TW202511564A - Felt material, conveying material and method for manufacturing felt material - Google Patents

Abstract

The present invention provides a felt material having high heat resistance and durability, and provides a novel felt material containing specific fibers which have not been used in a cotton felt fiber layer so far in the same layer. The felt material of the present invention comprises a base layer and a cotton felt fiber layer, wherein at least one layer of the cotton felt fiber layer is a heat-resistant cotton felt fiber layer containing at least one type of fiber selected from the group consisting of poly(phenylene oxadiazole) fiber and polyoxadiazole fiber.

Description

Felt material, conveying material and method for manufacturing felt material

The present invention relates to a felt material, a conveying material and a method for manufacturing the felt material.

In the production of aluminum extrusion profiles, if the aluminum extrusion profile is extruded by an extruder, it is pulled by a puller and moves on a run-out tube or is loaded on a run-out conveyor while entering the conveying step. Then, the aluminum profile is slowly cooled while being conveyed by a cooling belt and a stretcher belt, and is stretched and extended by the stretchers at both ends of the stretcher belt to adjust the shape before being conveyed to the saw belt.

Since aluminum extrusion profiles are very hot, heat-resistant felt is sometimes used for the roller covers of run-out conveyors, the pads installed on run-out conveyors, and conveyor belts such as cooling belts, stretching belts, and saw belts.

Furthermore, in the production of steel plates in a continuous galvanizing line (CGL), the steel plates electroplated in a zinc pot are transported by a top roller located downstream of the zinc pot of the CGL. Usually, the top roller is covered with a heat-resistant felt material as a roller cover to prevent zinc from adhering to the top roller or to prevent defects on the steel plate.

Patent document 1 describes a heat-resistant felt having a substrate layer having at least one substrate layer and used as a cover or conveyor belt of an aluminum extrusion molding conveyor roller, or a roller cover of a CGL, and discloses that the substrate layer comprises a base fabric having yarn, and the yarn comprises at least one fiber selected from the group consisting of aromatic polyamide fibers and poly(p-phenylene benzobis(oxazole)) fibers (hereinafter also referred to as "PBO fibers").

Furthermore, Patent Document 2 discloses a cylindrical nonwoven fabric roller for steelmaking, which has a nonwoven fabric composed of poly(p-phenylene benzobis(azole)) fibers as a surface layer, a nonwoven fabric composed of para-polyarylamide fibers as an inner layer, and a cylindrical base fabric composed of heat-resistant fibers is arranged on the inner side of the inner layer.

Furthermore, Patent Document 3 describes a heat-resistant felt for high-temperature products, which is a heat-resistant fiber mesh formed by compounding or laminating metal fibers or inorganic fibers, or compounding or laminating metal fibers or inorganic fibers with heat-resistant organic fibers, interlaced and integrated by needle rolling. In addition, it discloses the use of a fiber compounded with glass fibers and para-aromatic polyamide fibers as the above-mentioned heat-resistant fiber mesh. [Prior technical document] [Patent document]

[Patent Document 1] Japanese Patent Publication No. 2021-160092 [Patent Document 2] Japanese Patent Publication No. 2000-064014 [Patent Document 3] Japanese Patent Publication No. 8-296160

(Invent the problem you want to solve)

Conveyor belts and conveyor roller covers used for aluminum extruded products, and conveyor roller covers used for CGLs require higher heat resistance due to the further increase in the temperature of the conveyed metal, and further durability is required from the perspective of cost reduction.

The conveyor belt or roller cover described in Patent Document 1 has improved heat resistance by using heat-resistant fibers such as aromatic polyamide fiber or PBO fiber in the base material (woven fabric, base fabric) or the net (non-woven fabric) layered on the base material, which is a constituent element thereof. Furthermore, the cylindrical non-woven fabric roller for steelmaking described in Patent Document 2 has improved heat resistance by using a non-woven fabric composed of PBO fiber in the surface layer, which is a constituent element thereof. Furthermore, the heat-resistant felt for high-temperature products described in Patent Document 3 has improved heat resistance of the felt by compounding glass fiber in para-type aromatic polyamide fiber.

The above-mentioned conveying material using the known felt material shows sufficient heat resistance and durability for conveying objects at a temperature of 200 to 400°C. However, in recent years, new requirements have arisen for conveying objects at higher temperatures. If the known conveying material conveys the object in the high temperature state multiple times, the fiber strength will be significantly reduced due to thermal degradation (the progress of wear will become faster), and the heat resistance and durability may not be sufficient. In addition, from the perspective of environmental protection and the health and safety of operators, the use of inorganic materials such as glass fibers to improve heat resistance and durability should be avoided as much as possible.

The present invention is completed in view of the above-mentioned known facts, and its purpose is to provide: a felt material with high heat resistance and durability. In addition, another purpose of the present invention is to provide: a novel felt material containing specific fibers that have not been used in the felt fiber layer so far in the same layer. (Technical means to solve the problem)

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

That is, the present invention relates to the following. [1] A felt material comprising: a base material layer and a felt fiber layer, wherein at least one layer of the felt fiber layer is a heat-resistant felt fiber layer containing at least one fiber selected from the group consisting of poly(phenylene oxadiazole) fiber and poly(oxadiazole) fiber. [2] A felt material as described in [1], wherein the heat-resistant felt fiber layer is located at the outermost side in the stacking direction. [3] The felt material as described in [1] or [2], wherein the base material layer comprises at least one fiber selected from the group consisting of polyarylamide fiber, polyphenylene oxadiazole fiber, polyoxadiazole fiber, poly(p-phenylene benzobisoxazole) fiber and polyimide fiber. [4] The felt material as described in any one of [1] to [3], wherein the thickness is 1 mm to 16 mm. [5] The felt material as described in any one of [1] to [4], wherein the basis weight of at least one layer of the felt fiber layer is 350 g/ ^m2 to 5500 g/ ^m2 . [6] The felt material as described in any one of [1] to [5], wherein the felt fiber layer further comprises an additional felt fiber layer. [7] The felt material as described in [6], wherein the additional felt fiber layer comprises at least one fiber selected from the group consisting of polyaromatic amide fiber, carbon fiber, poly(p-phenylene benzobis(azole)) fiber, polyimide fiber, fluorine fiber, glass fiber and polyphenylene sulfide fiber.

