JPS59204982A - Production of moldable and heat adhesible carpet material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a floor covering material having moldability and thermal adhesive properties useful as a floor covering material for automobiles.

Tufted carpets lined with a resin layer of polyolefin or polyolefin containing an inorganic filler such as calcium carbonate are generally used as laying materials for automobile interiors. However, such car vents lack cushioning properties and are expensive. Furthermore, in order to facilitate the installation of carpets into automobiles, it is necessary to mold the carpets to match the shape of the recesses in the automobile floor, but the carpet lacks moldability.

In order to improve these drawbacks, a carpet has been proposed in which needle-punch carpet is impregnated with rubber latex or synthetic resin emulsion, water is removed, and the carpet is molded under heat and pressure to match the shape of the recess in an automobile. Ta.

Carpets molded using the former rubber latex have good flexibility or elasticity and feel good to the touch and underfoot, but have poor moldability and shape retention, and the carpet is in poor condition when laid inside a car. Become something.

Carpets using a resin emulsion having a softening point of 80° C. or higher as a backing material are easy to install in automobile interiors, but they have high rigidity, lack elasticity, and have a strange texture and feel as a carpet. This method uses materials such as low-density polyethylene, ethyl/vinyl acetate copolymer, etc. for the purpose of providing a carpet with a good balance of elasticity and rigidity due to the resin emulsion being impregnated throughout the needle-punched base layer. A needle punch is impregnated with rubber latex in which a thermoplastic resin powder with a low melting point is dispersed, and after drying, it is molded under heat and pressure to provide shape retention with the thermoplastic resin, and a good feel due to the elasticity of the rubber. I would like to suggest a carpet. However, it is difficult to impregnate the base layer of the needle-punched carpet with powder, and it has the disadvantage that more powder than necessary must be blended.

As a measure to improve this, in order to impart moldability to raw rugs such as needle-punched carpet base fabrics, an aqueous emulsion of thermoplastic resin with a softening point of 80°C or higher is used as a backing material.
For example, a method has been proposed in which an aqueous emulsion of styrene (95% by weight)/n-butyl acrylate (5% by weight) copolymer is applied and impregnated onto the back side of the original rug, and then heated and dried to form a backing layer. and is being implemented.

This method is useful for imparting moldability to the original rug, but when bonding backing materials such as felt or resin foam sheets by heat, the adhesive strength between these backing materials and the backing layer may be reduced. It is weak, and the backing material often peels off when press molding to give a shape to the laying material.

The present inventors investigated the possibility that thermal adhesion would be improved by blending a thermoplastic resin powder such as polyethylene into this moldability-imparting resin emulsion and using this as a backing material. The surface of the resin powder is
It was found that the resin powder was coated with an aqueous emulsion resin having a softening point higher than the melting point of powder, making it difficult to perform the functions of the resin powder.

Next, an aqueous emulsion of a resin with a high softening point (SO ℃ or higher) is used as a first backing material that imparts moldability to the original rug, and an aqueous emulsion of an acrylic resin with a low softening point (below 10 ℃) is used as a first backing material. When we produced a laying material using it as a second backing material that imparts adhesive properties, we were unable to roll up the laying material because the second backing layer was sticky at room temperature. Second
It has been found that the laying material can only be rolled up after the backing layer has been lined with felt, foam sheet, jute cloth, etc.

The present invention has been made for the purpose of providing a laying material including a second backing layer having thermal adhesive properties that allows the laying material to be rolled up without such backing. That is, the present invention has moldability and thermal adhesiveness characterized by providing a first backing layer formed from an aqueous resin emulsion and a second backing layer having the following composition on the back side of the original rug. The first backing material, which provides a method for producing a stepped structure: A resin aqueous emulsion whose main component is an aqueous dispersion of a resin with a softening point of 80° C. Second banking material: (a), (g) Thermoplastic resin particles (b) having a melting point lower than the softening point of the resin in the aqueous emulsion and having a melting point of 60 to 125 ° C., having a melting point that is the same as or lower than the melting point of the resin particles of (a) above. An aqueous emulsion of a resin having a melting point of 50 to 125°C.However, the resin particles of (a) are (
It is blended in an amount of 50 to 250 parts by weight based on 100 parts by weight of the solid resin content in the aqueous emulsion b).

Any material can be used as the rug raw material for the laying material in the present invention, and raw materials made from various fibers such as natural fibers, chemical fibers, and synthetic fibers can be used.

