Synthetic resin canvas excellent in dimensional balance stability and process for producing the same

Abstract

To provide a synthetic resin canvas (and a method for producing the same) having cotton canvas appearance, stable in balance of warp and weft dimensions, and hardly causing dimensional change.SOLUTION: A synthetic-resin canvas having a mass of 360 to 800g / m2, the synthetic-resin canvas being obtained by providing a soft vinyl chloride-resin-impregnated coating layer on an entire surface of a fabric, wherein the fabric is a plain weave fabric, a twill weave fabric, or a satin weave fabric, and a 10% tensile stress in a widthwise direction of the synthetic-resin canvas is 90 to 110% of a 10% tensile stress in a processing direction. Especially, the fabric is composed of a short fiber spun yarn, a combination of a short fiber spun yarn and a long fiber multifilament bulky yarn, or a long fiber multifilament bulky yarn, and the difference between the total fineness per inch (dtex / inch) of the weft yarn group and the total fineness per inch (dtex / inch) of the warp yarn group is within ± 10%.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a synthetic resin canvas with excellent warp and weft dimensional balance stability that can be used as the main material for tent warehouses (medium- to large-sized structures in which the entire steel frame is covered with synthetic resin canvas), house tents (assembly pipe tents with an awning attached that are used for athletic meets, outdoor events, management headquarters, assemblies, reception areas, etc.), truck canopies, truck bed covers, open-air storage sheets, etc., and to a method for manufacturing such a canvas. [Background technology]

[0002] Industrial material sheets are broadly divided into cotton canvas, synthetic resin canvas, tarpaulin, and mesh sheet, and are used for various indoor and outdoor purposes. In particular, for applications such as tent warehouses, roofed tents, truck canopies, truck bed covers, and open-air storage sheets, synthetic resin canvas of No. 4 to No. 6 class (the smaller the number, the heavier and more durable) spun fabric is impregnated and coated with a soft polyvinyl chloride resin composition (for example, thickness 0.38 to 0.55 mm, mass 420 to 560 g / m). 2 Spun fabrics are fabrics woven from short-fiber spun yarns, and the surface has a large amount of fuzz derived from the short-fiber spun yarns, which provides a high anchoring effect with the soft polyvinyl chloride resin composition. This anchoring effect gives the fabric superior bending durability and makes it less susceptible to shedding or peeling of the resin composition than tarpaulin, but it is inferior in tensile strength and tear strength. On the other hand, tarpaulin is a filament fabric woven from long-fiber multifilament yarns with a smooth surface, to which a soft polyvinyl chloride resin composition film is laminated. While it has superior tensile strength and tear strength compared to synthetic resin canvas, it lacks the anchoring effect, making it inferior in bending durability and prone to peeling of the film from the fabric. Staple spun yarn is a collection of short fibers made by twisting staples cut from long filament bundles into lengths of 3 to 7 cm and then spinning them. As such, it has poor tensile strength and tear strength, and tends to stretch if the number of twists is small. However, it is extremely useful as a highly durable substitute for cotton canvas (waterproof with paraffin), and the staple mentioned above imitates the fiber extracted from cotton.

[0003] In an example of synthetic resin canvas production, a spun fabric (defined width m x length m) is continuously dipped (immersed) in a liquid bath filled with a soft vinyl chloride resin composition paste (processing liquid). After impregnation, the spun fabric is pulled out of the liquid bath and simultaneously squeezed with a rubber mangle roll. After completion of impregnation, the fabric is subjected to a gelling heat treatment in a hot air tenter and wound up to obtain a long roll of synthetic resin canvas. In the hot air tenter process, to prevent width loss of the spun fabric due to tension in the processing direction and thermal shrinkage (e.g., shrinkage of 5 to 20 cm), the spun fabric is held in place by clips or pins at both ends in the hot air tenter to maintain the specified width. Once synthetic resin canvas of the specified width is obtained, the tension balance between the processing direction and the width direction is determined empirically by the processing machine operator. Another method involves continuously feeding spun fabric into a clip tenter or pin tenter, coating it with a processing solution in one or two passes using a doctor blade, passing it through a hot air oven to complete the gelling heat treatment, and then winding it up to obtain a long roll. Even with this coating method, the balance between the tension in the processing direction and the tension in the width direction of the spun fabric was determined by the operator's experience. As a result, the synthetic resin canvas obtained by these methods had residual strains that differed in the warp and weft directions, which caused problems with appearance changes due to dimensional imbalances, such as shrinkage in the warp direction and stretching in the weft direction during use.

[0004] In response to these problems, the applicant has invented a waterproof laminated membrane material for tent structures that has excellent creep balance in the warp and weft directions, where the laminated membrane material is made of a woven fabric containing staple spun yarns in the warp and multifilament yarns in the weft, and where the absolute value of the difference in creep strain rate after 24 hours under a stress load of 1 / 10 of the breaking stress in the warp and weft directions is within the range of 0 to 1 (Patent Document 1). The applicant has also invented a dimensionally stable waterproof membrane material for truck canopies, truck sheets, etc., where the flexible laminated body has a waterproof coating layer formed on a base fabric made of warp yarns made of staple spun yarns and weft yarns containing multifilament yarns, and where the absolute value of the difference in elongation (%) at a stress of 1 / 10 of the breaking stress in the warp and weft directions (SS curve) is within the range of 0 to 1%. These are all inventions that maintain dimensional stability in the warp and weft by using fabrics that use short fiber spun yarns for the warp and multifilament yarns for the weft, but the use of different yarns for the warp and weft results in partially different appearances, with the short fiber spun yarns (warp) having a matte texture and the multifilament yarns (weft) having a flat luster, which is a drawback in that it differs in appearance from conventional synthetic resin canvas.Therefore, there is currently a demand for synthetic resin canvas that has the appearance of cotton canvas, but also has a stable balance of warp and weft dimensions and is less likely to change in appearance due to dimensional changes. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 4143925 [Patent Document 2] Patent No. 4639301 Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention aims to provide a synthetic resin canvas (and a manufacturing method thereof) that has the appearance of cotton canvas, has stable warp and weft dimension balance, and is resistant to dimensional changes, and can be used as the main material for tent warehouses (medium- to large-sized structures in which the entire steel frame is covered with synthetic resin canvas), roofed tents (assembly pipe tents with attached awnings used for sports meets, outdoor events, management headquarters, assemblies, reception areas, etc.), truck canopies, truck bed covers, open-air storage sheets, etc. [Means for solving the problem]

[0007] As a result of extensive research and consideration of the above points, the present invention has been developed to provide a soft vinyl chloride resin impregnated coating layer on the entire surface of a fabric, with a mass of 360 to 800 g / m 2 The present inventors have discovered that synthetic resin canvas having the appearance of cotton canvas and excellent warp and weft dimensional balance stability can be obtained by making the fabric plain weave, twill weave, or satin weave, and keeping the difference between the 10% tensile stress in the width direction (based on JIS L1096A method) of the synthetic resin canvas and the 10% tensile stress in the processing direction (based on JIS L1096A method) within ±10%, thereby completing the present invention.

[0008] The synthetic resin canvas of the present invention is constructed such that the fabric is made of "staple fiber spun yarn," or "a combination of staple fiber spun yarn and long fiber multifilament bulky yarn," or "long fiber multifilament bulky yarn" as warp and weft yarn groups, and the long fiber multifilament bulky yarn is any one selected from taslan textured yarn, woolly textured yarn, and core spun sheath-core textured yarn, and it is preferable that the difference between the total inch fineness (dtex / inch) of the weft yarn group and the total inch fineness (dtex / inch) of the warp yarn group is within ±10%. This makes it possible to obtain a synthetic resin canvas with the appearance of cotton canvas and a stable warp and weft dimensional balance.

[0009] In the synthetic resin canvas of the present invention, the group of threads is preferably one selected from the following: 1) spun from a polymer that does not contain the radioactive carbon atom C14, 2) spun from a polymer that contains the radioactive carbon atom C14, 3) spun from a polymer repolymerized from monomers recovered from the depolymerization of synthetic resin molded products, and 4) spun from a polymer melted from synthetic resin molded products. 1) is a base fabric made from a synthetic resin obtained by polymerizing a monomer synthesized from petrochemical raw materials, 2) is a carbon-neutral base fabric made from a synthetic resin obtained by polymerizing a monomer derived from biomass, 3) is a chemically recycled base fabric made from a synthetic resin obtained by repolymerizing a monomer obtained by depolymerizing recycled products, and 4) is a base fabric made from a synthetic resin recycled by melting one or more of 1) to 3).

[0010] The synthetic resin canvas of the present invention preferably has a soft vinyl chloride resin-impregnated coating layer containing a cured liquid rubber, which is a polymer of one or more reactive liquid rubbers selected from butadiene, isoprene, and farnesene rubbers, or a polymer of the reactive liquid rubber and an isocyanate compound. This rubber crosslinking composite formation forms a polymer alloy in the soft vinyl chloride resin-impregnated coating layer, in which the molecular chains of the rubber component are entangled with the vinyl chloride resin main chain. This results in a synthetic resin canvas with excellent flexural durability (flutter resistance) and abrasion resistance, particularly at sub-zero temperatures and excellent joint durability (resistance to peeling at seams) under scorching sun.

