Humidity control component

Abstract

One aspect of this disclosure aims to provide a humidity-regulating component with high humidity-regulating function and rigidity. The humidity-regulating component of one aspect of this disclosure comprises at least two substrates and a humidity-regulating layer containing a humidity-regulating body that absorbs or releases water vapor between the substrates. The substrates contain a first low-melting-point component that is breathable and capable of thermally fusing with high-melting-point fibers. The substrates also include portions where the high-melting-point fibers are fused together via the first low-melting-point component through melting of at least the first low-melting-point component.

Description

Technical Field

[0001] This disclosure relates to a humidity regulating component. This disclosure claims priority based on Japanese Patent Application No. 2024-014515 filed on February 2, 2024, the contents of which are incorporated herein by reference. Background Technology

[0002] Previously, the humidity control components were disclosed.

[0003] For example, Patent Document 1 discloses a humidity-regulating sheet 10 having a humidity-regulating layer 7 between two substrate sheets 1 and 2. This humidity-regulating layer 7 is formed by bonding humidity-regulating particles 3 that reversibly absorb and release moisture vapor together using thermoplastic resin powder 4 to form a sheet. In addition, in Patent Document 1, since the proportion of voids 8 formed between the humidity-regulating particles 3 is large, the voids 8 between the humidity-regulating particles 3 are used as water-retaining spaces for absorbing and releasing moisture. This not only utilizes the original moisture absorption and release capacity of the humidity-regulating particles, but also the moisture absorption and release capacity brought by the voids between the humidity-regulating particles, resulting in high reversible moisture absorption and release performance and excellent moisture absorption and release response.

[0004] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2008-174730 Summary of the Invention The technical problem this disclosure aims to solve However, conventional humidity control sheets typically use nonwoven or woven fabrics physically wound with resin fibers as the base material, resulting in a softness derived from the fibers themselves and low rigidity. Therefore, for use as interior or wall materials for humidity control in spaces such as homes, offices, containers, truck compartments, and storage rooms, rigidity is required, making them difficult to use alone and necessitating combination with other materials. Furthermore, existing humidity control sheets lack rigidity and are prone to deformation, making it difficult to maintain a specific shape. In particular, when envisioned for use as interior components in automobiles, they need to conform to the target shape and are therefore attached to molded parts. As described above, in applications requiring a certain rigidity or specific three-dimensional shape, humidity control sheets alone are insufficient; even when attached to other parts, the low rigidity of the sheet results in exposed surfaces, hindering practicality. Patent Document 1 exemplifies nonwoven or woven fabrics as the base material, but the constituent fibers are not described, suggesting they are conventional nonwoven or woven fabrics, and therefore may suffer from the same problems as the aforementioned humidity control sheets.

[0005] In view of the above-mentioned problems, one aspect of this disclosure is to provide a humidity regulating component with high humidity regulating function and rigidity.

[0006] Technical solutions for solving technical problems One aspect of the humidity control component disclosed herein comprises: at least two substrates and a humidity control layer between the substrates including a humidity control body that absorbs or releases water vapor, the substrates including a first low-melting-point component that is breathable and capable of thermally fusing with high-melting-point fibers, and including portions therein where the high-melting-point fibers are fused together via the first low-melting-point component by melting at least the first low-melting-point component.

[0007] Beneficial effects As described above, according to one aspect of this disclosure, it is possible to provide a humidity control component with high humidity control function and rigidity. Attached Figure Description

[0008] Figure 1 This is a schematic cross-sectional view of the humidity regulating component of this disclosure, and a diagram showing that the first low-melting-point component contained in the substrate is in particulate form.

[0009] Figure 2 It is a schematic diagram of the substrate, showing that the first low-melting-point component contained in the substrate is in particulate form.

[0010] Figure 3 This is a schematic cross-sectional view of the humidity-regulating component of this disclosure, and a diagram showing that the second low-melting-point component contained in the humidity-regulating layer is fibrous.

[0011] Figure 4 This is a schematic diagram of the substrate, showing that the first low-melting-point component contained in the substrate is fibrous.

[0012] Figure 5 It is a schematic diagram of the substrate, and is a diagram showing that the first low-melting-point component contained in the substrate is present in at least a portion of the periphery of the high-melting-point fiber.

[0013] Figure 6 yes Figure 5 An enlarged view of section VI.

[0014] Figure 7 It is a schematic diagram of the substrate, and a diagram showing a high-melting-point skeleton fiber mixed with a low-melting-point component that is present on the periphery of the high-melting-point fiber, unlike the first low-melting-point component.

[0015] Figure 8 It is a schematic cross-sectional view of the humidity regulator.

[0016] Figure 9 This is a schematic cross-sectional view of the humidity regulating component of this disclosure, and a simplified diagram showing the manufacturing method.

[0017] Figure 10 This diagram illustrates the use of a mold to form the humidity-regulating component disclosed herein.

[0018] Figure 11 This is a diagram showing the humidity regulating component of this disclosure formed in a box shape.

[0019] Figure 12 This diagram shows a humidity-regulating component with a non-permeable layer on the opposite side of the surface in contact with the humidity-regulating layer in one of two substrates.

[0020] Figure 13 It is formed using molds Figure 12 The diagram shows the humidity control component.