[8] The felt material described in any one of [1] to [7], which is in the shape of a flat plate. [9] The felt material described in any one of [1] to [7], which is in the shape of a belt. [10] The felt material described in any one of [1] to [7], which is in the shape of a cylinder. [11] A conveying material comprising the felt material described in any one of [1] to [10].

[12] A method for manufacturing a felt material as described in any one of [1] to [10], comprising the following steps (a) and (b) in sequence: (a) a step of disposing a fiber web composed of felt fibers on at least one side of the above-mentioned base material layer; (b) a step of forming the above-mentioned felt fiber layer adjacent to the above-mentioned base material layer by interlacing the above-mentioned fiber web with the above-mentioned base material layer. (Compared with the effect of the prior art)

The felt material of the present invention has high heat resistance and durability.

<Felt material> The felt material of the embodiment of the present invention comprises: a base material layer and a felt fiber layer, wherein at least one layer of the felt fiber layer is a heat-resistant felt fiber layer containing at least one fiber selected from the group consisting of polyphenylene oxadiazole fiber and polyoxadiazole fiber (hereinafter, these fibers are collectively referred to as "POD fiber"). The following describes the preferred embodiment of the felt material of the embodiment of the present invention with reference to the drawings. In addition, when "~" is used in this specification, the numerical value or physical property value before and after it is used.

The felt material according to the embodiment of the present invention is shown in FIG. 1 , and includes a heat-resistant felt fiber layer 10 and a base material layer 20 .

The thickness of the felt material of the embodiment of the present invention is not particularly limited. From the perspective of wear resistance, the thickness is preferably 1 mm to 16 mm, more preferably 1.5 mm to 16 mm, and even more preferably 2 mm to 16 mm.

Furthermore, the basis weight of the felt material of the present invention is not particularly limited. From the viewpoint of abrasion resistance, it is preferably 400 g/m ² -6500 g/m ² , more preferably 600 g/m ² -6500 g/m ² , and even more preferably 750 g/m ² -6500 g/m ² .

[Felt fiber layer] The felt fiber layer contained in the felt material of the embodiment of the present invention is a layer composed of felt fibers. More specifically, the felt fiber layer is a fiber aggregate layer formed by interlacing felt fibers (preferably short-staple felt fibers) with each other, and one embodiment functions as a layer having heat resistance and abrasion resistance.

(Heat-resistant felt fiber layer) The felt material of the embodiment of the present invention has one or more felt fiber layers, and at least one of the felt fiber layers is a heat-resistant felt fiber layer containing at least one fiber selected from the group consisting of polyphenylene oxadiazole fiber and polyoxadiazole fiber. In other words, at least one of the felt fiber layers of the felt material of the embodiment of the present invention is a heat-resistant felt fiber layer containing POD fiber. Thus, the felt material of the embodiment of the present invention can have high heat resistance and durability.

In addition, in this specification, the felt fiber layer containing POD fibers is referred to as a "heat-resistant felt fiber layer", and other felt fiber layers are referred to as "additional felt fiber layers". The additional felt fiber layer is sometimes heat-resistant and sometimes not heat-resistant. Furthermore, the felt fiber layer may be formed by interlacing two or more layers made of the same material to form one felt fiber layer. When two or more layers made of different materials are interlaced, the two or more felt fiber layers have independent and different components. Such layers formed by stacking two or more different felt fiber layers are collectively referred to as "layered felt fiber layers".

The polyphenylene oxide and polyoxadiazole constituting the above-mentioned POD fiber are also called "polyphenylene-1,3,4-oxadiazole" and "poly-1,3,4-oxadiazole", respectively. Furthermore, in polyphenylene oxide, there are isomers of ortho (o-), meta (m-) and para (p-) positions regarding the bonding of the phenyl moiety. In the embodiment of the present invention, from the perspective of heat resistance, the POD fiber preferably uses poly(isophenylene oxide) belonging to the meta body, poly(paraphenylene oxide) belonging to the para body, or poly(isophenylene)(paraphenylene) oxide which is a copolymer of the meta body and the para body, or a combination thereof, and more preferably uses poly(isophenylene)(paraphenylene) oxide. Below, the structure and optimal state of the POD fiber mentioned in this manual are the same.

There is no particular restriction on the proportion of POD fibers in the heat-resistant felt fiber layer. From the perspective of obtaining high heat resistance and durability, the fiber composition ratio is preferably 50% to 100% by mass, more preferably 75% to 100% by mass, still more preferably 90% to 100% by mass, and particularly preferably 100% by mass. Furthermore, from the perspective of environmental protection and the health and safety of operators, the heat-resistant felt fiber layer preferably does not contain inorganic materials such as glass fibers.