[0011] The method for manufacturing synthetic resin canvas with excellent warp and weft dimensional balance stability of the present invention is a method for manufacturing synthetic resin canvas that includes a process of providing a soft vinyl chloride resin-impregnated coating layer on the entire surface of a fabric (plain weave, twill weave, or satin weave), and it is preferable that the soft vinyl chloride resin-impregnated coating layer is formed by a dipping method (including a heat treatment gelation process) or a coating method (including a heat treatment gelation process) under tension with the difference in tension (kgf / m) in the processing direction and width direction of the fabric being within ±20%, so that the 10% tensile stress (in accordance with JIS L1096A method) of the synthetic resin canvas in the width direction maintains 90 to 110% of the 10% tensile stress (in accordance with JIS L1096A method) in the processing direction.

[0012] The manufacturing method of the synthetic resin canvas of the present invention is configured such that the fabric has "short fiber spun yarn", or "a combination of short fiber spun yarn and long fiber multifilament bulky yarn", or "long fiber multifilament bulky yarn" as warp and weft yarn groups, and the long fiber multifilament bulky yarn is any one selected from taslan processed yarn, woolly processed yarn, and core spun sheath-core processed yarn, and further, it is preferable that the difference between the total inch fineness (dtex / inch) of the weft yarn group and the total inch fineness (dtex / inch) of the warp yarn group is within ±10%.

[0013] In the method for producing synthetic resin canvas of the present invention, it is preferable that the group of threads is any one of the following selected from 1) those spun from a polymer that does not contain the radioactive carbon atom C14, 2) those spun from a polymer that contains the radioactive carbon atom C14, 3) those spun from a polymer obtained by repolymerizing monomers recovered from the depolymerization of synthetic resin molded products, and 4) those spun from a polymer obtained by melting synthetic resin molded products. [Effects of the Invention]

[0014] This invention makes it possible to obtain synthetic resin canvas that has the appearance of cotton canvas, has stable balance in the warp and weft dimensions, and is less susceptible to dimensional changes, making it possible to widely use it as the main material for tent warehouses (medium- to large-sized structures in which the entire steel frame is covered with synthetic resin canvas), roof tents (assembly tents with attached awnings used for sports days, outdoor events, management headquarters, assemblies, reception areas, etc.), truck canopies, truck bed covers, open-air storage sheets, etc. DETAILED DESCRIPTION OF THE INVENTION

[0015] The synthetic resin canvas of the present invention, which has excellent warp and weft dimension balance stability, has a soft vinyl chloride resin impregnated coating layer on the entire surface of the fabric and has a mass of 360 to 800 g / m 2The synthetic resin canvas is a plain weave, twill weave, or satin weave, and the 10% tensile stress in the width direction (based on JIS L1096A) of the synthetic resin canvas is 90 to 110% of the 10% tensile stress in the processing direction (based on JIS L1096A).The manufacturing method includes a step of forming a soft vinyl chloride resin-impregnated coating layer by a dipping method (including a heat treatment gelation step) or a coating method (including a heat treatment gelation step) under tension with the difference in tension (kgf / m) between the processing direction and the width direction of the fabric being within ±20%. The fabric is also configured such that the warp and weft yarn groups are "staple fiber spun yarns," or "a combination of staple fiber spun yarns and long fiber multifilament bulky yarns," or "long fiber multifilament bulky yarns," and the long fiber multifilament bulky yarns are any one selected from taslan textured yarns, woolly textured yarns, and core spun sheath-core textured yarns, and the difference between the total inch fineness (dtex / inch) of the weft yarn group and the total inch fineness (dtex / inch) of the warp yarn group is within ±10%. Also, the yarn group is configured such that 1) a polymer not containing the radioactive carbon atom C14 is used. 1) a polymer spun from a polymer containing a radioactive carbon atom C14; 2) a polymer spun from a polymer containing a radioactive carbon atom C14; 3) a polymer spun from a polymer obtained by repolymerizing a monomer recovered from the depolymerization of a synthetic resin molded product; or 4) a polymer spun from a polymer obtained by melting a synthetic resin molded product. Also, the soft vinyl chloride resin-impregnated coating layer contains a cured liquid rubber, and this cured liquid rubber is a polymer of one or more reactive liquid rubbers selected from butadiene-based, isoprene-based, and farnesene-based rubbers, or a polymer of the reactive liquid rubber and an isocyanate compound.

[0016] The fabric used in the synthetic resin canvas of the present invention is made by weaving melt-spun yarns of synthetic resin, and the synthetic resin is 1) a fabric made from a synthetic resin synthesized from a petroleum-derived monomer that does not contain the radioactive carbon atom C14, specifically a petroleum-derived fabric made by weaving melt-spun yarns of polyethylene terephthalate obtained by polycondensation of dimethyl terephthalate (petroleum-derived) or terephthalic acid (petroleum-derived) with ethylene glycol (petroleum-derived), or 2) a carbon-neutral fabric made from a synthetic resin synthesized from a biomass-derived monomer that contains the radioactive carbon atom C14, specifically a plant-derived fabric made by weaving melt-spun yarns of polyethylene terephthalate obtained by polycondensation of dimethyl terephthalate (plant-derived) or terephthalic acid (plant-derived) with ethylene glycol (plant-derived). C-14 is a radioactive carbon atom with a mass number of 14, formed when nitrogen was converted by cosmic rays, and a half-life of 5,370 years. It is found in nature (especially in plants and animals) with a C-14C / C-12=1.2×10 -12 It is always present in equilibrium and cannot be contained in fossil fuels that are already hundreds of millions of years old. -12 Fabrics made from fibers with detectable concentrations are certified as biomass (plant-derived). Plant-derived refers to chemicals synthesized using sugars and fats as starting materials. The concentration of the carbon isotope C-14 (the ratio of C-14 to C-12 in the polymer) among all carbon atoms constituting the fiber is measured using accelerator mass spectrometry, and the biomass content is determined by the C-14 ratio. 3) Chemically recycled fabrics are fabrics made from synthetic resins repolymerized from monomers recovered from the depolymerization of recycled synthetic resin molded products. Specifically, these fabrics are fabrics woven from multifilament yarns melt-spun from polyethylene terephthalate, which is formed by repolymerizing ethylene glycol with terephthalic acid recovered from the depolymerization of polyethylene terephthalate products. 4) Melted synthetic resin molded products are fabrics woven from yarns melt-spun from synthetic resins recycled by melting one or more of 1) to 3).

[0017] The synthetic resins used as the raw material for the yarns include thermoplastic resins (colored or uncolored), such as polypropylene, polyethylene, polyvinyl alcohol, nylon (such as 6-nylon, 6,6-nylon, and 610-nylon), and polyester (polyethylene terephthalate, polynaphthalene terephthalate, and polyethylene furanoate). These thermoplastic resins are melted and extruded from a die nozzle, stretched thinly, and then cold-drawn to obtain filaments with a specified dtex. Polyesters (polyethylene terephthalate, polynaphthalene terephthalate, and polyethylene furanoate) are particularly preferred, as they have excellent load creep properties as fibers. Yarns made from these synthetic resins can be short-fiber spun yarns or long-fiber multifilament bulky yarns, or a combination of both is possible. Staple spun yarn is made by cutting a bundle of long filaments into 3-7 cm lengths, opening the staple, and drawing the resulting sliver through a doubling draft to achieve a uniform parallelism of the fibers. This roving is then tow-spun into a cotton-like yarn by drafting and twisting the roving to a specified count. The staple imitates the fibers extracted from cotton bolls. Twisted yarns are either single yarns or two-ply yarns made by twisting two single yarns together with an S (right) or Z (left) twist at 500-2000 turns / m. The twist factor, which represents the relationship between count and twist, is 1.3-3.0 for a soft twist, 3.0-4.5 for a normal twist, or 4.5-5.5 for a hard twist. Long-fiber multifilament bulky yarns can be obtained through taslan, woolly, or core-spun sheath-core processes. Taslan processing is a bulky processed yarn in which compressed air is blown onto multifilament yarn to entangle the filaments in a loop to form a bulky section; wooly processing is a bulky processed yarn in which multifilament yarn is twisted, heat-set, and then untwisted to form a bulky section; and core-spun core-sheath processing is a bulky processed yarn in which short fiber staples are twisted all around a multifilament yarn as a core to form a fluffy surface with a core-sheath structure in a mass ratio of 10:1 to 2:1.

