JP4756933B2 - Thick adhesive product with excellent adhesiveness and manufacturing method thereof - Google Patents

Description

  The present invention relates to a thick adhesive product in which a fiber layered material such as a soundproof nonwoven fabric or a sound absorbing material is bonded to a thick material such as a car mat or carpet having a large thickness and a rough adhesive surface, and a method for producing the same.

  Car mats, optional mats, and carpets are widely used because of their beautiful appearance, cushioning, sound absorption, and heat insulation. In particular, various types of car mats are used for the back side of the lining, and in recent years, non-woven fabrics are often used. However, there are various types of non-woven fabrics, from thick to thin. Adhesion is an important issue.

  Bonding between thin objects and thin and thick ones can be easily performed at one time, but in the case of thick objects, it takes time and time for bonding because heat conduction to the bonding surface is poor. There is concern about deterioration of the bonded body due to heat. That is, when pasting thick felt or the like on carpets, rugs or car mats, (b) liquid emulsion method, solvent method, (b) hot melt film, hot melt sheet, In the case of b), when thick materials are pasted together, they are absorbed by the adherend and cannot be bonded effectively, and there are significant inefficiencies such as the time required for drying. In the case of (b), it takes time to transfer heat to the inside due to its thickness, and in the case of a sheet made of film or thin fibers, it melts and the anchor effect is lost and sufficient adhesion is achieved. There are difficulties that cannot be obtained.

Therefore, the liquid bonding method used for conventional bonding, and the bonding method using hot melt films and sheets have various difficulties in bonding thick materials. The method of giving to is performed. For example, by spraying a hot melt adhesive powder dispersion on the back surface of the carpet body and drying, a backing material scattered in the form of dots is formed, and another sheet is adhered to the backing material (see, for example, Patent Document 1) And a carpet surface layer part and a backing part located on the back side are joined via a thermoplastic resin adhesive arranged in a streak pattern with a gap in one direction (see, for example, Patent Document 2), and further, a skin material layer and a nonwoven fabric It has been proposed to integrate a sound absorbing layer composed of the above through an air-permeable adhesive resin layer (see, for example, Patent Document 3).
JP 2000-319615 A JP 2003-225153 A JP 2003-341406 A

  However, the method of directly extruding and pasting the carpet and the thick nonwoven fabric is anxious about anisotropy in the bonding direction, and the method using the resin powder is not preferable because of the cost of the apparatus, and it still adheres well. It has not yet found a means.

In view of the such circumstances mentioned above, this was addressed, in particular the thickness is large and suitable adhesive sheet in the state of the bonding surface is bonded to facilitate coarse material together (hereinafter, abbreviated as adhesive sheet) Thus, the object of the present invention is to achieve the adhesion of thick objects at a low cost and without impairing the properties of the adherend using a conventional apparatus.

  That is, the present invention that achieves the above object is a thick adhesive product in which two kinds of thick layers made of a fibrous layered material having a thickness are bonded together by an adhesive sheet. The adhesive sheet is a random loop adhesive sheet made of a plastic resin, and the peel strength of the bonded product is 60 N / 5 cm or more, and the longitudinal and transverse peel strength ratio is 1.1 or less.

Here, the thick material composed of the two types of fiber layered materials to be bonded has a mass per unit area of 300 g / m ^{2 to} 3000 g / m ² and a thickness of ² mm to 25 mm. made adhesive sheet is in the range basis weight mass random looped adhesive sheet of ^{80g / m 2 ~1000g / m 2} , the random loop it is important constituent fiber diameter of 0.15~1.5mm The adhesive sheet is made of many yarns from the spinning nozzle, spun into a strand, and when descending directly to the cooling water bath located at the bottom, a large number of yarns are related to the cooling water in the cooling water immediately before the cooling water bath. Each of the strips swirls, presents a loop shape and enters a cooling water bath, randomly forms an indefinite circular hole in a loop shape by the swirl, and is wound as a sheet in that state. Spider web Thicker fiber diameter than in Tomeruto adhesive is a 0.15～1.5Mm, moreover basis weight mass is heavy and 80~1000g / m ^2, in which the adhesive force required for adhesion of thick material is sufficiently be ensured is there.

  In addition, as the thermoplastic resin constituting the adhesive sheet, a resin selected from modified polyester, modified polypropylene, polyethylene, and ethylene vinyl acetate (EVA) is effective. In addition, the present invention is another feature of the method of manufacturing the above thick article, and when the materials having a large thickness such as a rug and having a rough bonding surface are bonded to each other, the above-mentioned predetermined mass per unit area, thickness A thick adherend A having a thickness (for example, carpet, mat, etc.) is placed on the back surface, heated and melted, and a preheated thick adherend B (for example, nonwoven fabric, sound absorbing material, etc.) is placed thereon. This is a method in which the product is cooled and bonded after being pressure-bonded between rollers.

  It is possible to sandwich an adhesive sheet between the two thick adherends A and B in advance and heat the whole to melt the resin and pressure-bond them. Since the conductivity is low and it takes a long time to melt the internal adhesive resin or the heating temperature must be increased, the productivity is extremely poor. Thus, the method of heating and processing the three layers at a time is difficult because the adhesive sheet in the inner layer does not melt easily and it takes time to heat, and it is difficult for the resin to flow in between the fibers on the adhesive surface, so that it is on the back surface between the layers. Residual adhesion is insufficient. Therefore, it is important to heat and flow the adhesive resin. In that case, the resin stays on the surface of the layer, and there is no inflow by capillaries, but penetration into the interior of the fibers occurs by press-fitting. For this purpose, the resin for forming the adhesive sheet is preferably one having poor temperature sensitivity, that is, one having a low melt viscosity temperature dependency. In particular, since the fiber configuration of the adhesive sheet and the melt index of the resin are important, the above-described random loop shape is preferable for the adhesive sheet.

