers, and polyphenylene sulfide fibers.

[0031] [8] The felt material according to any one of [1] to [7], which is in the form of a flat plate.

[0032] [9] The felt material according to any one of [1] to [7], which is in a strip shape.

[0033]

[10] The felt material according to any one of [1] to [7], which is cylindrical.

[0034]

[11] A conveying material comprising the felt material according to any one of [1] to

[10] .

[0035]

[12] A method for producing a felt material according to any one of [1] to

[10] , comprising the following steps (a) and (b) in sequence:

[0036] (a) a step of disposing a fiber web composed of flocking fibers on at least one side of the substrate layer;

[0037] (b) A step of forming the flocked fiber layer adjacent to the base layer by entangled the fiber web and the base layer with each other.

[0038] Effects of the Invention

[0039] The felt material of the present invention has high heat resistance and durability. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 This is a schematic diagram showing one form of the felt material according to the embodiment of the present invention.

[0041] Figure 2 This is a schematic diagram showing one form of the felt material according to the embodiment of the present invention.

[0042] Figure 3 This is a schematic diagram showing one form of the felt material according to the embodiment of the present invention.

[0043] Figure 4 This is a schematic diagram showing one form of the felt material according to the embodiment of the present invention.

[0044] Figure 5 This is a schematic diagram showing one form of the felt material according to the embodiment of the present invention.

[0045] Figure 6This is a schematic diagram showing one form of the felt material according to the embodiment of the present invention.

[0046] Figure 7 This is a schematic diagram showing one form of the felt material according to the embodiment of the present invention.

[0047] Figure 8 This is a schematic diagram showing one form of the felt material according to the embodiment of the present invention.

[0048] Fig. 9 This is a schematic diagram showing one embodiment of a conveyor belt material when an aluminum extruded profile is produced using a felt material according to an embodiment of the present invention.

[0049] Fig.10 This is a schematic diagram showing one embodiment of a conveyor roller covering material when manufacturing an aluminum extruded profile using a felt material according to an embodiment of the present invention.

[0050] Fig.11 This is a schematic diagram showing one embodiment of a roll covering material of a continuous hot-dip galvanized steel sheet line (CGL) using a felt material according to an embodiment of the present invention.

[0051] Fig.12 Schematic diagram showing a felt material of a comparative example.

[0052] Fig.13 Schematic diagram showing a felt material of a comparative example.

[0053] Fig.14 This is a schematic diagram showing the outline of a heating wear tester used in the heating wear test of the example. DETAILED DESCRIPTION

[0054] <Felt material>

[0055] The felt material of the embodiment of the present invention includes a base material layer and a flocking fiber layer, at least one of the flocking fiber layers is a heat-resistant flocking fiber layer containing at least one fiber selected from the group consisting of polyphenylene oxadiazole fiber and polyoxadiazole fiber (hereinafter, these fibers are collectively referred to as "POD fiber").

[0056] Hereinafter, preferred aspects of the felt material according to the embodiment of the present invention will be described with reference to the accompanying drawings. It should be noted that when the expression "to" is used in the present specification, it is used as an expression including numerical values ​​or physical property values ​​before and after it.

[0057] The felt material of the embodiment of the present invention is, for example, Figure 1 As shown, it includes a heat-resistant flocking fiber layer 10 and a base material layer 20 .

[0058] The thickness of the felt material according to the embodiment of the present invention is not particularly limited, but is preferably 1 mm to 16 mm, more preferably 1.5 mm to 16 mm, and even more preferably 2 mm to 16 mm from the viewpoint of wear resistance.

[0059] The weight per unit area of ​​the felt material of the embodiment of the present invention is not particularly limited, but is preferably 400 g / m2 from the viewpoint of wear resistance. 2 ~6500g / m 2 , more preferably 600g / m 2 ~6500g / m 2 , more preferably 750g / m 2 ~6500g / m 2 .

[0060] [Flocking fiber layer]

[0061] The flocking fiber layer included in the felt material of the embodiment of the present invention is a layer composed of flocking fibers. In more detail, the flocking fiber layer is a fiber assembly layer formed by entanglement of flocking fibers (preferably short-fiber flocking fibers) with each other, and functions as a layer having heat resistance and wear resistance, etc.

[0062] (Heat-resistant flocking fiber layer)

[0063] The felt material of the embodiment of the present invention comprises one or more flocking fiber layers, and at least one of the flocking fiber layers is a heat-resistant flocking fiber layer comprising at least one fiber selected from the group consisting of polyphenylene oxadiazole fibers and polyoxadiazole fibers. In other words, at least one of the flocking fiber layers included in the felt material of the embodiment of the present invention is a heat-resistant flocking fiber layer comprising POD fibers.

[0064] Thus, the felt material according to the embodiment of the present invention can have high heat resistance and durability.

[0065] It should be noted that in this specification, the flocking fiber layer including POD fibers is referred to as a “heat-resistant flocking fiber layer”, and other flocking fiber layers are referred to as “additional flocking fiber layers.” The additional flocking fiber layer may or may not be heat-resistant.