[0021] Figure 14 This is a graph showing the moisture absorption rate in the examples and comparative examples. Detailed Implementation

[0022] Hereinafter, preferred embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Furthermore, the embodiments described below are not intended to unduly limit the content of the present disclosure as described in the technical solutions, and not all configurations described in these embodiments are necessary as solutions provided in the present disclosure.

[0023] Figure 1 This is a simulated cross-sectional view of the humidity regulating component 100 of this disclosure. Figure 2 This is a schematic diagram of substrate 10. (As shown) Figure 1 As shown, the humidity regulating component 100 of this disclosure includes at least two substrates 10, with a humidity regulating layer 23 between the substrates 10. Additionally, as... Figure 1 as well as Figure 2 As shown, the substrate 10 includes a first low-melting-point component 31 capable of thermally fusing with the high-melting-point fibers 11, including portions 311 where the high-melting-point fibers 11 are fused together by the melting of the first low-melting-point component 31. Thus, after melting, the first low-melting-point component 31 fuses and fixes the high-melting-point fibers 11 together, resulting in increased rigidity and reduced deformation compared to conventional nonwoven materials.

[0024] Furthermore, the humidity-regulating layer 23 includes a humidity-regulating body 20 that absorbs or releases water vapor. Further, the substrate 10 is breathable, allowing water vapor to pass through it, such as in an airflow 200, thus regulating the humidity of the air outside the humidity-regulating component 100. By employing this configuration, high rigidity can be maintained, and the external air can be humidified, resulting in a humidity-regulating component 100 shaped to the desired form.

[0025] Figure 3 This is a cross-sectional view simulating another embodiment of the humidity control component 100 of this disclosure. (See diagram below.) Figure 3As shown, the humidity-regulating layer 23 has a second low-melting-point component 32 with a melting point lower than that of the first low-melting-point component 31. Furthermore, the second low-melting-point component 32 fuses any one of the humidity-regulating bodies 20 together, the humidity-regulating body 20 with the substrate 10, or the substrate 10 together. This strengthens the overall bonding force of the humidity-regulating component 100, improves the peel strength of the substrate 10, and prevents the humidity-regulating body 20 from detaching from the end face of the substrate 10. Additionally, the humidity-regulating layer 23 is also rigid, further enhancing the rigidity of the humidity-regulating component 100.

[0026] In the case where the humidity regulating component 100 is manufactured using hot pressing as described later, a portion of the humidity regulating agent 20 or the second low-melting-point component 32 may enter the interior of the substrate 10. In this case, the humidity regulating component 100 may also have a mixed layer containing the humidity regulating agent 20 or the second low-melting-point component 32 between the substrate 10 and the humidity regulating layer 23.

[0027] exist Figure 1 The humidity control component 100 is composed of two substrates 10 and one humidity control layer 23. However, the number of substrates 10 and humidity control layer 23 forming the humidity control component 100 is not limited. There may be more than two substrates 10 and the number of humidity control layers 23 may be one less than the number of substrates 10.

[0028] According to this embodiment, the humidity regulating component 100 can be thickened, its rigidity improved, and it is easier to form into the target shape.

[0029] Examples of high-melting-point fibers 11 include high-melting-point polyester or plant fibers. The melting point of the high-melting-point fiber 1 is preferably 200°C or higher.

[0030] There is no particular limitation on high-melting-point polyesters. Examples include high-melting-point polyesters with fiber-forming ability, especially aromatic polyesters and semi-aromatic polyesters used as fibers.

[0031] Specifically, examples include polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate, polypropylene terephthalate, or copolyesters with these substances as their basic framework.

[0032] Other examples include polyethylene terephthalate, polyethylene isophthalate, polytetramethylene terephthalate, polyethylene oxybenzoate, polybutylene terephthalate, polyhexamethylene terephthalate, poly1,4-dimethylcyclohexane terephthalate, polyneoprolol, and copolyesters containing these substances.

[0033] Plant fibers are not specifically limited, but can include rayon, cellulose fibers, Manila hemp, sisal, coniferous kraft paper pulp (NBKP), broadleaf kraft paper pulp (LBKP), cotton linters, kenaf, sambar, paper mulberry, gampi, and other wood pulps.

[0034] Although it is stated that the substrate 10 has a first low-melting-point component 31 that can be heat-fused in addition to the high-melting-point fiber 11, the first low-melting-point component 31 is a thermoplastic component that can be heat-fused. The melting point of the first low-melting-point component 31 is preferably around 90 to 180°C.

[0035] In addition, examples of the first low-melting-point component 31 include polyester materials such as polyester, polyethylene, polypropylene, polyurethane, polyhydroxybutyrate, polylactic acid, polybutylene succinate, and their copolymers.

[0036] As a polyester material, there are no particular limitations, but aliphatic polyesters such as polyhydroxybutyrate, polybutylene succinate, polylactic acid, polycaprolactone, and polyglycolic acid, and their copolymers are preferred.

[0037] The composition ratio of high-melting-point fiber 11 to first low-melting-point component 31 is such that, relative to the total weight of high-melting-point fiber 11 and first low-melting-point component 31, the weight portion of first low-melting-point component 31 is preferably 20-60%, more preferably 30-50%. If the low-melting-point component accounts for more than 60% by weight, the air permeability of the moisture-regulating component 100 may be significantly reduced. If the low-melting-point component accounts for less than 20% by weight, the number of fused areas decreases, making it difficult to improve rigidity, and sometimes it is also unable to maintain its shape during hot pressing.