In general, needle-punched carpets made from fibers such as wool, nylon, polyacrylonitrile, polyacetate, polypropylene, etc., tufted carpet fabrics in which piles are erected on a primary base fabric knitted with 7-rat yarns, and the above-mentioned needles are used. A tufted carpet material is used, with a punched carpet as the primary base fabric and a pile on top of the tufted carpet. Among these, inexpensive needle punch carpets are preferred for automobile interiors.

Next, the softening point (glass transition point Tg) of component (4), which provides moldability to the carpet as a backing material, is 80°C.
The emulsion containing the above resin aqueous emulsion as the main component (50 to 100% by weight) is (a), polypropyl methacrylate (Tg 81°C), polystyrene (100% by weight),
℃), polyacrylonitrile (100℃), polymethyl methacrylate (105℃), polymethacrylic acid (130℃)
Φ), as well as aqueous emulsions of homopolymers such as polyitaconic acid (130°C) and polyacrylamide (153°C).

50 to 100% by weight, preferably 65 to 95% by weight of vinyl monomers, which are raw materials for these polymers, and other copolymerizable vinyl monomers, such as 2-ethylhexyl acrylate ('pg - 85°C) , n-butyl acrylate (-54℃
), ethyl acrylate (-22℃), inopropyl acrylate (-5℃), 2-ethylhexyl methacrylate (
-5℃), n-propyl lbate (8℃), n-butyl methacrylate (20℃), vinyl acetate (30℃)
, ethyl methacrylate (65℃), vinyl chloride (79℃)
) etc. or an aqueous emulsion of a copolymer with vinylidene chloride (-18°C) 50% by weight or less, preferably 35 to 5% by weight (in this section (b), T shown in parentheses)
g is the glass transition point of these vinyl monomers or vinylidene chloride homopolymers), (c), 'I'
Resin aqueous emulsion at O~155°C 50~
Examples include a mixture of 97% by weight, preferably 55 to 95% by weight, and 50 to 3% by weight, preferably 45 to 5% by weight of an aqueous resin emulsion or rubber latex having a Tg of from 185°C to less than +80°C.

The resin solid content concentration in the aqueous emulsion of these backing materials is usually 20 to 60% by weight, and the diameter of the dispersed resin particles is 10μ (microns) or less, preferably 0%.
．． 05-1.0μ.

This aqueous emulsion, which is the first backing material, contains substances such as calcium carbonate, aluminum hydroxide, clay, talc, barium sulfate, etc., materials such as red iron oxide, titanium oxide, flame retardants, dyes, iron powder, oxidized Coating aids such as iron, toluene, mineral spirits, methyl ethyl cellulose,
A thickener such as polyvinyl alcohol, an antifreeze agent, an antifoaming agent, a dispersing agent, a foaming agent, a wetting agent, etc. may be added.

The aqueous emulsion is coated onto the fiber mat at a rate of 40-1.000 f/m' (solid content), preferably 100-400 f/J, and impregnated by nip rolls. , infrared heating machine,
The first backing layer is formed by heating and drying using a heating means such as a suction dryer or a hot air dryer at a temperature of 100 to 180° C. that does not cause fiber deterioration.

The above (7) is applied to the surface of the first backing layer thus formed.
A second backing material consisting of (a) thermoplastic resin particles having a melting point of 60 to 125°C and (b) an aqueous emulsion of a resin having a melting point of 50 to 125°C is applied at a rate of 20 to 2 oot/rr?
c solid content), preferably 40 to 100 t/rr? The second backing layer is formed by applying the second backing layer and drying it by heating at a temperature higher than the film-forming temperature of the aqueous emulsion (b).

Alternatively, after applying the first backing material to the back side of the original rug, the second backing material is applied on top of the first backing material without drying, and then (b) in the second backing layer is applied.
The conditions under which the aqueous resin emulsion forms a film are preferably (a
) The first backing material and the second backing material may be dried simultaneously by heating under conditions that melt the resin particles.

The second backing layer is formed by first forming a film of the aqueous resin emulsion (b), and then dissolving the resin particles (a). Therefore, it was formed earlier (b
Since the resin particles of (a) are fixed by the film of (a)
Even if the resin particles in (a) are not sufficiently dissolved, the particles in (a) are prevented from falling off. It is rare for the resin particles in (a) to dissolve and form a continuous film only with the resin particles in (a), but due to the difference in specific gravity, some of them aggregate on the film (sea) in (b). The resin particles dissolved or intact (a) appear scattered like islands.