[0066] In addition, the flocking fiber layer may be formed by entanglement of two or more layers made of the same material to form one flocking fiber layer. In the case of entanglement of two or more layers made of different materials, each of them constitutes two or more independent flocking fiber layers that are different from each other. Sometimes, a layer formed by stacking two or more flocking fiber layers that are different from each other is collectively referred to as a "stacked flocking fiber layer".

[0067] The polyphenylene oxadiazole and polyoxadiazole constituting the above-mentioned POD fiber are also referred to as polyphenylene-1,3,4-oxadiazole and poly-1,3,4-oxadiazole, respectively.

[0068] In addition, in polyphenylene oxadiazole, there are isomers of ortho (o-), meta (m-) and para (p-) positions regarding the bonds of the phenylene part. In the embodiment of the present invention, from the perspective of heat resistance, as the POD fiber, it is preferred to use a meta-type poly(m-phenylene oxadiazole), a para-type poly(p-phenylene oxadiazole), or a meta-type and para-type copolymer poly(m-phenylene)(p-phenylene)oxadiazole, or a combination thereof, and it is more preferred to use a poly(m-phenylene)(p-phenylene)oxadiazole. Hereinafter, the structure of the POD fiber mentioned in this specification and its preferred embodiment can be said to be the same.

[0069] There is no particular restriction on the proportion of POD fibers in the heat-resistant flocking fiber layer, but from the perspective of obtaining high heat resistance and durability, the fiber composition ratio is preferably 50% to 100% by mass, more preferably 75% to 100% by mass, further preferably 90% to 100% by mass, and particularly preferably 100% by mass.

[0070] In addition, from the perspective of environmental protection and the health and safety of operators, the heat-resistant flocking fiber layer preferably does not contain inorganic materials such as glass fibers.

[0071] Examples of fibers other than POD fibers that may be included in the heat-resistant flocking fiber layer include aromatic polyamide fibers, carbon fibers, PBO fibers, polyimide fibers (hereinafter also referred to as “PI fibers”), fluorine fibers, glass fibers, and polyphenylene sulfide fibers.

[0072] In aromatic polyamide fibers, there are ortho (o-), meta (m-) and para (p-) isomers regarding the bond of the phenylene moiety. In the embodiment of the present invention, from the viewpoint of heat resistance, as aromatic polyamide fibers, m-aromatic polyamide fibers of meta-, p-aromatic polyamide fibers of para-, or mp-aromatic polyamide fibers of a copolymer of meta- and para-, or a combination thereof are more preferably used. Hereinafter, the structure of aromatic polyamide fibers and preferred embodiments thereof mentioned in this specification can be said to be the same.

[0073] (Additional flocking fiber layer)

[0074] The felt material of the embodiment of the present invention may further include an additional flocking fiber layer. As mentioned above, the "additional flocking fiber layer" in this specification refers to a flocking fiber layer that does not include POD fibers.

[0075] As the additional flocking fiber layer, for example, a flocking fiber layer containing at least one fiber selected from aromatic polyamide fiber, carbon fiber, poly(p-phenylene benzobisoxazole) fiber, polyimide fiber, fluorine fiber, glass fiber, and polyphenylene sulfide fiber can be cited. Among them, aromatic polyamide fiber is preferred from the perspective of wear resistance. In addition, from the perspective of environmental protection and the health and safety of operators, the additional flocking fiber layer preferably does not contain inorganic materials such as glass fiber.

[0076] However, from the viewpoint of heat resistance, the felt material according to the embodiment of the present invention preferably includes only the heat-resistant flocking fiber layer as the flocking fiber layer.

[0077] (Specific method of flocking fiber layer in felt material)

[0078] As specific aspects of the felt material of the embodiment of the present invention including the additional flocking fiber layer, for example, Figure 1 , Figure 4 , Figure 5 , Figure 8 In the embodiment shown in these figures, the felt material comprises, in addition to the heat-resistant flocking fiber layer 10, an additional flocking fiber layer 10A which does not contain POD fibers.

[0079] The felt material of the embodiment of the present invention may include only one flocking fiber layer (ie, only one heat-resistant flocking fiber layer), or may include more than two flocking fiber layers. Figure 2 , Figure 3 As shown, only one heat-resistant flocking fiber layer 10 may be included.

[0080] In the case where the felt material of the embodiment of the present invention comprises two or more flocking fiber layers, as Figure 1 , Figure 4 , Figure 5 , Figure 8 As shown, as the flocking fiber layer, both the heat-resistant flocking fiber layer 10 and the additional flocking fiber layer 10A may be included. Figure 6 , Figure 7 As shown, as the flocking fiber layer, only two or more heat-resistant flocking fiber layers 10 may be included.

[0081] From the perspective of obtaining high heat resistance and durability, the felt material of the embodiment of the present invention is preferably a felt material in which at least one of the flocking fiber layers is a heat-resistant flocking fiber layer located on the outermost side in the stacking direction. That is, the felt material of the embodiment of the present invention is preferably a felt material in which the heat-resistant flocking fiber layer is located on the outermost side in the stacking direction.

[0082] When the felt material includes two or more flocking fiber layers, the outermost layer in the stacking direction is preferably a heat-resistant flocking fiber layer, and the heat-resistant flocking fiber layer or the additional flocking fiber layer is located between the heat-resistant flocking fiber layer and the substrate.