Fibers other than POD fibers that may be contained in the heat-resistant felt fiber layer include, for example, polyarylamide fiber, carbon fiber, PBO fiber, polyimide fiber (hereinafter also referred to as "PI fiber"), fluorine fiber, glass fiber, polyphenylene sulfide fiber, etc. Polyarylamide fiber is an isomer having ortho (o-), meta (m-) and para (p-) positions in the bonding of the phenylene moiety. In the embodiment of the present invention, from the viewpoint of heat resistance, the polyarylamide fiber is preferably a meta-polyarylamide fiber belonging to the meta-body, a para-polyarylamide fiber belonging to the para-body, or a meta-para-polyarylamide fiber belonging to a copolymer of the meta-body and the para-body, or a combination thereof. Hereinafter, the structure of the polyarylamide fiber mentioned in this specification and its preferred embodiment are all the same.

(Additional felt fiber layer) The felt material of the embodiment of the present invention may further contain an additional felt fiber layer. As mentioned above, the "additional felt fiber layer" in this specification refers to a felt fiber layer that does not contain POD fibers.

The additional felt fiber layer may include, for example, a felt fiber layer containing at least one fiber selected from the group consisting of polyarylamide fiber, carbon fiber, poly(p-phenylene benzobis(azole)) fiber, polyimide fiber, fluorine fiber, glass fiber, and polyphenylene sulfide fiber. Among them, polyarylamide fiber is preferred from the perspective of wear resistance. In addition, from the perspective of environmental protection and the health and safety of operators, the additional felt fiber layer preferably does not contain inorganic materials such as glass fiber. However, from the perspective of heat resistance, the felt material of the embodiment of the present invention preferably contains only a heat-resistant felt fiber layer as the felt fiber layer.

(Specific aspects of the felt fiber layer in the felt material) As specific aspects of the implementation aspects of the present invention containing an additional felt fiber layer, for example, the aspects shown in FIG. 1, FIG. 4, FIG. 5, and FIG. 8 can be cited. In the aspects shown in these figures, the felt material may further include an additional felt fiber layer 10A that does not contain POD fiber in addition to the heat-resistant felt fiber layer 10.

The felt material of the embodiment of the present invention may contain only one layer of felt fiber (i.e., only one layer of heat-resistant felt fiber), or may contain two or more layers of felt fiber. For example, as shown in FIG. 2 and FIG. 3, it may contain only one layer of heat-resistant felt fiber 10. When the felt material of the embodiment of the present invention contains two or more felt fiber layers, it may contain both a heat-resistant felt fiber layer 10 and an additional felt fiber layer 10A as the felt fiber layer as shown in Figures 1, 4, 5, and 8, or it may contain only two or more heat-resistant felt fiber layers 10 as the felt fiber layer as shown in Figures 6 and 7.

From the perspective of obtaining high heat resistance and durability, the felt material of the embodiment of the present invention is preferably a felt material in which at least one layer of the felt fiber layer is the outermost heat-resistant felt fiber layer in the stacking direction. That is, the felt material of the embodiment of the present invention is preferably a felt material in which the heat-resistant felt fiber layer is the outermost heat-resistant felt fiber layer in the stacking direction. When the felt material contains two or more felt fiber layers, it is preferred that the outermost layer in the stacking direction is a heat-resistant felt fiber layer, and the heat-resistant felt fiber layer or an additional felt fiber layer is located between the heat-resistant felt fiber layer and the base material.

When the felt material of the embodiment of the present invention is used as the conveying material described below, it is preferred from the viewpoint of heat resistance and abrasion resistance that it contains only one heat-resistant felt fiber layer located at the outermost side in the stacking direction and does not contain an additional felt fiber layer. In this case, it is preferred that the heat-resistant felt fiber layer is arranged in contact with the conveying object in a high temperature state.

The felt fiber layer is preferably adjacent to and laminated on at least one side of the base layer, and may be adjacent to and laminated on both sides of the base layer. For example, a fiber web composed of felt fibers is arranged on the base layer and interlaced with each other by needle rolling to form a felt fiber layer adjacent to and laminated on the base layer.

(Preferred range of dimensions, etc.) The fiber length of the felt fibers constituting the felt fiber layer is not particularly limited. From the perspective of wear resistance, it is preferably 20 mm to 120 mm, more preferably 30 mm to 120 mm, and even more preferably 40 mm to 120 mm.

The fiber density of the felt fiber constituting the felt fiber layer is not particularly limited. From the viewpoint of abrasion resistance, it is preferably 1 dtex to 10 dtex, more preferably 2 dtex to 8 dtex, and even more preferably 3 dtex to 6 dtex.

There is no particular restriction on the basis weight of the felt fiber layer. From the viewpoint of abrasion resistance, the basis weight of at least one layer of the felt fiber layer is preferably 350 g/m ² to 5500 g/m ² , more preferably 540 g/m ² to 5500 g/m ² , and even more preferably 680 g/m ² to 5500 g/m ² . When the felt material of the embodiment of the present invention contains two or more felt fiber layers, it is preferred that both layers satisfy the above basis weight.

There is no particular restriction on the thickness of the felt fiber layer. From the perspective of wear resistance, it is preferably 1 mm to 16 mm, more preferably 1.5 mm to 16 mm, and even more preferably 2 mm to 16 mm. When the felt material of the embodiment of the present invention contains two or more layers of felt fiber layers, it is preferred that the above thickness is satisfied.

(Laminated felt fiber layer) When the felt material of the embodiment of the present invention contains a laminated felt fiber layer, the heat-resistant felt fiber layer may be arranged in a manner included in the laminated felt fiber layer or arranged outside the laminated felt fiber layer. In the case where the heat-resistant felt fiber layer is arranged in a manner included in the laminated felt fiber layer, and in the case where the heat-resistant felt fiber layer is arranged outside the laminated felt fiber layer, it is preferred that the felt material contains the heat-resistant felt fiber layer in a manner located at the outermost side in the laminated direction. For example, as a layer structure of a laminated felt fiber layer composed of a heat-resistant felt fiber layer and an additional felt fiber layer, the heat-resistant felt fiber layer is arranged so as to be located at the outermost side in the laminate direction of the felt material, and the heat-resistant felt fiber layer or the additional felt fiber layer is arranged adjacent to it.

