Multiaxial nonwoven fabric and tile unit

Abstract

The purpose of the present invention is to provide a multiaxial nonwoven fabric having excellent shape retention and capable of bonding tiles without using a separate adhesive. The multiaxial nonwoven fabric comprises a plurality of parallel first multifilament yarn strands and a plurality of intersecting multifilament yarn strands that intersect with the first multifilament yarn strands. The first multifilament yarn strands and the intersecting multifilament yarn strands are covered with an adhesive resin for which the phase angle is 25-55° as measured with a rotational rheometer under the conditions of 100°C and 5 Hz frequency.

Description

[Technical field]

[0001] The present invention relates to a multiaxial nonwoven fabric and a tile unit. [Background technology]

[0002] As a reinforcing material for thermoplastic resin sheets, a nonwoven fabric having two to four axes (multiaxial nonwoven fabric) has been proposed in which multifilament yarns such as glass fiber yarns are laminated as warp yarns, weft yarns, and diagonal yarns, and their intersections are fixed with an adhesive made of a thermoplastic resin (see, for example, Patent Document 1).Various applications of composite materials made of thermoplastic resin sheets and multiaxial nonwoven fabrics have been proposed, such as for aircraft, cars, and construction materials.

[0003] On the other hand, as an application of a multiaxial nonwoven fabric that is not compounded with a thermoplastic resin, a tile unit in which multiple building exterior wall tiles are bonded to a multiaxial nonwoven fabric with an adhesive is known (see, for example, Patent Document 2). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2019-026945 A [Patent Document 2] JP 2009-108603 A Summary of the Invention [Problem to be solved by the invention]

[0005] The inventors have discovered that if a multiaxial nonwoven fabric is used in which multifilament yarns are fixed at their intersections with a thermoplastic resin capable of adhering tiles, then it is possible to adhere multiple tiles to each other to form a tile unit without using a separate adhesive.

[0006] On the other hand, the inventors have found that in a tile unit made of such a multiaxial nonwoven fabric, if the tiles are heavy and the tile unit is stored in a high-temperature environment in summer and then handled at a construction site in a manner that subjects it to strong force, the shape of the multiaxial nonwoven fabric may become distorted and the tile unit may collapse.

[0007] The present invention has been made in view of the above circumstances, and has an object to provide a multiaxial nonwoven fabric to which tiles can be attached without using a separate adhesive and which has excellent shape retention. Another object of the present invention is to provide a tile unit including the multiaxial nonwoven fabric. [Means for solving the problem]

[0008] In order to achieve this object, the multiaxial nonwoven fabric of the present invention is a multiaxial nonwoven fabric comprising a plurality of first multifilament yarns arranged in parallel and a plurality of crossing multifilament yarns crossing the first multifilament yarns, wherein the first multifilament yarns and the crossing multifilament yarns are: It is made of a mixture of a thermoplastic resin with a melting point of 80 to 90°C and a thermosetting resin with a glass transition temperature of 10 to 30°C in a mass ratio of 9:1 to 6:4. The adhesive resin is coated with the adhesive, and the phase angle of the adhesive resin measured with a rotational rheometer at 100° C. and a frequency of 5 Hz is 25 to 55°. The phase angle is determined by processing the adhesive resin into a film having a thickness of 300 μm to prepare a measurement sample, measuring the phase angle at each temperature of the obtained measurement sample using a Bohlin CVO rheometer (manufactured by Malvern Instruments; using a φ20 mm parallel cone; measurement frequency: 5 Hz; measurement temperature range: 30 to 120° C.; heating rate: 10° C. / min), and reading the phase angle at a measurement temperature of 100° C. It is characterized by:

[0009] The multiaxial nonwoven fabric of the present invention can adhere tiles and has excellent shape retention because the phase angle is in the range of 25 to 55°. If the phase angle of the multiaxial nonwoven fabric of the present invention is less than 25°, tiles cannot be adhered to the multiaxial nonwoven fabric. On the other hand, if the phase angle of the multiaxial nonwoven fabric of the present invention is more than 55°, the shape retention of the multiaxial nonwoven fabric is reduced.

[0010] In the multiaxial nonwoven fabric of the present invention, the adhesive resin preferably contains a thermoplastic resin and a thermosetting resin.

[0011] In the multiaxial nonwoven fabric of the present invention, the glass transition temperature of the thermosetting resin is preferably 20° C. or lower.

[0012] The multiaxial nonwoven fabric of the present invention has excellent shape retention because the glass transition temperature of the thermosetting resin is 20° C. or lower.

[0013] In addition, in the multiaxial nonwoven fabric of the present invention, the adhesive resin preferably has a phase angle in the range of 46 to 55° as measured by a rotational rheometer at 100° C. and a frequency of 5 Hz.

[0014] In the multiaxial nonwoven fabric of the present invention, the phase angle is in the range of 46 to 55°, so that tiles can be adhered to the multiaxial nonwoven fabric of the present invention more efficiently.

[0015] In the multiaxial nonwoven fabric of the present invention, the multifilament yarn is preferably a glass fiber yarn.

[0016] The multiaxial nonwoven fabric of the present invention has excellent mechanical strength and versatility because the multifilament yarn is a glass fiber yarn. Furthermore, the fact that the multifilament yarn is a glass fiber yarn contributes to improving the rigidity of a tile unit when it is handled, improving the heat resistance and dimensional stability when the tile unit is manufactured, and improving the weather resistance when the tile unit is installed, in a tile unit containing the multiaxial nonwoven fabric of the present invention.

[0017] In addition, in the multiaxial nonwoven fabric of the present invention, it is preferable that the multiple crossing multifilament yarns comprise multiple first crossing multifilament yarns that cross the first multifilament yarn at an angle, and multiple second crossing multifilament yarns that cross the first multifilament yarn at an angle from the opposite direction to the first crossing multifilament yarn.