[0038] As the shape of the first low-melting-point component 31, such as Figure 4 As shown, the first low-melting-point component 31 can also be fibrous. By being fibrous, it can be wound around the high-melting-point fiber 11, increasing the contact points between the first low-melting-point component 31 and the high-melting-point fiber 11. Therefore, efficient fusion can be achieved with lower energy when hot-pressing the substrate 10.

[0039] Additionally, the first low-melting-point component 31 can also be in granular form. Furthermore, Figure 1 and Figure 2 The illustration shows the case where the first low-melting-point component 31 is in granular form. Because it is granular, it can be dispersed throughout the substrate 10, suppressing in-plane deviations at the locations where the high-melting-point fibers 11 are fused. Furthermore, the material options for the first low-melting-point component 31 are wider than for fibrous forms. Moreover, even when the first low-melting-point component 31 is granular, the mixing ratio between the fibrous and high-melting-point fibers 11 can be freely designed, increasing the design freedom regarding rigidity and breathability.

[0040] Figure 5 It is a schematic diagram of the substrate 10, and a diagram showing that the first low-melting-point component 31 contained in the substrate 10 exists in at least a portion of the outer periphery of the high-melting-point fiber 11. Figure 6 yes Figure 5 An enlarged view of section VI. (See attached image.) Figure 5and Figure 6 As shown, the first low-melting-point component 31 may also be present in at least a portion of the outer periphery of the high-melting-point fiber 11. Alternatively, a core-sheath structure of the high-melting-point fiber 11 coated with the first low-melting-point component 31 can be used. The high-melting-point fiber 11 is the core, and the first low-melting-point component 31 may also be the sheath. In this way, the low-melting-point component 31 is more uniformly dispersed in the substrate 10, and the uniformity of the voids after hot pressing is also increased, thus reducing deviations in the air permeability and humidity-regulating function of the humidity-regulating component 100. Furthermore, since the first low-melting-point component 31 is present at the contact points of the high-melting-point fiber 11, efficient fusion is possible, further improving the rigidity of the humidity-regulating component 100.

[0041] Figure 7 This is a schematic diagram of the substrate 10, and a diagram showing the additionally mixed skeleton fibers 12. The first low-melting-point component 31 is present in at least a portion of the outer periphery of the high-melting-point fibers 11, and may also have skeleton fibers 12 that are different from it. In this way, the rigidity of the humidity regulating component 100 can be easily adjusted by adjusting the mixing ratio of the high-melting-point fibers 11 to the skeleton fibers 12.

[0042] Furthermore, regarding the rigidity of the humidity regulating component 100 of this disclosure, its bending rigidity is preferably 500 MPa or more. By setting it to 500 MPa or more, it is possible to maintain its shape and to mold it into the desired shape.

[0043] Next, the humidity regulator 20 will be explained.

[0044] The humidity regulator 20 absorbs or releases water vapor, thus possessing a high humidity regulating function. The components of the humidity regulator 20 will be explained below.

[0045] The humidity regulator 20 includes a water-absorbing body 21 containing resin and / or clay minerals and a humidity-regulating component 22. The water-absorbing body 21 retains the humidity-regulating component 22. Additionally, the humidity regulator 20 regulates the amount of water vapor in the air. Furthermore, the humidity regulator 20 has the following characteristic: relative to its equilibrium humidity, it absorbs water vapor (hygroscopic) when the ambient relative humidity is relatively high, and conversely, it releases water vapor (dehumidification) when the ambient relative humidity is relatively low; this function is designated as "humidity regulation". Specifically, for example, when the equilibrium humidity of the humidity regulator 20 is 50%RH, if the ambient relative humidity is higher than 50%RH, the humidity regulator 20 absorbs water vapor (hygroscopic), and if the ambient relative humidity is lower than 50%RH, the humidity regulator 20 releases water vapor (dehumidification). Generally, the equilibrium humidity of the humidity regulator 20 is related to the material of the humidity regulator 20 and the moisture content of the humidity-regulating component 22. Through this humidity-regulating function, the humidity regulator 20 regulates the amount of water vapor in the air surrounding the humidity regulator component 100 via the breathable substrate 10, thereby suppressing fluctuations in relative humidity. That is, unlike desiccants such as type A silica gel, the humidity regulator 20 releases moisture on its own in low-humidity environments, eliminating the need for artificial regeneration through heating or other means. Instead, it repeatedly absorbs and releases moisture in response to daily environmental changes, thus providing a semi-permanent effect in principle. Furthermore, when used in enclosed spaces, where the amount of water held by the humidity regulator 20 overwhelmingly exceeds the amount of water vapor in the enclosed space, the relative humidity of the enclosed space can be regulated and maintained to approximately the same level as the equilibrium humidity of the humidity regulator 20.