In carrying out the present invention, the above (
The reason for using the hot melt resin particles (a) and the aqueous resin emulsion (b) will be described below.

That is, the resin particles of the emulsion (b) have a fine particle size of 10 microns or less, so if used alone, the thickness of the first backing layer would be very thick, and if it is not uniform, the resin particles will fill the voids between the fibers of the rug material. Like the resin of the first backing material, it gets stuck inside. Therefore, unless the amount of second backing material applied is significantly increased, adhesion to the backing material will deteriorate. In addition, when manufacturing the laying material continuously, the resin (b) alone has a low heat capacity, so it cools quickly and the adhesive strength with the backing material is small, so the backing material may peel off due to stress etc. when the laying material is taken off. There is a drawback that it can be damaged.

When only the hot melt resin particles (a) with a large particle size are used as the second backing material, the adhesive force with the backing material is sufficient, but due to the large particle size, the adhesion to the rug side is not sufficient and it falls off. There is a shortcoming. Therefore, in the present invention, the above-mentioned effects are exhibited by using a second backing material that uses both resins (a) and (b) in combination. That is, we expect (a) adhesion to the backing material due to the large particle resin, and (6) adhesion effect to the laying material due to the fine particle resin.

The resin particles of component (a) of the second backing material include low density polyethylene (melting point 105 to 121°C), atactic polypropylene (melting point 75 to 80°C), and ethylene/vinyl acetate copolymer (melting point 70 to 100°C). ℃), polyamide resin for hot melt materials (90 to 120℃), and other resins used as hot melts (petroleum resins, terpene resins, rosin resins, polyesters), etc. whose melting point is 6.
Examples include resin particles having a temperature of 0 to 125°C. The particle size of the resin particles is 50 to 1,000 microns, which is larger than the particle size of the resin particles of the aqueous emulsion (b).

These resin particles are selected from resins that have a film-forming temperature lower than the softening point (glass transition point) of the resin of the emulsion that is the first backing material, preferably 10°C or more lower (in the present invention, Both the softening point and the melting point refer to the maximum temperature at which the pronation peak is obtained using a differential thermal analyzer.

41 If the melting point of the resin particles in (a) is higher than the softening point of the emulsion of the first backing material, felt,
In order to obtain high adhesive strength to a backing material such as a foamed resin sheet, it is necessary to heat the backing material to a high temperature when adhering these backing materials, and the backing material will rupture over a long period of time when cooled.

The melting point of (b) above is 50 to 125°C (JIs K-59
03) Aqueous emulsion of resin L-11: Examples include aqueous emulsion of resin such as terpene resin, terpene-phenol copolymer, petroleum resin, and rosin. this(
The aqueous resin emulsion b) contains an organic surfactant such as unitoluene, xylene, ethylcelonorp, mineral spirit, etc., so that the emulsion has a film-forming temperature lower (preferably 10°C or more lower) than the melting point of the resin particles (&); Coating aids such as plasticizers such as dibutyl octyl phthalate may also be blended. Addition of this film-forming aid improves the film-forming properties of the emulsion (b). In addition, this film-forming agent is volatile and the amount remaining in the formed film is extremely small, so the adhesive strength with the backing material such as the second backing material Tofel will not decrease. Examples of resins include alkylstyrene indene resins, resins obtained by heating and polymerizing petroleum-based unsaturated hydrocarbons and/or cyclopentadiene in the presence of catalysts such as sulfuric acid, anhydrous aluminum chloride, and borofluoride; water additives etc. can be used. Examples of the rosin include processed rosins such as abietic acid rosin, water additives thereof, maleic acid adducts thereof, metal salts, and esterified products with alcohols such as glycerin, pentaerythritol, ethylene glycol, and diethylene glycol. In addition, terpene resins include α-pinene, β-pinene,
Homopolymers such as dipentene or copolymers thereof, terpene/phenol copolymers, α-pinene/phenol copolymers, and water additives thereof are used.