[0018] The multiaxial nonwoven fabric of the present invention is a triaxial nonwoven fabric composed of the first multifilament yarn, the first oblique multifilament yarn, and the second oblique multifilament yarn, and therefore the occurrence of twisting and deformation due to the oblique multifilament yarn is suppressed and the fabric has excellent productivity.

[0019] In the multiaxial nonwoven fabric of the present invention, the plurality of crossing multifilament yarns preferably comprise a plurality of orthogonal multifilament yarns that are orthogonal to the first multifilament yarn.

[0020] The nonwoven fabric of the present invention is a biaxial nonwoven fabric constituted by the first multifilament yarn and the orthogonal multifilament yarn, and thus has particularly excellent productivity.

[0021] In addition, in the multiaxial nonwoven fabric of the present invention, it is preferable that the multiple crossing multifilament yarns comprise multiple orthogonal multifilament yarns perpendicular to the first multifilament yarn, multiple first oblique multifilament yarns obliquely intersecting the first multifilament yarn, and multiple second oblique multifilament yarns obliquely intersecting the first multifilament yarn from the opposite direction to the first oblique multifilament yarn.

[0022] The multiaxial nonwoven fabric of the present invention is a quadriaxial nonwoven fabric composed of the first multifilament yarn, the orthogonal multifilament yarn, the first oblique multifilament yarn, and the second oblique multifilament yarn, and therefore the occurrence of twisting and deformation due to the oblique multifilament yarn is suppressed, and the rigidity in a direction perpendicular to the longitudinal direction of the first multifilament yarn is improved due to the orthogonal multifilament yarn.

[0023] The tile unit of the present invention comprises the above-mentioned multiaxial nonwoven fabric of the present invention and a plurality of tiles. [Brief description of the drawings]

[0024] [Figure 1] FIG. 1 is a schematic diagram illustrating one embodiment of a multiaxial nonwoven fabric (triaxial nonwoven fabric) of the present invention. [Diagram 2] FIG. 2 is a schematic diagram for explaining another embodiment (biaxial nonwoven fabric) of the multiaxial nonwoven fabric of the present invention. [Diagram 3]FIG. 2 is a schematic diagram illustrating yet another embodiment of the multiaxial nonwoven fabric of the present invention (four-axial nonwoven fabric). [Figure 4] FIG. 2 is a schematic diagram illustrating one embodiment of a method for producing a tile unit of the present invention. [Diagram 5] Schematic diagram for explaining another embodiment of the manufacturing method of the tile unit of the present invention. [Figure 6] Schematic diagram for explaining yet another embodiment of the manufacturing method of the tile unit of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] Next, embodiments of the present invention will be described in more detail with reference to the accompanying drawings.

[0026] As shown in FIG. 1, in one aspect, the multiaxial nonwoven fabric 1 of the present embodiment includes a plurality of first multifilament yarns 2 arranged in parallel, a plurality of first oblique multifilament yarns 3 that are obliquely intersecting the first multifilament yarns 2, and a plurality of first oblique multifilament yarns 3 that are intersecting the first multifilament yarns 2 in the opposite direction to the first oblique multifilament yarns 3. 2 and a plurality of second oblique multifilament yarns 4 that are obliquely intersecting the first multifilament yarn 2. Here, the first oblique multifilament yarn 3 and the second oblique multifilament yarn 4 correspond to crossing multifilament yarns that intersect the first multifilament yarn 2.

[0027] 2, in another aspect, the multiaxial nonwoven fabric 1 of the present embodiment is composed of a plurality of first multifilament yarns 2 arranged in parallel and a plurality of orthogonal multifilament yarns 5 perpendicular to the first multifilament yarns 2. Here, the orthogonal multifilament yarns 5 correspond to crossing multifilament yarns that cross the first multifilament yarns 2.

[0028] 3, in yet another aspect, the multiaxial nonwoven fabric 1 of the present embodiment is composed of a plurality of first multifilament yarns 2 arranged in parallel, a plurality of orthogonal multifilament yarns 5 perpendicular to the first multifilament yarns 2, a plurality of first oblique multifilament yarns 3 obliquely intersecting the first multifilament yarns 2, and a plurality of second oblique multifilament yarns 4 obliquely intersecting the first multifilament yarns 1 from the opposite direction to the first oblique multifilament yarns 3. Here, the first oblique multifilament yarns 3, the second oblique multifilament yarns 4, and the orthogonal multifilament yarns 5 correspond to crossing multifilament yarns intersecting the first multifilament yarns 2.

[0029] In the multiaxial nonwoven fabric 1 of the present embodiment, for example, glass fiber yarn, carbon fiber yarn, aramid fiber yarn, or vinylon fiber yarn can be used as the first multifilament yarn 2. Glass fiber yarn is preferable as the first multifilament yarn 2, which has excellent mechanical strength and versatility and contributes to improving the rigidity of a tile unit containing the multiaxial nonwoven fabric when it is handled, improving the heat resistance and dimensional stability when the tile unit is manufactured, and improving the weather resistance when the tile unit is installed.