[0018] Examples of the count of staple spun yarn include 10 count single yarn (590 dtex), 14 count single yarn (422 dtex), 14 count two-ply yarn (844 dtex), 15 count single yarn (394 dtex), 15 count two-ply yarn (788 dtex), 20 count single yarn (295 dtex), 20 count two-ply yarn (590 dtex), 30 count single yarn (197 dtex), and 30 count two-ply yarn (394 dtex). The fabric is a plain weave (having a minimum unit of two warp and two weft threads: including basket weave) made with a warp thread density of 40 to 80 threads per inch and a weft thread density of 30 to 70 threads per inch, or a twill weave (having a minimum unit of three warp and three weft threads: 3-ply twill, 4-ply twill, 5-ply twill, 6-ply twill, 8-ply twill, etc.), or a satin weave. (Both warp and weft threads have a minimum structural unit of at least five threads: regular twill such as 2-, 3-, 4-, or 5-step). The difference between the total inch fineness (dtex / inch) of the weft thread group and the total inch fineness (dtex / inch) of the warp thread group is within ±10% (total inch fineness: the product of the thread fineness and the number of threads). The void ratio of the fabric (woven fabric) is 0-12%, and the mass is 170g / m. 2 ~410g / m 2 The difference in total fineness between inches (%) is calculated as "(large total fineness - small total fineness) x 100) / large total fineness." If the porosity exceeds 12%, the pores become large, causing pinholes in the resulting synthetic resin canvas, and the tear strength and penetration resistance against protrusions decrease. The fabric size is No. 2 (approximately 410 g / m 2 ), No. 3 (approximately 340g / m 2 ), No. 4 (approximately 280g / m 2 ), No. 5 (approximately 250g / m 2 ), No. 6 (approximately 200g / m 2 ), No. 7 (approximately 170g / m 2) Particularly preferred is a plain weave fabric of size 5 or 6 with a void ratio of 5 to 10%, obtained by weaving a warp thread of 20 count two-ply yarn and a weft thread of 10 count single yarn at a density of 52 to 60 warp threads per inch and 44 to 52 weft threads per inch. This allows the 10% tensile stress (based on JIS L1096A) in the width direction of these synthetic resin canvases to be 90 to 110% of the 10% tensile stress (based on JIS L1096A) in the processing direction, resulting in stable warp and weft dimensional balance.

[0019] The fabric may be a "combination of staple spun yarn and long-fiber multifilament bulky yarn" fabric (plain weave, twill weave, or satin weave) in which some of the yarns in the weave of the fabric described in paragraph

[0018] are replaced with long-fiber multifilament bulky yarn (taslan bulky yarn, or woolly bulky yarn, or core-spun core-sheath yarn) (fineness 278 dtex to 1666 dtex, number of filaments 50 to 500) at a substitution rate of 25 to 75 mass %, particularly 25 to 50 mass %, based on the mass of the fabric. The substitution is preferably performed to approximate the dtex fineness, and examples thereof include substitution of a 10-count cotton single yarn (590 dtex) with a 500-denier (555 dtex) long-fiber multifilament bulky yarn, substitution of a 20-count cotton single yarn (295 dtex) with a 250-denier (278 dtex) long-fiber multifilament bulky yarn, substitution of a 15-count cotton two-ply yarn (788 dtex) with a 750-denier (832 dtex) long-fiber multifilament bulky yarn, and substitution of a 20-count cotton two-ply yarn (590 dtex) with a 500-denier (555 dtex) long-fiber multifilament bulky yarn. Substitution of both the warp yarn group and the weft yarn group is preferable in terms of excellent warp-to-warp balance of tensile strength and tear strength and also in terms of the quality of the uneven appearance. The substitutions are repeating units such as (SB), (SSB), and (SSSB) when S is a short fiber spun yarn and B is a long fiber multifilament bulky yarn.

[0020] Furthermore, the fabric "combined use of staple spun yarn and long multifilament bulky yarn" may be a twisted yarn of staple spun yarn and long multifilament bulky yarn, and these specifically include "278 dtex / 30 count single yarn", "278 dtex / 20 count single yarn", "278 dtex / 15 count single yarn", "555 dtex / 20 count double yarn", "555 dtex / 10 count single yarn", "555 dtex / 14 count single yarn", "833 dtex / 14 count two-ply yarn", "833dtex / 15 count two-ply yarn", "833dtex / 20 count two-ply yarn", "1111dtex / 14 count two-ply yarn", "1111dtex / 15 count two-ply yarn", "1111dtex / 20 count two-ply yarn", "278dtex / 278dtex / 20 count two-ply yarn", "278dtex / 278dtex / 30 count two-ply yarn", "278dtex / 555dtex / 14 count two-ply yarn", "278dtex / 555dtex / 15 count Two-ply yarn", "278dtex / 555dtex / 20-count two-ply yarn", "555dtex / 555dtex / 14-count single yarn", "555dtex / 555dtex / 15-count single yarn", "555dtex / 555dtex / 20-count two-ply yarn", "555dtex / 30-count single yarn / 30-count single yarn", "555dtex / 20-count single yarn / 30-count single yarn", "555dtex / 20-count single yarn / 20-count single yarn", "833dtex / 14-count single yarn / 14-count single yarn The number of ply-twisted yarns (two-ply yarns are counted as one yarn) is preferably two or three, and the number of ply-twisted turns is 100 to 500 turns / m, preferably 150 to 300 turns / m. The more the number of ply-twisted turns exceeds 500 turns / m, the tighter the yarn becomes, and the bulky portion of the long-fiber multifilament bulky yarn disappears, impairing the anchoring effect and the pseudo-appearance of short-fiber spun yarn.The packing density of the ply-twisted yarn (multifilament yarn / staple fiber spun yarn) is 25 to 55 warp yarns, preferably 30 to 46 warp yarns, and 28 to 58 weft yarns, preferably 34 to 50 weft yarns, per inch, and the difference between the total fineness per inch (dtex / inch) of the weft yarn group and the total fineness per inch (dtex / inch) of the warp yarn group is within ±10% (total fineness per inch: product of yarn fineness and number of yarns). A fabric with a void ratio of 5 to 12% is suitable, and the mass of the fabric is 170 g / m. 2 ~410g / m 2 , preferably 190 g / m 2 ~260g / m 2 The difference (%) in total fineness between inches is calculated as "(large total fineness - small total fineness) x 100) / large total fineness".

[0021] Furthermore, the fabric "using a combination of staple fiber spun yarns and long fiber multifilament bulky yarns" may be a woven fabric in which all of the warp thread groups are staple fiber spun yarns and all of the weft thread groups are long fiber multifilament bulky yarns, or a woven fabric in which all of the warp thread groups are long fiber multifilament bulky yarns and all of the weft thread groups are staple fiber spun yarns. Fabrics made from long-fiber multifilament bulky yarns include fabrics in which the warp and weft yarn groups are made of taslan bulky yarns (T), fabrics in which the warp and weft yarn groups are made of wooly bulky yarns (W), fabrics in which the warp and weft yarn groups are made of core-spun core-sheath bulky yarns (C), fabrics in which the warp and weft yarn groups are made of two types of yarns selected from T yarns, W yarns, and C yarns, used separately in the warp and weft directions (T / W, W / T, T / C, C / T, C / W, W / C), and fabrics in which two types of yarns selected from T yarns, W yarns, and C yarns are used in the warp and weft directions at specific intervals (TW / TW, TC / TC, CW / CW). The weft density of long fiber multifilament bulky yarn (fineness 278 dtex to 1666 dtex, number of filaments 50 to 500) is 12 to 36 warp and weft yarns per inch, and the difference between the total fineness per inch (dtex / inch) of the weft yarn group and the total fineness per inch (dtex / inch) of the warp yarn group is within ±10% (total fineness per inch: product of yarn fineness and number of yarns). A fabric with a void ratio of 5 to 12% is suitable, and the mass of the fabric is 170 g / m 2 ~410g / m 2 , preferably 190 g / m2 ~260g / m 2 The difference (%) in total fineness between inches is calculated as "(large total fineness - small total fineness) x 100) / large total fineness".

[0022] Tent warehouses, roofed tents, truck canopies, truck bed covers, open-air storage sheets, and other products made by sewing the synthetic resin canvas of the present invention suffer damage such as scratches, abrasions, or cracks in the soft polyvinyl chloride resin-impregnated coating layer, which allows rainwater to seep in through the damaged areas and cause leaks. Furthermore, the cut edges of the synthetic resin canvas expose the cross-sections of the densely packed filament yarns, causing capillary action, allowing rainwater to seep into the fabric and remain there for a long time, resulting in the development of mold, algae, and unpleasant odors. A common method of preventing such problems is to impregnate and apply a fluorine-based water repellent made from a perfluoroalkyl group-containing copolymer resin (a fluorine-based copolymer made from an ethylenically unsaturated monomer having a perfluoroalkyl group or a perfluoroalkenyl group) to the entire fabric. However, due to global restrictions on the use of PFOS (perfluorooctane sulfonic acid) and PFOA (perfluorooctanoic acid), which are contained as impurities in fluorine-based water repellents, a shift to fluorine-based water repellents with six or fewer carbon atoms has been considered. However, fluorine-based water repellents in general are avoided from an environmental perspective, so it is preferable to use non-fluorine-based water repellents such as silicon compounds such as methylchlorosilane, methylpolysiloxane resin, dimethylpolysiloxane, and methylhydrogenpolysiloxane, n-paraffin wax with 20 to 48 carbon atoms, crosslinkable polymers obtained by reacting urethane resins with functional groups with carbodiimide compounds (containing ethylene oxide moieties), or crosslinkable polymers obtained by reacting acrylic resins with functional groups with carbodiimide compounds (containing ethylene oxide moieties). These non-fluorine-based water repellents are used in the form of aqueous emulsions that can be diluted with water. The process of imparting water repellency (water absorption prevention) can be completed by immersing a fabric in an aqueous solution adjusted to a solids concentration of 1 to 10% by mass, adhering the water repellent component to the entire fabric (between the filaments of the yarns that make up the fabric and on the surfaces of the filaments), squeezing the fabric with a pair of rubber rolls, drying, and heat treating it.

