HK1116733B

HK1116733B - Layered product and textile product comprising the same

Info

Publication number: HK1116733B
Application number: HK08107475.1A
Authority: HK
Inventors: 秋守纯一; 定藤浩树
Original assignee: 日本奥亚特克斯股份有限公司
Priority date: 2005-03-10
Filing date: 2006-03-10
Publication date: 2012-03-02

Description

Laminate and textile product using the same

Technical Field

The present invention relates to textile products such as clothes, sheets, tents, and sleeping bags, and laminates (raw fabrics) constituting these products.

Background

For textile products such as clothing products, sheets, tents, bags, and sleeping bags used for applications requiring water repellency, dust repellency, wind resistance, and the like, materials obtained by laminating a fabric on a flexible base material having water repellency, moisture permeability, and the like are used.

For example, japanese patent laid-open No. s 55-7483 relates to a sheet-like water-resistant laminated product having a high water vapor transmission rate even in severe weather, which is suitable for use in raincoats and tents, and discloses a laminated product in which a water-repellent nylon taffeta 15, a porous polytetrafluoroethylene film 17 treated with a hydrophilic polyurethane resin, and a nylon tricot 19 are laminated (see fig. 3). Japanese patent application laid-open No. 2001-503107 discloses a composite lining material suitable for clothing and the like, which comprises a flexible base material 21 having a water-resistant property and a water vapor permeability and having a 1 st surface and a2 nd surface, a cloth fixed to the 1 st surface of the base material, and a plurality of separated dots 23 of an abrasion-resistant polymer provided on the 2 nd surface (see FIG. 4). Japanese patent laying-open No. 10-298869 discloses a moisture-permeable waterproof cloth in which a high-density cloth having a fiber density of 240 or more is laminated with 70 denier yarns on both sides of a moisture-permeable waterproof film.

Disclosure of The Invention

Such a laminate is cut into a desired size, and then subjected to sewing, welding, or the like to be processed into a textile product such as clothes, sheets, products, bags, sleeping bags, or the like. In order to prevent the intrusion of water, chemicals, wind, dust, and the like from the outside and to improve the strength of the obtained fiber product, a sealing treatment (sealing treatment) using a sealing tape having a hot-melt resin layer is generally performed on the sewn portion or the welded portion. However, in practice, there is a limit that the knitted fabric must be laminated on the side of the laminate to which the caulking process is applied for the following reason. The first reason is that if the knitted fabric is not laminated on the side on which the caulking treatment is performed, the hot-melt resin impregnation property of the caulking tape is lowered, and a sufficient caulking effect cannot be exhibited. The second reason is that, when the laminate is processed into a clothing product, the lining of the clothing product is usually subjected to caulking treatment, but when the knitted fabric is not provided as the lining of the product, the flexible base material is exposed and directly contacts the skin, and therefore the appearance and touch are poor.

On the other hand, a laminate using a knitted fabric on the side where the caulking treatment is performed (typically, the back side) has been pointed out to have a problem that weight reduction is not possible due to a large mass of the knitted fabric and a problem that the knitted fabric is deteriorated due to abrasion with a shirt, a button, a Velcro (Velcro), or the like.

The present invention has been made in view of the above circumstances, and an object thereof is to provide a lightweight laminate which overcomes the practical limitation that a knitted fabric must be used on the side on which a caulking treatment is performed when the laminate is processed into a textile product by sewing, welding, or the like, and which can be easily subjected to the caulking treatment without impairing the appearance and touch.

The laminate of the present invention is a laminate in which a woven fabric is laminated on a flexible film, wherein the woven fabric is laminated on a side to which a caulking treatment is applied when the laminate is processed into a textile product, and a total value of cover Coefficients (CF) calculated from the following formula is given to each of warp yarns and weft yarns constituting the woven fabric_total) Is 800 to 1200.

CF_total＝CF_m+CF_t

CF_m: cover factor of warp

CF_t: cover factor of weft

F_m: fineness of warp (dtex)

F_t: fineness of weft (dtex)

D_m: warp density (strips/2.54 cm)

D_t: density of weft yarns (strips/2.54cm)

The covering factor represents the size of the eye of the fabric, and is calculated by using the total value (CF) of the covering factor calculated for each of the warp and weft constituting the fabric_total) Within the above-mentioned predetermined range, the hot-melt resin impregnation property of the joint tape is improved. As a result, the caulking process becomes easy, and the effect of the caulking process is improved. The preferred form is the Coverage Factor (CF) of the warp yarns_m) And Cover Factor (CF) of weft_t) At least one of them is in the range of 300 to 800.

Preferably, at least one of the warp and weft constituting the fabric is constituted by 2 or more filaments. By using the warp or weft composed of 2 or more filaments, the hand of the resulting laminate becomes soft. The fineness of the filaments is preferably 12dtex or less. When the fineness of each 1 filament is 12dtex or less, the hand of the resulting laminate is further softened.

It is also preferable that at least one of the warp and weft constituting the fabric is a long fiber. This is because the use of the long fibers can suppress the fuzzing of the fabric surface and improve the impregnation of the hot melt resin into the joint tape.

At least one of the warp and weft constituting the fabric is preferably a processed yarn. By using the processing yarn, the impregnation of the hot melt resin of the joint sealing tape is improved. Further, this is because the appearance and touch are not impaired even when the fiber density of the fabric is reduced.

The weave of the fabric is preferably a plain weave, for example. This is because the fiber density is easily reduced by using the plain weave, and the impregnation property of the hot melt resin of the joint tape is improved.

The flexible film may be, for example, a waterproof film to impart water repellency to the resulting laminate, or a waterproof moisture-permeable film to impart water-moisture permeability to the resulting laminate.

The waterproof moisture-permeable film is preferably a porous film made of a hydrophobic resin, and more preferably a porous polytetrafluoroethylene film. The porous film made of a hydrophobic resin preferably has a hydrophilic resin layer on the side where the woven fabric is laminated. The hydrophilic resin layer formed on the porous film made of a hydrophobic resin is provided to suppress intrusion of body oil, dirt, and the like into pores of the porous film when the laminate of the present invention is processed into a clothing product or the like. This is because if body oil, dirt, or the like intrudes into the pores of the porous membrane, the water resistance is likely to decrease.

In the present invention, it is preferable that a fabric is further laminated on the other side of the flexible film (the side opposite to the side on which the woven fabric is laminated). This is because the physical strength and design feeling of the resulting laminate are improved by laminating the fabric on the other side.

The present invention also relates to a fibrous product obtained by processing a part or all of the laminate, which is obtained by applying a caulking treatment to the side of the laminate on which the woven fabric is laminated.

The practical limitation of having to use a knit on the side where the caulking process is performed when processing the laminate into a fibrous article can be overcome if the present invention is employed.

According to the present invention, a caulking process can be easily performed, and a lightweight laminate can be obtained without impairing the appearance and touch.

Brief description of the drawings

Fig. 1 is a cross-sectional view illustrating a laminate of the present invention.

Fig. 2 is a sectional view schematically illustrating a portion of the laminate of the present invention after sewing and caulking.

Fig. 3 is a sectional view illustrating a conventional laminate.

Fig. 4 is a sectional view illustrating a conventional laminate.

Fig. 5 is an electron micrograph of the caulk-treated side of the laminate 1.

Fig. 6 is an electron micrograph of the caulk-treated side of the laminate 12.

Best Mode for Carrying Out The Invention

The laminate of the present invention is a laminate in which a woven fabric is laminated on a flexible film, wherein the woven fabric is laminated on a side to which a caulking treatment is applied when the laminate is processed into a textile product, and a total value of cover Coefficients (CF) calculated from the following formula is given to each of warp yarns and weft yarns constituting the woven fabric_total) 700 to 1400.

CF_total＝CF_m+CF_t

CF_m: cover factor of warp

CF_t: cover factor of weft

F_m: fineness of warp (dtex)

F_t: fineness of weft (dtex)

D_m: warp density (strips/2.54 cm)

D_t: density of weft yarns (strips/2.54 cm)

First, the woven fabric used in the present invention stacked on the side on which the caulking treatment is performed will be described. In the fabric used in the present invention, the total value of the Cover Factor (CF) calculated from the above formula is calculated for each of the warp and weft constituting the fabric_total) At least 700, preferably at least 800, more preferably at least 900, at most 1400, preferably at most 1300, more preferably at most 1200. Here, the cover factor indicates the size of the eye of the fabric, and the larger the number, the smaller the gap between the fibers, and the smaller the number, the larger the gap between the fibers.

