JP3451366B2 - Rug - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention applies a sealing agent to the back surface of tufted carpet cloth, needle punching felt carpet cloth, and other carpet cloth to prevent surface pile fluff from falling off. It is applied, and a thick backing layer made of a resin composition is laminated on the coating film of the sealing adhesive, and is mainly used for entrance mats such as dust control mats, rental mats, tile carpets and vehicle floor mats. Rugs.

[0002]

2. Description of the Related Art Conventionally, a rubber or vinyl chloride resin composition has been used for a backing layer which is thickly laminated on the back surface of a rug of this type. Rubber and vinyl chloride resins have been widely used in various fields for many years, and various adhesives that strongly adhere to them are commercially available. Therefore, a general commercially available adhesive may be used for the sealing treatment of the carpet fabric finished by thickly laminating the rubber or vinyl chloride resin composition,
The problem of delamination between the coating film of the sealing adhesive and the backing layer of the rubber or vinyl chloride resin composition hardly occurs.

When laminating a thick backing layer of vulcanized rubber on the back surface of a rug, the unvulcanized rubber once formed into a sheet is
A method is used in which a carpet material that has been subjected to sealing treatment is pressure-bonded and the unvulcanized rubber sheet is heated and vulcanized as it is. When laminating a thick backing layer of a vinyl chloride resin composition on the back surface of the rug, the heat-melted vinyl chloride resin composition is extruded from the T-die extruder to be laminated on the back surface of the carpet fabric that has been subjected to the sealing treatment, and as it is. A method of passing through a pressure roll and crimping is adopted.

As is clear from a comparison between the two, when the vinyl chloride resin composition is used, it is not necessary to preliminarily mold the vinyl chloride resin composition into a sheet shape, unlike the case where rubber is used. Since it can be extruded from the T-die extruder and immediately laminated on the back surface of the carpet fabric, the production efficiency is good. In addition, when the vinyl chloride resin composition is used, it is not necessary to stack and heat-bond it as in the case of using rubber, so that there is no fear that the carpet fabric will be thermally deteriorated or discolored. Furthermore, the vinyl chloride resin composition that is melted by heating and extruded from the T-die extruder instantly adheres to the back surface of the carpet fabric, so that the pile is not set while being crushed. Furthermore, since the vinyl chloride resin is a thermoplastic resin, it is possible to form a rug with a backing and lamination of the vinyl chloride resin into a desired three-dimensional shape. Therefore, in particular, for a vehicle floor mat that is molded into a three-dimensional shape that fits the floor, a rug in which a vinyl chloride resin composition is lined and laminated is used.

[0005]

However, vinyl chloride resin requires a large-scale deodorizing device because it produces a foul odor during the lining process, and in recent years, industrial waste treatment has become a problem. Since a harmful gas is generated when incinerated, a thermoplastic resin replacing the vinyl chloride resin has been required. Under such circumstances, the styrene block copolymer resin does not contain chlorine, sulfur, nitrogen, etc., which are harmful gas components, and can be melted by heating and extruded from a T-die extruder. Although it is attracting attention as a substitute for resin, styrene block copolymer resin does not provide sufficient peel strength even if it is extruded from a T-die extruder and laminated on the back surface of a conventional carpet material subjected to a sealing treatment, Not used as a lining material for rugs.

[0006]

OBJECTS OF THE INVENTION Therefore, an object of the present invention is to obtain a rug in which a styrene block copolymer resin is firmly backed and laminated.

[0007]

The rug 4 according to the present invention comprises:
On the back side of the carpet material 1, a latex compound containing a natural rubber latex and containing no sulfur component is applied, dried and sealed to obtain a styrene block copolymer resin on the unvulcanized coating film 2. The backing layer 3 is formed by heat fusion.