[0046] like Figure 8As shown, the moisture-regulating body 20 is preferably granular. By being granular, the contact area between the air flowing in from the outside of the moisture-regulating component 100 and the unit volume is increased, thereby improving the rate of moisture absorption and release. Furthermore, when forming the moisture-regulating layer 23, it can be dispersed onto the substrate 10, suppressing deviations in the moisture-regulating performance of the moisture-regulating component 100. By adjusting the dispersion amount, the moisture-regulating performance can be adjusted, increasing design flexibility. Additionally, when the substrate 10 is porous, the particle size of the moisture-regulating body 20 is larger than the pores of the substrate 10. This prevents the moisture-regulating body 20 from detaching from the substrate 10. Moreover, the particle size of the moisture-regulating body 20 is preferably 50 to 1000 μm. If it is less than 50 μm, it is smaller than the pores between fibers in a typical nonwoven fabric, and the moisture-regulating body 20 may detach from the substrate 10. Furthermore, if it is 1000 μm or larger, the surface area per unit volume becomes larger, making it difficult to increase the rate of moisture absorption and release. The humidity regulator 20 absorbs moisture by absorbing water vapor from the air in the environment where it is placed, or releases moisture contained in the humidity regulator 20 into the air. By providing the absorbent body 21, even if the humidity-regulating component 22 excessively absorbs water vapor from the air, the absorbent body 21 can retain moisture, preventing moisture or the aqueous solution containing the humidity-regulating component 22 from leaking out of the humidity regulating component 100. Furthermore, when the humidity regulator 20 is composed of the absorbent body 21 and the humidity-regulating component 22, it is preferable that the melting point of each is higher than the melting point of the first low-melting-point component 31 and the second low-melting-point component 32. Therefore, during the bonding and hot-pressing of the substrates 10 in the manufacturing process described later, the humidity regulator 20 will not melt, and the deterioration of its humidity-regulating performance is minimized. In addition, "particulate" here refers to fine particles constituting a solid substance, and also includes powders and granules.

[0047] The moisture-regulating component 22 can be retained not only in the absorbent body 21, but also in the carrier that supports the moisture-regulating body 20.

[0048] The moisture-regulating component 22 can be incorporated into the absorbent body 21, or it can exist alone and in combination.

[0049] Specific examples of the humidity-regulating component 22 include salts such as sodium formate, potassium formate, sodium propionate, potassium propionate, potassium carbonate, calcium carbonate, sodium acetate, potassium acetate, lithium acetate, ammonium acetate, sodium lactate, potassium lactate, calcium chloride, lithium chloride, magnesium chloride, potassium chloride, sodium chloride, zinc chloride, aluminum chloride, magnesium chloride, lithium bromide, calcium bromide, potassium bromide, sodium hydroxide, citric acid, and sodium pyrrolidone carboxylate. These salts can absorb moisture or deliquesce as the relative humidity increases, exhibiting high hygroscopic capacity. Especially at high humidity (e.g., above 80% RH), the humidity-regulating component 22 can absorb a large amount of water per unit weight, thus being effective in suppressing condensation and fog caused by high humidity. Among these, carboxylates (sodium formate, sodium propionate, sodium acetate) and carbonates (sodium carbonate, potassium carbonate) with particularly low corrosivity are preferred, as they have a threshold for humidity-regulating properties at specific humidity levels. By having a threshold in its humidity-regulating properties, moisture absorption does not occur below a specified relative humidity, thus enabling production even without significantly managing the manufacturing or storage environment to a low humidity level. On the other hand, since it has a high moisture absorption capacity above a predetermined relative humidity, it is effective in suppressing condensation and fogging that occur under high humidity. Among the carboxylates, sodium formate and sodium propionate are further preferred because they exhibit small hysteresis during moisture absorption and release (the weight of water held by the humidity-regulating component 22 at a specified relative humidity equilibrium behaves differently during moisture absorption and release, even at the same relative humidity). Due to the small hysteresis, after moisture absorption at high humidity, a specified amount of moisture can be released and regenerated when the environment becomes low humidity. Among these salts, at least one is preferred.

[0050] Furthermore, from the viewpoint of improving humidity control performance and compensating for shortcomings, it is preferable to contain two or more of these salts. In particular, the carbonates mentioned above are alkaline on their own, and when combined with the carboxylate salts mentioned above, it is expected that they can prevent odor and component volatilization caused by the release of carboxylic acids, so it is also preferable to use these salts in combination.

[0051] In addition to the salts mentioned above, humectant 22 may also contain organic components such as polyols.

[0052] Specific examples of polyols include glycerol, propylene glycol, butanediol, pentanediol, trimethylolpropane, glycerol, ethylene glycol, diethylene glycol, and triethylene glycol. Among these, polyols having three or more hydroxyl groups, such as glycerol, are more preferred. Furthermore, polyols can form dimers or polymers. Additionally, they may contain only one type or two or more types.

[0053] The absorbent 21 preferably comprises at least one material selected from the group consisting of absorbent resins (particles, powders) and clay minerals. This allows the absorbent 21 to adequately retain the humidity-regulating component 22, further enhancing the humidity-regulating effect. Furthermore, as described above, the absorbent 21 functions to retain moisture when the humidity-regulating component 22 excessively absorbs water vapor from the air. However, by selecting the absorbent 21 from the group consisting of absorbent resins and clay minerals, its high absorbency further inhibits leakage of moisture or aqueous solutions containing the humidity-regulating component 22 from the humidity-regulating component 100.