[0023] The soft vinyl chloride resin impregnated coating layer provided on the entire surface of the fabric is formed by coating a soft vinyl chloride resin composition and then heat-treating to gel it, or by dipping the composition and then heat-treating to gel it. The mass of the synthetic resin canvas of the present invention is 360 to 800 g / m 2 In this case, the preferred fabric mass is 170 g / m 2 ~410g / m 2 Therefore, the soft vinyl chloride resin impregnated coating layer is set at 190 g / m 2 ~630g / m 2 and preferably 190 g / m 2 ~390g / m 2Here, vinyl chloride resins include vinyl chloride resin, cross-linked vinyl chloride resin, chlorinated vinyl chloride resin, ethylene-vinyl chloride copolymer, vinyl acetate-vinyl chloride copolymer, acrylic-(graft) vinyl chloride copolymer, and urethane-vinyl chloride (graft) copolymer. Flexible vinyl chloride resin compositions are paste sol fluids containing at least vinyl chloride resin (powder) and a plasticizer. Specifically, flexible vinyl chloride resin compositions contain a paste vinyl chloride resin (emulsion polymerization type, preferably a biomass-synthesized product) with a number-average molecular weight of 1,000 to 2,000 and a plasticizer (a biomass-synthesized product such as an adipic acid ester compound, a phthalate ester compound, a cyclohexane dicarboxylic acid ester compound, a cyclohexene dicarboxylic acid ester compound, a phosphate ester compound, a chlorinated paraffin compound, or a polyester compound), preferably containing 40 to 100 parts by mass of plasticizer per 100 parts by mass of the paste vinyl chloride resin. Furthermore, the soft vinyl chloride resin composition may contain 5 to 30 parts by mass of liquid synthetic rubber (such as butadiene rubber, isoprene rubber, farnesene rubber, or other biomass-synthesized products that can be converted into cured rubber later) per 100 parts by mass of the paste vinyl chloride resin.Other compounding agents include stabilizers (heat stabilizers such as barium-zinc complexes, calcium-zinc complexes, and epoxidized soybean oil, and light stabilizers such as hindered amine compounds), lubricants (low molecular weight polyethylene, paraffin, stearic acid compounds, amide compounds, aliphatic esters, fatty acid metal soaps, silicone resin powder, acrylic grafted silicone powder, and composite powders in which silicone rubber particles are coated with silicone resin), flame retardants (antimony trioxide, antimony pentoxide, aluminum hydroxide, magnesium hydroxide, zinc borate, and others), fillers (calcium carbonate, barium sulfate, talc, and others), and UV protection. Examples of blended compositions include absorbents (benzophenone tautomers, benzotriazole tautomers, triazine tautomers, etc.), adhesives (multifunctional isocyanate compounds, silane coupling agents, etc.), antifungal agents (imidazole compounds, thiazole compounds, isothiazolinone compounds, pyridine compounds, N-haloalkylthio compounds, phenoxyarsine compounds, etc.), insect repellents (pyrethroid compounds), pigments (titanium oxide, carbon black, inorganic compounds, azo compounds, phthalocyanine compounds, anthraquinone compounds, quinacridone compounds, metal oxide heat-shielding pigments, etc.), etc., which may be added in any desired amounts. These may further contain known additives such as antistatic agents, antioxidants, and deodorizers, as needed.

[0024] The reactive liquid rubber contained in the flexible vinyl chloride resin composition (3 to 15 parts by mass per 100 parts by mass of vinyl chloride resin, or 10 to 35% by mass per 100% by mass of plasticizer) is compatible with the plasticizer in the composition and penetrates into the vinyl chloride resin particles together with the plasticizer, acting as a softener for the vinyl chloride resin, with the reactive liquid synthetic rubber molecules becoming entangled with the vinyl chloride resin main chain. Heating the flexible vinyl chloride resin composition to gel and cure it in this state forms a flexible vinyl chloride resin-impregnated coating layer, and the entire interior of this flexible vinyl chloride resin-impregnated coating layer becomes a PVC / rubber hybrid in which a network of rubber molecular chains is entangled with the vinyl chloride resin main chain. This hybrid of vinyl chloride resin and cured liquid rubber toughens the flexible vinyl chloride resin-impregnated coating layer, improving its flex resistance, abrasion resistance, heat resistance, cold resistance, and other properties. This cured liquid rubber is a polymer of reactive liquid rubber such as butadiene, isoprene, or farnesene, or a polymer of reactive liquid rubber and an isocyanate compound.

[0025] Reactive butadiene liquid rubber forms a cured rubber by having either a -COOH group or a -OH group at the molecular end. The molecular weight Mn is preferably 1000 to 5000, particularly 1300 to 3500, and the viscosity is preferably 50 to 1000 poise (25°C), particularly 200 to 500 poise (25°C). The cured liquid rubber contains a block copolymer component containing 5 to 25% by mass of styrene and / or acrylonitrile, and a block copolymer component containing 10 to 50% by mass of isoprene or hydrogenated isoprene. Reactive butadiene liquid rubber has excellent rubber elasticity when it contains 75 to 80% of a 1,4-cis structure or a 1,4-trans structure and 20 to 25% of a 1,2-vinyl structure. The reactive isoprene-based liquid rubber preferably has a molecular weight of 3,000 to 25,000 and either a -COOH group or an -OH group at (both) molecular terminals. The cured liquid rubber contains a block copolymer component containing 5 to 25 mass% of styrene and / or acrylonitrile, or a block copolymer component containing 10 to 50 mass% of butadiene or hydrogenated isoprene. The reactive farnesene-based liquid rubber preferably has a molecular weight of 3,000 to 50,000 and either a -COOH group or an -OH group at (both) molecular terminals, such as α-farnesene ((3E,7E)-3,7,11-trimethyl-1,3,6,10-dodecatetraene) or β-farnesene (7,11-dimethyl-3-methylene-1,6,10-dodecatriene). The liquid rubber cured product is a copolymer rubber of these polymers, funnelthene and styrene, funnelthene and butadiene, or the like.

[0026] The liquid rubber cured product is formed by dehydration condensation of the -COOH and -OH groups at both molecular terminals. It can also be formed by addition reaction with crosslinkers such as diamines, polyamines, diisocyanates (e.g., hexamethylene diisocyanate (HMDI)), triisocyanates (e.g., isocyanurates formed from HMDI trimers), epoxyamines, aziridines, and oxazolines, or by condensation reaction with crosslinkers such as diols, polyols, dicarboxylic acids, and polycarboxylic acids. Dense and complex cured rubber products are particularly obtained by using crosslinkers with three or four functional groups. The conversion of the liquid synthetic rubber to cured rubber is carried out simultaneously with the gelation of the flexible vinyl chloride resin composition, resulting in the formation of a uniform cured rubber throughout the entire flexible vinyl chloride resin-impregnated coating layer. The reaction between the liquid synthetic rubber and the crosslinker is preferably an equimolar reaction, but excess liquid synthetic rubber may remain within the flexible vinyl chloride resin-impregnated coating layer. The remaining liquid synthetic rubber is compatible with the plasticizer and has the effect of lowering the glass transition temperature of the soft vinyl chloride resin impregnated coating layer, i.e., it acts as a cold resistance imparting agent. The remaining liquid synthetic rubber is about 1 to 10 parts by mass per 100 parts by mass of vinyl chloride resin. Furthermore, a portion of the cured liquid rubber is dispersed in silica particles (BET specific surface area 100 to 300 m). 2 It is also possible to use cured rubbers bonded with silica particles (silica particles of 10 ...

[0027] The method for manufacturing synthetic resin canvas with excellent warp and weft dimensional balance stability of the present invention includes a process of providing a soft vinyl chloride resin-impregnated coating layer on the entire surface of the fabric. In this process, the soft vinyl chloride resin-impregnated coating layer is formed by a dipping method (including a heat treatment gelling process) or a coating method (including a heat treatment gelling process) under tension with the difference in tension (kgf / m) between the processing direction and the width direction of the fabric being within ±20%. This results in the 10% tensile stress in the width direction (based on JIS L1096A) of the resulting synthetic resin canvas being 90-110% of the 10% tensile stress in the processing direction (based on JIS L1096A). The tension difference (%) is calculated as "(high tension - low tension) x 100) / high tension." Specifically, a long fabric roll with a width of 1-3 m is unwound and fed into the entrance of a dipping or coating machine, and then coated with No. 2 (approximately 410 g / m). 2 ), No. 3 (approximately 340g / m 2 ), No. 4 (approximately 280g / m 2 ), No. 5 (approximately 250g / m 2 ), No. 6 (approximately 200g / m 2 ) and No. 7 (approx. 170g / m 2 ) The soft vinyl chloride resin composition according to any one of paragraphs

[0023] to

[0026] is continuously applied to the entire surface of the fabric in an amount of 190 g / m by a dipping (immersion) method or a coating method. 2 ~630g / m 2 , preferably 190 g / m 2 ~390g / m 2 The fabric is then passed through a heat treatment drying oven to gel the soft vinyl chloride resin composition (solidify the film), and the resulting long synthetic resin canvas is wound up continuously to produce a canvas with a mass of 360 to 800 g / m. 2 These are No. 2 canvases (approximately 750 g / m 2 ), No. 3 canvas (approx. 640g / m 2 ), No. 4 canvas (approx. 560g / m 2 ), No. 5 canvas (approx. 530g / m 2 ), No. 6 canvas (approx. 470g / m 2 ), No. 7 canvas (approx. 430g / m 2 ) and other sizes of canvas.

