JP2747440B2 - mat - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mat suitable for use as, for example, a leisure seat, in addition to a mat for laying a car and a mat for mounting a car.

[0002]

2. Description of the Related Art In a car, a piece-like mat is sometimes laid at the feet of a driver or a passenger. Such laying mats are required to have good flexibility and elasticity, especially for the backing layer, so as to be able to provide comfort to the drivers, and to prevent unintended misalignment. A predetermined frictional force (slip resistance) is required for the laying surface. In addition, it is required to be impermeable to water so as to avoid the adverse effect of absorbing water from the laying surface. However, in the car,
Since the temperature inside the vehicle changes more than expected depending on the parking position, etc., in the case of the car mat as described above, -30 ° C.
Development under severe conditions is being promoted so that the above properties can be maintained under a severe temperature environment of about + 90 ° C.

Conventionally, resin compositions for backing carpets and mats include synthetic rubbers such as polyvinyl chloride, styrene butadiene rubber latex (SBR latex), and the like.
Those containing natural rubber, polyethylene, ethylene-vinyl acetate copolymer or the like as a main component are generally used.

[0004] Of these, the most widely used polyvinyl chloride compositions generate a large amount of harmful hydrogen chloride gas during combustion, and thus cause environmental pollution when burning in waste treatment, and have recently become a social problem. It is not preferable in terms of environmental problems. Moreover, the elasticity and flexibility of this composition are relatively easily affected by the ambient temperature, and it is difficult to maintain good physical properties in a high temperature environment or a low temperature environment. And it is somewhat uneasy in terms of durability and weather resistance.

In the case of using synthetic rubber such as SBR latex or natural rubber, it is necessary to carry out a cross-linking reaction in the step of forming the backing layer, which increases the number of steps and makes production difficult. This leads to an increase in cost. Further SB
The one made of R latex easily permeates moisture and has a problem in terms of water impermeability.

Further, those using polyethylene or an ethylene-vinyl acetate copolymer are inferior in flexibility, difficult to follow the laying surface and inferior in laying stability, have low frictional resistance to the laying surface, and have poor slip resistance. It has the disadvantage of being inferior.

[0007] While the above description has been directed to a mat for a car, leisure mats (leisure sheets) and the like used outdoors are rarely used under such severe temperature conditions. There is no difference that it is advantageous to be able to cope with a certain degree of temperature change. In addition, in the leisure sheet, if the fold formed by folding at the time of storage remains at the time of unfolding, good laying stability and the like cannot be obtained. Required.

The present invention has been made in view of the above circumstances, and can prevent the generation of harmful gas during combustion. In addition, the physical properties such as elasticity, flexibility and slip resistance are affected by the influence of the ambient temperature. It is hard to be affected, maintained in a good condition even under severe temperature environment, and is excellent in non-permeability and bending recovery,
An object of the present invention is to provide a mat which can be easily manufactured at low cost and which can be suitably used as, for example, a laying mat for a car or a leisure mat.

[0009]

Means for Solving the Problems As a result of intensive studies, the present inventors have found that a mat capable of achieving the above object can be provided by blending specific components.

That is, in the mat of the present invention, the backing layer provided on the back surface of the fiber-based fabric has a first blend component of 30 to 50% by weight of a styrene-based thermoplastic elastomer having a styrene-based monomer content of 10 to 50% by weight. A second blend component comprising 90% by weight and one or more selected from an ethylene-propylene-diene terpolymer, an ethylene-vinyl acetate copolymer, and an olefin-based polymer A gist comprising a composition containing 1 to 30% by weight.

In the present invention, the first blend component is one or more selected from polystyrene / polybutadiene / polystyrene block copolymer, polystyrene / polyisobrene / polystyrene block copolymer, and hydrogenated product thereof. It is preferable to adopt a configuration composed of two or more types.

In the present invention, the composition may contain one or more selected from calcium carbonate, aluminum hydroxide, magnesium hydroxide, barium sulfate, calcium silicate, calcium sulfate, magnesium phosphate, and titanium oxide. It is preferable to adopt a configuration in which two or more inorganic compounds are contained in an amount of 70% by weight or less.