In the case where the laminated felt fiber layer is composed of a heat-resistant felt fiber layer and an additional felt fiber layer, the additional felt fiber layer may be composed of at least one fiber selected from the group consisting of polyaramid fiber, carbon fiber, poly(p-phenylene benzobis(azole)) fiber, polyimide fiber, fluorine fiber, glass fiber, and polyphenylene sulfide fiber. Among these, polyaramid fiber is preferred from the viewpoint of wear resistance.

[Base layer] The felt material of the embodiment of the present invention has one or more base layers. The fiber constituting the base layer is not particularly limited. From the viewpoint of strength and heat resistance, it is preferably at least one fiber selected from the group consisting of polyarylamide fiber, polyphenylene oxadiazole fiber, polyoxadiazole fiber, poly(p-phenylene benzobisoxadiazole) fiber and polyimide fiber, more preferably polyarylamide fiber, polyphenylene oxadiazole fiber or polyoxadiazole fiber, or a combination thereof, and even more preferably polyarylamide fiber.

The felt material of the embodiment of the present invention may contain only one substrate layer or may contain two or more substrate layers. From the perspective of dimensional stability and strength, it is preferred to contain two or more substrate layers. When the felt material of the embodiment of the present invention contains two or more substrate layers, all substrate layers may be adjacent to each other, or may contain layers other than substrate layers between substrate layers, or a pair of substrate layers may be adjacent to each other, and another pair of substrate layers may contain layers other than substrate layers between them.

Even if two or more layers of the base material layer are adjacent to each other and are made of the same material, two or more base material layers that are independent and different from each other are formed.

The base material layer can be composed of, for example, woven fabric, non-woven fabric or lattice material. Woven fabric, non-woven fabric and lattice material can be formed using spun yarn or raw yarn obtained from fiber. When the base material layer is a woven fabric, the weave of the woven fabric is not particularly limited, and can be a plain weave, a twill weave, a satin weave, or any of the multiple weaves thereof. If the felt material of the embodiment of the present invention contains two or more base material layers, each layer can be composed of the above-mentioned woven fabric, non-woven fabric or lattice material.

There is no particular restriction on the thickness of the substrate layer. From the perspective of strength, it is preferably 0.1 mm to 3 mm, more preferably 0.15 mm to 2 mm, and even more preferably 0.2 mm to 1 mm. When the felt material of the embodiment of the present invention contains two or more substrate layers, it is preferred that each substrate layer meets the above thickness.

The basis weight of the substrate layer is not particularly limited. From the viewpoint of smoothness, it is preferably 50 g/ ^m2 to 500 g/ ^m2 , more preferably 60 g/ ^m2 to 300 g/ ^m2 , and even more preferably 70 g/ ^m2 to 200 g/ ^m2 . When the felt material of the embodiment of the present invention has two or more substrate layers, it is preferred that each substrate layer meets the above basis weight.

From the viewpoint of dimensional stability and strength, the felt material of the embodiment of the present invention preferably contains two or more substrate layers consisting of a single layer.

[Other layers] The felt material of the embodiment of the present invention may have other layers in addition to the base material layer and the felt fiber layer. Examples of the other layers include a film layer, a paper layer, a series, a sheet, a foam, etc. The felt material of the embodiment of the present invention preferably has only a base material layer and a felt fiber layer, and more preferably has only a base material layer and a heat-resistant felt fiber layer.

[Shape] The felt material of the present invention can be made into various shapes according to its application, such as a flat plate shape, a belt shape or a cylindrical shape.

[Application] The felt material of the embodiment of the present invention has high heat resistance and durability, and is therefore suitable for use as a conveying material for conveying objects in a high temperature state. Examples of high temperature objects include metals (aluminum, iron, etc.), glass, and ceramics at a temperature of 200°C to 500°C. In addition, examples of such applications include conveying roller covers used in the manufacture of aluminum extrusion profiles and roller covers for continuous galvanized steel plate production lines (CGL).

<Conveying material> The conveying material of the embodiment of the present invention contains the above-mentioned felt material. The following describes the preferred embodiment of the conveying material of the embodiment of the present invention with reference to the drawings.

FIG9 is a schematic diagram showing an example of a felt material 100 used as a conveyor belt material when manufacturing aluminum extrusion moldings according to an embodiment of the present invention. In this example, the felt material 100 is formed into an endless belt shape. In the example shown in FIG9 , the felt material 100 has: a base material layer 120 and a laminated felt fiber layer 110. The laminated felt fiber layer 110 is a layer formed by laminating a heat-resistant felt fiber layer and an additional felt fiber layer in such a manner that the heat-resistant felt fiber layer is located at the outermost side in the lamination direction.

FIG10 is a schematic diagram showing an example of a felt material 200 used as a conveying roller cover material when manufacturing an aluminum extrusion profile according to an embodiment of the present invention. In this example, the felt material 200 is formed into a cylindrical shape. In the example shown in FIG10 , the felt material 200 has: a base material layer 220 and a laminated felt fiber layer 210. The laminated felt fiber layer 210 is a layer formed by laminating a heat-resistant felt fiber layer and an additional felt fiber layer in such a manner that the heat-resistant felt fiber layer is located at the outermost side in the lamination direction.

FIG11 is a schematic diagram showing an example of a felt material 300 used as a roller cover material of a continuous hot-dip galvanized steel plate production line (CGL) according to an embodiment of the present invention. In this example, the felt material 300 is formed into a cylindrical shape. In the example shown in FIG11 , the felt material 300 has: a base material layer 320 and a laminated felt fiber layer 310. The laminated felt fiber layer 310 is a layer formed by laminating a heat-resistant felt fiber layer and an additional felt fiber layer in such a manner that the heat-resistant felt fiber layer is located at the outermost side in the lamination direction.

The heat resistance and durability that the above-mentioned conveying materials should have are usually enough to convey objects at a temperature of 200~400℃. However, in recent years, there are demands for conveying objects at higher temperatures, for example, conveying materials that can convey objects at a temperature of 400~550℃. Therefore, the requirements for heat resistance and durability of conveying materials are gradually increasing.

The conveying material according to the embodiment of the present invention has higher heat resistance and durability than conventional materials by having the above-mentioned felt material, and thus can fully meet such requirements.

<Method for manufacturing felt material> The method for manufacturing felt material of the embodiment of the present invention preferably comprises the following steps (a) and (b) in sequence. (a) A step of disposing a fiber web composed of felt fibers on at least one side of a base layer. (b) A step of forming a felt fiber layer adjacent to the base layer by interlacing the fiber web and the base layer.

In the manufacturing method of the felt material of the embodiment of the present invention, at least one layer of the felt fiber layer is a heat-resistant felt fiber layer containing at least one fiber selected from the group consisting of polyphenylene oxadiazole fiber and polyoxadiazole fiber.

The details and preferred embodiments of the base material layer, felt fibers, fiber-fiber webs, and felt fiber layers used in the method for manufacturing the felt material of the embodiment of the present invention are the same as those described above.

The manufacturing method of the felt material of the embodiment of the present invention can be appropriately changed according to the embodiment of the specific felt material to be manufactured. For example, when the felt fiber layer is composed of multiple layers, that is, when two or more layers composed of the same material are interlaced to form a felt fiber layer, or when two or more layers composed of different materials are interlaced to form different felt fiber layers, the fiber net in the above step (b) can also be formed by interlacing multiple fiber nets to form a felt fiber layer. Alternatively, in the above step (b), after the fiber web and the base material layer are intertwined, another fiber web made of the same or different material is intertwined with the above fiber web, thereby forming a felt fiber layer. [Example]

The present invention is further described below in detail using embodiments, but the present invention is not limited by these embodiments.

[Example 1] Base material layer: polyaramid fiber/additional felt fiber layer: polyaramid fiber (base material layer side)/heat-resistant felt fiber layer: POD fiber (outermost side in the stacking direction) (Formation of base material layer) Polyaramid fiber (trade name: CONEX, meta-polyaramid fiber manufactured by Teijin Co., Ltd.) was spun into a plain weave to form a base material layer. The base material layer had a thickness of 0.5 mm and a basis weight of 160 g/m ² .

(Formation of heat-resistant felt fiber layer and additional felt fiber layer, and production of felt material) On one side of the above-produced base material layer, a fiber mesh (fiber length: 51 mm, fineness: 2.5 dtex) made of polyarylamide fiber (trade name: KEVLAR (registered trademark), para-type polyarylamide fiber manufactured by DuPont Toray) is laminated and needle-rolled. Furthermore, a fiber mesh (fiber length: 64 mm, fiber fineness: 4.4 dtex) composed of poly(m-phenylene) (p-phenylene) diazole fiber (POD fiber) (trade name: PODRUN, manufactured by Jiangsu Pod New Material Co., Ltd.) is layered on the above-mentioned fiber mesh and needle-rolled to produce the felt material of Example 1. The felt material of Example 1 is schematically represented by FIG. 1

The felt material of Example 1 comprises a laminated felt fiber layer composed of a heat-resistant felt fiber layer (POD fiber layer) and an additional felt fiber layer (polyaramid fiber layer). Of the two layers constituting the laminated felt fiber layer, the additional felt fiber layer is located on the substrate layer side, and the heat-resistant felt fiber layer is located on the outermost side in the laminated direction of the felt material. The thickness of the heat-resistant felt fiber layer is 3 mm and the basis weight is 1200 g/m ² , and the thickness of the additional felt fiber layer is 9 mm and the basis weight is 3600 g/m ² .

[Example 2] Base material layer: polyaramid fiber/heat-resistant felt fiber layer: POD fiber The felt material of Example 2 is prepared in the same manner as Example 1, except that a fiber mesh composed of POD fiber is used instead of a fiber mesh composed of polyaramid fiber when the felt fiber layer is formed. The felt material of Example 2 is schematically represented by FIG. 2.

The heat-resistant felt fiber layer of the felt material of Example 2 is formed by needle rolling the same fiber web (POD fiber). When the felt material is manufactured, the fiber web (POD fiber) on the base layer side is intertwined with the base layer, and then the same fiber web (POD fiber) is intertwined with the above fiber web to form a heat-resistant felt fiber layer. The heat-resistant felt fiber layer has a thickness of 12 mm and a basis weight of 4800 g/ ^m2 .

[Example 3] Base material layer: polyaramid fiber/Additional felt fiber layer: carbon fiber and polyaramid fiber (base material layer side)/Heat-resistant felt fiber layer: POD fiber (outermost side in the stacking direction) The felt material of Example 3 is prepared in the same manner as in Example 1, except that when forming the additional felt fiber layer, a fiber mesh (fiber length: 51 mm, fiber fineness: 2.2 dtex) containing 70% by mass of carbon fibers (trade name: PYROMEX (registered trademark), manufactured by Teijin Co., Ltd.) and 30% by mass of fiber mesh composed of polyaramid fibers are used instead of the fiber mesh composed of polyaramid fibers. The felt material of Example 3 is schematically represented by FIG. 1

The felt material of Example 3 comprises a laminated felt fiber layer composed of a heat-resistant felt fiber layer (POD fiber layer) and an additional felt fiber layer (carbon fiber layer). Of the two layers constituting the laminated felt fiber layer, the additional felt fiber layer is located on the base material layer side, and the heat-resistant felt fiber layer is located on the outermost side in the laminate direction of the felt material. The heat-resistant felt fiber layer has a thickness of 3 mm and a basis weight of 1200 g/m ² , and the additional felt fiber layer has a thickness of 9 mm and a basis weight of 3600 g/m ² .

[Example 4] Base material layer: POD fiber/Additional felt fiber layer: polyaramid fiber (base material layer side)/Heat-resistant felt fiber layer: POD fiber (outermost side in the stacking direction) The felt material of Example 4 is prepared in the same manner as Example 1, except that a yarn composed of POD fiber is used instead of a yarn composed of polyaramid fiber when forming the base material layer. The felt material of Example 4 is schematically represented by FIG. 1.

The felt material of Example 4 comprises a laminated felt fiber layer composed of a heat-resistant felt fiber layer (POD fiber layer) and an additional felt fiber layer (polyaramid fiber layer). Of the two layers constituting the laminated felt fiber layer, the additional felt fiber layer is located on the substrate layer side, and the heat-resistant felt fiber layer is located on the outermost side in the laminate direction of the felt material. The thickness of the heat-resistant felt fiber layer is 3 mm and the basis weight is 1200 g/m ² , and the thickness of the additional felt fiber layer is 9 mm and the basis weight is 3600 g/m ² .

[Example 5] Base material layer: polyaramid fiber/additional felt fiber layer: polyaramid fiber (base material layer side)/heat-resistant felt fiber layer: POD fiber (outermost side in the stacking direction) The felt material of Example 5 is prepared in the same manner as Example 1, except that the amount of the fiber net composed of POD fiber and the fiber net composed of polyaramid fiber used when forming the heat-resistant felt fiber layer and the additional felt fiber layer is set to half of that of Example 1. The felt material of Example 5 is schematically shown in FIG. 1.

The felt material of Example 5 comprises a laminated felt fiber layer composed of a heat-resistant felt fiber layer (POD fiber layer) and an additional felt fiber layer (polyaramid fiber layer). Of the two layers constituting the laminated felt fiber layer, the additional felt fiber layer is located on the substrate layer side, and the heat-resistant felt fiber layer is located on the outermost side in the laminated direction of the felt material. The thickness of the heat-resistant felt fiber layer is 1.5 mm and the basis weight is 600 g/m ² , and the thickness of the additional felt fiber layer is 4.5 mm and the basis weight is 1800 g/m ² .

[Comparative Example 1] Base material layer: polyaramid fiber/additional felt fiber layer: polyaramid fiber (base material layer side)/additional felt fiber layer: PI fiber (outermost side in the stacking direction) The felt material of Comparative Example 1 was prepared in the same manner as in Example 1, except that a fiber net (fiber length: 64 mm, fiber fineness: 6.7 dtex) composed of PI fiber (trade name: YILUN, manufactured by Changchun Hipolyking Co., Ltd.) was used instead of a fiber net composed of POD fiber when forming the additional felt fiber layer. The felt material of Comparative Example 1 is schematically shown in FIG. 12.

The felt material of Comparative Example 1 comprises a laminated felt fiber layer composed of an additional felt fiber layer (PI fiber layer) and another additional felt fiber layer (polyaramid fiber layer). Of the two layers constituting the laminated felt fiber layer, the polyaramid fiber layer is located on the substrate layer side, and the PI fiber layer is located on the outermost side in the laminate direction of the felt material. The additional felt fiber layer (PI fiber layer) has a thickness of 3 mm and a basis weight of 1200 g/m ² , and the other additional felt fiber layer (polyaramid fiber layer) has a thickness of 9 mm and a basis weight of 3600 g/m ² .

[Comparative Example 2] Base material layer: polyaramid fiber/Additional felt fiber layer: polyaramid fiber (base material layer side)/Additional felt fiber layer: polyaramid fiber (outermost side in the stacking direction) The felt material of Comparative Example 2 was prepared in the same manner as in Example 1, except that a fiber net (fiber length: 51 mm, fiber fineness: 3.8 dtex) composed of polyaramid fiber (trade name: TECHNORA (registered trademark), para-polyaramid fiber manufactured by Teijin Co., Ltd.) was used instead of a fiber net composed of POD fiber when forming the additional felt fiber layer. The felt material of Comparative Example 2 is schematically shown in FIG12 .

The felt material of Comparative Example 2 includes a laminated felt fiber layer consisting of an additional felt fiber layer (a layer of polyaramid fibers) and another additional felt fiber layer (a layer of polyaramid fibers). In addition, the two additional felt fiber layers are composed of different polyaramid fibers, and thus constitute independent additional felt fiber layers. Of the two layers constituting the laminated felt fiber layer, the polyaramid fiber (KEVLAR (registered trademark)) layer is located on the base material layer side, and the polyaramid fiber (TECHNORA (registered trademark)) layer is located on the outermost side in the laminated direction of the felt material. The additional felt fiber layer (polyaramid fiber (TECHNORA) layer) has a thickness of 3 mm and a basis weight of 1200 g/m ² , and the other additional felt fiber layer (polyaramid fiber (KEVLAR) layer) has a thickness of 9 mm and a basis weight of 3600 g/m ² .

[Comparative Example 3] Base material layer: polyaramid fiber/Additional felt fiber layer: polyaramid fiber (base material layer side)/Additional felt fiber layer: polyaramid fiber (outermost side in the stacking direction) The felt material of Comparative Example 3 was prepared in the same manner as in Example 1, except that a fiber net (fiber length: 51 mm, fiber fineness: 2.5 dtex) composed of polyaramid fiber (trade name: TOWARON (registered trademark), para-polyaramid fiber manufactured by Teijin Co., Ltd.) was used instead of a fiber net composed of POD fiber when forming the additional felt fiber layer. The felt material of Comparative Example 3 is schematically shown in FIG12 .

The felt material of Comparative Example 3 includes a laminated felt fiber layer consisting of an additional felt fiber layer (polyaramid fiber layer) and another additional felt fiber layer (polyaramid fiber layer). In addition, the two additional felt fiber layers are composed of different polyaramid fibers, so they constitute independent additional felt fiber layers. Of the two layers constituting the laminated felt fiber layer, the layer of polyaramid fiber (KEVLAR (registered trademark)) is located on the base material layer side, and the layer of polyaramid fiber (TOWARON (registered trademark)) is located on the outermost side in the laminated direction of the felt material. The additional felt fiber layer (polyaramid fiber (TOWARON) layer) has a thickness of 3 mm and a basis weight of 1200 g/m ² , and the other additional felt fiber layer (polyaramid fiber (KEVLAR) layer) has a thickness of 9 mm and a basis weight of 3600 g/m ² .

[Comparative Example 4] Base material layer: polyaramid fiber/additional felt fiber layer: polyaramid fiber The felt material of Comparative Example 4 was prepared in the same manner as in Example 1, except that a fiber net (fiber length: 51 mm, fiber fineness: 2.5 dtex) composed of polyaramid fiber (trade name: KEVLAR (registered trademark), para-polyaramid fiber manufactured by DuPont Toray) was used instead of a fiber net composed of POD fiber when forming the additional felt fiber layer. The felt material of Comparative Example 4 is schematically shown in FIG. 13 .

The additional felt fiber layer of the felt material of Comparative Example 4 is formed by needle rolling the same fiber web (polyaramid fiber). When the felt material is produced, the fiber web (polyaramid fiber) on the base layer side is intertwined with the base layer, and then the same fiber web (polyaramid fiber) is intertwined with the above-mentioned fiber web to form an additional felt fiber layer. The additional felt fiber layer has a thickness of 12 mm and a basis weight of 4800 g/m ² .

[Comparative Example 5] Base material layer: polyaramid fiber/additional felt fiber layer: polyaramid fiber (base material layer side)/additional felt fiber layer: PBO fiber (outermost side in the stacking direction) The felt material of Comparative Example 5 was prepared in the same manner as in Example 1, except that a fiber net (fiber length: 44 mm, fiber fineness: 1.7 dtex) composed of PBO fiber (trade name: XYRON (registered trademark), manufactured by Toyobo Co., Ltd.) was used instead of a fiber net composed of POD fiber when forming the additional felt fiber layer. The felt material of Comparative Example 5 is schematically shown in FIG. 12.

The felt material of Comparative Example 5 includes a laminated felt fiber layer composed of an additional felt fiber layer (a layer of PBO fibers) and another additional felt fiber layer (a layer of polyaramid fibers). Of the two layers constituting the laminated felt fiber layer, the layer constituting polyaramid fibers (KEVLAR (registered trademark)) is located on the substrate layer side, and the layer of PBO fibers (XYRON (registered trademark)) is located on the outermost side in the laminate direction of the felt material. The additional felt fiber layer (PBO fiber layer) has a thickness of 3 mm and a basis weight of 1200 g/m ² , and the other additional felt fiber layer (polyaramid fiber (KEVLAR) layer) has a thickness of 9 mm and a basis weight of 3600 g/m ² .

<Evaluation of heat wear reduction> Evaluation of heat wear reduction was performed on each felt material obtained in Examples 1 to 5 and Comparative Examples 1 to 5 according to the following method. In addition, in this specification, the "longitudinal" direction of the felt material and the "longitudinal" direction in the heat wear test refer to the direction parallel to the direction in which the base material layer and the like are moved in order to install the heat-resistant felt fiber layer by needle rolling when the felt materials of the embodiments and comparative examples are made. In addition, the "transverse" direction of the felt material and the "transverse" direction in the heat wear test refer to the direction perpendicular to the above-mentioned "longitudinal" direction and on the same plane.

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

[Felt material heating (dry heat exposure) conditions] ・Heating temperature: 300℃ ・Heating time: 20 hours ・Heating device: Asahi Scientific Co., Ltd. high temperature oven H-80

[Heating wear tester] The heating wear tester 500 shown in FIG. 14 fixes a wear element 520 on a test bench 510. The wear element 520 is configured to be heated to any temperature using a heater 511 provided in the test bench 510. With respect to such a heatable wear element 520, the outer surface of the heat-resistant felt fiber layer 10 located at the outermost side in the stacking direction of the felt material 1 as the test piece is supported by a supporting portion 530 in such a manner that the wear element 520 is in contact with the outer surface. Furthermore, a weight 540 is arranged on the felt material 1 on the opposite side of the wear element 520, thereby generating a predetermined load (stress) between the outer surface of the heat-resistant felt fiber layer 10 and the wear element 520. In this state, the felt material 1 is slid in the horizontal direction, i.e., the direction of the arrow in the figure, relative to the wear element 520, so that the outer surface of the heat-resistant felt fiber layer 10 in the felt material 1 is worn.

For the obtained test pieces, the heat wear test was carried out according to the above-mentioned testing machine and the following conditions, and the heat wear loss (mm) was calculated by the following formula. The results are shown in Tables 1~2. Heat wear loss = thickness before wear - thickness after wear

[Heating wear test conditions] ・Test (wear element) temperature: 400℃ (heated by heater) ・Number of reciprocating times of wear plate: 3000 reciprocations (50 reciprocations/min) ・Test piece sliding distance: 100mm ・Load: 1720g

[Table 1] Table 1 Heating (dry heat exposure) Embodiment 1 Embodiment 2 Embodiment 3 Embodiment 4 Embodiment 5 Heating wear loss (mm) without 1.3 1.2 1.2 1.3 1.3 have 1.0 0.9 1.2 1.1 1.2

[Table 2] Table 2 Heating (dry heat exposure) Comparison Example 1 Comparison Example 2 Comparison Example 3 Comparison Example 4 Comparison Example 5 Heating wear loss (mm) without 2.1 1.7 3.3 2.2 1.6 have 1.8 1.6 2.5 1.8 1.5

As shown in Table 1, the felt materials of Examples 1 to 5 show high heat resistance and durability. Such a felt material having high heat resistance and durability can be used as a conveying material, for example. In contrast, as shown in Table 2, the felt materials of Comparative Examples 1 to 5 show poor heat resistance and durability. (Industrial Applicability)

The felt material of the present invention has high heat resistance and durability, and therefore can be used as a conveying belt or conveying roller cover material when manufacturing aluminum extruded profiles, or a roller cover material of a molten galvanized steel plate production line (CGL), etc., to convey objects in a high temperature state.

1,100,200,300: Felt material 10: Heat-resistant felt fiber layer 10A: Additional felt fiber layer 20: Base material layer 110,210,310: Laminated felt fiber layer 120,220,320: Base material layer 500: Heating wear tester 510: Test bench 511: Heater 520: Wear element 530: Support part 540: Weight

FIG. 1 is a schematic diagram showing one aspect of a felt material in an embodiment of the present invention. FIG. 2 is a schematic diagram showing one aspect of a felt material in an embodiment of the present invention. FIG. 3 is a schematic diagram showing one aspect of a felt material in an embodiment of the present invention. FIG. 4 is a schematic diagram showing one aspect of a felt material in an embodiment of the present invention. FIG. 5 is a schematic diagram showing one aspect of a felt material in an embodiment of the present invention. FIG. 6 is a schematic diagram showing one aspect of a felt material in an embodiment of the present invention. FIG. 7 is a schematic diagram showing one aspect of a felt material in an embodiment of the present invention. FIG. 8 is a schematic diagram showing one aspect of a felt material in an embodiment of the present invention. FIG. 9 is a schematic diagram showing one aspect of a conveying belt material when an aluminum extrusion profile is manufactured using a felt material of an embodiment of the present invention. FIG. 10 is a schematic diagram showing one aspect of a conveying roller cover material when an aluminum extrusion profile is manufactured using a felt material of an embodiment of the present invention. FIG. 11 is a schematic diagram showing one aspect of a roller cover material in a continuous galvanized steel plate production line (CGL) using a felt material of an embodiment of the present invention. FIG. 12 is a schematic diagram showing a felt material of a comparative example. FIG. 13 is a schematic diagram showing a felt material of a comparative example. FIG. 14 is a schematic diagram showing the outline of the heating wear tester used in the heating wear test of the embodiment.

1: Felt material

10: Heat-resistant felt fiber layer

10A: Additional felt fiber layer

20: Base material layer

Claims (12)

A felt material comprises: a base material layer and a felt fiber layer, wherein, at least one layer of the felt fiber layer is a heat-resistant felt fiber layer containing at least one fiber selected from the group consisting of polystyrene oxadiazole fiber and polyoxadiazole fiber. The felt material of claim 1, wherein the heat-resistant felt fiber layer is located at the outermost side in the stacking direction. The felt material of claim 1, wherein the base layer contains at least one fiber selected from the group consisting of polyaromatic amide fiber, polyphenylene oxadiazole fiber, polyoxadiazole fiber, poly(p-phenylene benzobisoxazole) fiber and polyimide fiber. For example, the felt material in Request Item 1 has a thickness of 1mm~16mm. The felt material of claim 1, wherein the basis weight of at least one layer of the felt fiber layer is 350 g/m ² -5500 g/m ² . The felt material of claim 1, wherein the felt fiber layer further comprises an additional felt fiber layer. The felt material of claim 6, wherein the additional felt fiber layer contains at least one fiber selected from the group consisting of polyaromatic amide fiber, carbon fiber, poly(p-phenylene benzobis(azole)) fiber, polyimide fiber, fluorine fiber, glass fiber and polyphenylene sulfide fiber. The felt material as claimed in claim 1 is in the shape of a flat plate. The felt material in claim 1 is in the shape of a belt. The felt material of claim 1 is in a cylindrical shape. A transport material comprising the felt material of any one of claims 1 to 10. A method for manufacturing a felt material is a method for manufacturing a felt material according to any one of claims 1 to 10, which comprises the following steps (a) and (b) in sequence: (a) a step of disposing a fiber web composed of felt fibers on at least one side of the above-mentioned base material layer; (b) a step of forming the above-mentioned felt fiber layer adjacent to the above-mentioned base material layer by interlacing the above-mentioned fiber web with the above-mentioned base material layer.