Examples of the styrene block copolymer resin (also referred to as a polystyrene-based thermoplastic elastomer) include a styrene / butadiene block copolymer resin (also referred to as SB) and an ABA type having a polystyrene / butadiene / polystyrene structure. Styrene / butadiene / styrene block copolymer resin (also referred to as SBS), polystyrene / polyisoprene / polystyrene structure ABA type styrene / isoprene / styrene block copolymer resin (also referred to as SIS), SBS hydrogenated copolymer resin (also called SEBS), hydrogenated styrene.
Butadiene rubber (also referred to as HSBR) is used, and these are KRATON and CARIFLEX-TR.
(Trade name of Shell Chemical Co., Ltd.), Toughprene (Trade name of Asahi Kasei Corporation), Sorprene-T (Trade name of Nippon Elastomer Co., Ltd.), JSR-TR, SIS (Trade name of Japan Synthetic Rubber Co., Ltd.), Denka It is marketed under the trade name such as STR (trade name of Denki Kagaku Kogyo Co., Ltd.). Styrene block copolymer resins include tackifying resins such as aliphatic petroleum resins, aromatic petroleum resins, ethylene vinyl acetate copolymer resins, hardness adjusting resins such as polystyrene resins, polyester resins, acrylic resins, and naphthenic acid. , Plasticizers such as process oil, aluminum hydroxide,
Fillers such as calcium carbonate, conductive material powder such as carbon fibers and metal fibers, and other pigments can be added. In that case, if the compounding amount of the tackifying resin becomes large, it will be easily extruded from the T die extruder and the adhesiveness will be improved, but the rubber elasticity peculiar to the styrene block copolymer resin will be impaired and the backing layer will be easily cracked. Further, when the blending amount of the hardness adjusting resin or the filler is large, the backing layer becomes hard and cracks easily occur, so that it is meaningless to use the styrene block copolymer resin in the backing layer. Taking these points into consideration,
The compounding amount of the tackifying resin is 50 parts by weight or less, preferably 30 parts by weight, based on 100 parts by weight of the styrene block copolymer resin.
The amount of the hardness adjusting resin is 100 parts by weight or less, preferably 50 parts by weight or less, the plasticizer is 50 parts by weight or less, preferably 40 parts by weight or less, and the filler is 200 parts by weight. The amount is preferably 100 parts by weight or less, and particularly preferably the total amount of the tackifying resin and the plasticizer is 50 parts by weight or less.

The natural rubber latex includes natural rubber latex, methyl methacrylate / graft-polymerized natural rubber latex, ethyl methacrylate / graft-polymerized natural rubber latex, butyl methacrylate / graft-polymerized natural rubber latex, 2-ethylhexyl.
Graft-polymerized natural rubber latex is used. These natural rubber-based latexes include isoprene rubber latex, styrene-butadiene rubber latex, for adjusting the yarn removal strength of piles, the bending resistance of coating films, and the feel of rugs.
Carboxy-modified styrene-butadiene rubber latex,
Butadiene rubber latex, chloroprene latex,
Polystyrene latex or the like can be blended. Latex compounds are made into natural rubber latex by using conventional methods such as dispersants (sodium tripolyphosphate, etc.), anti-aging agents (styrenated phenol, etc.), thickeners (sodium polyacrylate, etc.), and fillers (calcium carbonate, etc.). Prepared by blending, 100-300g /
m ^{2 is} applied and heat-dried.

In the present invention, it is essential that the coating film of the applied latex compound is dried without being vulcanized, that is, without being crosslinked by sulfur. Therefore, the vulcanizing agent, that is, the sulfur component is not added to the latex compound. The reason is that when the latex compound coating film is vulcanized, the strength, impact resilience and oil resistance of the coating film are improved, but the peel strength from the styrene block copolymer resin is extremely reduced, and the styrene block copolymer is While the resin backing layer is easily peeled off, the coating film is covered with a thick styrene block copolymer resin backing layer, so it is meaningless to increase the strength, impact resilience, and oil resistance of the coating film by vulcanization. Because it will be. However, increasing the yarn removal strength of the pile,
If you want to reduce hair loss on the rug surface, or if you want to make the rug a little harder, crosslink the latex compound with a non-sulfur crosslinking agent such as melamine or blocked isocyanate. You can also do it.

The styrene block copolymer resin is formed on the dry coating film of the latex compound on the back surface of the carpet.
It is heat-melted and laminated. To fuse the styrene block copolymer resin, an existing T-die extruder used for lining a vinyl chloride resin composition can be used, but a styrene block copolymer resin preformed in a sheet shape can be used. Place the united resin on the releasable sheet to heat and melt it,
It is also possible to press-bond a dry coating film of a latex compound to the melting surface of the styrene block copolymer resin, peel off the release sheet, and transfer / laminate the styrene block copolymer resin on the rug.

[0012]

EXAMPLE Natural rubber latex solid content 100 parts by weight, antioxidant 1 part by weight, dispersant 0.5 part by weight, calcium carbonate 100 parts by weight and thickener 3 parts by weight, solid content content 50. A polyester fiber woven fabric was prepared with a latex compound having a viscosity of 12,000 cps (measured with a rotational viscometer BM type manufactured by Tokyo Keiki Co., Ltd. using a No. 3 rotor at a rotation speed of 12 rpm) in a polyester fiber fabric in an amount of 150% by weight.
g / m ^{2 was} applied and dried at 120 ° C. for 15 minutes to prepare a carpet sample piece (A).