The backing layer of the mat of the present invention comprises a resin composition comprising a first blend component comprising a styrene-based thermoplastic elastomer, an ethylene-propylene-diene terpolymer, and ethylene-vinyl acetate. It comprises a copolymer and a second blend component of one or more selected from olefin polymers at a specific ratio. Since these blend components do not contain halogen, they do not generate harmful gases at the time of combustion as in the case of using conventional general-purpose vinyl chloride resins, and have low smoke emission. In addition, the combination of the first and second blend components imparts various properties such as flexibility, elasticity, and slip resistance as a mat,
Further, their physical properties are hardly affected by the ambient temperature, are maintained even in a severe temperature environment, and are excellent in water impermeability and bending recovery. In addition, since the above composition has excellent moldability by melt extrusion, it can be easily formed into a sheet by a general extruder such as a T-die without any trouble. By crimping, it is possible to easily manufacture a mat or a leisure sheet for a car.

In the present invention, as the styrene-based thermoplastic elastomer of the first blend component, specifically, a block copolymer (SBS) of polystyrene / polybutadiene / polystyrene, polystyrene / polyisobrene / polystyrene, etc.
Block copolymer of polystyrene (SIS), block copolymer of polystyrene / poly (ethylene / butylene) / polystyrene obtained as a hydrogenated product of SBS (S
EBS) and polystyrene / poly (ethylene / propylene) / polystyrene block copolymer (SEPS) obtained as a hydrogenated product of SIS, and the like. More than one species may be used in combination. Of these,
It is desirable to use SBS and / or SIS in terms of economy. Further, it is necessary to use the first blend component having a styrene-based monomer content of 10 to 50% by weight, with the lower limit being 20% by weight or more and the upper limit being 4% by weight.
Those having 0% by weight or less can be suitably used. If this content is low, the formability by extrusion deteriorates. If the content is less than the above specified value, the extrusion molding as a backing sheet becomes difficult, and the heat resistance is reduced, and the surface of the extruded sheet becomes rough. Is not preferred. Conversely, when the content of the styrene monomer is high, the rigidity is high, and when the content exceeds the above specified value, it is not preferable because sufficient flexibility and elasticity cannot be obtained as a backing layer.

The first blend component must be contained in the composition as the backing layer in an amount of from 30 to 90% by weight. Among them, those having a lower limit of 40% by weight or more and an upper limit of 70% by weight or less are preferably used. Can be used. If the content is too small, the molding processability as a backing sheet deteriorates and extrusion molding becomes difficult, which is not preferable. On the other hand, if the amount is too large, extrusion molding becomes difficult, and the heat resistance is reduced, and the surface of the extruded sheet may be roughened, which is not preferable.

On the other hand, in the present invention, ethylene, propylene and a diene compound (1 ·
Terpolymers (EPDM) of 4-hexadiene, dicyclomentadiene, etc.), copolymers of ethylene and vinyl acetate (EVA), and one or more kinds selected from olefin polymers. You need to use something.

Specific examples of the olefin-based polymer include crystalline polyethylene such as low-density polyethylene (LDPE) and linear polyethylene (LLPE), and crystalline polypropylene.

The second blend component must be contained in the composition in an amount of 1 to 30% by weight in order to improve moldability and heat resistance, and preferably has a lower limit of 2% by weight or more and an upper limit of 2% by weight. Is preferably contained at 20% by weight or less.

More specifically, when EPDM is contained in the second blend component, the content of EPDM in the composition is 1 to 30% by weight, preferably the lower limit is 2% by weight or more, and the upper limit is 20% by weight. % By weight or less. If the content is too small, the heat resistance may be reduced, and the extruded sheet may be roughened.If the content is too large, sufficient elasticity and flexibility cannot be obtained as the extruded sheet.
Not preferred.

Further, when EVA is contained in the second blend component, the content of EVA in the composition is 1 to 30% by weight,
Preferably, the lower limit is 2% by weight or more, and the upper limit is 20% by weight.
It is better to do the following. If this content is too small, the moldability deteriorates, and extrusion molding may become difficult,
Conversely, if the amount is too large, the extruded sheet may be rough due to a decrease in heat resistance, which is not preferable.

When the second blend component contains an olefin polymer, its content in the composition is from 1 to 3
The lower limit is preferably 2% by weight or more and the upper limit is preferably 20% by weight or less. If the content is too small, the heat resistance may be reduced, and the extruded sheet may be rough.If the content is too large, sufficient elasticity and flexibility cannot be obtained as the extruded sheet. Not preferred. When a polypropylene-based polymer is used among the olefin-based polymers, excellent heat resistance can be obtained although the flexibility is inferior to that of the polyethylene-based polymer.

The composition of the present invention may contain an inorganic compound, if necessary, in addition to the above-mentioned first and second blend components, in order to improve economy, rigidity, and the effect of increasing the amount. good. As the inorganic compound, for example, calcium carbonate, aluminum hydroxide, magnesium hydroxide, barium sulfate, calcium silicate, calcium sulfate, magnesium phosphate, titanium oxide, etc., can be used those used in ordinary plastic molding techniques, among these In particular, it is recommended to use calcium carbonate as a main component in view of economy and moldability.

The content of the inorganic compound in the composition is 7
It is good to be 0% by weight or less, preferably 60% by weight or less.

When the composition of the present invention is used as a backing material for a leisure sheet, the amount of the above-mentioned inorganic compound to be mixed is preferably small in order to reduce the weight.

The composition of the present invention may contain a plasticizer such as DOP, if necessary, in order to obtain good moldability.
You may make it contain in the range of 0 weight% or less.

Further, in the present invention, various additives such as a lubricant, a softener, a coloring agent, an antistatic agent and the like used in general plastic molding techniques can be appropriately compounded as required. It is.

On the other hand, the fibrous fabric in the present invention is not particularly limited, and any fabric can be used. For example, in addition to fabrics made by weaving yarns made of polyester fiber, nylon fiber, polypropylene fiber, acrylic fiber, etc., various fibers and yarns are mechanically bonded by a needle punch or the like, or chemically bonded by an adhesive or the like. Non-woven fabrics and the like bonded to can be used.

The fabric may be a pile fabric having a pile layer formed on the surface thereof or a flat fabric having no pile layer formed thereon. When the pile layer is formed, the pile material is not particularly limited, and those made of the above fibers can be suitably used. The means for forming the pile layer is also not particularly limited. And a means for forming a pile layer by bonding pile yarns using an adhesive.

When the present invention is applied to a leisure mat, the fabric is not directional and has a good folding recovery property, for example, a needle-punched nonwoven fabric made of polyester fiber so that the folding storage can be performed without any trouble. It is preferable to use
It is even more preferable to use one having a mm and a basis weight of about 100 to 500 g / m ² .

In addition, a thin nonwoven fabric having a basis weight of 5 to 70 g / m ² may be bonded to the backing layer for appearance of the backing resin, protection and reinforcement of the resin layer.

In the present invention, a mat is obtained by using, for example, the following method using a composition comprising the first and second blend components and an inorganic compound, a plasticizer, and additives to be blended as required. . That is, the above composition is mixed with a suitable mixer such as a Henschel mixer or a Banbury mixer, and the mixture is used as a molding material, or the mixture is pelletized to obtain a molding material. Alternatively, the above composition is used as a molding material as it is (direct blending method), or the above composition is mixed by a mixer such as a tumbler blender, and the mixture (dry blend pellets) is used as a molding material.

Subsequently, the above-mentioned molding material is extruded using a single-screw or twin-screw extruder equipped with a T-die or the like, and before the sheet is cooled and solidified, the T-die exit is formed. The back surface of the fibrous fabric is continuously coated as a backing layer by a pressure roll or the like installed adjacent to the base material to obtain a mat (extrusion lamination method). Alternatively, after the extruded backing sheet is cooled and solidified, one side of the sheet is melted and heated, and the melted surface is bonded to the back surface of the fibrous fabric to obtain a mat.

In the case of manufacturing a mat with a pile, such as a mat for automobiles, in the coating of the backing layer, it is necessary to ensure sufficient flexibility and elasticity, etc., and to make sure that sealing is performed. In addition, the coating amount of the backing layer is made relatively thick, specifically, 800 to 2000 g /
m ² , preferably the lower limit is 1000 g / m ² or more, and the upper limit is 1800 g / m ² or less. Also, when manufacturing mats without piles, such as leisure sheets, while ensuring good flexibility and elasticity,
The coating amount of the backing material may be the minimum necessary so as not to impair the lightness, specifically, 200 g / m ² or more, preferably 300 g / m ² or more, and 800 g / m ² or more.
g / m ² or less.

On the other hand, in the present invention, it is also possible to obtain a mat by cooling and solidifying the backing sheet extruded as described above, and then bonding the sheet to the back surface of the fibrous fabric by hot pressing. . However,
In this method, the fiber-based fabric may be thermally degraded at the time of reheating (at the time of hot pressing). Therefore, it is preferable to employ the extrusion lamination method.

[0035]

EXAMPLES Examples of the present invention and comparative examples for deriving the effects will be described below. In the following description, “%” means “% by weight”.

<Materials Used> In carrying out the examples and the like,
The following materials were prepared.

1. First blend component SBS: block copolymer of polystyrene / polybutadiene / polystyrene (styrene content: 35%) SIS: block copolymer of polystyrene / polyisobrene / polystyrene (styrene content: 17%) SEBS: polystyrene / poly ( 1. Ethylene / butylene / polystyrene block copolymer (styrene content 30%) Second blend component EPDM: ethylene content 20%, propylene content 40
% Ethylene / propylene / diene compound random terpolymer EVA: ethylene / vinyl acetate copolymer with ethylene content of 72% PE: low density polyethylene 3. Plasticizer and inorganic compound DOP: di-2-ethylhexyl phthalate Charcoal: calcium carbonate (average particle diameter 7.41 μm) Other backing materials ・ PVC: polyvinyl chloride ・ SBR: styrene / butadiene rubber latex <Fibrous fabric to be used> In carrying out the examples, a needle-punched nonwoven fabric made of polyester fiber (thickness: 1)
Polyester fiber yarns were planted on the surface of 100 mm / m ^{2 (} mm, basis weight) by a tufting machine to prepare a loop pile type mat substrate (fiber-based fabric) having a pile basis weight of 400 g / m ² .

<Example 1>

[Table 1] As shown in Table 1 above, SBS 64%, EPDM 16%,
Using a twin-screw extruder equipped with a T-die, a composition containing 20% of charcoal was added to a composition having a thickness of 0.5 mm and a width of 2000 mm.
Before extrusion-molding the backing molded sheet, and before cooling and solidifying the sheet, the back side of the fabric is continuously coated with a basis weight of 500 g / m ² as a backing layer by a pressure roll installed adjacent to the die outlet. Then, a continuous mat was obtained, which was cut to obtain a sample as a leisure mat (leisure sheet) of 600 mm × 900 mm.

<Example 2> SBS 64%, EPDM8
%, 8% PE, and 20% charcoal blended,
A sample as a leisure mat was obtained in the same manner as above.

Example 3 67% SBS, EPDM8
%, EVA 10%, DOP 5%, and charcoal 10% were used, and a sample as a leisure mat was similarly obtained.

<Embodiment 4> 46% SBS, EPDM10
%, DOP 4%, Charcoal 40%, and a car mat (lay-on mat) in the same manner.
As a sample.

<Embodiment 5> 45% SBS, EVA10
%, PE 5%, DOP 5%, and charcoal 35% were used to obtain a sample as a mat for an automobile.

<Example 6> SBS 50%, EVA 5%,
Using a composition containing 10% PE and 35% charcoal, a sample as an automobile mat was similarly obtained.

<Example 7> SIS 70%, EVA 5%,
Similarly, a sample as a leisure mat was obtained using a composition containing 5% of PE and 20% of charcoal.

Example 8 SIS 40%, EPDM25
%, And a sample as an automobile mat was obtained in the same manner using a composition containing 35% of charcoal.

Example 9 SEBS 45%, EPDM2
Using a composition containing 0%, 5% DOP, and 30% charcoal, a sample as an automobile mat was similarly obtained.

<Comparative Example 1> SBS 60%, charcoal 40%
A sample as an automotive mat was obtained using the composition containing

Comparative Example 2 EVA 60%, charcoal 40%
Similarly, a sample as an automobile mat was obtained by using the composition of Example 1.

<Comparative Example 3> Using a composition of 60% PE and 40% charcoal, a sample as an automobile mat was similarly obtained.

Comparative Example 4 PVC 50%, DOP 30
%, And a composition as a mat for leisure was obtained using a composition of 20% by weight of charcoal.