In the present invention, the total value of the Cover Factor (CF) calculated from the above formula is used for each of the warp and weft constituting the fabric_total) Above 700 is to maintain the minimum required appearance and feel while ensuring the strength of the fabric used and improving handling and processability. If the total value of the cover factor is less than 700, the physical strength of the laminate is insufficient in practical use, and the appearance and touch are poor. The appearance of the laminate is determined by the appearance of the surface exposed to the outside, and if the total value of the cover factors is less than 700, the degree of penetration of the flexible film from the gaps between the fibers of the woven fabric is increased, and the quality required for the general textile product cannot be satisfied. The feel of the laminate is the feel (skin feel) when a human body touches the laminate, and if the total value of the cover factors is less than 700, a rough skin feel occurs. On the other hand, in order to ensure the impregnation of the hot melt resin of the caulking tape, the fabric used in the present invention needs to have a large to some extent of eyes. Therefore, the total value of the coverage coefficients calculated by the above expression is preferably 1400 or less. If the total value of the cover factor is more than 1400, the hot melt resin impregnation of the caulking tape becomes insufficient, and not only the sealing property of the caulking portion cannot be secured, but also the hand of the laminate becomes hard and weight reduction becomes difficult.

Coating of the aforementioned warpCover Factor (CF)_m) And Cover Factor (CF) of weft_t) At least one of them is preferably 300 or more, preferably 400 or more, and 800 or less, preferably 700 or less. This is because the strength and handling property of the woven fabric, the impregnation property of the hot melt resin of the caulking tape, and the like are improved by setting the coverage coefficient of at least one of the warp and weft within the above range. Further, as can be seen from the above formula, the cover factor of the warp and weft can be controlled by appropriately selecting the fineness and the density.

The fineness of the warp and weft constituting the fabric is preferably 5dtex or more, preferably 7dtex or more, and 55dtex or less, preferably 33dtex or less. When the fineness is 5dtex or more, the physical strength of the obtained laminate can be secured, and the abrasion resistance of a practical level can be exhibited. Further, by setting the fineness to 55dtex or less, the obtained laminate is light in weight and soft in texture. In addition, the caulking tape has improved hot melt resin impregnation properties.

Preferably, at least one of the warp and weft constituting the fabric is constituted by 2 or more filaments. This is because the use of the warp or weft composed of 2 or more filaments can make the hand of the resulting laminate soft. More preferably, the fineness of each of the filaments constituting the warp or weft is 12dtex or less. By making the fineness of each filament constituting the warp or weft yarn 12dtex or less, the hand of the resulting laminate can be further softened.

The density of the warp and weft constituting the fabric may be determined as appropriate under the condition that the range of the total value of the cover factor is satisfied.

The fibers constituting the woven fabric (fibers constituting the warp or weft) used in the present invention preferably have heat resistance higher than the softening point of the hot-melt resin used for the joint tape. In general, the softening point of the hot-melt resin is less than about 140 ℃, so it is preferable to use fibers having heat resistance with a softening point of 140 ℃ or more and without significant deformation at a temperature of less than 140 ℃, and it is more preferable to use fibers having heat resistance with a softening point of 170 ℃ or more and without significant deformation at a temperature of less than 170 ℃.

The fibers may be natural fibers or synthetic fibers. Examples of the natural fibers include plant fibers such as cotton and hemp, and animal fibers such as silk, wool, and other animal hair. Examples of the synthetic fibers include polyamide fibers, polyester fibers, and acrylic fibers. Particularly when used for clothing and the like, polyamide fibers, polyester fibers and the like are preferred from the viewpoints of softness, strength, durability, cost, lightweight and the like.

The fibers constituting the fabric used in the present invention may be either long fibers or short fibers, but it is preferable to use long fibers or fibers substantially close to long fibers. This is because, if short fibers are used, fuzz of the short fibers is likely to occur on the surface of the laminate to be obtained, and the hot-melt resin of the caulking tape may be less impregnated into the laminate, resulting in a decreased caulking effect. Therefore, when short fibers are used, it is preferable that fuzz on the surface of the obtained laminate is treated (removed) by singeing or melting.

Further, the type of the yarn of the fiber is not particularly limited, but if the warp and weft constituting the low-density woven fabric are raw yarns in the scouring and dyeing step after the manufacture of the raw fabric, the warp and weft are likely to cause a defective appearance due to a knitting defect, or the manufacture is difficult. Therefore, the yarn is preferably a processed yarn, more preferably a false twist processed yarn. Further, by using the processed yarn, the impregnation property of the hot melt resin of the joint tape is further improved as compared with the base yarn. This is because, if a processed yarn is used, the unevenness of the gaps between the fibers becomes large, and the anchor effect of the caulking tape after the hot-melt resin is impregnated between the fibers becomes large.

The weave of the woven fabric is not particularly limited, and may be a twill weave, a satin weave, a plain weave, or the like. Among them, plain weave is preferable, and rip-stop weave is more preferable. This is because if a plain weave is used as the weave of the woven fabric, the fiber density is easily reduced, and the hot melt resin impregnation property of the joint tape is improved. Further, if the weave of the woven fabric is a crack-preventing weave, the required physical strength can be easily achieved even if the fiber density is low, and the design feeling is improved.

Hereinafter, a flexible film used in the present invention will be described.

The flexible film is not particularly limited as long as it is a film having flexibility, and examples thereof include films of polyester resins such as polyurethane resins, polyethylene terephthalate and polybutylene terephthalate, polyolefin resins such as acrylic resins, polyethylene and polyolefins, polyamide resins, vinyl chloride resins, synthetic rubbers, natural rubbers, fluorine-containing rubbers, and the like.

The thickness of the flexible film is preferably 5 μm or more, preferably 10 μm or more, and 300 μm or less, preferably 100 μm or less. This is because, if the thickness of the flexible film is less than 5 μm, a problem arises in handling property at the time of production, and if it is more than 300 μm, flexibility of the flexible film is impaired. The thickness of the flexible film was measured using a direct-reading thickness meter (using an 1/1000mm direct-reading thickness meter manufactured by dele corporation, measured without applying a load other than the own spring load).

As the flexible film, a film having, for example, water repellency, wind repellency or dust repellency is preferably used. The flexible film may be a waterproof film to impart water repellency to the resulting laminate, or a waterproof moisture-permeable film to impart water-moisture-permeability to the resulting laminate. In addition, a film having water-proof properties or water-proof moisture-permeable properties generally has both wind-proof properties and dust-proof properties.

In applications where water repellency is particularly required, such as raincoats, a flexible film having water repellency of 100cm or more, preferably 200cm or more, in terms of water resistance (water repellency) measured by JIS L1092A is preferably used.

In the present invention, it is preferable to use a waterproof moisture-permeable film as the flexible film. The waterproof moisture-permeable film refers to a flexible film having "waterproofness" and "moisture permeability". That is, the laminate of the present invention is provided with not only the above-described "water repellency" but also "moisture permeability". For example, when the laminate of the present invention is used as a clothing article, since the water vapor of sweat generated from the body of the wearer is diffused to the outside through the laminate, the feeling of air impermeability can be prevented when the wearer wears the clothing article. Here, the term "moisture permeability" refers to the property of permeating water vapor, and preferably has a value of 50g/m in a hygroscope measured by JIS L1099B-2 method²H or more, preferably 100g/m²Moisture permeability of h or more.

Examples of the waterproof moisture-permeable film include hydrophilic resin films such as polyurethane resins, polyester resins, silicone resins, and polyvinyl alcohol resins, and porous films (hereinafter, also simply referred to as "hydrophobic porous films") formed of hydrophobic resins such as polyester resins, polyolefin resins such as polyethylene and polypropylene, fluorine-containing resins, and polyurethane resins subjected to water repellent treatment. The term "hydrophobic resin" as used herein means a resin molded into a smooth and flat plate, and the contact angle of a water droplet placed on the surface of the plate is 60 degrees or more (measurement temperature 25 ℃ C.), preferably 80 degrees or more.

The hydrophobic porous film maintains moisture permeability by a porous structure having pores (continuous pores) inside, and the hydrophobic resin constituting the film base material suppresses the intrusion of water into the pores, thereby exhibiting water repellency as a whole film. Among them, the waterproof moisture-permeable film is preferably a porous film made of a fluorine-containing resin, and more preferably a porous polytetrafluoroethylene film (hereinafter also referred to as "porous PTFE film"). In particular, in the porous PTFE film, polytetrafluoroethylene, which is a resin component constituting the film base material, has high hydrophobicity (water repellency), and thus water repellency and moisture permeability can be simultaneously achieved.

The porous PTFE membrane is a membrane obtained by removing a molding aid from a molded product of a paste obtained by mixing fine powder of Polytetrafluoroethylene (PTFE) with the molding aid and then stretching the molded product at high temperature and high speed into a planar shape, and has a porous structure. That is, the porous PTFE film is composed of nodules as aggregates of primary particles of polytetrafluoroethylene connected to each other by fine crystal bands and fibrils as bundles of stretched crystal bands drawn from these primary particles, and pores are formed in spaces defined by the fibrils and the nodules connecting the fibrils. The porosity, maximum pore diameter, and the like of the porous PTFE membrane described later can be controlled by the expansion ratio and the like.

The maximum pore diameter of the hydrophobic porous membrane is preferably 0.01 μm or more, preferably 0.1 μm or more, and 10 μm or less, preferably 1 μm or less. If the maximum pore diameter is less than 0.01 μm, the production becomes difficult; conversely, if it exceeds 10 μm, the water repellency of the hydrophobic porous membrane decreases, and since the membrane strength becomes weak, handling in subsequent steps such as lamination becomes difficult easily.