[0054] Specific examples of absorbent resin materials include ionic and nonionic resins. Examples of ionic resins include alkali metal salts of polyacrylic acid (such as sodium polyacrylate) and starch-acrylate graft polymers, with alkali metal salts of polyacrylic acid being preferred. Specific examples of alkali metal salts of polyacrylic acid include sodium polyacrylate. Examples of nonionic resins include vinyl acetate copolymers, maleic anhydride copolymers, polyvinyl alcohol, and polyepoxides.

[0055] Specific examples of clay minerals include silicate minerals such as montmorillonite, sepiolite, palygorskite, kaolinite, perlite, and dolomite, as well as zeolites.

[0056] When the humidifying component 22 is included, the weight ratio of its total weight to the weight of the absorbent 21 is preferably 1:1 to 3:7. This ensures that the amounts of the absorbent 21 and the humidifying component 22 are appropriate, further improving the humidification function. Furthermore, if the proportion of the humidifying component 22 is too high, the risk of dehydration in high humidity ranges is high; if the proportion of the humidifying component 22 is too low, the humidification moisture content (the weight of water vapor that can be absorbed or released per unit weight of the humidifying component) may sometimes become smaller.

[0057] In addition to being in powder or granule form, the humidity regulator 20 can also be formed into a block shape. It can also be used by loading the humidity regulator 22 and the absorbent 21 onto the ventilated substrate to effectively contact the air.

[0058] In addition, the humidity regulator 20 also includes type A silica gel, type B silica gel, zeolite, polymer adsorbent materials, etc.

[0059] The aforementioned humidity-regulating layer 23 has a second low-melting-point component 32 with a melting point lower than that of the first low-melting-point component 31, but the melting point of the second low-melting-point component 32 is preferably around 70~120°C.

[0060] The second low-melting-point component 32 only needs to be able to bond the humidity-regulating bodies 20 together and the humidity-regulating layer 23 to the substrate 10 by thermal fusion. It can be a thermoplastic resin such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, polyvinyl acetate, saponified ethylene-vinyl acetate copolymer, polyvinyl alcohol, polyester, polyamide, polyurethane, ionomer resin, and their modified forms. It is preferred to use thermoplastic resins such as polyvinyl acetate, saponified ethylene-vinyl acetate copolymer, polyvinyl alcohol, polyester, polyamide, polyurethane, ionomer resin, and their modified forms. One of them can be used alone, or two or more can be used in combination.

[0061] As described above, the humidity regulating component 100 of this disclosure includes a substrate 10 made of at least fibers and a humidity regulating layer 23. Furthermore, the composition of the high-melting-point fibers 11 and the humidity regulating body 20 contained in the substrate 10 can be detected by compositional analysis such as FT-IR or EDX. Additionally, the humidity regulating body 20 has a moisture absorption rate (the ratio of the increase in weight due to water vapor absorption to its weight when dry) of 30% or more at a relative humidity of 90%.

[0062] When the DSC (Differential Scanning Calorimeter) of the substrate 10 is measured, melting occurs in two stages (melting point of the high-melting-point fiber 11 / first low-melting-point component 31). When the DSC of the humidity-regulating layer 23 is measured, melting from the second low-melting-point component 32 can be confirmed. Furthermore, the respective melting points indicate the relationship between the second low-melting-point component 32 < the first low-melting-point component 31 < the high-melting-point fiber 11.

[0063] By observing the cross-sections of the substrate 10 and the humidity-regulating layer 23 using optical microscopes and electron microscopes (SEM), the internal structure can be confirmed. The substrate 10 contains a first low-melting-point component 31 that can be thermally fused with the high-melting-point fibers 11. Through the melting of the first low-melting-point component 31, it can be confirmed that there are portions 311 where the high-melting-point fibers 11 are fused together via the first low-melting-point component 31. The humidity-regulating layer 23 has a second low-melting-point component 32, and it can be confirmed that any one of the following is fused together: the humidity-regulating bodies 20, the humidity-regulating bodies 20 and the substrate 10, or the substrate 10 itself.

[0064] Figure 9 This is a simplified diagram illustrating the manufacturing method of the humidity-regulating component 100 of this disclosure. First, a substrate 10 comprising a first low-melting-point component 31 in a state not fused with the high-melting-point fiber 11, a humidity-regulating body 20, and a second low-melting-point component 32 in a state not fused with the fiber 11 are prepared, and the humidity-regulating body 20 and the second low-melting-point component 32 are sandwiched between the two substrates 10.

[0065] Next, as a first processing step, the components are heated and pressed together at a temperature higher than the melting temperature of the second low-melting-point component 32 and lower than the melting temperature of the first low-melting-point component 31. At this time, only the second low-melting-point component 32 melts, causing the humidity-regulating bodies 20 to fuse together to form a humidity-regulating layer 23, and then the humidity-regulating layer 23 and the substrate 10 are fused together to form an integral unit.