[0083] When the felt material of the embodiment of the present invention is used as the following conveying material, from the perspective of heat resistance and wear resistance, it is preferred that only one heat-resistant flocking fiber layer is included, which is located on the outermost side in the stacking direction, and no additional flocking fiber layer is included. In this case, as a preferred mode, the heat-resistant flocking fiber layer is configured to contact the conveying object in a high temperature state.

[0084] The flocking fiber layer is preferably stacked adjacent to at least one side of the substrate layer, and can also be stacked adjacent to both sides of the substrate layer. For example, a fiber web composed of flocking fibers is arranged on the substrate layer and entangled with each other by needle punching, thereby forming a flocking fiber layer stacked adjacent to the substrate layer.

[0085] (Preferred range of size, etc.)

[0086] The fiber length of the flocking fibers constituting the flocking fiber layer is not particularly limited, but is preferably 20 mm to 120 mm, more preferably 30 mm to 120 mm, and even more preferably 40 mm to 120 mm from the viewpoint of abrasion resistance.

[0087] The fineness of the flocking fibers constituting the flocking fiber layer is not particularly limited, but is preferably 1 dtex to 10 dtex, more preferably 2 dtex to 8 dtex, and further preferably 3 dtex to 6 dtex from the viewpoint of abrasion resistance.

[0088] There is no particular restriction on the weight per unit area of ​​the flocking fiber layer, but from the perspective of wear resistance, the weight per unit area of ​​at least one layer of the flocking fiber layer is preferably 350 g / m 2 ~5500g / m 2 , more preferably 540g / m 2 ~5500g / m 2 , more preferably 680g / m 2 ~5500g / m 2 .

[0089] When the felt material according to the embodiment of the present invention includes two or more flocked fiber layers, it is preferred that both layers satisfy the above-mentioned weight per unit area.

[0090] The thickness of the flocking fiber layer is not particularly limited, but is preferably 1 mm to 16 mm, more preferably 1.5 mm to 16 mm, and even more preferably 2 mm to 16 mm from the viewpoint of abrasion resistance.

[0091] When the felt material according to the embodiment of the present invention includes two or more flocking fiber layers, it is preferable that both layers satisfy the above-mentioned thickness.

[0092] (Laminated flocking fiber layers)

[0093] In the case where the felt material of the embodiment of the present invention includes a stacked flocking fiber layer, the heat-resistant flocking fiber layer can be configured to be included in the stacked flocking fiber layer, or it can be configured outside the stacked flocking fiber layer. In the case where the heat-resistant flocking fiber layer is configured to be included in the stacked flocking fiber layer, and in the case where the heat-resistant flocking fiber layer is configured outside the stacked flocking fiber layer, the felt material preferably includes the heat-resistant flocking fiber layer in a manner of being located at the outermost side in the stacking direction.

[0094] For example, as a layer structure of a stacked flocking fiber layer including a heat-resistant flocking fiber layer and an additional flocking fiber layer, the heat-resistant flocking fiber layer is arranged so as to be located outermost in the stacking direction of the felt material, and the heat-resistant flocking fiber layer or the additional flocking fiber layer is arranged adjacent to it.

[0095] When the laminated flocking fiber layer is constituted to include a heat-resistant flocking fiber layer and an additional flocking fiber layer, similarly, as the fiber constituting the additional flocking fiber layer, for example, at least one fiber selected from aromatic polyamide fiber, carbon fiber, polyparaphenylene benzobisoxazole fiber, polyimide fiber, fluorine fiber, glass fiber and polyphenylene sulfide fiber can be cited. Among them, aromatic polyamide fiber is preferred from the viewpoint of wear resistance.

[0096] [Base material layer]

[0097] The felt material according to the embodiment of the present invention includes one or two or more base material layers.

[0098] The fibers constituting the substrate layer are not particularly limited, but from the viewpoint of strength and heat resistance, preferably at least one fiber selected from aromatic polyamide fibers, polyphenylene oxadiazole fibers, polyoxadiazole fibers, polyparaphenylene benzobisoxazole fibers and polyimide fibers is used, more preferably aromatic polyamide fibers, polyphenylene oxadiazole fibers or polyoxadiazole fibers, or a combination thereof, and still more preferably aromatic polyamide fibers.

[0099] The felt material according to the embodiment of the present invention may include only one substrate layer or two or more substrate layers. From the viewpoint of dimensional stability and strength, it is preferred to include two or more substrate layers.

[0100] When the felt material of an embodiment of the present invention includes more than two substrate layers, all substrate layers may be adjacent to each other, or layers other than substrate layers may be included between the substrate layers. Furthermore, a pair of substrate layers may be adjacent to each other, and another pair of substrate layers may include layers other than substrate layers between them.

[0101] In addition, even if two or more layers consisting of the same material are adjacent to each other, two or more base material layers that are independent and different from each other are formed.

[0102] The base material layer may be composed of, for example, woven fabric, nonwoven fabric or lattice material. The woven fabric, nonwoven fabric and lattice material may be formed using staple yarn or filament yarn obtained from fibers. When the base material layer is woven fabric, the structure of the woven fabric is not particularly limited, and any one of plain weave, twill weave, satin weave or multiple weaves thereof may be used.