70 parts by weight of solid content of natural rubber latex, 30 parts by weight of solid content of polystyrene latex, 1 part by weight of antioxidant, 0.5 part by weight of dispersant and 10 parts of calcium carbonate.
A latex compound containing 0 parts by weight and 3 parts by weight of a thickener, having a solid content of 50% by weight and a viscosity of 12000 cps, was added to a polyester fiber woven fabric in an amount of 15% by weight.
A carpet sample piece (B) was prepared by applying 0 g / m ² and drying at 120 ° C. for 15 minutes.

As comparative samples, 100 parts by weight of carboxy-modified latex solids, 1 part by weight of antioxidant, 0.5 part by weight of dispersant, 100 parts by weight of calcium carbonate and thickener 3
Consists of a part by weight, the solids content to 50 wt%, the latex compounds that were prepared viscosity 12000 cps, 150 g / m ² was applied to a polyester fiber fabric,
A carpet comparison sample piece (C) was prepared by drying at 120 ° C. for 15 minutes.

Next, 100 parts by weight of styrene / butadiene / styrene block copolymer resin, 30 parts by weight of plasticizer (process oil), 100 parts by weight of filler (calcium carbonate), and 30 parts by weight of hardness adjusting resin (polystyrene). A 2 mm thick styrene block consisting of 1 part by weight of an anti-aging agent (Ouchi Shinko Chemical Co., Ltd .; Nocklac NS-6), 1 part by weight of lubricant (zinc stearate) and 5 parts by weight of pigment (carbon black). A copolymer resin sheet is placed on a releasable sheet, heated and melted at 150 ° C., and the carpet sample pieces (A), (B) and (C) are placed thereon.
And the release sheet is peeled off to prepare test pieces (A), (B), and (C), and each carpet sample piece (A), (B), (C), and styrene block co-weigh The peel strength from the united resin backing layer was tested based on JIS-K-6301.

As a result, the peel strength of the carpet sample piece (A) was 4.3 kg / 25 mm, and the carpet sample piece (B) was
Peel strength of 2.8 Kg / 25 mm, and the peel strength of the carpet comparative sample (C) is 0.3 Kg / 25 mm,
It was confirmed that the higher the ratio of the natural rubber latex in the latex compound, the higher the peel strength, and that a practical rug cannot be obtained when the natural rubber latex is not used (Carpet Comparative Sample C).

[0017]

According to the present invention, the pile yarn and other fibers forming the back surface of the carpet cloth 1 and continuing to the surface of the carpet cloth 1 are adhered to the non-vulcanized dry coating film 2 of the natural rubber latex. At the same time as it becomes difficult to come off, the non-vulcanized dry coating film 2 of the natural rubber latex strongly adheres to the styrene block copolymer resin backing layer 3, so that the peripheral edge 5 of the rug 4 is
And the styrene block copolymer resin backing layer 3 did not peel off,
A styrene block copolymer resin can be used as a substitute for the vinyl chloride resin composition to obtain a rug 4 which is non-polluting when incinerated.

Since the existing T-die extruder used for backing the vinyl chloride resin composition is used as it is for backing the styrene block copolymer resin 3, the resin forming the backing layer 3 is vinyl chloride. Even if the resin composition is changed to a styrene block copolymer resin, no special capital investment is required and existing equipment is not discarded, which is a great industrial advantage of the present invention.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a rug according to the present invention.

[Explanation of symbols]

1 carpet fabric 2 Unvulcanized coating of natural rubber latex 3 Styrene block copolymer resin backing layer 4 rug 5 rim

─────────────────────────────────────────────────── ─── Continuation of front page (58) Fields surveyed (Int.Cl. ⁷ , DB name) D06N ⁷ /00-7/06 A47L 23/22 A47G 27/00-27/02 D06M 15/693

Claims (4)

(57) [Claims] 1. A rug characterized in that a backing layer of a styrene block copolymer resin is laminated on a non-vulcanized coating film of a latex compound containing a natural rubber latex backed on the back surface of a carpet fabric. 2. The rug according to claim 1, wherein the natural rubber-based latex contained in the latex compound is natural rubber latex, methylmethacrylate / graft-polymerized natural rubber latex, ethylmethacrylate / graft-polymerized natural rubber latex, A rug characterized by comprising at least one of butyl methacrylate / graft-polymerized natural rubber latex and 2-ethylhexyl / graft-polymerized natural rubber latex. 3. The rug according to claim 2, wherein the latex compound is isoprene rubber latex,
A rug characterized by containing unmodified styrene butyl rubber latex, polystyrene rubber latex, and chloroprene rubber latex. 4. The rug according to claim 1, wherein the latex compound lined on the back surface of the carpet comprises:
A rug characterized by being cross-linked with melamine, blocked isocyanate and other non-sulfur type cross-linking agents.