[0066] Next, as a second processing step, hot pressing is performed at a temperature above the melting point of the first low-melting-point component 31. In this way, the first low-melting-point component 31 is fused with the high-melting-point fibers 11 under compression, creating a rigid humidity-regulating component 100. At this time, the first low-melting-point component 31 melts, creating portions 311 where the high-melting-point fibers 11 are fused together. During hot pressing, by placing spacers of a specified length and height on the outer periphery of the area necessary for the product, the overall thickness of the humidity-regulating component 100 is fused and fixed at a state close to its specified height. Therefore, even after hot pressing, the humidity-regulating component 100 maintains its shape with this overall thickness. In this way, the overall thickness of the humidity-regulating component 100 can be adjusted.

[0067] In this embodiment, the humidity-regulating layer 23 includes a second low-melting-point component 32, which allows for continuous processing in a roller manner up to the first processing step, increasing mass production capability. Alternatively, the humidity-regulating layer 23 may also have an increased internal fusion point, thereby improving the rigidity of the formed humidity-regulating component 100. Therefore, it is more preferable that the humidity-regulating layer 23 includes the second low-melting-point component 32. Furthermore, the above manufacturing method describes a configuration in which the humidity-regulating layer 23 includes the second low-melting-point component 32. Even without the second low-melting-point component 32, by hot pressing the humidity-regulating body 20 between two substrates 10 and performing the second processing step, the first low-melting-point component 31 fuses the humidity-regulating component 100 together, resulting in a humidity-regulating component 100 that combines humidity-regulating function and rigidity.

[0068] Figure 10 This diagram illustrates the case where the humidity-regulating component 100 of this disclosure is formed using a mold 40 of the target shape. (See diagram for reference.) Figure 10 As shown, in the second processing described above, the humidity-regulating component 100 of this disclosure is hot-pressed using a mold 40 at a temperature above the melting point of the first low-melting-point component 31, and can be formed into a target shape along the mold 40. Therefore, in the state where the humidity-regulating component 100 is compressed and formed into the target shape, since the first low-melting-point component 31 fuses and fixes the high-melting-point fiber 11, this formed state can be maintained. The shape of the humidity-regulating component 100 of this disclosure can be, for example, as shown below. Figure 11The box shape shown can also be plate-shaped or boat-shaped. In this way, it can be hot-pressed into a three-dimensional molded article. Furthermore, as described later, the substrate 10 retains air permeability even under compression, so its moisture-regulating properties will not decrease even when hot-pressed using the mold 40.

[0069] Furthermore, the humidity regulating component 100 of this disclosure can have a fine structure pattern formed on its surface. This increases the surface area, thereby further improving the humidity regulating speed. While it's possible for warping to occur during hot pressing in the second processing step when the size of the humidity regulating component 100 increases, this warping can be minimized by providing a periodic structure pattern. There are no particular limitations on the shape of the fine structure.

[0070] Figure 12 This diagram shows a humidity regulating member 100 in which a non-permeable layer 50 is provided on the opposite side of the surface in contact with the humidity regulating layer 23 in either of the two substrates 10. The humidity regulating member 100 of this disclosure may also have a non-permeable layer 50 on the opposite side of the surface in contact with the humidity regulating layer 23 in either of the two substrates 10. Figure 12 The humidity regulating component 100 shown has a non-permeable layer 50 on the lower surface of the substrate 10. The non-permeable layer 50 is made of a material that prevents or makes it difficult for water molecules to pass through, such as a resin sheet without a porous structure, an aluminum vapor-deposited film, or a metal plate.

[0071] Alternatively, the humidity-regulating component 100, which has a non-permeable layer 50 on the lower surface of the substrate 10, can be hot-pressed to form... Figure 13 The molded article has a three-dimensional shape as shown. A lid or similar cover can be placed on the molded article to store the object to be conditioned. As a result, the humidity conditioning performance can be concentrated on the side opposite to the non-permeable layer 50, and the object contained inside the molded article, that is, inside the container made of the molded article, can be effectively conditioned.

[0072] Example The humidity regulating component 100 of this disclosure will be specifically described below through embodiments and comparative examples, but this disclosure is not limited to the embodiments described herein.

[0073] (Example 1) As the substrate, a substrate containing high-melting-point fibers and a first low-melting-point component was prepared. The unit area mass of both the upper and lower substrates is 100 g / m². 2 The high-melting-point fiber is polyester. The first low-melting-point component is set to low-melting-point PET (melting point 110°C). Furthermore, the composition ratio of the high-melting-point fiber and the first low-melting-point component is set to 50% by weight of the first low-melting-point component relative to the total weight of the high-melting-point fiber and the first low-melting-point component (hereinafter, only the proportion of the first low-melting-point component is considered). Additionally, the substrate is a core-sheath structure in which the first low-melting-point component covers the outer periphery of the high-melting-point fiber.

[0074] The humidity-regulating agent is a substance obtained by mixing carboxylates (sodium propionate) and sodium carbonate as humidity-regulating components in a 3:1 ratio, and a water-absorbing resin (sodium polyacrylate) as the absorbent. The average particle sizes of the respective components are 300 μm for sodium propionate, 400 μm for sodium carbonate, and 500 μm for sodium polyacrylate. Furthermore, the unit area mass of the humidity-regulating layer, including the second low-melting-point component and the humidity-regulating agent, is 80 g / m². 2 The second low-melting-point component is polyethylene (melting point 80°C). Furthermore, the melting points of the components in the humidifier are as follows: sodium propionate 289°C, sodium carbonate 851°C, and sodium polyacrylate 150°C, which are higher than the melting points of the first and second low-melting-point components.

[0075] In addition, each substrate has a thickness of 1.0 mm and a density of 0.10 g / m³. 3 .

[0076] The above-mentioned humidity-regulating layer is sandwiched between the upper and lower substrates and pressed and bonded at a temperature of 100°C, which is higher than the melting temperature of the second low-melting-point component but lower than the melting temperature of the first low-melting-point component (first processing). Then, a spacer with a thickness of 1.0 mm is placed and pressure is applied at a temperature of 120°C, which is higher than the melting temperature of the first low-melting-point component, thereby manufacturing a plate-shaped humidity-regulating component of Example 1 (second processing).

[0077] The moisture-regulating component of Example 1, after pressing (heat compression), has a thickness of 1.0 mm and a density of 0.20 g / m³. 3 .

[0078] (Example 2) As an example 2, a substrate with a unit area mass of 200 g / m² was prepared. 2 The substrate is used. Furthermore, the ratio of the first low-melting-point component is set to 30%. The thickness of one substrate is set to 2.0 mm. The spacer used in the second processing is set to 2.0 mm. Everything else is manufactured under the same conditions as in Example 1.

[0079] The moisture-regulating component of Example 2, after pressing (heat compression), has a thickness of 2.0 mm and a density of 0.20 g / m³. 3 .

[0080] (Example 3) As an example 3, a substrate with a unit area mass of 200 g / m² was prepared. 2 The substrate is used. Furthermore, the ratio of the first low-melting-point component is set to 40%. The thickness of one substrate is set to 2.0 mm. The spacer used in the second processing is set to 2.0 mm. Everything else is manufactured under the same conditions as in Example 1.

[0081] The moisture-regulating component of Example 3, after pressing (heat compression), has a thickness of 2.0 mm and a density of 0.20 g / m³. 3 .

[0082] (Example 4) As an example 4, a substrate with a unit area mass of 350 g / m² was prepared. 2 The substrate. Additionally, the thickness of one substrate is set to 3.0 mm and the density to 0.12 g / m³. 3 Additionally, the spacer in the second processing step is set to 3.0 mm. Everything else is manufactured under the same conditions as in Example 1.

[0083] The thickness of the humidity-regulating component in Example 4 after pressing (heat compression) is 3.0 mm, and the density is 0.23 g / m³. 3 .

[0084] (Example 5) As an example 5, a substrate with a unit area mass of 600 g / m² was prepared. 2 The substrate. Additionally, the thickness of one substrate is set to 4.0 mm, and the density to 0.15 g / m³. 3 Additionally, the spacer in the second processing step was set to 4.0 mm. Everything else was manufactured under the same conditions as in Example 1.

[0085] The moisture-regulating component of Example 5, after pressing (heat compression), has a thickness of 4.0 mm and a density of 0.30 g / m³. 3 .

[0086] (Comparative Example 1) As a comparative example 1, a substrate was prepared consisting solely of high-melting-point fibers that did not contain the first low-melting-point component. The mass per unit area of ​​this substrate was 50 g / m². 2 The high-melting-point fiber is polyester. The substrate does not contain the first low-melting-point component. Furthermore, there is no hot pressing (hot compression). In this way, the humidity-regulating component of Comparative Example 1 was manufactured.

[0087] The above conditions and results are shown in Table 1.

[0088] [Table 1] As shown in Table 1, in all embodiments, due to the presence of a first low-melting-point component in the substrate capable of thermally fusing with the high-melting-point fibers, the high-melting-point fibers and the first low-melting-point component are fused together, resulting in a bending stiffness of 500 MPa or more, a representative value of stiffness. Therefore, good stiffness is obtained in all embodiments. Furthermore, despite hot pressing, the humidity regulator is granular with an average particle size of 50-1000 µm. Therefore, even though hot pressing on the substrate side melts the first low-melting-point component and fuses the high-melting-point fibers together, areas of uneven density and enlarged pores in the high-melting-point fibers are anticipated, but almost no detachment of the humidity regulator from the substrate is observed. Moreover, by using a second low-melting-point component in the humidity regulator layer, the bonding strength between the substrates and between the substrate and the humidity regulator layer increases, and virtually no detachment of the humidity regulator from the substrate end face is observed.

[0089] On the other hand, in Comparative Example 1, which did not undergo hot pressing (hot compression), the substrate did not have a first low-melting-point component that could be thermally fused with the high-melting-point fibers. Instead, the fibers were physically entangled without fusion, resulting in poor rigidity.

[0090] In addition, the humidity control speed of the humidity control components of the embodiments and comparative examples manufactured as described above was compared when they were placed in a high humidity environment.

[0091] The humidity-regulating component was cut into 10cm square pieces and placed in a constant temperature and humidity chamber at 23°C and 40%RH for 24 hours, with the initial weight measured. Then, it was placed in a constant temperature and humidity chamber at 23°C and 90%RH for 10 minutes, and the subsequent weight was measured. The humidity-regulating rate per unit time and per unit area was calculated by dividing this weight change (grams) by the area of ​​the humidity-regulating component (0.01 square meters) and the elapsed time (10 minutes).

[0092] Figure 13 The results of the humidification speed are shown.

[0093] like Figure 13 As shown, the results of the humidity-regulating components in all embodiments are the same as those in Comparative Example 1 without hot pressing, exhibiting excellent air permeability of the substrate and humidity-regulating properties of the humidity-regulating components.

[0094] In addition, the substrate's unit area mass is between 100 and 600 g / m². 2 Density 0.20~0.30 g / m³ 3 Within the range, regardless of the composition ratio of high-melting-point fibers and the first low-melting-point component, the moisture conditioning speed was similar to that of the nonwoven fabric without the rigidity, low unit area mass, and low density (unit area mass 50 g / m²) of Comparative Example 1. 2 Density 0.1 g / m³ 3The moisture-regulating components of all embodiments maintain the air permeability of the substrate after hot pressing, and also maintain the moisture-regulating performance. It is believed that by compressing and fusing the substrate while retaining the porous structure formed by the gaps between the fibers in the substrate, the moisture-regulating function will not decrease even if the mass per unit area and density increase. In addition, since the moisture-regulating body is composed of a water-absorbing body and a moisture-regulating component, the melting points of each are higher than the melting points of the first low-melting-point component and the second low-melting-point component. Therefore, despite hot pressing, the moisture-regulating performance is not inferior to that of Comparative Example 1.

[0095] As described above, according to this disclosure, a humidity regulating component 100 with high humidity regulating function and rigidity can be provided.

[0096] Furthermore, as described above, various embodiments and examples of this disclosure have been described in detail. However, those skilled in the art will readily understand that various modifications can be made without substantially departing from the present disclosure in terms of new features and effects. Therefore, all such modifications are included within the scope of this disclosure.

[0097] For example, a term described at least once in the specification or drawings, along with a different term that is more general or synonymous, may be replaced with that different term anywhere in the specification or drawings. Furthermore, the configuration and operation of the humidification component are not limited to the descriptions in the various embodiments and examples of this disclosure, and various modifications can be implemented.

Claims

1. A humidity regulating component, characterized in that, The humidity regulating component comprises: at least two substrates and a humidity regulating layer between the substrates, including a humidity regulating body that absorbs or releases water vapor. The substrate includes a first low-melting-point component that is breathable and capable of thermally fusing with high-melting-point fibers, and includes portions in which the high-melting-point fibers are fused together via the first low-melting-point component through the melting of at least the first low-melting-point component.

2. The humidity regulating component according to claim 1, characterized in that, The humidity-regulating layer contains a second low-melting-point component with a melting point temperature lower than that of the first low-melting-point component, and the second low-melting-point component fuses any one of the humidity-regulating bodies, the humidity-regulating bodies and the substrate, or the substrates with each other.

3. The humidity regulating component according to claim 1 or 2, characterized in that, The first low-melting-point component is fibrous or granular.

4. The humidity regulating component according to claim 1 or 2, characterized in that, The first low-melting-point component is fibrous and is formed by being present in at least a portion of the outer periphery of the high-melting-point fiber.

5. The humidity regulating component according to claim 1 or 2, characterized in that, In the substrate, the composition ratio of the high melting point fiber and the first low melting point component is: the weight part of the first low melting point component is 20-60% relative to the total weight of the high melting point fiber and the first low melting point component.

6. The humidity regulating component according to claim 1 or 2, characterized in that, The humidity regulator is in granular form.

7. The humidity regulating component according to claim 6, characterized in that, The substrate is porous, and the particle size of the humidity regulator is larger than that of the fine pores.

8. The humidity regulating component according to claim 6, characterized in that, The average particle size of the humidity regulator is 50 μm to 1000 μm.

9. The humidity regulating component according to claim 1 or 2, characterized in that, The bending stiffness is above 500 MPa.

10. The humidity regulating component according to claim 1 or 2, characterized in that, The humidity regulating component is plate-shaped, box-shaped, or boat-shaped.

11. The humidity regulating component according to claim 1 or 2, characterized in that, On one of the two substrates, a non-permeable layer is provided on the opposite side of the surface in contact with the moisture-regulating layer.

12. The humidity regulating component according to claim 1 or 2, characterized in that, The humidity regulator has a water-absorbing body and a humidity-regulating component.

13. The humidity regulating component according to claim 12, characterized in that, The humidifying ingredient contains salt.

14. The humidity regulating component according to claim 13, characterized in that, The salt is a carboxylate, and is at least one selected from the group consisting of sodium formate, sodium propionate, and sodium acetate.

15. The humidity regulating component according to claim 13, characterized in that, The salt is a carbonate, and is at least one selected from the group consisting of sodium carbonate and potassium carbonate.

16. The humidity regulating component according to claim 13, characterized in that, The salt comprises two or more salts, respectively selected from carboxylate and carbonate, wherein the carboxylate is selected from one or more of the group consisting of sodium formate, sodium propionate, and sodium acetate, and the carbonate is selected from one or more of the group consisting of sodium carbonate and potassium carbonate.

17. The humidity regulating component according to claim 12, characterized in that, The absorbent is selected from at least one of the groups consisting of absorbent resins and clay minerals.

18. The humidity regulating component according to claim 12, characterized in that, The melting point of the absorbent and the moisture-regulating component is higher than that of the first low-melting-point component.

Images