[0028] The soft vinyl chloride resin composition can be either infiltrated into the gaps between the filaments of the yarn constituting the fabric, impregnating the entire yarn, or controlled so that the core of the yarn is not impregnated. During this series of processes, the fabric, intermediate product, and synthetic resin canvas all flow through the machine at the same processing speed. The synthetic resin canvas is wound under tension in the processing direction, resulting in longitudinal elongation and, conversely, width loss in the width direction for all fabrics, intermediate products, and synthetic resin canvas. This dimensional change is primarily influenced by the weave structure (yarn density) and porosity of the fabric. The lower the thread count and the higher the porosity, the greater the dimensional change due to tension. Furthermore, during the gelation (coating solidification) process at 180-200°C, the synthetic fiber yarn is slightly softened, resulting in tension elongation in the processing direction, and the yarn is thermally shrunk, resulting in unraveling of the stretched yarn. Similarly, in the width direction, the yarns undergo width loss due to thermal shrinkage and stretching, but the large tension in the processing direction is not involved. This results in significant imbalance in the warp (processing direction) and weft (width direction), and the final synthetic resin canvas is manufactured with this warp-to-width imbalance remaining. Therefore, the resulting synthetic resin canvas tends to stretch in the width direction to recover from the width loss, and shrink in the length direction to recover from the stretching. In particular, synthetic resin canvas sewn products are attached to the entire frame of items such as seat warehouses and truck canopies, which tend to lose dimensional balance over time due to slack and hanging. To avoid this problem, it is effective to apply tension in the width direction equivalent to the tension in the processing direction, at least for intermediate products and later. It is particularly essential that the 10% tensile stress (JIS L1096A method) in the width direction of the resulting synthetic resin canvas be 90 to 110% of the 10% tensile stress (JIS L1096A method) in the processing direction. If it is outside the range of 90-110%, the synthetic resin canvas may sag, causing width hanging and resulting in a poor appearance.Tension in the width direction can be achieved by pinning the left and right edges (selvages) of the fabric, intermediate product, and synthetic resin canvas onto the pins of the left and right pin tenter guide rails or by fixing them with the left and right clips of the clip tenter guide rails, preventing the fabric, intermediate product, and synthetic resin canvas from shrinking below their original width, or by expanding the fabric, intermediate product, and synthetic resin canvas beyond their original width. The tension in the process direction is adjusted by the rotational force and rotation speed of the winding roll shaft, while the tension in the width direction can be adjusted by adjusting the distance between the left and right tenter guide rails. The tension in the process direction and width direction can be measured using commercially available tension sensors. Since tension increases significantly during the thermal shrinkage of the yarn, real-time tension correction is required to maintain uniform tension in the process direction and width direction throughout the entire process. This manufacturing process includes a step of slitting and removing 1 to 5 cm from both ends of the synthetic resin canvas pinned or clipped by the tenter to adjust the product width, and a finishing step of winding it up to the product length. For applications such as sheet storage, truck canopies, etc., the resulting synthetic resin canvas rolls (e.g., 1-3m wide x 50m rolls) are overlapped at specific measurements, for example, by a 2-5cm width, and the overlapping portions are then crimped with a high-frequency welding machine's metal weld bar and current is applied. The high-frequency oscillation generates instantaneous heat, melting the soft vinyl chloride resin layers and fusing them together to produce a sewn product. By repeating this process, a membrane material sewn product can be produced for use in sheet storage, truck canopies, etc. This sewing can also be performed using a self-propelled hot air welding machine or a heat iron welding machine.

[0029] The synthetic resin canvas of the present invention may also be provided with an anti-fouling layer, such as a transparent layer made of acrylic resin, fluorine-based copolymer resin, acrylic-silicone copolymer resin, acrylic-fluorine copolymer resin, acrylic-urethane copolymer resin, a blend of acrylic resin and fluorine-based copolymer resin, or a layer containing these resins and silica particles, colloidal silica, organosilicate, silane coupling agent, UV absorber (benzophenone tautomer, benzotriazole tautomer, triazine tautomer, etc.). These anti-fouling layers can be formed by gravure coating and drying the coating, or by laminating a fluorine-containing resin film or a multilayer film such as a fluorine-containing resin / acrylic resin layer with an adhesive or by thermal fusion. Furthermore, a photocatalytic layer containing a photocatalytic inorganic material (e.g., photocatalytic titanium oxide, photocatalytic tungsten oxide, etc.) on the anti-fouling layer.

[0030] The production of the synthetic resin canvas of the present invention may include a surface decorative embossing process. Surface decorative embossing can be achieved by known embossing techniques, such as glossing with a mirror-finish roll, matting with a matte finish roll, or designing with a pattern roll. It is particularly preferable to apply identification markings, such as the manufacturer's name (e.g., "HIRAOKA") or logo, product name (e.g., "ULTRA MAX"), recycling mark, or biomass mark, at specific intervals (e.g., every 100 cm) on the edge or specific portions of the synthetic resin canvas. Such identification markings may be designed such that the entire canvas is matte-finish embossed and only the identifying marking is mirror-finish embossed, or the entire canvas is mirror-finish embossed and only the identifying marking is matte-finish embossed, or embossed with a recessed area for the identifying marking. These markings facilitate identification during recycling. In-house recycling allows for more effective utilization of recycled products, as details such as the resin composition and fabric are clearly known. The embossing is performed by pressing an embossing roll set at 100 to 180°C against a pair of rubber rolls, and the embossing is fixed by cooling (air-cooling and water-cooling rolls) after embossing.

[0031] The present invention will now be described in more detail with reference to examples and comparative examples, but the present invention is not limited to the scope of these examples. The test methods used in the examples and comparative examples of the present invention are as follows. (1) 10% tensile stress (JIS L1096A method) (2) Creep test Test pieces measuring 3 cm wide x 30 cm long (warp direction) and 3 cm wide x 30 cm long (weft direction) were taken to prepare creep test pieces, and the elongation in the warp direction and the elongation in the weft direction were measured within a 20 cm gauge line of the test piece (5 cm above and below the test piece was the creep tester mounting area) under the conditions of 25°C x 50 kgf load x 24 hours using a creep tester (100LDR model manufactured by Toyo Seiki Seisakusho Co., Ltd.). (3) Dematcha cold bending fatigue endurance test (JIS K6301 compliant) A 50mm wide x 150mm long sample was taken from the synthetic resin canvas and left to rest in a -10°C environment for 24 hours, after which it was folded in half, top and bottom, from the center 25mm of the width, to create a 25mm wide x 150mm long folded test piece. This was then attached to a YSS Dematcha Flexing Tester (manufactured by Yasuda Seiki Seisakusho) and subjected to 100 cycles of repeated folding and unfolding of synthetic resin canvas in cold conditions in a constant temperature room at -10°C. The surface condition of the test piece was observed and the dynamic cold resistance was determined as follows: 1: No abnormalities are observed 2: Minor cracks observed in the flame-retardant resin coating layer 3: Large cracks were observed in the flame-retardant resin coating layer.