The porosity of the hydrophobic porous membrane is preferably 50% or more, more preferably 60% or more, and 98% or less, more preferably 95% or less. The water vapor permeability can be ensured by setting the porosity of the hydrophobic porous membrane to 50% or more; by setting the ratio to 98% or less, the strength of the film can be ensured.

Further, the maximum pore diameter is a value measured in accordance with the specification of ASTM F-316. The porosity was calculated from the apparent density (. rho.) measured by the apparent density measurement according to JIS K6885 by the following equation.

Porosity (%) - (2.2. rho)/2.2X 100

The thickness of the hydrophobic porous membrane is preferably 5 μm or more, preferably 10 μm or more, and 300 μm or less, preferably 100 μm or less. If the thickness of the hydrophobic porous film is less than 5 μm, a problem arises in handling property during production, and if it is more than 300 μm, flexibility of the hydrophobic porous film is impaired and moisture permeability is reduced. The thickness of the hydrophobic porous membrane was measured using a direct-reading thickness meter (using an 1/1000mm direct-reading thickness meter manufactured by dele corporation, measured without applying a load other than the own spring load).

The hydrophobic porous film is preferably used after the inner surfaces of the pores are coated with a polymer having water repellency and oil repellency. By coating the inner surface of the pores of the hydrophobic porous film with a polymer having water repellency and oil repellency in advance, it is possible to suppress permeation or retention of various contaminants such as body fat and oil, beverages, and detergents into the pores of the hydrophobic porous film. This is because these contaminants reduce the hydrophobicity of PTFE preferably used for the hydrophobic porous membrane, and cause a loss in water resistance.

In this case, a polymer having a fluorine-containing branch may be used as the polymer. Specific descriptions of such a polymer and a method for combining the polymer with a porous membrane are disclosed in WO94/22928 and the like, and one example thereof is given below.

As the coating polymer, those represented by the following general formula (1) can be preferably used

(wherein n is an integer of 3 to 13, and R is hydrogen or methyl)

The fluorinated branched polymer is a polymer obtained by polymerizing a fluoroalkyl acrylate and/or a fluoroalkyl methacrylate (the fluoroalkyl moiety preferably has 4 to 16 carbon atoms). When the pores of the porous film are coated with the polymer, an aqueous microemulsion (average particle diameter of 0.01 to 0.5 μm) of the polymer is formed using a fluorine-containing surfactant (for example, ammonium perfluorooctanoate), and the polymer is immersed in the pores of the porous film and then heated. By this heating, the water and the fluorinated surfactant are removed, and the polymer having a fluorinated branch chain is melted to coat the inner surface of the pores of the porous membrane while maintaining continuous pores, thereby obtaining a hydrophobic porous membrane having excellent water repellency and oil repellency.

Further, as other coating polymers, "AF polymer" (trade name of dupont) and "CYTOP" (trade name of asahi glass) may be used. When these polymers are coated on the inner surface of the pores of the hydrophobic porous membrane, the polymers may be dissolved in an inert solvent such as "Fluorinert" (trade name of 3M corporation) to be impregnated into the porous PTFE membrane, and then the solvent may be evaporated off.

In the present invention, the hydrophobic porous film preferably has a hydrophilic resin layer on the side where the woven fabric is laminated. The form having the hydrophilic resin layer is particularly useful when the laminate of the present invention is processed into a clothing article or the like having a fabric side as a lining. That is, the hydrophilic resin absorbs moisture such as sweat generated from the human body and emits the moisture to the outside, and prevents various contaminants such as body fat and hair oil from entering pores of the hydrophobic porous film from the human body side. This is because, as described above, these contaminants reduce the hydrophobicity of PTFE preferably used for the hydrophobic porous membrane, resulting in a loss of water resistance. Further, by forming the hydrophilic resin layer in advance, the mechanical strength of the hydrophobic porous film is also improved, and therefore a hydrophobic porous film having excellent durability can be obtained. The hydrophilic resin layer may be formed on the surface of the hydrophobic porous film, and preferably the hydrophilic resin is impregnated in the surface layer portion of the hydrophobic porous film. Since the hydrophilic resin is impregnated into the pores of the surface layer of the hydrophobic porous film, the anchor effect is exhibited, and a laminate having good adhesive strength between the hydrophilic resin layer and the hydrophobic porous film is formed. Further, if the hydrophobic porous film is entirely impregnated with the hydrophilic resin in the thickness direction, the moisture permeability is lowered.

As the hydrophilic resin, a water-swellable and water-insoluble polymer material having hydrophilic groups such as hydroxyl groups, carboxyl groups, sulfonic acid groups, and amino acid groups is preferably used. Specifically, a hydrophilic polymer such as polyvinyl alcohol, cellulose acetate, or nitrocellulose, which is at least partially crosslinked, and a hydrophilic urethane resin can be exemplified, and a hydrophilic urethane resin is particularly preferable if heat resistance, chemical resistance, processability, moisture permeability, and the like are taken into consideration.

The hydrophilic urethane resin may be polyester-based or polyether-based polyurethane or prepolymer containing a hydrophilic group such as a hydroxyl group, an amino group, a carboxyl group, a sulfonic acid group, or an oxyethylene group, and diisocyanates, triisocyanates, or adducts thereof having 2 or more isocyanate groups may be used alone or in combination as a crosslinking agent for adjusting the melting point (softening point) of the resin. In addition, 2-or more-functional polyols such as diols and triols, and 2-or more-functional polyamines such as diamines and triamines may be used as the curing agent for the isocyanate-terminated prepolymer. In order to maintain high moisture permeability, 2 functions are better than 3 functions.

As a method for forming a hydrophilic resin layer such as a hydrophilic urethane resin on the surface of a hydrophobic porous film, a coating liquid is prepared by dissolving a urethane resin or the like in a solvent or by heating and melting the resin, and the coating liquid is applied to a hydrophobic porous film by a roll coater or the like. The viscosity of the coating liquid suitable for impregnating the hydrophilic resin into the surface layer of the hydrophobic porous film is 20000cps (mPas) or less, preferably 10000cps (mPas) or less at the coating temperature. When the solution is made by using a solvent, the viscosity is too low, and the solution diffuses into the entire hydrophobic porous film after application to hydrophilize the entire hydrophobic porous film, and a uniform resin layer cannot be formed on the surface of the hydrophobic porous film, and there is a high possibility that a problem arises in water repellency, and therefore, it is preferable to maintain the viscosity of 500cps (mPa · s) or more. The viscosity can be measured using, for example, a B-type viscometer manufactured by eastern industries.

The laminate of the present invention is also preferably in a form in which the above-described woven fabric is laminated on one side to which a caulking treatment is applied when the laminate is processed into a fiber product, and a fabric is further laminated on the other side. This is because the physical strength and design feeling of the resulting laminate are improved by laminating the fabric on the other side. Further, the woven fabric is laminated on one surface of the flexible film so as to be the side of the laminate to which the caulking treatment is applied, and the woven fabric is further laminated on the other side. A typical embodiment includes a form in which a woven fabric laminated on one side to be subjected to caulking is used as a liner and a woven fabric laminated on the other side is used as a face fabric. This is because, in particular, when the laminate of the present invention is used for clothing or the like, the appearance of the obtained clothing or the like can be improved by using the side subjected to the caulking treatment as a liner.

The fabric is not particularly limited, and examples thereof include woven fabric, knitted fabric, net, nonwoven fabric, felt, synthetic leather, and natural leather. The material constituting the fabric may be natural fibers such as cotton, hemp, and animal hair, synthetic fibers, metal fibers, ceramic fibers, or the like, and may be appropriately selected according to the use of the laminate. For example, when the laminate of the present invention is used for outdoor products, a woven fabric made of polyamide fibers, polyester fibers, or the like is preferable in view of softness, strength, durability, cost, lightweight, and the like. The fabric may be subjected to conventionally known water repellency treatment, softening treatment, antistatic treatment, and the like as necessary.

The method for producing the laminate of the present invention will be described below.

In the present invention, a conventionally known adhesive can be used for laminating the flexible film and the woven fabric or the cloth. Such adhesives include a curable resin adhesive which is curable by heat, light, a reaction with moisture, or the like, in addition to a thermoplastic resin adhesive. For example, various resin adhesives such as polyester resin, polyamide resin, polyurethane resin, silicone resin, (meth) acrylic resin, polyvinyl chloride resin, polyolefin resin, polybutadiene rubber, and other rubbers may be mentioned. Among them, a urethane resin adhesive can be preferably exemplified. The polyurethane resin adhesive is particularly preferably a curing reaction type hot melt adhesive.

The curing reaction type hot melt adhesive is an adhesive which is solid at normal temperature, forms a low viscosity liquid by melting by heating, and forms a high viscosity liquid or cured product by maintaining a heated state or further raising the temperature, or by bringing into contact with moisture or other polyfunctional compounds having active hydrogen to cause a curing reaction. The curing reaction may be promoted by the presence of a curing catalyst, a curing agent, or the like.

The curable reactive polyurethane resin hot-melt adhesive used for bonding the flexible film to the woven fabric or the cloth is, for example, a liquid having a low viscosity formed by melting under heating (i.e., when applied for bonding), and the viscosity is preferably 500 to 30000Pa · s (more preferably 3000Pa · s or less). The viscosity referred to herein is a value measured with a conical rotor and a set temperature of 125 ℃ by an ICI cone and plate viscometer manufactured by RESEARCH EQUIPMENT. The curing reaction type polyurethane resin hot-melt adhesive is preferably a known polyurethane prepolymer which can be cured by moisture (moisture). The polyurethane prepolymer can be obtained by addition reaction of a polyol such as a polyester polyol or a polyether polyol with an aliphatic or aromatic polyisocyanate such as TDI (toluene diisocyanate), MDI (diphenylmethane diisocyanate), XDI (xylylene diisocyanate), IPDI (isophorone diisocyanate) under conditions in which an isocyanate group remains at the end. The resulting polyurethane prepolymer has an isocyanate group at the terminal, and therefore undergoes a curing reaction by moisture in the air. The melting temperature of the polyurethane prepolymer is above 50 ℃ slightly higher than room temperature, preferably 80-150 ℃.

The polyurethane prepolymer may, for example, be a "Bondmaster" commercially available from NSC of Japan. The polymer is heated to 70 to 150 ℃ to form a molten liquid having a viscosity capable of being applied to a woven fabric or a woven fabric, and the molten liquid is used to bond a flexible film to the woven fabric or the woven fabric, and then the bonded fabric or the woven fabric is cooled to about room temperature, thereby forming a semisolid state, suppressing excessive permeation and diffusion to the woven fabric or the woven fabric, and performing a curing reaction with moisture in the air to enable soft and firm bonding.

The method of applying the adhesive is not particularly limited, and various known methods (roll coating, spray coating, brush coating, etc.) may be used. When the laminated fabric is to have moisture permeability, it is recommended to apply the adhesive in a dot or line form. The bonding area (coating area of the adhesive) is preferably 5 to 95%, more preferably 15 to 50% of the total area of the laminated surfaces. The amount of the adhesive to be applied may be set in consideration of the unevenness of the fabric surface, the fiber density, the required adhesiveness, the required durability, and the like. The coating amount is preferably 2 to 50g/m²More preferably 5 to 20g/m². If the amount of the adhesive applied is too small, the adhesiveness is insufficient, and durability such as durability against washing cannot be obtained. On the other hand, if the amount of the adhesive applied is too large, the hand of the resulting laminate becomes too hard, which is not preferable.

As a preferred lamination method, for example, the following methods can be mentioned: the melt of the curable polyurethane resin adhesive is applied or sprayed onto a flexible film by a roller having a gravure pattern, and the woven fabric or cloth is superimposed thereon and pressure-bonded by the roller. In particular, when a coating method using a roller having a gravure pattern is used, good adhesion can be secured, and the hand and yield of the resulting laminate are good.

The laminates of the present invention may be used, in part or in whole, to form fibrous articles. For example, when the laminate of the present invention is used as a whole to manufacture a fiber product, the laminate of the present invention is cut into a desired shape and size, and the cut materials are sewn or welded to manufacture a fiber product. When a fiber product is partially processed using the laminate of the present invention, the fiber product may be processed using the laminate of the present invention and a conventional fabric or the like in the same manner.

The laminate may be sewn using a sewing machine or the like. The sewing thread used for sewing may be any material such as cotton, silk, hemp, viscose, polyamide resin, polyester resin, polyvinyl alcohol fiber, polyurethane resin, or a mixture thereof, and it is preferable to use polyamide resin or polyester resin from the viewpoint of strength, heat resistance, and the like. The thickness of the sewing thread may be appropriately adjusted depending on the thickness of the sewn laminate and the required product strength, and for example, in the case of a 3-layer laminate obtained by sewing a polyester resin sewing thread to one surface of a fabric (78dtex nylon taffeta) and laminating an expanded porous PTFE film with an adhesive layer and a woven fabric (22dtex nylon taffeta: the total value of the cover factor of the warp and weft is 700 to 1400), it is preferable to use 40 to 70-gauge sewing thread.

The sewing method is not particularly limited as long as it is a method of sewing with 1 or more threads, and examples of the sewing form include a method of sewing into a straight line, a curved line, a zigzag line, and the like by using a flat seam, a single-thread chain seam, a double-thread lock seam, and the like.

The laminate may be welded by, for example, a method of directly welding the laminates cut into a desired shape and size by thermocompression bonding, or a method of indirectly welding the laminates by using a sheet made of a hot-melt resin (hereinafter, also simply referred to as "hot-melt sheet").

Examples of the hot-melt Sheet include a "Gore-seam Adhesive Sheet (Sheet Adhesive)" manufactured by austex, japan. The hot-melt resin of the hot-melt sheet may be the same resin as that of a hot-melt resin layer of a joint tape described later, and the conditions for welding the laminate using the hot-melt sheet may be the same conditions as those for pressure-bonding of the joint tape.

The portion where the laminate is sewn or welded is subjected to caulking treatment. This is because the sealing properties such as water resistance, dust resistance, and wind resistance and the strength of the obtained fiber product are improved by the caulking treatment. The caulking treatment method is not particularly limited as long as it can ensure the required properties such as water resistance, wind resistance, dust resistance, and the like for the seamed portion or the welded portion.

For example, when the laminate of the present invention is sewn and processed into a fiber product, a method of blocking the needle hole portion with a resin is preferable from the viewpoint of achieving high water repellency. As a method for blocking the needle hole portion with resin, a method of applying resin to the seam portion or a method of bonding or welding a tape-like resin (caulking tape) may be mentioned, and a method using a caulking tape is more preferable because the caulking-treated portion has good waterproof durability. In addition, when the laminate of the present invention is welded to be processed into a fiber product, the strength of the obtained fiber product is reduced, and therefore, the strength of the obtained fiber product is improved by caulking the welded portion with a caulking tape or the like.

In the present invention, as the caulking tape for caulking the seamed portion or the welded portion, a tape in which a low melting point adhesive resin is laminated on the back surface (the side of the seamed portion) of a base tape of a high melting point resin, or the like can be used, and a caulking tape in which a hot melt resin layer is provided on the back surface of a base tape can be preferably exemplified. A knitted fabric, a net, or the like may be laminated on the front surface (exposed surface) of the base tape. As the caulking tapes, for example, a caulking tape such as "T-2000" or "FU-700" manufactured by Sun chemical Co., Ltd, a caulking tape such as "MF-12T 2" or "MF-10F" manufactured by Nisshinbo Co., Ltd, a caulking tape such as a porous PTFE film, a caulking tape such as "GORE-SEATAPE" manufactured by Nippon Aux Co., Ltd, a caulking tape using a polyurethane hot melt resin as a base material tape, and the like can be suitably used.

As the hot melt resin of the joint sealing tape, various resins such as polyethylene resin or a homopolymer resin thereof, polyamide resin, polyester resin, butyral resin, polyvinyl acetate resin or a copolymer resin thereof, cellulose derivative resin, polymethyl methacrylate resin, polyvinyl ether resin, polyurethane resin, polycarbonate resin, polyvinyl chloride resin, etc. may be used alone or in combination of 2 or more thereof, and when used for clothing, the polyurethane resin is preferred. This is because in the case of use in clothing articles, durability to dry cleaning or durability to washing and soft hand are required. The thickness of the hot-melt resin layer of the caulking tape is preferably 25 μm or more, preferably 50 μm or more, and 400 μm or less, preferably 200 μm or less. If the thickness of the hot-melt resin layer is less than 25 μm, the resin amount is too small to completely block the uneven portions of the thread in the needle hole portion, and the water repellency of the stitched portion may be insufficient. On the other hand, if the thickness of the hot-melt resin layer exceeds 400 μm, the time required for the hot-press bonding to melt sufficiently is long, and the productivity is lowered, or the bonded flexible film side may be thermally damaged. Further, if the thermocompression bonding time is shortened, the hot-melt resin layer is not sufficiently melted, and sufficient adhesive strength and water resistance cannot be obtained. The hand of the caulked portion after the bonding process is hard, and for example, when the laminate of the present invention is applied to a clothing article, the caulked portion feels hard.

These caulking tapes can be welded to an adherend by blowing hot air to the side of the hot-melt resin layer of the tape and pressing the molten resin against a pressure roller using a conventional hot air sealing machine. For example, "QHP-805" manufactured by Queen Light electronics industries, or "5000E" manufactured by w.l.gore & assosiates may be used. In addition, in order to more easily weld and process the short seam, the tape may be caulked by a commercially available hot press or iron hot press. At this time, heat and pressure are applied from above the joint tape in a state of being overlapped on the seamed portion.

The thermocompression bonding condition of the caulking tape may be appropriately set according to the softening point of the hot-melt resin used for the tape, the thickness, material, and welding speed of the flexible film. As an example of the thermocompression bonding of the caulking tape, for example, in the case of a 3-layer laminate formed by laminating a porous PTFE film on one surface of a fabric (nylon taffeta of 78 dtex) and laminating a woven fabric (nylon taffeta of 22 dtex: the sum of the cover factor of the warp and weft is 700 to 1400), the 22dtex nylon taffeta surfaces are thermocompression bonded to each other with the caulking tape (W.L. GORE & ASSOCIATES "5000E"), and the caulking tape is attached to a hot air sealer, and thermocompression bonding is performed under the condition that the surface temperature of the hot melt resin is 150 to 180 ℃, preferably 160 ℃. Then, the temperature is cooled to a heating portion temperature and returned to room temperature in this state, thereby completing the thermocompression bonding. In this case, the hot-melt resin is preferably a polyester urethane resin.

The flow value (measured at 180 ℃ by using a flow tester "CFT-500" manufactured by Shimadzu corporation) of the hot-melt resin is preferably 40 to 200X 10^-3cm³In the range of/s, preferably 60 to 100X 10^-3cm³In the range of/s. This is because if the flow value of the hot-melt resin is too low, the adhesive strength is insufficient, and if it is too high, the resin bleeds from the sewing needle hole and the belt edge portion and adheres to the pressure roller or the like. Further, if the surface temperature of the hot-melt resin is too low, the resin is not sufficiently melted, resulting in insufficient adhesive strength and water resistance; if the amount is too high, the fluidity is too high, and not only does the problem occur that the resin at the seam part oozes out, but also the hot-melt resin itself is thermally decomposed, and the adhesive strength and water resistance may be lowered.

As described above, the laminate of the present invention is processed into a textile product such as clothes, sheets, tents, bags, and sleeping bags.

The present invention will be described below with reference to the drawings, but the present invention is not limited to the embodiments shown in the drawings. Fig. 1 is a cross-sectional view illustrating a laminate of the present invention. A laminate 1 shown in FIG. 1 is a form in which a porous film made of a hydrophobic resin is used as a flexible film 3, and a woven fabric 5 having a total cover factor of 700 to 1400 for warp and weft is laminated on one side of the laminate 1 subjected to caulking treatment when the laminate 1 is processed into a fiber product, and a cloth 7 is laminated on the other side of the laminate 1, and the woven fabric 5, the cloth 7 and the flexible film 3 are bonded by a hot-melt resin adhesive 8. Further, a hydrophilic resin layer 10 is formed on one side of the laminated fabric 5 of the porous membrane formed of a hydrophobic resin.

Fig. 2 is a sectional view schematically illustrating a sewn portion obtained by sewing the laminate of the present invention and performing a caulking process using a caulking tape having a hot-melt resin layer. The laminate 1 comprises a flexible film 3, a woven fabric 5 laminated on one side of the laminate and having a total cover factor of 700 to 1400, and a fabric 7 laminated on the other side.

In the laminate 1, the end portion is welted, and the welt portion is overlapped with the end portion of the other laminate 1' and sewn with a sewing thread 9. The joint tape 11 is adhered so as to cover the joint portion, and a part of the hot-melt resin layer 13 is impregnated into the surface (not shown) of the fabric 5 laminated in the laminate 1.

Examples

[ evaluation method ]

1. Determination of the fineness

The fineness of the warp and weft of the fabric was measured according to JIS L1096. The fineness of the filaments constituting the warp and weft is calculated by dividing the fineness of the warp or weft by the number of filaments constituting the warp or weft.

2. Determination of Density

The warp density and weft density (strip/2.54 cm) of the fabric were measured based on JIS L1096, respectively.

3. Thickness of

The thickness of the test piece was measured in accordance with JIS L1096. A direct-reading thickness meter "PF-15" manufactured by Delauer corporation was used for the measurement.

4. Mass per unit area

The mass per unit area (g/m) of the test piece was measured in accordance with JIS L1096²)。

5. Moisture permeability

The moisture permeability (g/m) of the test piece was measured according to JIS L1099B-2 method²·h)。

6. Tear strength

The tear strength (N) of the test piece was measured according to JIS L1096D method (swing method).

7. Tensile strength

The tensile strength (N/5cm) of the test piece was measured in accordance with JIS L1096A method (marker bar method: width of test piece 5cm, grip interval 20cm, and stretching speed 20 cm/min).

8. Velcro wear durability

The hook side of the hook was attached to a II-type friction pad of a friction tester described in JIS L0849 ("quick klon 1 QN-N20" manufactured by YKK), and the test piece was attached to a test piece stand. The hook was attached to the friction element so that the hook side faced the test piece side. The test piece was mounted on the test piece stand with the side on which the caulking treatment of the laminate was performed facing the upper surface (the friction side). In this state, a 2N load was applied to the friction element, and the state of the rubbed portion of the test piece was observed by rubbing 100 times. The case where any damage was present in the test piece was regarded as abnormal, and the case where no damage was found was regarded as no abnormality.

9. Water-removing property

The laminate was cut into a circular shape having a diameter of 140mm by a rotary cutter ("RC-14" manufactured by Daorhiki Seisakusho K.K.) to obtain a test piece. Test piece was applied to an electronic balance (A)&"FA 200" manufactured by D corporation) was weighed to a unit of 1mg, and immersed in ion-exchanged water for 1 minute. Subsequently, the mixture was dehydrated by a dehydration apparatus (manufactured by Daorhizi Seiki Seisaku-Sho Ltd.) set to a rotation speed of 1000rpm for 10 seconds, and immediately weighed by the electronic balance in the same manner as described above. The difference between the weighed value of the test piece after dehydration and the weighed value of the test piece before immersion (mass increase) was obtained, and the mass was divided by the area of the test piece (0.0154 square meter) to calculate the amount of water adhered per unit area after dehydration (unit: g/m)²) As the dehydration property.

10. Water resistance of joint

Production of test piece for caulked portion

The resulting laminate was cut into a square 30cm in side length, and the blank was cut into 4 square test pieces of the same size at the center in a cross-cut manner. The test pieces were sewn together in the original shape to form a test piece with a cross-shaped stitch at the center. As shown in FIG. 2, the width of the hem was set to 7mm, and after folding the hem, double-sewing was performed parallel to the ends of the stitches. The sewing thread used was polyester sewing machine thread (No. 50). The test piece was passed through a hot air sealer (w.l.gore)&"5000E" manufactured by ASSOCIATES corporation) was used under the conditions of a set temperature of 700 ℃ and a processing speed of 4 m/min with a caulking tape ("GORE-SEATMAPE" manufactured by Ottex corporation, Japan, and a resin flow value of 100X 10 at 180 DEG C^-3cm³Per second, the resin thickness was 100 μm and 150 μm, respectively, and the width was 22 mm).

The water resistance test of the caulked portion was performed on the test pieces after the initial and 20-time washing treatments using a water resistance test apparatus described in JIS L1096 (low water pressure method) (shobby type water resistance tester WR-DM manufactured by honor scientific essences co.). After applying a water pressure of 20kPa to the portion of the test piece subjected to the caulking treatment from the side subjected to the caulking treatment and holding for 1 minute, when water appears on the surface of the test piece opposite to the side to which the water pressure is applied, the test piece is judged as being defective due to poor water resistance, and is judged as being acceptable when no water is observed at all.

The washing treatment was carried out by using a household full-automatic washing machine ("NA-F70 PX 1" manufactured by panasonic electric industry) and drying the laundry for 24 hours at room temperature as 1 cycle. The test piece obtained by repeating this cycle 20 times was subjected to a water resistance test after 20 washing treatments. For washing, a 35 × 35cm load cloth (made of a cotton wide and thin cloth as specified in JIS L1096, and subjected to a lock-stitch treatment by sewing the periphery) was adjusted so that the total amount of the load cloth and the cloth as a test piece became 300 ± 30 g. The washing was carried out for 6 minutes using 40 liters of tap water and 30g of a synthetic detergent for washing ("Jieba" manufactured by Kao corporation), followed by washing 2 times and dehydrating for 3 minutes.

11. Coefficient of friction

The static friction coefficient and the dynamic friction coefficient between the fabric surfaces of the test pieces (laminates) laminated on the side to be subjected to caulking treatment were measured by a measuring apparatus "Tribo Gear 14DR model" manufactured by New eastern science according to ASTM D1894-99. The static friction coefficient and the dynamic friction coefficient of the fabric laminated on the side to be subjected to caulking treatment were measured as the average values of the static friction coefficient and the dynamic friction coefficient of the fabric which was measured between the longitudinal direction and the transverse direction of the fabric surface.

[ preparation of laminate ]

Laminate 1

The mass per unit area of the flexible waterproof moisture-permeable film was 33g/m²The porous PTFE film (manufactured by Ottx corporation, Japan, having a void fraction of 80%, a maximum pore diameter of 0.2 μm, and an average thickness of 30 μm) of (1) a woven fabric having a plain weave of nylon A (having a total of the cover factors of the warp and weft of 17dtex, and the number of filaments of the warp and weft of 5, and having a warp density of 138 pieces/2.54 cm, a weft density of 133 pieces/2.54 cm, and a mass per unit area of 19g/m2) and a woven fabric having a plain weave of nylon B (having a warp and weft of 17dtex, a warp density of 165 pieces/2.54 cm, a weft density of 194 pieces/2.54 cm, and a mass per unit area of 27 g/m) were used as the woven fabric laminated on one side of the fabric to which the caulking was performed during the processing into a fiber product²)。

Further, as the hydrophilic resin to be applied to the porous PTFE membrane, ethylene glycol was added to a hydrophilic polyurethane resin ("Hypol 2000", manufactured by dow chemical corporation) at an NCO/OH equivalent ratio of 1/0.9, and the mixture was mixed and stirred to prepare a coating liquid of a polyurethane prepolymer.

The coating liquid of the polyurethane prepolymer is applied (impregnated in a part of the surface layer of the film) to one of the porous PTFE films by a roll coaterAnd (5) kneading. The coating weight was 10g/m². Subsequently, the porous PTFE film was put into a heating furnace adjusted to a temperature of 80 ℃ and a humidity of 80% RH for 1 hour, and cured by reaction with moisture, thereby forming a hydrophilic polyurethane resin layer on one surface of the porous PTFE film. The fabric a is laminated on one side of the hydrophilic urethane resin layer formed on one surface of the porous PTFE membrane, and the fabric B is laminated on the other side.

The bonding of the fabric A, B to the porous PTFE film was performed using a polyurethane moisture-curable reactive hot-melt adhesive ("Hibon 4811" by hitachi chemical polymer corporation). The temperature of the adhesive is up to 120 ℃ and 5g/m²The adhesive transfer amount of (3) was applied in a dot form to a porous PTFE film by passing the melt through a gravure roll having a coverage of 40%, and then the resultant was pressed against the porous PTFE film by a roll. After the press-bonding with a roller, the resultant was left to stand in a constant temperature and humidity chamber at 60 ℃ and 80% RH for 24 hours to cure the reactive hot-melt adhesive, thereby obtaining a laminate having a 3-layer structure.

Next, the fabric B of the laminate having a 3-layer structure was subjected to water repellent treatment. A dispersion obtained by mixing 3 mass% of a water repellent (Asahi Guard AG7000, manufactured by minghem chemical industries) and 97 mass% of water was prepared, applied to the surface of fabric B in an amount equal to or more than the saturation amount by a kiss coater, and an excess of the dispersion was squeezed out by a nip roll. The amount of the dispersion absorbed into the fabric at this time was about 20g/m². Then, the raw fabric was dried in a hot air circulation oven at 130 ℃ for 30 seconds to obtain a water-repellent 3-layer laminate 1. Fig. 5 is an electron micrograph (magnification: 25 times) of the fabric laminated on the caulking-treated side of the laminate 1.

Laminate 2

Except that a plain weave fabric C made of nylon was used (both of the fineness of the warp and weft was 78dtex, the density of the warp was 120 pieces/2.54 cm, the density of the weft was 90 pieces/2.54 cm, the mass per unit area was 66g/m²) Processing was performed under the same conditions as in the laminate 1 except for the fabric B in the laminate 1, to obtain a laminate 2 having a 3-layer structure. The amount of the water repellent dispersion applied was 25g/m²。

Laminate 3

The fabric laminated on the side to be subjected to caulking treatment in the laminate 1 was plain weave fabric D made of nylon having a total value of coverage factors of warp and weft of 1275 (both the fineness of the warp and weft were 33dtex, the number of filaments of the warp was 6, the number of filaments of the weft was 10, the density of the warp was 121 pieces/2.54 cm, the density of the weft was 101 pieces/2.54 cm, and the mass per unit area was 25g/m²) Otherwise, processing was performed under the same conditions as for the laminate 1 to obtain a laminate 3 having a 3-layer structure.

Laminate 4

A plain weave fabric C made of nylon was used, and subjected to water repellent processing. The water repellent treatment is performed so that a polyurethane resin solution described later does not permeate through the fabric when the solution is applied. A dispersion obtained by mixing 1 mass% of a water repellent (DIC Guard F-18, manufactured by Dainippon ink chemical industries Co., Ltd.) and 99 mass% of water was prepared, applied to the surface of the fabric C in an amount of not less than the saturation amount by a kiss coater, and the excess dispersion was extruded by a roll. The amount of the dispersion applied was about 25g/m². Then, the raw fabric was dried in a hot air circulation oven at 130 ℃ for 30 seconds.

One side of the water-repellent treated fabric C was coated at 200g/m using a doctor blade coater²The polyurethane resin solution having the composition shown in Table 1 was applied at the coating weight of (A). The coated fabric C was immersed in a coagulation bath filled with a 10 mass% aqueous solution of N, N-dimethylformamide at a temperature of 30 ℃ for 5 minutes to wet-coagulate the polyurethane resin. Subsequently, the fabric was washed with hot water at 60 ℃ for 10 minutes and dried with hot air at 140 ℃ to form a porous polyurethane layer on one surface of the fabric C after the water repellent treatment.

Next, on the other surface of the porous polyurethane layer (corresponding to the side to be subjected to caulking treatment when processing into a fiber product), a plain weave fabric a made of nylon was laminated by the same method as that of the laminate 1, to obtain a laminate 4 having a 3-layer structure.

[ Table 1]

Composition (I)	Content (parts by mass)
		Polyester urethane resin solution "Crisvon MP-829" manufactured by Japan ink chemical industries, Ltd "	50
Polyester urethane resin solution manufactured by Crisvon MP-829H, product of Japan ink chemical industries, Ltd "	20
		Isocyanate crosslinking agent "Crisvon CL-10" manufactured by Dainippon ink chemical industries Ltd "	1
Film-forming aid "Crisvon SD-17B" manufactured by Dainippon ink chemical industries, Ltd "	2

N, N-dimethylformamide

27

Laminate 5

A plain weave fabric C made of nylon was used, and subjected to water repellent processing. The water repellent treatment is performed so that an acrylic resin solution described later does not permeate through the fabric when the solution is applied. A dispersion obtained by mixing 5 mass% of a water repellent (DIC Guard NH-10, manufactured by Dainippon ink chemical industries Co., Ltd.) and 95 mass% of a mineral turpentine was prepared, applied to the surface of the fabric C in an amount of not less than the saturation amount by a kiss coater, and the excess dispersion was extruded by a roll. The amount of the dispersion applied was about 25g/m². Then, the raw fabric was dried in a hot air circulation oven at 150 ℃ for 60 seconds.

One side of the water-repellent treated fabric C was coated at 40g/m using a doctor blade coater²The acrylic resin solution having the composition shown in Table 2 was applied at the coating weight of (A). The coated fabric C was hot-air dried at 90 ℃ for 40 seconds to form an acrylic resin layer on one surface of the fabric C.

Then, on the other surface of the acrylic resin layer (corresponding to the side to be subjected to caulking treatment in processing into a fiber product), a plain weave fabric a made of nylon was laminated in the same manner as in the laminate 1 to obtain a laminate 5 having a 3-layer structure.

[ Table 2]

Composition (I)	Content (parts by mass)
		Acrylic resin solutionCriscoat AC-100 manufactured by Dainippon ink chemical industries Ltd "	82
Isocyanate crosslinking agent "Crisvon NX" manufactured by Dainippon ink chemical industries Co., Ltd "	2
		Toluene	16

Laminate 6

The fabric laminated on the side to be subjected to caulking treatment in the laminate 1 was a plain weave fabric E made of nylon having a total value of covering factors of warp and weft of 1352 (both the fineness of the warp and weft was 17dtex, the number of filaments of the warp and weft was 5, the density of the warp was 182 pieces/2.54 cm, the density of the weft was 146 pieces/2.54 cm, and the mass per unit area was 30g/m²) Otherwise, the processing was performed under the same conditions as for the laminate 1, to obtain a laminate 6 having a 3-layer structure.

Laminate 7

The fabric a laminated on the side to be subjected to the caulking treatment in the laminate 1 is also coated with the water repellent mixture used in the laminate 1 in an amount equal to or more than the saturation amount with the kiss coating agent, and the excess dispersion is squeezed out by the nip roller. The amount of the dispersion absorbed into the raw fabric was about 15g/m². Then, the raw fabric was dried in a hot air circulation oven at 130 ℃ for 30 seconds to obtain a laminate 7.

Laminate 8

The surface of the fabric a laminated on the side to be subjected to the caulking treatment in the laminate 2 was also subjected to the water repellent treatment in the same manner as in the laminate 7, to obtain a laminate 8.

Laminate 9

The surface of the fabric D laminated on the side to be subjected to the caulking treatment in the laminate 3 is also subjected to the water repellent treatment in the same manner as in the laminate 7, to obtain a laminate 9.

Laminate 10

The surface of the fabric a laminated on the side to be subjected to the caulking treatment in the laminate 4 is also subjected to the water repellent treatment in the same manner as in the laminate 7, to obtain a laminate 10.

Laminate 11

The surface of the fabric E laminated on the side to be subjected to the caulking treatment in the laminate 6 was also subjected to the water repellent treatment in the same manner as in the laminate 7, to obtain a laminate 11.

Laminate 12

Except that a tricot F composed of nylon 66 fibers (fineness of both wales and courses is 22dtex, density of wales is 36 pieces/2.54 cm, density of courses is 50 pieces/2.54 cm, mass per unit area is 33 g/m)²) Instead of the woven fabric laminated on the side on which the caulking treatment was performed in the laminate 1, the adhesive transfer amount at the time of lamination was set to 8g/m²Otherwise, the processing was performed under the same conditions as in the laminate 1 to obtain a laminate 12 having a 3-layer structure. Fig. 6 is an electron micrograph (magnification: 25 times) of the tricot warp knitted fabric laminated on the caulking-treated side of the laminate 12.

Laminate 13

A laminate 13 having a 3-layer structure was obtained by processing under the same conditions as the laminate 12, except that the fabric C was used instead of the fabric B in the laminate 12.

Laminate 14

A waterproof moisture-permeable composite film having an abrasion-resistant layer composed of the hydrophilic urethane resin disclosed in example 1 of japanese patent No. 3346567 (example 1 of U.S. patent No. 5209969 specification) was produced. The hydrophilic urethane resin is used as a constituent material of the dots of the abrasion resistant polymer.

100 parts by mass of Hexamethylenediamine (HMD) was added to 244 parts by mass of ethylene/propylene oxide polyol at 45 ℃ and CO was introduced into the resulting mixture₂A paste having a solid content of 35 mass% was prepared. Until all HMD in the paste was converted to HMD carbamate, the content of free HMD was monitored by titration, and the reaction was stopped immediately after the free HMD disappeared.

Next, 31 parts by mass of the paste was added to 126 parts by mass of a polyurethane prepolymer, which is a reaction product of 43 parts by mass of diphenylmethane diisocyanate and 83 parts by mass of polytetramethylene glycol, at room temperature to obtain a mixed solution containing the polyurethane prepolymer and HMD urethane. The resulting mixture contained 7 mass% HMD carbamate.

The surface of the porous PTFE film used in the laminate 1 on which the hydrophilic urethane resin layer was formed was printed by gravure printing to 15g/m²The above-mentioned mixed solution adjusted to 70 ℃ was applied to the coating amount of (1). Here, the gravure roll used was a roll having a density of 8 lines/2.54 cm and an open area ratio of 40% (dot form in which dots were circular with a diameter of 2.1mm, the distance between the centers of adjacent dots was 3.175mm, and dots were arranged at the vertexes and the center of a continuous regular hexagon). The coated film was heated on a hot plate heated to 180 ℃ to cure the coated urethane resin, thereby obtaining a flexible waterproof moisture-permeable film having a dot of an abrasion-resistant polymer on one side (corresponding to the side to be subjected to caulking treatment when processing into a fiber product).

The other side of the waterproof moisture-permeable film obtained as described above was laminated with the fabric B under the same conditions as in the laminate 1 and subjected to water repellent treatment, to obtain a laminate 14 having a 2-layer structure.

Laminate 15

A plain weave fabric G made of nylon having a total value of the cover factors of the warp and weft 1480 (both of the fineness of the warp and weft 17dtex and the density of the warp 165 pieces) was used except for the side of the laminate 1 to which the caulking treatment was applied2.54cm, density of the weft yarn 194 strips/2.54 cm, mass per unit area 27g/m²) Otherwise, the processing was performed under the same conditions as in the laminate 1 to obtain a laminate 15 having a 3-layer structure.

Laminate 16

The fabric laminated on the side to be subjected to caulking treatment in the laminate 1 was a plain weave fabric H made of nylon having a total value of cover factors of the warp and the weft of 1436 (both the fineness of the warp and the weft were 33dtex, the number of filaments of the warp was 6, the number of filaments of the weft was 10, the density of the warp was 126 pieces/2.54 cm, the density of the weft was 124 pieces/2.54 cm, and the mass per unit area was 28g/m²) Otherwise, the processing was performed under the same conditions as in the laminate 1, to obtain a laminate 16 having a 3-layer structure.

Laminate 17

The laminate 12 was subjected to the same water repellency treatment as the laminate 7 on the surface of the tricot knitted fabric F, and a laminate 17 was obtained.

Laminate 18

The laminate 13 was subjected to the same water repellency treatment as the laminate 7 on the surface of the tricot fabric F, to obtain a laminate 18.

Laminate 19

The laminate 14 was subjected to the same water repellent treatment as that of the laminate 7 on the surface having the dots provided on the porous PTFE film, to obtain a laminate 19.

Laminate 20

The laminate 15 was subjected to the same water repellency treatment as the laminate 7 on the surface of the woven fabric G, and a laminate 20 was obtained.

Laminate 21

The laminate 16 was subjected to water repellency treatment on the surface of the fabric H in the same manner as in the laminate 7, to obtain a laminate 21.

Laminate 22

Except that a plain weave fabric I made of nylon having a total value of the cover factors of the warp and the weft of 688 (both of the fineness of the warp and the weft are 17dtex, the number of the filaments of the warp and the weft are 5, the density of the warp is 99 pieces/2.54 cm, the density of the weft is 68 pieces/2.54 cm, and the mass per unit area is 16g/m²) After the laminate 1 was processed under the same conditions as those of the laminate 1 except for the web a in the laminate 1, a large number of knitting defects and creases were generated on the surface of the web I in the lamination step, which resulted in poor appearance, and a laminate could not be obtained.

The laminates 1 to 21 thus obtained were subjected to various tests for the laminates and their caulked portions. The results are shown in tables 3 to 4.

[ Table 3]

Table 3 shows the cover factor of the woven fabric disposed on the side where caulking treatment was performed when the obtained laminate was processed into a fibrous product. Further, since the laminates 12 to 14 and 17 to 19 are provided with tricot or abrasion resistant layers on the side to be subjected to caulking treatment, the cover factor cannot be calculated.

[ Table 4]

Table 4 shows the results of evaluation of the water resistance of the caulking-treated part of the obtained laminate. As is clear from Table 4, the laminates 1 to 11 having the cover factor of the fabric laminated on the side subjected to the caulking treatment of 700 to 1400 had good water resistance in the initial stage and after 20 times of washing, and had good water-repellent effect by the caulking treatment.

On the other hand, in laminates 15 and 16 in which plain woven fabrics made of nylon, as used for the facing material of the conventional laminate, were used as the woven fabrics laminated on the side on which the caulking treatment was performed, it was confirmed that the initial water resistance of the caulking-treated part was low, and the water-repellent effect by the caulking treatment could not be obtained. This is considered to be because the plain woven fabric made of nylon used in the conventional face fabric has an excessively small hole and the hot-melt resin of the caulking tape becomes insufficiently impregnated. The water resistance of the caulking portions of the laminates 6 and 11 after washing 20 times was low, but the water resistance was at the same level as that of the caulking portions of the laminates 12 and 13 having the same structure as that of the currently commercially available products, and this level was not problematic in practical use. Further, it was confirmed that the laminates 7 to 11 obtained a water repellent effect by the caulking treatment, although the water repellent treatment was applied to the fabric on the side to which the caulking treatment was applied. On the other hand, the same structure as that of the commercially available products, and the water resistance of the fabric on the side to be subjected to caulking treatment, tricot knitted fabric, and laminate 17 to 21 obtained by subjecting the abrasion resistant layer to water repellent treatment was found to be low after washing the caulked portion 20 times, and the water repellent effect by caulking treatment was insufficient. When the laminate is used for a raincoat, the side of the laminate to which the caulking treatment is applied is usually used for the inner side (human body side), but if the raincoat is worn in rainy weather, rainwater flows into the inner side of the raincoat from the opening (cuff and hem) of the raincoat, and a phenomenon (capillary phenomenon) occurs in which the rainwater penetrates into the cloth inside the raincoat. This phenomenon can be prevented by subjecting the fabric on the inner side of the raincoat (the fabric on the side to which the caulking treatment is applied) to water repellency treatment, but if the fabric on the side to which the caulking treatment is applied is subjected to water repellency treatment in advance, the caulking treatment performed after sewing the raincoat is adversely affected, and therefore, there is a problem in the prior art that it is difficult to adopt an effective countermeasure against the capillary phenomenon. The laminate of the present invention can obtain a water repellent effect by the caulking treatment even when the water repellent treatment is performed on the fabric on the side to which the caulking treatment is performed, and is therefore very useful from the viewpoint of preventing the capillary phenomenon.

Further, if laminates 1 and 2 and laminates 12 and 13 are compared, the laminates 1 and 2 can obtain a water-repellent effect by caulking treatment even when the thickness of the hot-melt resin layer is 100 μm or 150 μm, whereas laminates 12 and 13 of the conventional example are inferior in water resistance after washing the caulking portion 20 times when a caulking tape having a thickness of the hot-melt resin layer of 100 μm is used. This result means that if the present invention is used, the amount of the hot melt resin of the caulking tape to be used can be reduced, and the cost of the textile product obtained by processing the laminate of the present invention and performing caulking treatment can be reduced.

[ Table 5]

Table 5 shows the results of evaluating the thickness, quality, moisture permeability, tear strength, tensile strength, friction coefficient, dehydration property, velcro abrasion durability, and the like of the obtained laminates 1 to 6 and laminates 12 to 16. The same results (dewatering property) as described below were also confirmed for laminates 7 to 11 and laminates 17 to 21 obtained by subjecting the fabric laminated on the side subjected to the caulking treatment to the water repellent treatment.

[ light weight ]

For weight reduction, laminates having the same structure except for the fabric laminated on the side to which the caulking treatment was performed were compared with each other. For example, the laminate 1 is laminated with a nylon plain woven fabric having a total cover factor of 1117 on the caulking-treated side, and the laminate 12 is laminated with a tricot warp knit instead of the nylon plain woven fabric. The mass of the laminate 1 was 78g/m²The mass of the laminate 12 was 93g/m²This indicates that the weight reduction is about 16%. The laminates 2 and 13 can be compared in the same manner, and the weight of the laminate 2 is 118g/m²The mass of the laminate 13 was 131g/m²This indicates that the weight reduction is about 10%. From the above results, it is understood that the weight of the laminate can be reduced by the present invention. Particularly, outdoor articles such as rain gear, bag, tent, sleeping bag, etc. are required to be lightweight and suitable for useThe invention is adopted.

[ regarding moisture permeability ]

The moisture permeability of each of the laminates 1 to 4 and the laminate 6 was confirmed to be 300g/m²H or more, and there is no practical problem. In particular, laminates 1 to 3 and 6 using porous PTFE films as waterproof moisture-permeable films were confirmed to have good moisture permeability. The reason why the laminate 5 has low moisture permeability is that an acrylic resin layer having low moisture permeability is used as the flexible film.

[ tear Strength and tensile Strength ]

Regarding tear strength and tensile strength, laminates having the same structure except for the portion of the fabric laminated on the side subjected to the caulking treatment were compared with each other. The tear strengths of the laminates 1 and 2 were lower than those of the laminates 12 and 13, respectively, but both exceeded the tear strength required for a 10N coveralls (requiring high strength), and there was no practical problem. The tensile strengths of the laminates 1 and 2 were confirmed to be substantially the same level as the tensile strengths of the laminates 12 and 13, and there was no practical problem. On the other hand, the laminate 14 having dots of the abrasion resistant polymer without laminating a fabric on the caulking treatment side was confirmed to have low tear strength and tensile strength.

[ concerning the coefficient of friction ]

The laminates 1 to 3 all had a coefficient of friction of about 0.5 or less, and exhibited good smoothness, while the laminates 12 and 13 had a high coefficient of friction. This is presumably because the knitted fabric stitches stacked on the side to which the caulking treatment is performed involve each other. Further, the laminate 14 has a higher coefficient of friction, presumably due to frictional resistance and drag caused by the points of abrasion resistant polymer disposed on the side where the caulking process is performed. Since the magnitude of the friction coefficient greatly affects the wearing feeling such as the ease of putting on and taking off and the ease of movement during wearing, it can be said that the wearing feeling of the clothing using the laminate of the present invention is greatly improved.

[ dehydration Property ]

When the laminates 1 and 2 and the laminates 12 and 13 are compared, it is confirmed that the laminates 1 and 2 have a smaller amount of water adhered after dehydration than the laminates 12 and 13. The small amount of water attached after dehydration means that, for example, clothes (layered product) wetted by rainfall, washing, or the like in mountaineering can be quickly dried after dehydration. The laminate of the present invention was confirmed to have a small amount of water adhered after dehydration, and was suitable for clothes for outdoor use.

[ with respect to Velcro wear durability ]

The velcro wear durability means the wear resistance of a liner constituting a laminate such as clothes to a velcro represented by MagicTape (registered trademark), and the laminate of the present invention has good velcro wear durability as shown below. The laminates 1 to 6 subjected to the velcro abrasion test did not have an appearance abnormality. On the other hand, the tricot warp knitted fabric laminated on the caulking process side of the laminates 12, 13 is damaged. In addition, the porous PTFE film of the laminate 14 is damaged. These damages cause a decrease in waterproofness, and therefore, in the case of using the velcro fastener for clothing articles, waterproofness of the clothing articles may be impaired.

[ evaluation in clothes ]

The outdoor jacket is sewn using the laminate 1. As shown in FIG. 2, the width of the hem was set to 7mm, and after folding the hem, double-sewing was performed parallel to the ends of the stitches. The sewing thread used was polyester sewing machine thread (No. 50). The seam was sealed with a sealing tape (GORE-SEATMAPE manufactured by Ottx, Japan; resin flow value 100X 10 at 180 ℃)^-3cm³Per second, resin thickness 100 μm, width 22 mm). The joint filling treatment uses a hot air sealer (W.L. GORE)&"5000E" manufactured by ASSOCIATES corporation) was performed under the conditions of a set temperature of 700 ℃ and a processing speed of 4 m/min. Next, the outdoor jacket having the same shape is sewn using the laminate 12. A caulking tape (GORE-SEATAPE, manufactured by Ottex Japan) having a resin thickness of 150 μm was used except for the caulked portion, and the resin flow value was 180 DEG C100×10^-3cm³Per second, width 22mm) was prepared under the same conditions as in the laminate 1. If the quality of the resulting garment is compared, 340g of garment made from laminate 1 and 410g of garment made from laminate 12. From the results, it is clear that the jacket made of laminate 1 is about 17% lighter in weight than the jacket made of laminate 12. When the appearance of the joint processed part of the jacket is observed, the joint processed part of the jacket made of the laminate 1 is not obvious, but the jacket made of the laminate 12 has a fold at the edge of the joint tape, and the joint tape is easily developed.

Possibility of industrial utilization

The laminate of the present invention is suitably used for textile products such as clothing products, sheets, tents, and sleeping bags, and textile products requiring waterproof moisture permeability (e.g., waterproof sheets for medical use, clothing products for outdoor use, tents, sleeping bags, and the like).

Claims

1. A laminate comprising a woven fabric laminated on a flexible film, wherein the woven fabric is laminated on the side to be subjected to caulking treatment when the laminate is processed into a textile product, and the total value CF of the cover coefficients calculated by the following formula for each of the warp and weft constituting the woven fabric_totalIs 800 to 1200;

CF_total＝CF_m+CF_t

CF_m: the cover factor of the warp yarns is such that,

CF_t: the cover factor of the weft yarns is,

F_m: the titer of the warp yarns is dtex;

F_t: the fineness of the weft in dtex;

D_m: the density of the warp yarns, in terms of roots/2.54 cm,

D_t: the density of the weft yarns was in roots/2.54 cm.

2. Laminate according to claim 1, characterized in that the covering factor CF of the warp threads is the same as the covering factor CF of the warp threads_mAnd cover factor CF of weft_tAt least one of them is in the range of 300 to 800.

3. The laminate according to claim 1, wherein at least one of the warp and weft constituting the fabric is constituted by 2 or more filaments.

4. The laminate according to claim 2, wherein at least one of the warp and weft constituting the fabric is constituted by 2 or more filaments.

5. The laminate of claim 3, wherein said filaments have a denier of less than 12 dtex.

6. The laminate of claim 4, wherein said filaments have a denier of less than 12 dtex.

7. The laminate according to any one of claims 1 to 6, wherein at least one of warp yarns and weft yarns constituting the fabric is a long fiber.

8. The laminate according to any one of claims 1 to 6, wherein at least one of warp and weft constituting the fabric is a processed yarn.

9. A laminate according to any one of claims 1 to 6, wherein the fabric is a plain weave fabric.

10. The laminate according to any one of claims 1 to 6, wherein the flexible film is a waterproof film.

11. The laminate according to any one of claims 1 to 6, wherein said flexible film is a waterproof moisture-permeable film.

12. The laminate according to claim 11, wherein the waterproof moisture-permeable film is a porous film made of a hydrophobic resin.

13. The laminate according to claim 12, wherein the porous film made of a hydrophobic resin has a hydrophilic resin layer on a side where the woven fabric is laminated.

14. The laminate according to claim 12 or 13, wherein the porous film made of a hydrophobic resin is a porous polytetrafluoroethylene film.

15. The laminate according to claim 1, wherein a fabric is further laminated on the other side of the flexible film, i.e., on the side opposite to the side on which the woven fabric is laminated.

16. A fiber product obtained by processing a part or all of the laminate according to any one of claims 1 to 15, wherein one side of the laminate on which the woven fabric is laminated is subjected to caulking treatment.

17. A fibrous article according to claim 16, wherein said fibrous article is an article of clothing.