<Comparative Example 5> A composition comprising 60% SBR (solid content) and 40% charcoal was coated on the back surface of the above fiber-based fabric at a coating amount of 400 g / m ² (solid content) by a roll coater. Then, a sample as a leisure mat was obtained.

<Evaluation> In each of the above samples, the following measurements were performed to evaluate the respective characteristics.

1. Flammability The amount of generated hydrogen chloride gas was measured by the NBS (National Bureau of Standards) flammability test method, and those that did not generate were evaluated as “○”, and those that generated were evaluated as “x”.

2. Elasticity Measure the tensile modulus in accordance with JIS K 6301,
Those with 200 kgf / cm ² or less are marked with “○”, and those exceeding 200 f / cm ²
A sample having a particle size of not more than 000 f / cm ² was evaluated as “の も の”, and a sample having a density exceeding 1000 f / cm ² was evaluated as “×”.

3. Flexibility A flexibility test was carried out in accordance with JIS L 1096, and those having a measured value of 4.0 kgf / cm ² or less were evaluated as “O”,
Those with more than 4.0 f / cm ^{2 and 5} f / cm ² or less are marked with “△” and 5 f / cm ²
The super-large ones were evaluated as "x".

4. Slip resistance The coefficient of friction was measured in accordance with the friction coefficient test for plastic films and sheets of JIS K 7125, and was determined to be 7.0.
Those with kgf or more were evaluated as “O”, those with less than 7.0 kgf or more as 5.0 kgf were evaluated as “Δ”, and those with less than 5.0 kgf were evaluated as “x”.

5. Non-water-permeability A waterproof test was carried out in accordance with JIS L 1092, and a sample in which water did not drip was evaluated as “O”, and a sample in which water was drained was evaluated as “X”.
Was evaluated.

6. Bending recovery property The rebound rate was measured in accordance with JIS L 1096, and
% Or less was evaluated as “２０”, less than 40% and 20% or more as “Δ”, and less than 20% as “X”.

The results of the above evaluations are shown in Table 2 below. In addition,
Of the evaluation results, those with “○” were acceptable, and those with other evaluations (“△” and “x”) were unacceptable.

[0060]

[Table 2] As is evident from Table 2 above, those of the examples related to the present invention have good evaluations in any of the characteristics, and are particularly suitable for laying mats for automobiles and leisure sheets. I understand. On the other hand, those of comparative examples that deviate from the gist of the present invention are inferior in any of the characteristics. For example, mats used for automobiles, leisure sheets, etc. It turns out that it is not suitable.

[0061]

As described above, according to the mat of the present invention, generation of harmful gas during combustion can be prevented, and various properties such as elasticity, flexibility, and slip resistance can be reduced at ambient temperature. Hardly affected, maintained in good condition even under severe temperature environment, and excellent in water-impermeable and bending recovery,
It can be easily manufactured at low cost, and can be suitably used, for example, as a car laying mat or a leisure sheet. Particularly when used as a car laying mat, it can be post-processed according to the shape of the laying surface. Is obtained.

 ──────────────────────────────────────────────────の Continued on the front page (72) Inventor Taro Hattori 634-1, Kubota, Oaza, Anju-cho, Ikoma-gun, Nara Prefecture Sumitomo Textile Co., Ltd. Nara Works

Claims (3)

(57) [Claims] 1. A backing layer provided on the back surface of a fibrous fabric, comprising a first blend component of 30 to 90% by weight of a styrene-based thermoplastic elastomer having a styrene-based monomer content of 10 to 50% by weight. A second blend component composed of one or more selected from an ethylene-propylene-diene terpolymer, an ethylene-vinyl acetate copolymer, and an olefin-based polymer, in an amount of 1 to 30% by weight; % Of a mat. 2. The first blend component comprises a polystyrene / polybutadiene / polystyrene block copolymer,
The mat according to claim 1, comprising one or more selected from a polystyrene / polyisobrene / polystyrene block copolymer and a hydrogenated product thereof. 3. The composition according to claim 1, further comprising calcium carbonate, aluminum hydroxide, magnesium hydroxide, barium sulfate, calcium silicate, calcium sulfate, magnesium phosphate,
The mat according to claim 1, wherein one or more inorganic compounds selected from titanium oxide and titanium oxide are contained in an amount of 70% by weight or less.