[0032] Example 1 <Fabric (1)> The warp yarn group is polyester staple spun yarn (20 count two-ply yarn: 590 dtex) 48 strands / inch, and the weft yarn group is polyester staple spun yarn (20 count two-ply yarn: 590 dtex) 48 strands / inch, and the void ratio is 8%. 2) was used, and this plain weave fabric was treated with a water-repellent treatment (dipping and heat treatment) using a non-fluorinated resin copolymer emulsion (solid content 8% by mass) to prevent water leakage in the event of damage to the soft vinyl chloride resin impregnated coating layer, and to prevent rainwater from penetrating (absorbing water) through the cut surface of the canvas. Fabric (1) was used. The weft and weft are 28,320 dtex (590 dtex x 48 threads) per inch. <Soft vinyl chloride resin impregnated coating layer> A processing solution consisting of a vinyl chloride resin composition paste for forming a soft vinyl chloride resin-impregnated coating layer was prepared according to the following formula (1). Next, fabric (1) was dipped (immersed) in a liquid bath filled with this processing solution, and the processing solution of formula (1) was impregnated into fabric (1) at normal pressure. After that, fabric (1) was pulled out of the liquid bath and simultaneously squeezed with a rubber mangle roll to remove excess processing solution, forming a precursor for the soft vinyl chloride resin-impregnated coating layer. Next, a gelation heat treatment was performed in a hot air oven at 180°C for 3 minutes (process direction tension 5 kgf / 10 cm × width direction tension 5 kgf / 10 cm) to form a soft vinyl chloride resin-impregnated coating layer of 300 g / m. 2 is formed on the entire surface of the fabric (1), and the mass is 530 g / m 2 This resulted in a No. 5 canvas (synthetic resin canvas 1). This gelation heat treatment converts the vinyl chloride resin composition paste into soft vinyl chloride resin and simultaneously converts the butadiene-based liquid rubber into a cured rubber, forming a polymer alloy throughout the entire soft vinyl chloride resin-impregnated coating layer in which the molecular chains of the cured rubber are entangled with the vinyl chloride resin main chain. The resulting synthetic resin canvas 1 had a 10% tensile stress in the width direction of 96% of the 10% tensile stress in the processing direction, a warp creep elongation of 5 mm and a weft creep elongation of 6 mm, and a rating of "1" in the cold bending fatigue durability test. <Formulation 1> Processing fluid for forming soft vinyl chloride resin impregnated coating layer Paste: vinyl chloride resin (degree of polymerization 1700) 100 parts by mass Diisononyl phthalate (DINP plasticizer) 60 parts by mass Butadiene liquid rubber* 10 parts by mass Isocyanurate (HMDI* trimer: NCO crosslinking agent) 2 parts by mass Chlorinated paraffin (flame retardant and plasticizer) 5 parts by mass Epoxidized soybean oil (stabilizer and plasticizer) 4 parts by mass Antimony trioxide (flame retardant) 20 parts by mass Zinc stearate (stabilizer) 2 parts by mass UV absorber (triazine tautomer) 0.5 parts by mass Titanium oxide (white pigment) 1 part by mass Phthalocyanine green (green pigment) 3 parts by mass Carbon black (black pigment) 0.5 parts by mass Silicone resin powder (lubricant: average particle size 2 μm) 4 parts by mass Trichloroethylene (dilution solvent) 20 parts by mass *Butadiene liquid rubber: Contains 15% by mass of styrene as a block copolymer component. Properties: Average molecular weight 3000 with -COOH groups at both ends of the molecule *HMDI: Hexamethylene diisocyanate HMDI trimer (isocyanurate) has three isocyanate groups

[0033] Example 2 A mass of 530 g / m was obtained by the same processing steps and processing conditions as in Example 1, except that Fabric (1) in Example 1 was changed to Fabric (2) and Blend 1 was changed to Blend 2. 2 Synthetic resin canvas 2 was obtained. The resulting synthetic resin canvas 2 had a 10% tensile stress in the width direction of 96% of the 10% tensile stress in the processing direction, a warp creep elongation of 5 mm x weft creep elongation of 6 mm, and a rating of "1" in the cold bending fatigue durability test. In <Mixture 2>, 10 parts by mass of the butadiene-based liquid rubber in <Mixture 1> is replaced with 10 parts by mass of isoprene-based liquid rubber. The isoprene-based liquid rubber contains 10% by mass of acrylonitrile as a block copolymer component, has -COOH groups at both ends of the molecule, and has an average molecular weight of 2500. <Fabric (2)> The warp yarn group is polyester staple spun yarn (20 count two-fold yarn: 590 dtex) 48 ends / inch, and the weft yarn group is polyester staple spun yarn (20 count two-fold yarn: 590 dtex) 48 ends / inch. The fabric has a three-ply twill pattern with a void ratio of 8% (weight 230 g / m2 The three-ply twill fabric was made of fabric (2) that had been treated with a non-fluorine-based resin copolymer emulsion (solid content 8% by mass) for water repellency (immersion and heat treatment). The warp and weft were 28,320 dtex (590 dtex x 48 threads) per inch.

[0034] Example 3 A mass of 530 g / m was obtained by the same processing steps and processing conditions as in Example 1, except that Fabric (1) in Example 1 was changed to Fabric (3) and Blend 1 was changed to Blend 3. 2 Synthetic resin canvas 3 was obtained. The resulting synthetic resin canvas 3 had a 10% tensile stress in the width direction of 96% of the 10% tensile stress in the processing direction, a warp creep elongation of 5 mm x weft creep elongation of 6 mm, and a rating of "1" in the cold bending fatigue durability test. In <Mixture 3>, 10 parts by mass of the butadiene-based liquid rubber in <Mixture 1> is replaced with 10 parts by mass of β-funnelsen-based liquid rubber. The β-funnelsen-based liquid rubber contains 10% by mass of butadiene as a block copolymer component, has -COOH groups at both ends of the molecule, and has an average molecular weight of 5,000. <Fabric (3)> The warp yarn group is polyester staple spun yarn (20 count two-ply yarn: 590 dtex) 48 ends / inch, and the weft yarn group is polyester staple spun yarn (20 count two-ply yarn: 590 dtex) 48 ends / inch. The fabric has a void ratio of 8% and a two-ply satin weave (mass 230 g / m 2 ) was used, and for this two-way satin weave fabric, fabric (3) was used which had been subjected to water-repellent treatment (immersion, heat treatment) with a non-fluorine-based resin copolymer emulsion (solid content 8 mass%). Both the warp and weft had a dtex of 28,320 (590 dtex x 48 threads) per inch.

[0035] Example 4 A mass of 530 g / m was obtained by the same processing steps and processing conditions as in Example 1, except that the fabric (1) in Example 1 was changed to fabric (4). 2Synthetic resin canvas 4 was obtained. The resulting synthetic resin canvas 4 had a 10% tensile stress in the width direction of 106% of the 10% tensile stress in the processing direction, a warp creep elongation of 5 mm x weft creep elongation of 3 mm, and a rating of "1" in the cold bending fatigue durability test. <Fabric (4)> The warp yarn group is polyester staple spun yarn (20 count two-fold yarn: 590 dtex) 48 strands / inch, and the weft yarn group is polyester long fiber multifilament bulky yarn (1111 dtex: 192 filaments) 26 strands / inch, with a void ratio of 10%. The plain weave fabric (mass 230 g / m 2 The plain weave fabric used was a fabric (4) that had been subjected to a water-repellent treatment (immersion and heat treatment) using a non-fluorinated resin copolymer emulsion (solid content 8% by mass). The warp was 28,320 dtex (590 dtex x 48 threads) per inch, and the weft was 28,886 dtex (1,111 dtex x 26 threads) per inch.

[0036] Example 5 A mass of 530 g / m was obtained by the same processing steps and processing conditions as in Example 1, except that Fabric (1) in Example 1 was changed to Fabric (5) and Blend 1 was changed to Blend 2. 2 Synthetic resin canvas 5 was obtained. The resulting synthetic resin canvas 5 had a 10% tensile stress in the width direction of 106% of the 10% tensile stress in the processing direction, a warp creep elongation of 5 mm x weft creep elongation of 3 mm, and a rating of "1" in the cold bending fatigue durability test. <Fabric (5)> The warp yarn group is polyester staple spun yarn (20 count two-fold yarn: 590 dtex) 48 ends / inch, and the weft yarn group is polyester long fiber multifilament woolly processed bulky yarn (1111 dtex: 192 filaments) 26 ends / inch. The void ratio is 10% and the fabric is a three-ply twill fabric (weight 230 g / m 2 The three-ply twill fabric was made from fabric (5) that had been treated with a non-fluorine-based resin copolymer emulsion (solid content 8% by mass) for water repellency (dipping and heat treatment). The warp was 28,320 dtex (590 dtex x 48 threads) per inch, and the weft was 28,886 dtex (1,111 dtex x 26 threads) per inch.

[0037] Example 6 A mass of 530 g / m was obtained by the same processing steps and processing conditions as in Example 1, except that the fabric (1) in Example 1 was changed to fabric (6) and blend 1 was changed to blend 3. 2 Synthetic resin canvas 6 was obtained. The resulting synthetic resin canvas 6 had a 10% tensile stress in the width direction of 106% of the 10% tensile stress in the processing direction, a warp creep elongation of 6 mm x weft creep elongation of 4 mm, and a rating of "1" in the cold bending fatigue durability test. <Fabric (6)> The warp yarn group is polyester staple spun yarn (20 count two-ply yarn: 590 dtex) 48 ends / inch, and the weft yarn group is polyester long fiber multifilament bulky yarn with core spun core-sheath processing 34 ends / inch. The fabric has a void ratio of 4% and a two-ply satin weave (mass 230 g / m 2 ) was used, and this two-leaf satin weave was fabric (6) that had been subjected to a water-repellent treatment (dipping and heat treatment) with a non-fluorinated resin copolymer emulsion (solid content 8% by mass). The core-spun core-sheath bulky yarn had a polyester 555 dtex (96 filaments) multifilament yarn (twist count 100 turns / m) as the core, completely covered with 1.4 denier (1.56 dtex) polyester staple fiber with a length of 100 mm to give a core / sheath ratio of 70 / 30. This was a core-sheath composite yarn equivalent to 832 dtex. The warp was 28,320 dtex (590 dtex x 48 threads) per inch, and the weft was 28,288 dtex (832 dtex x 34 threads) per inch.

[0038] Example 7 A mass of 530 g / m was obtained by the same processing steps and processing conditions as in Example 1, except that the fabric (1) in Example 1 was changed to fabric (7). 2 Synthetic resin canvas 7 was obtained. The resulting synthetic resin canvas 7 had a 10% tensile stress in the width direction of 98% of the 10% tensile stress in the processing direction, a warp creep elongation of 3 mm x weft creep elongation of 3 mm, and a rating of "1" in the cold bending fatigue durability test. <Fabric (7)> The warp yarn group is a bulky yarn (1111 dtex: 192 filaments) with 26 threads / inch made from taslan-processed polyester long fiber multifilament, and the weft yarn group is a bulky yarn (1111 dtex: 192 filaments) with 26 threads / inch made from taslan-processed polyester long fiber multifilament. The plain weave fabric (mass 230 g / m) has a void ratio of 9%. 2 ) was used, and for this plain weave fabric, fabric (7) was used which had been subjected to a water-repellent treatment (immersion, heat treatment) using a non-fluorine-based resin copolymer emulsion (solid content 8 mass%). The warp and weft dimensions were 28,886 (1,111 dtex x 26 threads) dtex per inch.

[0039] Example 8 A mass of 530 g / m was obtained by the same processing steps and processing conditions as in Example 1, except that the fabric (1) in Example 1 was changed to fabric (8) and <Composition 1> was changed to <Composition 2>. 2 Synthetic resin canvas 8 was obtained. The resulting synthetic resin canvas 8 had a 10% tensile stress in the width direction of 98% of the 10% tensile stress in the processing direction, a warp creep elongation of 3 mm x weft creep elongation of 3 mm, and a rating of "1" in the cold bending fatigue durability test. <Fabric (8)> The warp yarn group consisted of bulky yarn (1111 dtex: 192 filaments) with 26 ends / inch, which was made of woolly processed polyester long fiber multifilament, and the weft yarn group consisted of bulky yarn (1111 dtex: 192 filaments) with 26 ends / inch, which was made of woolly processed polyester long fiber multifilament. The fabric had a void ratio of 9% and a three-ply twill pattern (mass 230 g / m 2 The three-ply twill fabric was made of fabric (8) that had been treated with a non-fluorine-based resin copolymer emulsion (solid content 8% by mass) for water repellency (immersion and heat treatment). The warp and weft dimensions were 28,886 (1,111 dtex x 26 threads) dtex per inch.

[0040] Example 9 A mass of 530 g / m was obtained by the same processing steps and processing conditions as in Example 1, except that the fabric (1) in Example 1 was changed to fabric (9) and <Composition 1> was changed to <Composition 3>. 2Synthetic resin canvas 9 was obtained. The resulting synthetic resin canvas 9 had a 10% tensile stress in the width direction of 96% of the 10% tensile stress in the processing direction, a warp creep elongation of 4 mm x weft creep elongation of 4 mm, and a rating of "1" in the cold bending fatigue durability test. <Fabric (9)> The warp yarn group is a bulky yarn of 34 threads / inch made of polyester long fiber multifilament with core spun sheath / core processing, and the weft yarn group is a bulky yarn of 34 threads / inch made of polyester long fiber multifilament with core spun sheath / core processing. The fabric has a void ratio of 7% and a double-stranded satin weave (mass 230 g / m 2 ) was used, and this two-leaf satin weave was fabric (9) that had been subjected to a water-repellent treatment (dipping and heat treatment) with a non-fluorinated resin copolymer emulsion (solid content 8% by mass). The core-spun core-sheath bulky yarn was a core-sheath composite yarn equivalent to 832 dtex, with a polyester 555 dtex (96 filaments) multifilament yarn (twist count 100 turns / m) as the core, completely covered with 1.4 denier (1.56 dtex) polyester staple fiber with a length of 100 mm to give a core / sheath ratio of 70 / 30 by mass. The warp and weft were 28,288 dtex (832 dtex x 34) per inch.

[0041] Example 10 A mass of 530 g / m was obtained by the same processing steps and processing conditions as in Example 1, except that the fabric (1) in Example 1 was changed to fabric (10). 2 The synthetic resin canvas 10 thus obtained had a 10% tensile stress in the width direction of 97% of the 10% tensile stress in the processing direction, a creep elongation in the warp direction of 6 mm and a creep elongation in the weft direction of 7 mm, and was rated "1" in the cold bending fatigue durability test. <Fabric (10)> The warp yarn group is made of biomass-derived polyester staple fiber spun yarn (20 count two-ply yarn: 590 dtex) at 48 strands / inch, and the weft yarn group is made of biomass-derived polyester staple fiber spun yarn (20 count two-ply yarn: 590 dtex) at 43 strands / inch. The plain weave fabric (mass 230 g / m) has a void ratio of 10%. 2The plain weave fabric was made of biomass-derived fabric (10), which was treated with a water-repellent treatment (dipping and heat treatment) using a non-fluorinated resin copolymer emulsion (solid content 8% by mass) to prevent water leakage in case of damage to the soft vinyl chloride resin-impregnated coating layer and to prevent rainwater from penetrating (absorbing water) through the cut edges of the canvas. The weft and weft dimensions were 28,320 dtex (590 dtex x 48 threads) per inch. The biomass-derived polyester that makes up the biomass-derived polyester staple spun yarn is a polyester (polyethylene terephthalate) obtained by polycondensation of terephthalic acid (containing the radioactive carbon atom C14) and ethylene glycol (containing the radioactive carbon atom C14). Terephthalic acid is obtained, for example, by dehydrating isobutanol produced by fermenting corn sugar to form isobutylene, which is then dimerized and cyclized by a radical reaction to produce orthoxylene, which is then converted into terephthalic acid. It contains the plant-derived radioactive carbon atom C14. Similarly, ethylene glycol is obtained, for example, by dehydrating bioethanol produced by fermenting sugarcane molasses to form ethylene, which is then oxidized to ethylene oxide and further hydrolyzed, and it also contains the plant-derived radioactive carbon atom C14. C-14 is a radioactive carbon atom with a mass number of 14, formed when nitrogen was converted by cosmic rays, and a half-life of 5,370 years. It is found in nature (especially in plants and animals) with a C-14C / C-12=1.2×10 -12 It is always present in equilibrium and cannot be contained in fossil fuels that are already hundreds of millions of years old. -12 Fabrics made from fibers detected by concentration are proof of biomass (plant origin).

[0042] Examples 11 to 20 The surfaces of canvases 1 to 10 in Examples 1 to 10 were coated with the fluororesin paint of the following <Formulation 4> using a 100-mesh gravure roll, and then heated and dried in a hot air oven at 120°C for 2 minutes to harden the fluororesin paint, forming an antifouling coating film layer (4 g / m 2 Synthetic resin canvases 11 to 20 having the following properties were obtained. [Formulation 4] Fluorine-based resin paint (for forming antifouling coating layer) Hydroxyl group-containing fluoroolefin vinyl ether copolymer (fluorine-based resin) 100 parts by mass Hexamethylene diisocyanate isocyanurate trimer (isocyanate) 10 parts by mass Colloidal silica (antistatic) 8 parts by weight Triazine tautomer (ultraviolet absorber) 5 parts by mass Curing catalyst: Dibutyltin dilaurate (approximately 10 ppm for fluororesin) Toluene / butyl acetate (diluent with a mass ratio of 1:1) 400 parts by mass

[0043] [Table 1]

[0044] [Table 2]

[0045] [Table 3]

[0046] In Examples 1 to 3 and 10, plain weave fabrics, twill weave fabrics, satin weave fabrics, etc. were used in which the warp and weft yarn groups were composed of short fiber spun yarns, and the difference between the total inch fineness (dtex / inch) of the weft yarn group and the total inch fineness (dtex / inch) of the warp yarn group was 0%.Furthermore, the difference between the processing direction tension and the width direction tension was set to 0%, so the 10% tensile stress in the width direction of the resulting synthetic resin canvas was 96% of the 10% tensile stress in the processing direction, and the canvas had excellent warp and weft dimensional balance in the creep test, resulting in a high-quality canvas appearance. In Examples 4 to 6, the warp yarns were composed of staple spun yarns, and the weft yarns were composed of long multifilament bulky yarns (Taslan, woolly, sheath-and-core, etc.). The differences between the total inch fineness (dtex / inch) of the weft yarns and the total inch fineness (dtex / inch) of the warp yarns were 1.96%, 1.96%, and 0.11%, respectively. The fabrics were manufactured using plain weave, twill, and satin weave fabrics with a tension difference of 0% in the processing direction and width direction. The 10% tensile stress in the width direction of the synthetic resin canvases in Examples 4 to 6 was 106%, 106%, and 103% of the 10% tensile stress in the processing direction, respectively, demonstrating excellent warp and weft dimensional balance in creep tests. The canvas appearance of Examples 1 to 3 and 10 was superior. In Examples 7 to 9, plain weave, twill, satin, etc. were used, in which the warp and weft yarn groups were made of long-fiber multifilament bulky yarns (Taslan processed, woolly processed, core-sheath processed, etc.), and the difference between the total inch fineness (dtex / inch) of the weft yarn group and the total inch fineness (dtex / inch) of the warp yarn group was 0%, and the difference between the tension in the processing direction and the width direction was 0%.By setting the difference between the tension in the processing direction and the width direction to 0%, the 10% tensile stress in the width direction of the synthetic resin canvases in Examples 7 to 9 was 98%, 98%, and 96% of the 10% tensile stress in the processing direction, and the warp and weft dimensional balance was excellent in the creep test.The canvas appearance of Examples 4 to 6 was superior. In addition, the synthetic resin canvases of Examples 1 to 10 (compounds 1 to 3) had a high anchor effect in the adhesive strength between the fabrics (1) to (10) and the soft vinyl chloride resin-impregnated coating layer, and in particular, the soft vinyl chloride resin-impregnated coating layer contained a synthetic rubber cured product, with molecular chains of rubber structure stretching throughout the entire area, resulting in excellent bending durability at sub-zero temperatures.This advantage is evident in the comparison with synthetic resin canvases with a soft vinyl chloride resin-impregnated coating layer formed using [Recipe 5], which omitted 10 parts by weight of butadiene-based liquid rubber and 2 parts by weight of isocyanurate from [Recipe 1]. Furthermore, synthetic resin canvases 11-20, each coated with a fluorine-based antifouling coating, were exposed outdoors (facing 15° south) for four months from April to July on the roof of Hiraoka Weaving & Dyeing Co., Ltd. in Soka City, Saitama Prefecture. Rainfall removed some of the soot stains on the canvas, leaving only light rain streaks. The light rain streaks were easily removed by wiping with a wet nonwoven cloth. In contrast, synthetic resin canvases 1-10 were poorly removably affected by rainfall, resulting in dark rain streaks due to the accumulation of soot on the surface. This stain was oily due to the plasticizer bled into the soot, and therefore could not be removed by wiping with a wet nonwoven cloth.

[0047] Comparative Example 1 The fabric (1) in Example 1 was changed to fabric (11), and the processing conditions in Example 1 were partially changed, but the fabric was the same as in Example 1, with a mass of 510 g / m 2 Synthetic resin canvas 21 was obtained. The change in processing conditions was to reduce the width direction tension during the gelation heat treatment from 5 kgf / 10 cm to 2 kgf / 10 cm, making the tension difference 60%. As a result, the gelation heat treatment was performed on a fabric in which the tension balance between the processing direction (warp) and the width direction (weft) was greatly disrupted, and the 10% tensile stress in the width direction of the synthetic resin canvas was 66%, which does not meet the ideal dimensional balance of 90 to 110% of the 10% tensile stress in the processing direction. In a creep test, the resulting synthetic resin canvas 21 had poor warp and weft dimensional balance and was numerically evaluated as being prone to stretching in the width direction (weft). <Fabric (11)> A plain weave fabric (mass 212 g / m) with a warp group of 48 strands / inch of polyester staple fiber spun yarn (20 count two-ply yarn: 590 dtex) and a weft group of 40 strands / inch of polyester staple fiber spun yarn (20 count two-ply yarn: 590 dtex), a void ratio of 12%, and the same water-repellent treatment as fabric (1) was applied. 2The warp is 28,320 (590 dtex x 48 threads) dtex per inch, and the weft is 23,600 (590 dtex x 40 threads) dtex per inch.

[0048] Comparative Example 2 The processing conditions were the same as in Example 1 except that some of them were changed, and the mass was 530 g / m 2 A synthetic resin canvas 22 was obtained. The change in processing conditions was to reduce the tension in the processing direction during the gelation heat treatment from 5 kgf / 10 cm to 2 kgf / 10 cm, making the tension difference 60%. As a result, the gelation heat treatment was performed on a fabric in which the tension balance between the processing direction (warp) and the width direction (weft) was greatly disrupted, and the 10% tensile stress in the width direction of the synthetic resin canvas became 142%, which does not meet the ideal dimensional balance of 90 to 110% of the 10% tensile stress in the processing direction. The resulting synthetic resin canvas 22 had poor warp and weft dimensional balance in the creep test and was numerically evaluated as being prone to stretching in the processing direction (warp).

[0049] Comparative Example 3 The processing conditions were the same as in Example 1 except that some of them were changed, and the mass was 530 g / m 2 Synthetic resin canvas 23 was obtained. The change in processing conditions was to reduce the width direction tension during the gelation heat treatment from 5 kgf / 10 cm to 2 kgf / 10 cm, making the tension difference 60%. As a result, the gelation heat treatment was performed on a fabric in which the tension balance between the processing direction (warp) and the width direction (weft) was greatly disrupted, and the 10% tensile stress in the width direction of the synthetic resin canvas was 76%, which did not meet the ideal dimensional balance of 90 to 110% of the 10% tensile stress in the processing direction. In a creep test, the resulting synthetic resin canvas 23 had poor warp and weft dimensional balance and was numerically evaluated as being prone to stretching in the width direction (weft).

[0050] [Table 4] [Industrial Applicability]

[0051] As is clear from the above examples and comparative examples, according to the present invention, it is possible to obtain synthetic resin canvas that has the appearance of cotton canvas, and furthermore, has a stable balance of warp and weft dimensions and is less susceptible to dimensional changes, which allows for a wide range of uses as the main material for tent warehouses (medium to large structures in which the entire steel frame is covered with synthetic resin canvas), roof tents (assembly tents with attached awnings used for sports days, outdoor events, management headquarters, assemblies, reception areas, etc.), truck canopies, truck bed covers, open-air storage sheets, etc.

Claims

1. A soft vinyl chloride resin impregnated coating layer is provided on the entire surface of the fabric, with a mass of 360 to 800 g / m ２ A synthetic resin canvas having excellent warp and weft dimensional balance stability, characterized in that the fabric is a plain weave, a twill weave, or a satin weave, and the 10% tensile stress (based on JIS L1096A method) in the width direction of the synthetic resin canvas is 90 to 110% of the 10% tensile stress (based on JIS L1096A method) in the processing direction.

2. The synthetic resin canvas of claim 1, wherein the fabric is configured with warp and weft yarn groups consisting of "short fiber spun yarn", or "a combination of short fiber spun yarn and long fiber multifilament bulky yarn", or "long fiber multifilament bulky yarn", and the long fiber multifilament bulky yarn is any one selected from taslan processed yarn, woolly processed yarn, and core spun core-sheath processed yarn, and further, the difference between the total inch fineness (dtex / inch) of the weft yarn group and the total inch fineness (dtex / inch) of the warp yarn group is within ±10%.

3. The synthetic resin canvas according to claim 2, wherein the group of threads is any one of the following selected from the group consisting of: 1) threads spun from a polymer that does not contain the radioactive carbon atom C14; 2) threads spun from a polymer that contains the radioactive carbon atom C14; 3) threads spun from a polymer obtained by repolymerizing monomers recovered from the depolymerization of synthetic resin moldings; and 4) threads spun from a polymer obtained by melting synthetic resin moldings.

4. The synthetic resin canvas according to any one of claims 1 to 3, wherein the soft vinyl chloride resin impregnated coating layer contains a cured liquid rubber, and the cured liquid rubber is a polymer of one or more reactive liquid rubbers selected from butadiene-based, isoprene-based, and farnesene-based rubbers, or a polymer of the reactive liquid rubber and an isocyanate compound.

5. This is a method for manufacturing synthetic resin canvas, which includes a process of providing a soft vinyl chloride resin-impregnated coating layer on the entire surface of a fabric (plain weave, twill weave, or satin weave), and by forming the soft vinyl chloride resin-impregnated coating layer using a dipping method (including a heat treatment gelling process) or a coating method (including a heat treatment gelling process) under tension with the difference in tension (kgf / m) between the processing direction and the width direction of the fabric being within ±20%, the 10% tensile stress (based on JIS L1096A method) in the width direction of the synthetic resin canvas is maintained at 90 to 110% of the 10% tensile stress (based on JIS L1096A method) in the processing direction. This method is characterized by the fact that it is a method for manufacturing synthetic resin canvas with excellent warp and weft dimensional balance stability.

6. The method for manufacturing synthetic resin canvas described in claim 5, wherein the fabric is composed of warp and weft yarn groups consisting of "short fiber spun yarn", or "a combination of short fiber spun yarn and long fiber multifilament bulky yarn", or "long fiber multifilament bulky yarn", and the long fiber multifilament bulky yarn is any one selected from taslan processed yarn, woolly processed yarn, and core spun core-sheath processed yarn, and further, the difference between the total inch fineness (dtex / inch) of the weft yarn group and the total inch fineness (dtex / inch) of the warp yarn group is within ±10%.

7. A method for producing synthetic resin canvas as described in claim 6, wherein the group of threads is any one of the following selected from the group consisting of: 1) threads spun from a polymer that does not contain the radioactive carbon atom C14; 2) threads spun from a polymer that contains the radioactive carbon atom C14; 3) threads spun from a polymer obtained by repolymerizing monomers recovered from the depolymerization of synthetic resin molded products; and 4) threads spun from a polymer obtained by melting synthetic resin molded products.

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