[0103] When the felt material according to the embodiment of the present invention includes two or more base material layers, each layer may be composed of the above-mentioned woven fabric, nonwoven fabric or lattice-shaped material.

[0104] The thickness of the substrate layer is not particularly limited, but is preferably 0.1 mm to 3 mm, more preferably 0.15 mm to 2 mm, and even more preferably 0.2 mm to 1 mm from the viewpoint of strength.

[0105] When the felt material according to the embodiment of the present invention includes two or more base material layers, it is preferred that each base material layer satisfy the above-mentioned thickness.

[0106] The weight per unit area of ​​the substrate layer is not particularly limited, but is preferably 50 g / m 2 ~500g / m 2 , more preferably 60g / m 2 ~300g / m 2 , more preferably 70g / m 2 ~200g / m 2 .

[0107] When the felt material according to the embodiment of the present invention includes two or more substrate layers, it is preferred that each substrate layer satisfy the above-mentioned weight per unit area.

[0108] From the viewpoint of dimensional stability and strength, the felt material according to the embodiment of the present invention preferably includes two or more base material layers consisting of one layer.

[0109] [Other layers]

[0110] The felt material of the embodiment of the present invention may include other layers in addition to the base material layer and the flocking fiber layer. Examples of other layers include a film layer, a paper layer, a series, a sheet, and a foam.

[0111] The felt material according to the embodiment of the present invention preferably includes only a base material layer and a flocking fiber layer, and more preferably includes only a base material layer and a heat-resistant flocking fiber layer.

[0112] [shape]

[0113] The felt material according to the embodiment of the present invention can be made into various shapes according to its application, and may be, for example, in the form of a flat plate, a belt, or a cylinder.

[0114] [use]

[0115] Since the felt material of the embodiment of the present invention has high heat resistance and durability, it is suitable for use as a conveying material for conveying objects in a high temperature state. Examples of the objects in a high temperature state include metals (aluminum, iron, etc.), glass, ceramics, etc., which are in a temperature state of 200°C to 500°C.

[0116] In addition, examples of such applications include conveyor roll covering materials used in the production of aluminum extruded profiles and roll covering materials for a continuous hot-dip galvanized steel sheet line (CGL).

[0117] <Conveying materials>

[0118] The conveying material according to the embodiment of the present invention includes the above-mentioned felt material.

[0119] Hereinafter, preferred modes of conveying materials according to the embodiments of the present invention will be described with reference to the drawings.

[0120] Fig. 9 1 is a schematic diagram showing an example of a felt material 100 according to an embodiment of the present invention used as a conveyor belt material when manufacturing an aluminum extruded profile. In this example, the felt material 100 is in the shape of an endless belt. Fig. 9 In the example shown, the felt material 100 includes a base material layer 120 and a laminated flocking fiber layer 110. The laminated flocking fiber layer 110 is a layer formed by laminating a heat-resistant flocking fiber layer and an additional flocking fiber layer so that the heat-resistant flocking fiber layer is located outermost in the lamination direction.

[0121] Fig.10 1 is a schematic diagram showing an example of a felt material 200 according to an embodiment of the present invention used as a conveyor roller covering material when manufacturing an aluminum extruded profile. In this example, the felt material 200 is cylindrical. Fig.10In the example shown, the felt material 200 includes a base material layer 220 and a laminated flocking fiber layer 210. The laminated flocking fiber layer 210 is a layer formed by laminating a heat-resistant flocking fiber layer and an additional flocking fiber layer so that the heat-resistant flocking fiber layer is located outermost in the lamination direction.

[0122] Fig.11 1 is a schematic diagram showing an example of a felt material 300 according to an embodiment of the present invention used as a roll covering material for a continuous hot-dip galvanized steel sheet production line (CGL). In this example, the felt material 300 is cylindrical. Fig.11 In the example shown, the felt material 300 includes a base material layer 320 and a laminated flocking fiber layer 310. The laminated flocking fiber layer 310 is a layer formed by laminating a heat-resistant flocking fiber layer and an additional flocking fiber layer so that the heat-resistant flocking fiber layer is located outermost in the lamination direction.

[0123] The heat resistance and durability that the above-mentioned conveying materials should have are generally such that they can convey objects at a temperature of 200 to 400° C. However, in recent years, it is sometimes necessary to convey objects at a higher temperature, for example, it is sometimes necessary to convey materials that can convey objects at a temperature of 400 to 550° C. Therefore, the requirements for heat resistance and durability of conveying materials are becoming increasingly higher.

[0124] The conveying material according to the embodiment of the present invention includes the felt material and thus has higher heat resistance and durability than conventional products, and can therefore fully meet such demands.

[0125] <Method for producing felt material>

[0126] The method for producing a felt material according to an embodiment of the present invention preferably includes the following steps (a) and (b) in sequence.

[0127] (a) A step of disposing a fiber web composed of flocking fibers on at least one surface of a base material layer.

[0128] (b) A step of forming a flocked fiber layer adjacent to the base layer by entanglement of the fiber web and the base layer with each other.