[0030] Examples of glass fiber yarns that can be used as the first multifilament yarn 2 include yarns having an E-glass fiber composition, yarns having a high-strength glass fiber composition, and yarns having an alkali-resistant glass fiber composition. The E-glass fiber composition is a composition in which SiO 2 52 to 56 mass% of B 2 O 3 5 to 10 mass%, Al 2 O 3 12 to 16 mass%, CaO and MgO in total 20 to 25 mass%, Na 2 O and K 2 O and Li 2 The high-strength glass fiber composition contains 0 to 1 mass % in total of SiO and O with respect to the total amount of the glass fibers. 2 57 to 70 mass%, Al 2 O3 18 to 30 mass%, CaO 0 to 13 mass%, MgO 5 to 15 mass%, Na 2 O and K 2 O and Li 2 O and TiO 2 0 to 1 mass%, B 2 O 3 The alkali-resistant glass fiber composition contains 0 to 2 mass % of SiO 2 54 to 65 mass%, Al 2 O 3 0 to 2 mass%, CaO, MgO, SrO, BaO and ZnO in total 0 to 10 mass%, Na 2 O 10 to 17 mass%, K 2 O 0 to 8 mass%, Li 2 O 0 to 5 mass%, TiO 2 and 12 to 25 mass % of ZrO. As the first multifilament yarn 2, a yarn having an E-glass fiber composition is preferred because of its excellent versatility.

[0031] In the multiaxial nonwoven fabric 1 of the present embodiment, the first multifilament yarn 2 may be a doubled yarn or a doubled / twisted yarn made of a plurality of the same type of multifilament yarn, or different types of multifilament yarn.

[0032] In the multiaxial nonwoven fabric 1 of the present embodiment, the filaments constituting the first multifilament yarn 2 have a filament diameter of, for example, 3 to 30 μm, preferably 4 to 24 μm, and more preferably 5 to 18 μm.

[0033] In the multiaxial nonwoven fabric 1 of the present embodiment, the number of filaments in the first multifilament yarn 2 is, for example, 50 to 6,000, preferably 100 to 5,000, more preferably 200 to 4,000, even more preferably 400 to 2,000, and particularly preferably 500 to 1,200.

[0034] In the multiaxial nonwoven fabric 1 of the present embodiment, the weight of the first multifilament yarn 2 is, for example, 1 to 10,000 tex (g / 1000 m), preferably 3 to 5,800 tex, more preferably 10 to 2,500 tex, even more preferably 50 to 1,000 tex, particularly preferably 100 to 800 tex, and most preferably 150 to 500 tex.

[0035] In the multiaxial nonwoven fabric 1 of the present embodiment, the twist number of the first multifilament yarn 2 is, for example, 0 to 500 T / m, preferably 0 to 300 T / m, more preferably 0 to 200 T / m, even more preferably 0 to 150 T / m, particularly preferably 0 to 100 T / m, particularly preferably 0 to 50 T / m, especially preferably 0 to 10 T / m, and most preferably 0 to 0.5 T / m. When the first multifilament yarn 2 is a ply-twisted yarn, the twist number of the first multifilament yarn 2 means the twist number imparted during plying and twisting.

[0036] In the multiaxial nonwoven fabric 1 of the present embodiment, the first multifilament yarn 2 has a yarn width of, for example, 1.0 to 4.0 mm, preferably 1.5 to 3.5 mm, and more preferably 1.8 to 3.2 mm.

[0037] In the multiaxial nonwoven fabric 1 of the present embodiment, the multiple first multifilament yarns 2 are arranged in parallel at, for example, 2.0 to 25.0 yarns / 25 mm, preferably 2.0 to 10.0 yarns / 25 mm, more preferably 2.0 to 6.0 yarns / 25 mm, even more preferably 2.2 to 6.0 yarns / 25 mm, particularly preferably 2.5 to 6.0 yarns / 25 mm, especially preferably 3.0 to 5.5 yarns / 25 mm, and most preferably 4.0 to 5.0 yarns / 25 mm.

[0038] In the multiaxial nonwoven fabric 1 of the present embodiment, the yarn spacing between adjacent first multifilament yarns 2 is, for example, 1.0 to 20.0 mm, preferably 2.0 to 15.0 mm, more preferably 3.0 to 15.0 mm, even more preferably 3.0 to 8.0 mm, and particularly preferably 5.0 to 10.0 mm.

[0039] In the multiaxial nonwoven fabric 1 of the present embodiment, the first oblique multifilament yarn 3 can be a multifilament yarn having the same characteristics as the first multifilament yarn 2. The first oblique multifilament yarn 3 may be the same yarn as the first multifilament yarn 2, or may be a different yarn.

[0040] In the multiaxial nonwoven fabric 1 of the present embodiment, the first oblique multifilament yarn 3 is obliquely intersecting with the first multifilament yarn 2, and the angle formed between the first oblique multifilament yarn 3 and the first multifilament yarn 2 is, for example, 40 to 70°, preferably 40 to 65°, more preferably 40 to 50°, even more preferably 43 to 47°, and particularly preferably 45°.

[0041] In the multiaxial nonwoven fabric 1 of the present embodiment, the multiple first oblique multifilament yarns 3 are arranged in parallel at, for example, 1.4 to 14.0 yarns / 25 mm, preferably 1.4 to 10.5 yarns / 25 mm, more preferably 1.4 to 7.0 yarns / 25 mm, even more preferably 1.4 to 4.2 yarns / 25 mm, particularly preferably 2.1 to 3.9 yarns / 25 mm, and more preferably 2.8 to 3.5 yarns / 25 mm.

[0042] In the multiaxial nonwoven fabric 1 of the present embodiment, the yarn spacing between adjacent first oblique multifilament yarns 3 is, for example, 1.5 to 20.0 mm, preferably 2.0 to 20.0 mm, more preferably 3.0 to 20.0 mm, even more preferably 4.0 to 15.0 mm, particularly preferably 5.0 to 9.5 mm, and most preferably 7.0 to 9.0 mm.

[0043] In the multiaxial nonwoven fabric 1 of the present embodiment, the second oblique multifilament yarn 4 can be a multifilament yarn having the same characteristics as the first multifilament yarn 2. The second oblique multifilament yarn 4 may be the same yarn as the first multifilament yarn 2, or may be a different yarn.

[0044] In the multiaxial nonwoven fabric 1 of the present embodiment, the second oblique multifilament yarn 4 is obliquely intersecting with the first multifilament yarn 2 from the opposite direction to the first oblique multifilament yarn 3, and the angle formed between the second oblique multifilament yarn 4 and the first multifilament yarn 2 is, for example, 40 to 70°, preferably 40 to 65°, more preferably 40 to 50°, even more preferably 43 to 47°, and particularly preferably 45°. In addition, the second oblique multifilament yarn 4 is preferably perpendicular to the first oblique multifilament yarn 3.

[0045] In the multiaxial nonwoven fabric 1 of the present embodiment, the second oblique multifilament yarns 4 are arranged in parallel at, for example, 1.4 to 14.0 yarns / 25 mm, preferably 1.4 to 10.5 yarns / 25 mm, more preferably 1.4 to 7.0 yarns / 25 mm, even more preferably 1.4 to 4.2 yarns / 25 mm, particularly preferably 2.1 to 3.9 yarns / 25 mm, and most preferably 2.8 to 3.5 yarns / 25 mm.

[0046] In the multiaxial nonwoven fabric 1 of the present embodiment, the yarn spacing between adjacent second oblique multifilament yarns 4 is, for example, 1.5 to 20.0 mm, preferably 2.0 to 20.0 mm, more preferably 3.0 to 20.0 mm, even more preferably 4.0 to 15.0 mm, particularly preferably 5.0 to 9.5 mm, and most preferably 7.0 to 9.0 mm.

[0047] In the multiaxial nonwoven fabric 1 of this embodiment, the orthogonal multifilament yarn 5 can be a multifilament yarn having the same characteristics as the first multifilament yarn 2. The orthogonal multifilament yarn 5 may be the same yarn as the first multifilament yarn 2, or may be a different yarn.

[0048] In the multiaxial nonwoven fabric 1 of the present embodiment, the orthogonal multifilament yarns 5 are arranged in parallel at, for example, 2.0 to 25.0 yarns / 25 mm, preferably 2.0 to 10.0 yarns / 25 mm, more preferably 2.0 to 6.0 yarns / 25 mm, even more preferably 2.5 to 6.0 yarns / 25 mm, particularly preferably 3.0 to 5.5 yarns / 25 mm, and most preferably 4.0 to 5.0 yarns / 25 mm.

[0049] In the multiaxial nonwoven fabric 1 of the present embodiment, the yarn spacing between adjacent orthogonal multifilament yarns 5 is, for example, 1.0 to 20.0 mm, preferably 1.0 to 15.0 mm, more preferably 1.5 to 15.0 mm, even more preferably 2.0 to 12.0 mm, particularly preferably 3.0 to 9.5 mm, particularly preferably 3.0 to 8.0 mm, and most preferably 4.0 to 7.0 mm.

[0050] In the multiaxial nonwoven fabric 1 of this embodiment, the first multifilament yarn 2 and the crossing multifilament yarns (i.e., the first oblique multifilament yarn 3, the second oblique multifilament yarn 4, and the orthogonal multifilament yarn 5) are coated with an adhesive resin. The adhesive resin fixes the first multifilament yarn 2 and the crossing multifilament yarns adjacent thereto in the vertical direction, or the crossing multifilament yarns adjacent thereto in the vertical direction (for example, the first oblique multifilament yarn 3 and the second oblique multifilament yarn 4) at their intersections, and also contributes to adhesion between the multiaxial nonwoven fabric 1 and an adherend such as a tile.

[0051] In the multiaxial nonwoven fabric 1 of this embodiment, the adhesive resin has a phase angle in the range of 25 to 55° as measured by a rotational rheometer at 100°C and a frequency of 5 Hz. If the phase angle is less than 25°, tiles cannot be adhered. On the other hand, if the phase angle is more than 55° in the multiaxial nonwoven fabric of the present invention, the shape retention of the multiaxial nonwoven fabric decreases.

[0052] In the multiaxial nonwoven fabric 1 of this embodiment, the phase angle of the adhesive resin measured by a rotational rheometer under the conditions of 100 ° C. and a frequency of 5 Hz is first processed into a film having a thickness of 300 μm to prepare a measurement sample, and then the phase angle at each temperature is measured for the obtained measurement sample by a Bohlin CVO rheometer (manufactured by Malvern Instruments; using a φ20 mm parallel cone; measurement frequency 5 Hz; measurement temperature range 30 to 120 ° C.; heating rate 10 ° C. / min), and the phase angle at the measurement temperature of 100 ° C. can be obtained. The measurement sample can also be prepared by extracting the adhesive resin from the multiaxial nonwoven fabric 1 using a solvent that dissolves the adhesive resin, such as chloroform or toluene, and processing the extracted adhesive resin into a film.

[0053] In the multiaxial nonwoven fabric 1 of this embodiment, the phase angle of the adhesive resin measured with a rotational rheometer at 100°C and a frequency of 5 Hz is preferably in the range of 46 to 55°, more preferably in the range of 47 to 55°, even more preferably in the range of 48 to 54°, and particularly preferably in the range of 49 to 53°, since this enables tiles to be adhered to the multiaxial nonwoven fabric 1 more efficiently.

[0054] The phase angle of the adhesive resin measured by a rotational rheometer at 100°C and a frequency of 5Hz can usually be increased by using a thermoplastic resin with a low melting point as the adhesive resin. Also, when the adhesive resin contains a thermoplastic resin and a thermosetting resin, the phase angle of the adhesive resin measured by a rotational rheometer at 100°C and a frequency of 5Hz can be increased by increasing the content of the thermoplastic resin.

[0055] In the multiaxial nonwoven fabric 1 of the present embodiment, the adhesive resin has a phase angle measured by a rotational rheometer at 50° C. and a frequency of 5 Hz, which is, for example, in the range of 3 to 20° C., preferably in the range of 5 to 15° C., more preferably in the range of 8 to 14° C., and particularly preferably in the range of 10 to 12° C. The phase angle of the adhesive resin measured by a rotational rheometer at 50° C. and a frequency of 5 Hz can be measured in exactly the same manner as the phase angle of the adhesive resin measured by a rotational rheometer at 100° C. and a frequency of 5 Hz, except that the phase angle at the measurement temperature of 50° C. is read instead of that at 100° C.

[0056] In the multiaxial nonwoven fabric 1 of the present embodiment, the adhesive resin preferably contains a thermoplastic resin and a thermosetting resin. Whether the adhesive resin contains a thermoplastic resin and a thermosetting resin can be confirmed by differential scanning calorimetry (DSC), thermomechanical analysis (TMA), simultaneous differential thermal and thermogravimetry (TG-DTA), Fourier transform infrared spectroscopy (FT-IR), gas chromatography mass spectrometry (GC-MS), nuclear magnetic resonance spectroscopy (NMR), or the like.

[0057] In the multiaxial nonwoven fabric 1 of the present embodiment, the thermoplastic resin is preferably a thermoplastic resin having a melting point of 70 to 150° C., more preferably a thermoplastic resin having a melting point of 75 to 105° C., and even more preferably a thermoplastic resin having a melting point of 80 to 90° C. The melting point of the thermoplastic resin can be measured in accordance with JIS K 7121:2012.

[0058] In the multiaxial nonwoven fabric 1 of the present embodiment, examples of the thermoplastic resin that may be contained in the adhesive resin include ethylene-acrylic copolymer resin, ethylene-vinyl acetate copolymer resin, polyamide resin, and polyethylene resin.

[0059] In the multiaxial nonwoven fabric 1 of this embodiment, the thermosetting resin contributes to improving the shape retention of the multiaxial nonwoven fabric, and is therefore preferably a thermosetting resin having a glass transition temperature of 20° C. or less, more preferably a thermosetting resin having a glass transition temperature of −10 to 20° C., even more preferably a thermosetting resin having a glass transition temperature of −5 to 15° C., and particularly preferably a thermosetting resin having a glass transition temperature of −3 to 12° C. The glass transition temperature of the thermosetting resin can be measured in accordance with JIS K 7121:2012. The glass transition temperature of the thermosetting resin can also be measured by using a solvent that dissolves the adhesive resin, such as chloroform or toluene, to extract the adhesive resin from the multiaxial nonwoven fabric 1, and then using a solvent that does not dissolve the thermoplastic resin but dissolves the thermosetting resin.

[0060] In the multiaxial nonwoven fabric 1 of the present embodiment, examples of the thermosetting resin that may be contained in the adhesive resin include thermosetting acrylic resin, vinyl acetate resin, and urethane resin.

[0061] In the multiaxial nonwoven fabric 1 of the present embodiment, when the adhesive resin contains a thermoplastic resin and a thermosetting resin, the content ratio of the thermoplastic resin to the thermosetting resin (mass ratio; thermoplastic resin / thermosetting resin) is, for example, in the range of 94 / 6 to 55 / 45, preferably in the range of 93 / 7 to 80 / 20, and more preferably in the range of 92 / 8 to 85 / 15. The content ratio of the thermoplastic resin to the thermosetting resin can be determined using Fourier transform infrared spectroscopy (FT-IR), gas chromatography mass spectrometry (GC-MS), or the like.

[0062] In the multiaxial nonwoven fabric 1 of the present embodiment, when the adhesive resin contains a thermoplastic resin and a thermosetting resin, the adhesive resin may be a mixture of the thermoplastic resin and the thermosetting resin, and may cover the first multifilament yarn 2 and the cross multifilament yarn as a single adhesive resin layer. Alternatively, the adhesive resin may cover the first multifilament yarn 2 and the cross multifilament yarn as a two-layer adhesive resin layer, such that a thermosetting resin layer is formed on the surface of the first multifilament yarn 2 and the cross multifilament yarn, and a thermoplastic resin layer is formed thereon. From the viewpoint of productivity of the multiaxial nonwoven fabric 1 of the present embodiment, it is preferable that the adhesive resin is a mixture of the thermoplastic resin and the thermosetting resin, and may cover the first multifilament yarn 2 and the cross multifilament yarn as a single adhesive resin layer.

[0063] The multiaxial nonwoven fabric 1 of the present embodiment can be manufactured, for example, by appropriately modifying the design of a manufacturing apparatus described in JP-A-2005-163220.

[0064] The weight per unit area of ​​the multiaxial nonwoven fabric 1 of this embodiment is, for example, 50 to 250 g / m 2 and preferably 60 to 200 g / m 2 and more preferably 70 to 150 g / m 2 It is.

[0065] The multiaxial nonwoven fabric 1 of the present embodiment has a thickness of, for example, 100 to 700 μm, preferably 200 to 550 μm, and more preferably 300 to 450 μm.

[0066] The ratio of the mass of the adhesive resin to the mass of the multiaxial nonwoven fabric 1 of this embodiment is, for example, 10 to 40 mass%, preferably 15 to 35 mass%, and more preferably 20 to 30 mass%. When the multifilament yarn constituting the multiaxial nonwoven fabric 1 of this embodiment is an inorganic fiber yarn, the ratio of the mass of the adhesive resin to the mass of the multiaxial nonwoven fabric 1 of this embodiment can be measured as the loss on ignition in accordance with JIS R 3420:2013.

[0067] The multiaxial nonwoven fabric 1 of the present embodiment can be suitably used for tile units, but can also be suitably used as a reinforcing material for nonwoven fabrics, a reinforcing material for films, a reinforcing material for aluminum foils, and the like.