Methods for producing emulsions of these petroleum resins, rosin resins, and terpene resins are described in JP-A-56-78623, JP-A-56-87421, JP-A-56-159244, and JP-A-57.
Since it is described in patent publications such as No.-125255,
The explanation will be omitted here. As for the product names, the petroleum resin emulsion is Toho Oil Resin ■ 75 Emulsion.
90 emulsion people, ND-10 (both prototypes),
Harinister DS-70L, DS, 70E1DS-9 from Harima Kasei Kogyo ■ are used as emulsions of rosin resin.
Examples include 0E or Bar Size E Nl-305, Bar Size EM-505, and Emax 800 (prototype) manufactured by Ayasu Oil Co., Ltd., which is an aqueous emulsion of a terpene resin. In the aqueous emulsions and emulsions of these petroleum resins, rosin resins, and terpene resins, the average particle diameter of the dispersed resin is generally 0.03 to 3 μm or less.
micron, and the solid content concentration is 20 to 65% by weight.

The original melting point of the resin in the aqueous emulsion (b) is (
It is important that the melting point is equal to or lower than the melting point of the resin particles in L). When the resin particles in (a) have a higher melting point than the resin in (a), the surface of the resin particles in (a) exhibits a higher melting point (b)
Since the resin particles of 0(a) are covered with a film of the resin of the emulsion of In order to effectively exhibit the adhesive strength of the hot melt adhesive to the laying material during continuous collection of the laying material, the aqueous resin emulsion (b) must have an original melting point equal to or equal to the melting point of the resin particles (a). It is necessary to make it lower.

Furthermore, in order to improve the adhesion of the resin particles (a) to the laying material, the resin emulsion (b) must have a film forming temperature of (a
It is important that the temperature is 10°C or more lower than the melting point of the resin particles. Therefore, it is useful to blend the above-mentioned plasticizer or organic solvent as a film-forming aid into the resin emulsion (b) in a proportion of 1 to 10% by weight to lower the film-forming temperature.

In the second bucking material, the blending ratio of (a) resin particles and (b) resin aqueous emulsion is 50 to 250 parts by weight of (a) resin particles per 100 parts by weight of resin in the aqueous emulsion (b). parts, preferably 75 to 150 parts by weight. If the amount is less than 50 parts by weight, the effect of adding resin particles to further improve the adhesion of the second layer to the backing material will be small.On the other hand, if it exceeds 250 parts by weight, the storage of the second layer will be less effective. (a) Percentage of resin particles that are unstable, causing resin particles to float to the surface, or falling off from the laying material during and after the formation of the backing layer by heating and drying after applying the second backing material. will increase.

In addition, the second bucking material contains the first buckling agent (like the buckling material, a film forming aid, a thickener, a dispersant, an antifreeze agent, a coloring agent, a pigment, a wetting agent, an extender pigment, and an antifoaming agent. , a flame release agent, etc. may be added within a range that does not significantly change the original quality.

The laying material produced in this way has moldability and thermal adhesiveness, and can also be rolled up and stored before bonding with the backing material.

Examples of the backing material include felt, jute cloth, foamed polyethylene sheet, foamed polyvinyl chloride sheet, foamed polypropylene sheet, foamed ethylene/acetic acid U-scented vinyl sheet, and foamed polystyrene sheet.

After heating and melting the second backing layer, these backing materials are pressed and bonded to the second backing layer with a roll. When press forming the laying material, the first backing layer, the second
After heating to a state where both resins of the backing layer are melted and softened, a backing material is laminated, and then a shape is given by compression molding using a press mold. Furthermore, adhesion of the backing material and the second backing material and shaping of the laying material can be performed simultaneously in the press mold.

The multi-layered laying material manufactured in this way is bent, cut, and sewn as necessary to give a shape suitable for laying.

Further, it is also possible to perform molding at the same time as adhering each layer.

The present invention will be explained in more detail below using actual manufacturing examples.

Example 1 Manufacture of needle-punched nonwoven fabric 915 denier,
Cards made of recovered polyethylene terephthalate fiber waste with a fiber length of 75 to 125% were randomly stacked, and then the cards (weighing weight 650 f/n?) were stacked at 15-18-32-3.
Needling was performed using RB needles at a rate of 50 needles per square inch to obtain a fiber mat.

An aqueous emulsion obtained by emulsion polymerization of styrene (80% by weight) and n-butyl acrylate (20% by market weight) on this needled fiber mat [average particle size of resin 2 microns, solid content 50%] , softening point: 120° C.] was applied using a licker roller to give a solid content of 250 l/l, and then the entire fiber mat was impregnated with the emulsion using a nip roll.

Next, this was heated at 140°C to remove moisture, and the first
A backing layer was formed.