[0129] In the method for producing a felt material according to the embodiment of the present invention, at least one layer of the flocked fiber layers is a heat-resistant flocked fiber layer including at least one fiber selected from the group consisting of polyphenylene oxadiazole fibers and polyoxadiazole fibers.

[0130] The details and preferred embodiments of the base material layer, flocking fibers, fiber web, and flocking fiber layer used in the method for producing a felt material according to the embodiment of the present invention are the same as those described above.

[0131] The method for producing the felt material according to the embodiment of the present invention can be appropriately changed according to the form of the specific felt material to be produced.

[0132] For example, when the flocking fiber layer is composed of multiple layers, that is, when two or more layers composed of the same material are entangled to form a flocking fiber layer, or when two or more layers composed of different materials are entangled to form different flocking fiber layers, as the fiber web of the above step (b), a plurality of fiber webs that are pre-entangled with each other can also be used to form the flocking fiber layer. Alternatively, in the above step (b), after the fiber web and the base material layer are entangled with each other, the flocking fiber layer can be formed by entanglement of other fiber webs composed of the same or different materials with the above fiber web.

[0133] Example

[0134] Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to these Examples.

[0135] [Example 1] Base material layer: aromatic polyamide fiber / additional flocking fiber layer: aromatic polyamide fiber (base material layer side) / heat-resistant flocking fiber layer: POD fiber (outermost side in the stacking direction)

[0136] (Formation of Base Material Layer)

[0137] The base layer was formed by weaving short staple yarn of aromatic polyamide fiber (trade name: Conex; meta-aromatic polyamide fiber manufactured by Teijin Limited) into a plain weave. The base layer had a thickness of 0.5 mm and a unit weight of 160 g / m 2 .

[0138] (Formation of heat-resistant flocking fiber layer and additional flocking fiber layer and production of felt material)

[0139] A fiber web (fiber length: 51 mm; fineness: 2.5 dtex) composed of aromatic polyamide fibers (trade name: Kevlar (registered trademark); para-aromatic polyamide fibers manufactured by DuPont Toray Industries, Inc.) is stacked on one side of the substrate layer prepared above and needle-punched. Furthermore, a fiber web (fiber length: 64 mm; fineness: 4.4 dtex) composed of poly(m-phenylene)(p-phenylene)oxadiazole fibers (POD fibers) (trade name: PODRUN; manufactured by Jiangsu Baode New Materials Co., Ltd.) is stacked on the above-mentioned fiber web and needle-punched to produce the felt material of Example 1. By Figure 1 The felt material of Example 1 is schematically shown.

[0140] The felt material of Example 1 includes a laminated flocking fiber layer consisting of a heat-resistant flocking fiber layer (POD fiber layer) and an additional flocking fiber layer (aromatic polyamide fiber layer). In the above two layers constituting the laminated flocking fiber layer, the additional flocking fiber layer is located on the substrate layer side, and the heat-resistant flocking fiber layer is located on the outermost side in the lamination direction of the felt material. In addition, the thickness of the heat-resistant flocking fiber layer is 3 mm, and the weight per unit area is 1200 g / m 2 The additional flocking fiber layer has a thickness of 9 mm and a unit area weight of 3600 g / m 2 .

[0141] [Example 2] Base material layer: aromatic polyamide fiber / heat-resistant flocking fiber layer: POD fiber

[0142] The felt material of Example 2 was prepared in the same manner as in Example 1, except that a fiber web composed of POD fibers was used instead of a fiber web composed of aromatic polyamide fibers when forming the flocking fiber layer. Figure 2 The felt material of Example 2 is schematically shown.

[0143] The heat-resistant flocking fiber layer of the felt material of Example 2 is formed by needle-punching the same fiber web (POD fiber). In the production of the felt material, after the fiber web (POD fiber) on the substrate layer side and the substrate layer are entangled with each other, the same fiber web (POD fiber) is entangled with the above-mentioned fiber web to form a heat-resistant flocking fiber layer. In addition, the thickness of the heat-resistant flocking fiber layer is 12 mm, and the weight per unit area is 4800 g / m 2 .

[0144] [Example 3] Base material layer: aromatic polyamide fiber / additional flocking fiber layer: carbon fiber and aromatic polyamide fiber (base material layer side) / heat-resistant flocking fiber layer: POD fiber (outermost side in the stacking direction)

[0145] The felt material of Example 3 was prepared by the same method as in Example 1, except that a fiber web (fiber length: 51 mm; fineness: 2.2 dtex) composed of 70% by mass of carbon fibers (trade name: Pyromex (registered trademark); manufactured by Teijin Limited) and 30% by mass of a fiber web composed of aromatic polyamide fibers was used instead of the fiber web composed of aromatic polyamide fibers when forming the additional flocking fiber layer. Figure 1 The felt material of Example 3 is schematically shown.

[0146] The felt material of Example 3 includes a laminated flocking fiber layer consisting of a heat-resistant flocking fiber layer (POD fiber layer) and an additional flocking fiber layer (carbon fiber layer). In the above two layers constituting the laminated flocking fiber layer, the additional flocking fiber layer is located on the substrate layer side, and the heat-resistant flocking fiber layer is located on the outermost side in the lamination direction of the felt material. In addition, the thickness of the heat-resistant flocking fiber layer is 3 mm, and the weight per unit area is 1200 g / m 2 The additional flocking fiber layer has a thickness of 9 mm and a unit area weight of 3600 g / m 2 .

[0147] [Example 4] Base material layer: POD fiber / additional flocking fiber layer: aromatic polyamide fiber (base material layer side) / heat-resistant flocking fiber layer: POD fiber (outermost side in the stacking direction)

[0148] The felt material of Example 4 was prepared in the same manner as in Example 1, except that spun yarn composed of POD fibers was used instead of spun yarn composed of aromatic polyamide fibers when forming the base material layer. Figure 1 The felt material of Example 4 is schematically shown.

[0149] The felt material of Example 4 includes a laminated flocking fiber layer consisting of a heat-resistant flocking fiber layer (POD fiber layer) and an additional flocking fiber layer (aromatic polyamide fiber layer). In the above two layers constituting the laminated flocking fiber layer, the additional flocking fiber layer is located on the substrate layer side, and the heat-resistant flocking fiber layer is located on the outermost side in the lamination direction of the felt material. In addition, the thickness of the heat-resistant flocking fiber layer is 3 mm, and the weight per unit area is 1200 g / m 2 The additional flocking fiber layer has a thickness of 9 mm and a unit area weight of 3600 g / m 2 .

[0150] [Example 5] Base material layer: aromatic polyamide fiber / additional flocking fiber layer: aromatic polyamide fiber (base material layer side) / heat-resistant flocking fiber layer: POD fiber (outermost side in the stacking direction)

[0151] The felt material of Example 5 was prepared in the same manner as in Example 1, except that the amounts of the fiber web composed of POD fibers and the fiber web composed of aromatic polyamide fibers used in forming the heat-resistant flocking fiber layer and the additional flocking fiber layer were each set to half of those in Example 1. Figure 1 The felt material of Example 5 is schematically shown.

[0152] The felt material of Example 5 includes a laminated flocking fiber layer consisting of a heat-resistant flocking fiber layer (POD fiber layer) and an additional flocking fiber layer (aromatic polyamide fiber layer). In the above two layers constituting the laminated flocking fiber layer, the additional flocking fiber layer is located on the substrate layer side, and the heat-resistant flocking fiber layer is located on the outermost side in the lamination direction of the felt material. In addition, the thickness of the heat-resistant flocking fiber layer is 1.5 mm, and the weight per unit area is 600 g / m 2 The thickness of the additional flocking fiber layer is 4.5mm and the weight per unit area is 1800g / m 2 .

[0153] [Comparative Example 1] Base layer: aromatic polyamide fiber / additional flocking fiber layer: aromatic polyamide fiber (base layer side) / additional flocking fiber layer: PI fiber (outermost side in the stacking direction)

[0154] The felt material of Comparative Example 1 was prepared in the same manner as in Example 1, except that a fiber web (fiber length: 64 mm; fineness: 6.7 dtex) composed of PI fibers (trade name: Yilun; Changchun Gaoqi Polyimide Materials Co., Ltd.) was used instead of a fiber web composed of POD fibers when forming the additional flocking fiber layer. Fig.12 The felt material of Comparative Example 1 is schematically shown.

[0155] The felt material of Comparative Example 1 includes a stacked flocking fiber layer consisting of an additional flocking fiber layer (PI fiber layer) and another additional flocking fiber layer (aromatic polyamide fiber layer). In the above two layers constituting the stacked flocking fiber layer, the aromatic polyamide fiber layer is located on the substrate layer side, and the PI fiber layer is located on the outermost side in the stacking direction of the felt material. In addition, the thickness of the additional flocking fiber layer (PI fiber layer) is 3 mm, and the weight per unit area is 1200 g / m 2 The thickness of the additional flocking fiber layer (aromatic polyamide fiber layer) is 9 mm and the weight per unit area is 3600 g / m 2 .

[0156] [Comparative Example 2] Base material layer: aromatic polyamide fiber / additional flocking fiber layer: aromatic polyamide fiber (base material layer side) / additional flocking fiber layer: aromatic polyamide fiber (outermost side in the stacking direction)

[0157] The felt material of Comparative Example 2 was prepared in the same manner as in Example 1, except that a fiber web (fiber length: 51 mm; fineness: 3.8 dtex) composed of aromatic polyamide fibers (trade name: Technora (registered trademark); para-aromatic polyamide fibers manufactured by Teijin Limited) was used instead of a fiber web composed of POD fibers when forming the additional flocking fiber layer. Fig.12 The felt material of Comparative Example 2 is schematically shown.

[0158] The felt material of Comparative Example 2 includes a stacked flocking fiber layer consisting of an additional flocking fiber layer (aromatic polyamide fiber layer) and another additional flocking fiber layer (aromatic polyamide fiber layer). It should be noted that the above two additional flocking fiber layers are composed of different aromatic polyamide fibers, and therefore constitute independent additional flocking fiber layers respectively. In the above two layers constituting the stacked flocking fiber layer, the aromatic polyamide fiber (Kevlar (registered trademark)) layer is located on the substrate layer side, and the aromatic polyamide fiber (Technora (registered trademark)) layer is located on the outermost side in the stacking direction of the felt material. In addition, the thickness of the additional flocking fiber layer (aromatic polyamide fiber (Technora) layer) is 3 mm, and the weight per unit area is 1200 g / m 2 The thickness of the additional flocking fiber layer (Kevlar fiber layer) is 9 mm and the weight per unit area is 3600 g / m 2 .

[0159] [Comparative Example 3] Base material layer: aromatic polyamide fiber / additional flocking fiber layer: aromatic polyamide fiber (base material layer side) / additional flocking fiber layer: aromatic polyamide fiber (outermost side in the stacking direction)

[0160] The felt material of Comparative Example 3 was prepared in the same manner as in Example 1, except that a fiber web (fiber length: 51 mm; fineness: 2.5 dtex) composed of aromatic polyamide fibers (trade name: Twaron (registered trademark); para-aromatic polyamide fibers manufactured by Teijin Limited) was used instead of a fiber web composed of POD fibers when forming the additional flocking fiber layer. Fig.12 The felt material of Comparative Example 3 is schematically shown.

[0161] The felt material of Comparative Example 3 includes a stacked flocking fiber layer consisting of an additional flocking fiber layer (aromatic polyamide fiber layer) and another additional flocking fiber layer (aromatic polyamide fiber layer). It should be noted that the above two additional flocking fiber layers are composed of different aromatic polyamide fibers, and therefore constitute independent additional flocking fiber layers respectively. In the two layers constituting the stacked flocking fiber layer, the aromatic polyamide fiber (Kevlar (registered trademark)) layer is located on the substrate layer side, and the aromatic polyamide fiber (Twaron (registered trademark)) layer is located on the outermost side in the stacking direction of the felt material. In addition, the thickness of the additional flocking fiber layer (aromatic polyamide fiber (Twaron) layer) is 3 mm, and the weight per unit area is 1200 g / m 2 The thickness of the additional flocking fiber layer (Kevlar fiber layer) is 9 mm and the weight per unit area is 3600 g / m 2 .

[0162] [Comparative Example 4] Base material layer: aromatic polyamide fiber / additional flocking fiber layer: aromatic polyamide fiber

[0163] The felt material of Comparative Example 4 was prepared in the same manner as in Example 1, except that a fiber web (fiber length: 51 mm; fineness: 2.5 dtex) composed of aromatic polyamide fibers (trade name: Kevlar (registered trademark); para-aromatic polyamide fibers manufactured by DuPont Toray Industries, Inc.) was used instead of a fiber web composed of POD fibers when forming the additional flocking fiber layer. Fig.13 The felt material of Comparative Example 4 is schematically shown.

[0164] The additional flocking fiber layer of the felt material of Comparative Example 4 is formed by needle-punching the same fiber web (aromatic polyamide fiber). In the production of the felt material, after the fiber web (aromatic polyamide fiber) on the substrate layer side and the substrate layer are entangled with each other, the same fiber web (aromatic polyamide fiber) is entangled with the above-mentioned fiber web to form an additional flocking fiber layer. In addition, the thickness of the additional flocking fiber layer is 12 mm, and the weight per unit area is 4800 g / m 2 .

[0165] [Comparative Example 5] Base layer: aromatic polyamide fiber / additional flocking fiber layer: aromatic polyamide fiber (base layer side) / additional flocking fiber layer: PBO fiber (outermost side in the stacking direction)

[0166] The felt material of Comparative Example 5 was prepared in the same manner as in Example 1, except that a fiber web (fiber length: 44 mm; fineness: 1.7 dtex) composed of PBO fibers (trade name: Zylon (registered trademark); manufactured by Toyobo Co., Ltd.) was used instead of a fiber web composed of POD fibers when forming the additional flocking fiber layer. Fig.12 The felt material of Comparative Example 5 is schematically shown.

[0167] The felt material of Comparative Example 5 includes a stacked flocking fiber layer consisting of an additional flocking fiber layer (PBO fiber layer) and another additional flocking fiber layer (aromatic polyamide fiber layer). In the above two layers constituting the stacked flocking fiber layer, the aromatic polyamide fiber (Kevlar (registered trademark)) layer is located on the substrate layer side, and the PBO fiber (Zylon (registered trademark)) layer is located on the outermost side in the stacking direction of the felt material. In addition, the thickness of the additional flocking fiber layer (PBO fiber layer) is 3 mm, and the weight per unit area is 1200 g / m 2 The thickness of the additional flocking fiber layer (Kevlar fiber layer) is 9 mm and the weight per unit area is 3600 g / m2 .

[0168] <Evaluation of wear loss due to heating>

[0169] The felt materials obtained in Examples 1 to 5 and Comparative Examples 1 to 5 were evaluated for loss due to heating wear by the following method.

[0170] It should be noted that, in this specification, the "longitudinal" direction of the felt material and the "longitudinal" direction in the heating wear test refer to the direction parallel to the direction in which the base material layer, etc. is moved in order to install the heat-resistant flocking fiber layer by needle punching when the felt materials of the embodiments and comparative examples are produced. In addition, the "transverse" direction of the felt material and the "transverse" direction in the heating wear test refer to the direction perpendicular to the above-mentioned "longitudinal" direction and in the same plane.

[0171] A felt material (40 cm in length x 20 cm in width) was heated under the following conditions (dry heat exposure). The unheated felt material and the heated felt material were each cut into pieces of 35 cm in length x 5 cm in width to obtain test pieces.

[0172] [Heating (dry heat exposure) conditions of felt material]

[0173] Heating temperature: 300℃

[0174] Heating time: 20 hours

[0175] Heating device: Asahi Science Co., Ltd. high temperature oven H-80

[0176] [Heating wear tester]

[0177] exist Fig.14 In the heating wear tester 500 shown, a wear part 520 is fixed on the top of the sample table 510. The wear part 520 is configured to reach an arbitrary temperature by a heater 511 provided in the sample table 510. Such a heatable wear part 520 is supported by a support portion 530 so that the outer surface of the heat-resistant flocking fiber layer 10 located on the outermost side in the stacking direction of the felt material 1 as the test sheet contacts the wear part 520. In addition, a weight 540 is arranged on the felt material 1 on the opposite side of the wear part 520, thereby generating a predetermined load (stress) between the outer surface of the heat-resistant flocking fiber layer 10 and the wear part 520. In this state, the felt material 1 is slid in the horizontal direction, that is, the direction of the arrow in the figure, relative to the wear part 520, so that the outer surface of the heat-resistant flocking fiber layer 10 of the felt material 1 is worn.

[0178] The obtained test piece was subjected to a heating wear test using the above-mentioned testing machine under the following conditions, and the heating wear loss (mm) was determined as follows. The results are shown in Tables 1 and 2.

[0179] Heating wear loss = thickness before wear - thickness after wear

[0180] [Heating wear test conditions]

[0181] Test (wear parts) temperature: 400°C (heated by heater)

[0182] Wear plate reciprocating times: 3000 reciprocating times (50 reciprocating times / minute)

[0183] ·Test piece sliding distance: 100mm

[0184] ·Load: 1720g

[0185] [Table 1]

[0186]

[0187] [Table 2]

[0188]

[0189] As shown in Table 1, the felt materials of Examples 1 to 5 exhibited high heat resistance and durability. Such a felt material having high heat resistance and durability can be suitably used as a conveying material, for example.

[0190] On the other hand, as shown in Table 2, the felt materials of Comparative Examples 1 to 5 were inferior in heat resistance and durability.

[0191] [Industrial Applicability]

[0192] Since the felt material of the present invention has high heat resistance and durability, it can be used as a conveying material for conveying objects in a high temperature state, such as a conveyor belt material or a conveyor roller covering material in the manufacture of aluminum extruded profiles, or a roller covering material in a hot-dip galvanized steel plate production line (CGL).

[0193] [Explanation of symbols]

[0194] 1, 100, 200, 300 Felt material

[0195] 10 Heat-resistant flocking fiber layer

[0196] 10A Additional flocking fiber layer

[0197] 20 Base material layer

[0198] 110, 210, 310 stacked flocking fiber layers

[0199] 120, 220, 320 base material layer

[0200] 500 Heating Wear Tester

[0201] 510 Sample table

[0202] 511 Heater

[0203] 520 Wear parts

[0204] 530 Support

[0205] 540 Heavy Object

Claims

1. A felt material comprising a substrate layer and a flocking fiber layer, At least one of the flocked fiber layers is a heat-resistant flocked fiber layer including at least one fiber selected from the group consisting of polyphenylene oxadiazole fibers and polyoxadiazole fibers.

2. The felt material according to claim 1, wherein The heat-resistant flocking fiber layer is located at the outermost side in the stacking direction.

3. The felt material according to claim 1, wherein The base layer includes at least one fiber selected from the group consisting of aromatic polyamide fiber, polyphenylene oxadiazole fiber, polyoxadiazole fiber, polyparaphenylene benzobisoxazole fiber, and polyimide fiber.

4. The felt material according to claim 1, wherein The thickness of the felt material is 1 mm to 16 mm.

5. The felt material according to claim 1, wherein The unit area weight of at least one layer of the flocking fiber layer is 350g / m 2 ~5500g / m 2 . The felt material according to claim 1 , further comprising an additional flocking fiber layer as the flocking fiber layer.

7. The felt material according to claim 6, wherein: The additional flocking fiber layer includes at least one fiber selected from the group consisting of aromatic polyamide fiber, carbon fiber, polyparaphenylene benzobisoxazole fiber, polyimide fiber, fluorine fiber, glass fiber, and polyphenylene sulfide fiber. The felt material according to claim 1 , which is in the form of a flat plate.

9. The felt material according to claim 1, which is in the form of a strip.

10. The felt material according to claim 1, which is cylindrical.

11. A conveying material comprising the felt material according to any one of claims 1 to 10.

12. A method for producing a felt material according to any one of claims 1 to 10, comprising the following steps (a) and (b) in sequence: (a) a step of disposing a fiber web composed of flocking fibers on at least one side of the substrate layer; (b) A step of forming the flocked fiber layer adjacent to the base layer by entangled the fiber web and the base layer with each other.

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