[0068] The tile unit of this embodiment includes the multiaxial nonwoven fabric 1 of this embodiment and a plurality of tiles. The plurality of tiles are fixed onto the multiaxial nonwoven fabric 1 of this embodiment by the adhesive resin of the multiaxial nonwoven fabric 1 of this embodiment.

[0069] The tiles used in the tile unit of the present embodiment are not particularly limited, and may be tiles for the exterior walls of buildings or tiles for the interiors of buildings. The number of tiles is, for example, 10 to 100.

[0070] In one aspect, the tile unit of this embodiment can be obtained by a manufacturing apparatus 11 shown in FIG. 4. In the manufacturing apparatus 11, the multiaxial nonwoven fabric 1 of this embodiment is pulled out from the core material 12 through a nip roller 13, and while being conveyed by a first conveyor 14, it is cut to a predetermined size by a cutter 15 provided in the middle of the first conveyor 14. Next, the multiaxial nonwoven fabric 1 cut to a predetermined size is laminated on a tile set 17 (a plurality of tiles arranged in a predetermined pattern) conveyed by a second conveyor 16, and the resulting laminate is heated in a heating furnace 18 under conditions of 100 to 300 ° C. for 1 to 20 minutes, and then compressed at a pressure of 0.1 to 1.0 MPa using a plate-type compression device 19. Then, the laminate after compression is cooled by a cooling blow 20 to obtain the tile unit of this embodiment.

[0071] The tile unit of this embodiment can be obtained by a manufacturing apparatus 21 shown in FIG. 5 in another aspect. In the manufacturing apparatus 21, the multiaxial nonwoven fabric 1 of this embodiment is pulled out from the core material 12 through the nip roller 13, and while being conveyed by the first conveyor 14, it is cut to a predetermined size by the cutter 15 provided in the middle of the first conveyor 14. Next, the multiaxial nonwoven fabric 1 cut to a predetermined size is laminated on the tile set 17 conveyed by the second conveyor 16. The tile set 17 is heated for 10 to 60 seconds under the condition of 100 to 300 ° C. by the heater 22 provided directly above the second conveyor 16. Next, the heated tile set 17 and the multiaxial nonwoven fabric 1 of this embodiment cut to a predetermined size are laminated, and the obtained laminate is compressed at a pressure of 0.1 to 1.0 MPa using the plate-type compression device 19. Then, the laminate after compression is cooled by the cooling blow 20 to obtain the tile unit of this embodiment.

[0072] In yet another embodiment, the tile unit of this embodiment can be obtained by a manufacturing apparatus 31 shown in FIG. 6. In the manufacturing apparatus 31, the multiaxial nonwoven fabric 1 of this embodiment is pulled out from the core material 12 through a nip roller 13, and while being conveyed by a first conveyor 14, it is cut to a predetermined size by a cutter 15 provided in the middle of the first conveyor 14. Next, the multiaxial nonwoven fabric 1 cut to a predetermined size is laminated on a tile set 17 conveyed by a second conveyor 16, and the resulting laminate is heat-pressed by a steel heating belt 32 at 100 to 300°C and 0.1 to 1.0 MPa for 10 to 60 seconds. Next, the heat-pressed laminate is cooled while being pressed at a pressure of 0.1 to 1.0 MPa using a cooling roller 33, thereby obtaining the tile unit of this embodiment. The cooling roller 33 is cooled by cooling water supplied from a cooling water tank 34 via a circulation pump 35 and a chiller 36.

[0073] The present invention will be described in more detail below with reference to examples, although the present invention is not limited to these examples. EXAMPLES

[0074] [Example 1] A multiaxial nonwoven fabric 1 (triaxial nonwoven fabric) of Example 1 was obtained using glass fiber yarns having an E-glass composition of 135 tex, each consisting of 800 filaments with a filament diameter of 9 μm, as the first multifilament yarn 2, the first oblique multifilament yarn 3, and the second oblique multifilament yarn 4, and an adhesive resin that covers these glass fiber yarns. The adhesive resin is a mixture of an ethylene-acrylic copolymer resin as a thermoplastic resin having a melting point of 85°C and a thermosetting acrylic resin having a glass transition temperature of 10°C, mixed in a mass ratio of 9:1. The adhesive resin has a phase angle of 51° as measured by a rotational rheometer at 100°C and a frequency of 5 Hz, and a phase angle of 10° as measured by a rotational rheometer at 50°C and a frequency of 5 Hz. The mass per unit area of ​​the multiaxial nonwoven fabric 1 of this example is 100 g / m 2The ratio of the mass of the adhesive resin to the mass of the multiaxial nonwoven fabric 1 was 24 mass %.

[0075] Next, the shape retention and tile adhesion of the multiaxial nonwoven fabric 1 of this example were evaluated as follows. The results are shown in Table 1.

[0076] [Method of evaluating shape retention] The multiaxial nonwoven fabric 1 obtained in Example 1 was cut to A4 size, and eight tiles coated with a vinyl acetate adhesive were laminated on it, followed by pressure bonding at 100°C and 0.5 MPa to prepare an evaluation sample. The evaluation sample was then held in an oven heated to 50°C for 30 minutes while hanging from the top of the oven. The evaluation sample was then removed from the oven and its appearance was observed. If there was no change in shape, it was rated as "A", if there was a slight change in shape such as sagging, it was rated as "B", and if there was a major change in shape such as peeling at intersections, it was rated as "C".

[0077] [Method of evaluating tile adhesion] Eight tiles heated to a surface temperature of 90°C or 100°C were placed on the multiaxial nonwoven fabric 1 of Example 1 and pressed at 0.5 MPa. When all eight tiles were stably fixed even when the multiaxial nonwoven fabric 1 with the pressed tiles was lifted vertically, it was judged that the tiles could be bonded to the multiaxial nonwoven fabric 1. When tiles heated to a surface temperature of 90°C and 100°C could be bonded, the tile adhesion of the multiaxial nonwoven fabric 1 was evaluated as "A." When tiles heated to a surface temperature of 90°C could not be bonded but tiles heated to a surface temperature of 100°C could be bonded, the tile adhesion of the multiaxial nonwoven fabric 1 was evaluated as "B." When tiles heated to a surface temperature of 90°C and 100°C could not be bonded, the tile adhesion of the multiaxial nonwoven fabric 1 was evaluated as "C." [Example 2] Multiaxial nonwoven fabric 1 (triaxial nonwoven fabric) of this example was obtained in exactly the same manner as in Example 1, except that the adhesive resin used was a mixture of an ethylene-vinyl acetate copolymer resin as a thermoplastic resin with a melting point of 85°C and a thermosetting acrylic resin with a glass transition temperature of 10°C, mixed in a mass ratio of 6:4. The adhesive resin has a phase angle of 31° as measured by a rotational rheometer at 100°C and a frequency of 5 Hz, and a phase angle of 12° as measured by a rotational rheometer at 50°C and a frequency of 5 Hz. The mass per unit area of ​​multiaxial nonwoven fabric 1 of this example was 100 g / m 2 The ratio of the mass of the adhesive resin to the mass of the multiaxial nonwoven fabric 1 was 26 mass %.

[0078] Next, the shape retention and tile adhesion of the multiaxial nonwoven fabric 1 of this example were evaluated in exactly the same manner as in Example 1. The results are shown in Table 1. [Example 3] Multiaxial nonwoven fabric 1 (triaxial nonwoven fabric) of this example was obtained in exactly the same manner as in Example 1, except that the adhesive resin used was a mixture of an ethylene-vinyl acetate copolymer resin as a thermoplastic resin with a melting point of 85°C and a vinyl acetate resin with a glass transition temperature of 30°C, mixed in a mass ratio of 9:1. The adhesive resin has a phase angle of 41° as measured by a rotational rheometer at 100°C and a frequency of 5 Hz, and a phase angle of 8° as measured by a rotational rheometer at 50°C and a frequency of 5 Hz. The mass per unit area of ​​multiaxial nonwoven fabric 1 of this example was 100 g / m 2 The ratio of the mass of the adhesive resin to the mass of the multiaxial nonwoven fabric 1 was 25 mass %.

[0079] Next, the shape retention and tile adhesion of the multiaxial nonwoven fabric 1 of this example were evaluated in exactly the same manner as in Example 1. The results are shown in Table 1. [Comparative Example 1] A multiaxial nonwoven fabric 1 (triaxial nonwoven fabric) of this comparative example was obtained in exactly the same manner as in Example 1, except that the adhesive resin used was a mixture of an ethylene-vinyl acetate copolymer resin as a thermoplastic resin with a melting point of 85°C and a thermosetting acrylic resin with a glass transition temperature of 9°C, mixed in a mass ratio of 4:6. The adhesive resin has a phase angle of 15° as measured by a rotational rheometer at 100°C and a frequency of 5 Hz, and a phase angle of 16° as measured by a rotational rheometer at 50°C and a frequency of 5 Hz. The mass per unit area of ​​multiaxial nonwoven fabric 1 of this comparative example was 100 g / m 2 The ratio of the mass of the adhesive resin to the mass of the multiaxial nonwoven fabric 1 was 25 mass %.

[0080] Next, the shape retention and tile adhesion of the multiaxial nonwoven fabric 1 of this comparative example were evaluated in exactly the same manner as in Example 1. The results are shown in Table 2. [Comparative Example 2] A multiaxial nonwoven fabric 1 (triaxial nonwoven fabric) of this comparative example was obtained in exactly the same manner as in Example 1, except that the adhesive resin used was a mixture of an ethylene-vinyl acetate copolymer resin as a thermoplastic resin with a melting point of 85°C and a thermosetting acrylic resin with a glass transition temperature of 10°C, mixed in a mass ratio of 95:5. The adhesive resin has a phase angle of 59° as measured by a rotational rheometer at 100°C and a frequency of 5 Hz, and a phase angle of 7° as measured by a rotational rheometer at 50°C and a frequency of 5 Hz. The mass per unit area of ​​multiaxial nonwoven fabric 1 of this comparative example was 100 g / m 2 The ratio of the mass of the adhesive resin to the mass of the multiaxial nonwoven fabric 1 was 25 mass %.

[0081] Next, the shape retention and tile adhesion of the multiaxial nonwoven fabric 1 of this comparative example were evaluated in exactly the same manner as in Example 1. The results are shown in Table 2. [Comparative Example 3] A multiaxial nonwoven fabric 1 (triaxial nonwoven fabric) of this comparative example was obtained in exactly the same manner as in Example 1, except that the adhesive resin used was a mixture of a polyamide resin as a thermoplastic resin with a melting point of 130°C and a thermosetting acrylic resin with a glass transition temperature of 10°C, mixed in a mass ratio of 9:1. The adhesive resin has a phase angle of 9° as measured by a rotational rheometer at 100°C and a frequency of 5 Hz, and a phase angle of 15° as measured by a rotational rheometer at 50°C and a frequency of 5 Hz. The mass per unit area of ​​multiaxial nonwoven fabric 1 of this comparative example was 100 g / m 2 The ratio of the mass of the adhesive resin to the mass of the multiaxial nonwoven fabric 1 was 24 mass %.

[0082] Next, the shape retention and tile adhesion of the multiaxial nonwoven fabric 1 of this comparative example were evaluated in exactly the same manner as in Example 1. The results are shown in Table 2. [Comparative Example 4] A multiaxial nonwoven fabric 1 (triaxial nonwoven fabric) of this comparative example was obtained in exactly the same manner as in Example 1, except that only an ethylene-vinyl acetate copolymer resin having a melting point of 85°C as a thermoplastic resin was used as the adhesive resin. The adhesive resin has a phase angle of 63° as measured by a rotational rheometer at 100°C and a frequency of 5Hz, and a phase angle of 9° as measured by a rotational rheometer at 50°C and a frequency of 5Hz. The mass per unit area of ​​the multiaxial nonwoven fabric 1 of this comparative example was 100g / m 2 The ratio of the mass of the adhesive resin to the mass of the multiaxial nonwoven fabric 1 was 25 mass %.

[0083] Next, the shape retention of the multiaxial nonwoven fabric 1 of this comparative example was evaluated in exactly the same manner as in Example 1. Note that the shape retention of the multiaxial nonwoven fabric 1 of this comparative example was so poor that it was deformed by the heat generated when the tiles were pressed against it, and it was therefore determined to be unsuitable as a base material for tile units, and therefore the tile adhesiveness was not evaluated. The results are shown in Table 3. [Comparative Example 5] A multiaxial nonwoven fabric 1 (triaxial nonwoven fabric) of this comparative example was obtained in exactly the same manner as in Example 1, except that only a thermosetting acrylic resin with a glass transition temperature of 10°C was used as the adhesive resin. The adhesive resin had a phase angle of 14° as measured by a rotational rheometer at 100°C and a frequency of 5 Hz, and a phase angle of 17° as measured by a rotational rheometer at 50°C and a frequency of 5 Hz. The mass per unit area of ​​multiaxial nonwoven fabric 1 of this comparative example was 87 g / m 2 The thickness was 280 μm, and the ratio of the mass of the adhesive resin to the mass of the multiaxial nonwoven fabric 1 was 13 mass %. Next, the shape retention and tile adhesion of the multiaxial nonwoven fabric 1 of this comparative example were evaluated in exactly the same manner as in Example 1. The results are shown in Table 3.

[0084] [Table 1]

[0085] [Table 2]

[0086] [Table 3]

[0087] As shown in Table 1, the multiaxial nonwoven fabrics 1 of Examples 1 to 3, in which the phase angle of the adhesive resin measured by a rotational rheometer at 100°C and a frequency of 5Hz is 25 to 55°, clearly have excellent shape retention and tile adhesion. On the other hand, as shown in Tables 2 and 3, the multiaxial nonwoven fabrics 1 of Comparative Examples 1 to 5, in which the phase angle of the adhesive resin measured by a rotational rheometer at 100°C and a frequency of 5Hz is less than 25° or more than 55°, clearly do not have sufficient shape retention or tile adhesion. [Explanation of symbols]

[0088] 1...multiaxial nonwoven fabric, 2...first multifilament yarn, 3...first oblique multifilament yarn, 4...second oblique multifilament yarn, 5...orthogonal multifilament yarn, 11...manufacturing apparatus, 12...core material, 13...nip roller, 14...first conveyor, 15...cutter, 16...second conveyor, 17...tile set, 18...heating furnace, 19...plate pressing device, 20...cooling blow, 21...manufacturing apparatus, 22...heating heater, 31...manufacturing apparatus, 32...steam heating belt, 33...cooling roller, 34...cooling water tank, 35...circulation pump, 36...chiller.

Claims

1. A plurality of first multifilament yarns arranged in parallel; A multiaxial nonwoven fabric comprising: a first multifilament yarn and a plurality of intersecting multifilament yarns intersecting the first multifilament yarn; the first multifilament yarn and the cross multifilament yarn are coated with an adhesive resin made of a mixture of a thermoplastic resin having a melting point of 80 to 90°C and a thermosetting resin having a glass transition temperature of 10 to 30°C in a mass ratio of 9:1 to 6:4; A multiaxial nonwoven fabric, characterized in that the adhesive resin has a phase angle of 25 to 55° as measured by a rotational rheometer under conditions of 100° C. and a frequency of 5 Hz, and the phase angle is determined by processing the adhesive resin into a film having a thickness of 300 μm to prepare a measurement sample, measuring the phase angle at each temperature of the obtained measurement sample using a Bohlin CVO rheometer (manufactured by Malvern Instruments; using a φ20 mm parallel cone; measurement frequency: 5 Hz; measurement temperature range: 30 to 120° C.; heating rate: 10° C. / min), and reading the phase angle at a measurement temperature of 100° C.

2. 2. The multiaxial nonwoven fabric according to claim 1, wherein the multifilament yarn is a glass fiber yarn.

3. The multiaxial nonwoven fabric according to claim 1 or 2, The plurality of cross multifilament yarns are a plurality of first oblique multifilament yarns that are obliquely crossed with the first multifilament yarn; A multiaxial nonwoven fabric comprising the first oblique multifilament yarn and a plurality of second oblique multifilament yarns that obliquely intersect the first multifilament yarn from the opposite direction.

4. The multiaxial nonwoven fabric according to any one of claims 1 to 3, wherein the plurality of crossing multifilament yarns are made of a plurality of orthogonal multifilament yarns that are perpendicular to the first multifilament yarn.

5. The multiaxial nonwoven fabric according to any one of claims 1 to 4, The plurality of cross multifilament yarns are orthogonal to the first multifilament yarn; A plurality of first oblique multifilament yarns that are obliquely intersecting the first multifilament yarn; A multiaxial nonwoven fabric comprising the first oblique multifilament yarn and a plurality of second oblique multifilament yarns that obliquely intersect the first multifilament yarn from the opposite direction.

6. A tile unit comprising the multiaxial nonwoven fabric according to any one of claims 1 to 5 and a plurality of tiles.

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