A second backing material having the following composition (film forming temperature: 20°C) was added on top of this first backing material at a solid content of 601/rrl.
The second backing layer was formed by applying and drying with a hot air dryer at 140° C. for 10 minutes to obtain a laying material.

(a) 2 100 parts by weight of low-density polyethylene particles with a melt index of zor/lo, a melting point of 108° C., and passed through a 60-mesh sieve (“Frocene MG-801”, trade name of Seitetsu Kagaku Kogyo) (b), Toho Oil Resin ■Produced petroleum resin aqueous emulsion”
ND-10'' (trade name, resin softening point 80°C, solid content concentration 57% by weight, average particle size 1 micron) 100 parts by weight (c), 3 parts by weight of luene This second backing layer was heated at 20°C It did not show any stickiness.

The laying material was heated to 180°C from the second backing layer side using a heater to melt the resin of the first backing layer and the second backing layer, and then a felt with a wall thickness of 10 mm was added to the second backing layer. The material was brought into contact with a roller using a roll, and then compression molded using a press mold to obtain a laying material having a desired shape (shape).

This shaped laying material was evaluated for shape retention, adhesive strength between the felt and the second backing layer, and prevention of powder (a) from falling off by the following methods.

The results are shown in Table 1.

Evaluation method (1) Shape retention: Place the molded laying material on a model with the same shape as the male mold of the press mold, leave it in a room at 85°C for one day, and check whether there is any misalignment between the model and the laying material. 0. Those with no deviation were evaluated as good (0), and those with two or more deviations were evaluated as poor (x).

(2) Adhesive strength to felt Cut out 5 sample pieces with a width of 30 ffll + 1 length of 250 ul from the molded laying material, and further 2 cITt each from one end.
Cut out only the felt side across the width, then fix one end of the non-woven fabric side with your hand, grab the felt with the other hand,
When the felt was peeled off, a case where the felt layer peeled off was judged as good adhesion (O), and a case where it peeled off between the felt and nonwoven fabric was judged as poor adhesion (x). Further, when both cases occurred, it was defined as normal (Δ).

(3) Preventing powder from falling off When adhesive tape (Cello tape (trade name manufactured by Chiban)) was applied to the second backing layer of the laying material before press molding and then peeled off, powder adhered to the adhesive soup. We evaluated the degree of

◎ Not at all ○ Somewhat (10 worries 4 or less) Δ
Slightly high × Very high Example 2 Instead of the needled fiber mat, a Fujira drag rug original fabric obtained by embroidering nylon on a primary base fabric made of polypropylene flat yarn knitted in a lattice pattern was used. A laying material was obtained in the same manner as in Example 1, except that a second backing material was applied by a foam coating method to prevent impregnation of the backing material.

Table 1 shows the performance of this laying material.

Examples 3 to 7, Comparative Examples 1 to 7 Laying materials having the performance shown in Table 1 were obtained in the same manner as in Example 1, except that the material shown in Table 1 was used as the second backing material.

(Margin below)

Claims (1)

[Claims] 1) Formability and thermal adhesion characterized by providing a first backing layer formed with an aqueous resin emulsion and a second backing layer having the following composition on the back side of the original rug fabric. First backing material (2): Resin aqueous emulsion whose main component is an aqueous dispersion of a resin with a softening point of 80°C or higher.Second backing material: Aqueous (a) and (2). Thermoplastic resin particles (b) having a melting point lower than the softening point of the emulsion resin and having a melting point of 60 to 125°C; and an aqueous emulsion of a resin having a melting point of 50 to 125°C.However, the resin particles of (a) contain 50 to 250 parts by weight per 100 weight parts of the resin solid content in the aqueous emulsion of (b). 2) The resin aqueous emulsion has a softening point of +80°C.
~+155°C resin aqueous emulsion 55-95% by weight
and 45-5% by weight of an aqueous resin emulsion or rubber latex with a softening point of 185°C to less than +80°C. 3), the first backing layer has a weight ratio of 60~x,ooof/-, the second backing layer has a weight ratio of 20~2009/d
2. The method for manufacturing a laying material according to claim 1, wherein the laying material is provided at a weight ratio of . 4) The thermoplastic resin particles (a) in the second backing material have a particle size of 50 to 1,000μ, and the resin in the aqueous resin emulsion (b) has a particle size of 10μ or less. A method for manufacturing a laying material according to claim 1, characterized in that: