Laminated body and process for producing the same

Patent metadata

Field	Value
Publication number	US-10279561-B2
Application number	US-201414777934-A
Country	US
Kind code	B2
Filing date	Mar 25, 2014
Priority date	Mar 26, 2013
Publication date	May 7, 2019
Grant date	May 7, 2019

Abstract

A laminated body that exhibits heat resistance, chemical resistance, good interfacial adhesion, good varnish-impregnation and also has a three-dimensional formability and results in low variability in the shapes of the products in a forming process and an excellent forming process yield. The laminated body includes a thermoplastic resin sheet layer having a heat of crystallization of 10 J/g or more and a wet-laid nonwoven layer including polyphenylene sulfide fibers and having a heat of crystallization of 10 J/g or more, the wet-laid nonwoven layer being stacked on at least one surface of the thermoplastic resin sheet layer without an adhesive therebetween.

First claim

The invention claimed is:

1. A laminated body consisting of:
a thermoplastic resin film comprising polyphenylene sulfide fibers and having a heat of crystallization of 10 J/g or more as measured with a differential scanning calorimeter; and
a wet-laid nonwoven layer comprising polyphenylene sulfide fibers and having a heat of crystallization of 10 J/g or more as measured with a differential scanning calorimeter;
wherein the wet-laid nonwoven layer is stacked on at least one surface of the thermoplastic resin film without an adhesive therebetween, and a heat of crystallization Q 1 of the thermoplastic resin film as measured with a differential scanning calorimeter and a heat of crystallization Q 2 of the wet-laid nonwoven layer as measured with a differential scanning calorimeter satisfy; 0.5<Q 1 /Q 2 <2.0, and
the laminated body is thermoformable and capable of being deep drawn at a draw ratio of depth to a diameter of 0.7 or more, or a ratio of the number of inspected and passed products to the total number of formed products of deep drawing at a draw ratio of depth to a diameter of 0.5 is 95% to 100%.

2. The laminated body according to claim 1 , wherein the polyphenylene sulfide fibers constituting the wet-laid nonwoven layer comprise 80 to 100% by mass of unstretched polyphenylene sulfide fibers and 20 to 0% by mass of stretched polyphenylene sulfide fibers.

3. The laminated body according to claim 1 , wherein the heat of crystallization Q 1 and the heat of crystallization Q 2 satisfy: 0.8 <Q 1 /Q 2 <1.3.

4. The laminated body according to claim 2 , wherein the heat of crystallization Q 1 and the heat of crystallization Q 2 satisfy: 0.8 <Q 1 /Q 2 <1.3.

5. The laminated body according to claim 1 , wherein the heat of crystallization Q 1 and the heat of crystallization Q 2 satisfy: 0.96 <Q 1 /Q 2 <1.21.

6. The laminated body according to claim 2 , wherein the heat of crystallization Q 1 and the heat of crystallization Q 2 satisfy: 0.96 <Q 1 /Q 2 <1.21.

Assignees

• Toray Industries

Inventors

• Naruko Satoshi
• Kimura Takashi
• Kamiya Tatsushi
• Masegi Takahiro
• Kondo Shinichi

Classifications

• B32B2262/00

  Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives · CPC title

• B32B27/06

  as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} · CPC title

• B32B2274/00

  Thermoplastic elastomer material · CPC title

• B32B5/08

  the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres} · CPC title

• B32B2262/02

  Synthetic macromolecular fibres · CPC title