  The thick adhesive product according to the present invention has a good adhesion state between the thick materials, and therefore has good adhesion peeling properties, and it is possible to bond the thick materials which have been regarded as difficult to each other at low cost without impairing the properties of the thick materials. It becomes easy.

  Hereinafter, specific embodiments of the present invention will be described in detail.

  In the present invention, as described above, two kinds of thick materials made of a fiber layered material such as a rug having a predetermined basis weight and thickness and having a rough adhesive surface are passed through a random loop adhesive sheet made of a thermoplastic resin. The present invention provides a thick adhesive product excellent in adhesiveness having a peel strength of 60 N / 5 cm or more and a longitudinal and lateral peel strength ratio of 1.1 or less.

Here, as the two kinds of thick materials to be bonded, one of them includes a loop tuft carpet, a cut tuft carpet, a short fiber nonwoven fabric, a spunbond nonwoven fabric, and the like having a predetermined basis weight and thickness, The other one B includes substantially the same sound absorbing and soundproofing nonwoven fabric. That is, these adherend and is two heavy materials A, B are those in the range both basis weight range of ^{300g / m 2 ~3000g / m 2} , the thickness is preferably in 2~25mm It is a range.

  The thickness range is a processing method in which processing is difficult when the three-layer structure is integrally processed for adhesion, and as a result, the cushioning property, heat insulation, and sound absorption performance are excellent. If the thickness is less than 2 mm, cushioning properties, heat insulation, and sound absorption are inferior. When the thickness exceeds 25 mm, the cushioning property, the heat insulation and the sound absorption are excellent, but the quality is excessive and the cost is not preferable.

  Moreover, hot-melt resin is used as the thermoplastic resin constituting the adhesive sheet, and specifically includes modified polyester (L-PET), PP-modified polypropylene, polyethylene (PE) ethylene vinyl acetate (EVA), and the like.

  The melting point of the hot-melt resin is preferably in the range of 60 to 140 ° C., and if it is less than 60 ° C., it becomes a limit to exposure to floor warming and the like, and heat resistance is insufficient. If it exceeds 140 ° C., the temperature required to melt the adhesive becomes high, and a high temperature is required, so that the adherend may be damaged. In addition, as a fluid characteristic (melt index), the range of 10-100 is preferable. If it is less than 10, the melt viscosity of the adhesive is high, so that the fibers on the surface of the adherend cannot be sufficiently wrapped, the anchor effect cannot be obtained, and the adhesion becomes weak, which is not preferable. On the other hand, if it exceeds 100, the melt viscosity of the adhesive is low, so that the resin does not stay on the surface of the adherend and penetrates to the inside, reducing the effective adhesion amount and weakening the adhesion.

The adhesive sheet made of the hot melt resin has a random loop shape as described above, and has a weight of 0.15 mmφ to 3.0 mmφ, preferably 0.15 mmφ to 1.5 mmφ. The mass is 80 to 1000 g / m ² , preferably 80 to 500 g / m ² . If the thickness of the thread is less than 0.15 mmφ, the adhesive thread diameter is small, so that it is difficult to capture fibers on the surface of the adherend, and the anchor effect is small, so that the desired adhesive strength cannot be obtained. If the thickness of the yarn exceeds 3.0 mmφ, it takes a long time to melt because the adhesive yarn is thick, and a high temperature is required, so that the adherend is damaged. If the mass per unit area is less than 80 g / m ² , the adhesive for the adherend is insufficient, and the adhesive strength is insufficient. On the other hand, when the weight per unit area exceeds 1000 g / m ² , the adhesion amount of the adherend is sufficient, but the air permeability is lost and the texture becomes hard, and the adhesion amount is excessive quality, which is preferable from the viewpoint of cost. Absent.

  Next, when adhering the above-mentioned two types of thick adherends A and B using an adhesive sheet, a random loop adhesive sheet made of hot melt resin is overlaid on the thick adherend A. The hot melt adhesive sheet is heated and melted, and pre-heated before the thick adherend B is stacked, and the adherend B is stacked on the molten hot melt adhesive sheet and sandwiched between nip rolls. Pressurize and cool.

  When the thick material A is a carpet and the non-woven fabric for soundproofing and sound absorption is bonded to the backing layer on the back surface as the thick material B, the molten hot melt of the adhesive sheet is the backing surface of the thick material A and the nonwoven material surface of the thick material B. Adhere both.

  In addition, in order to adhere | attach a thick material fully, 60 N / 5cm or more is required for peeling strength. If it is less than 60 N / 5 cm, it is not preferable as a product because adhesion is insufficient and peeling easily occurs when the carpet is bent or misaligned. Further, the ratio of longitudinal and lateral peel strength is preferably 1.1 or less, and exceeding 1.1 is not preferred because the direction of handling is limited due to the anisotropy of the product. For this reason, the peel strength of the product is required to be 60 N / 5 cm or more, and the longitudinal / lateral peel strength ratio is required to be 1.1 or less.

Examples of the present invention will be further described below.
In addition, the random loop adhesive sheets in Examples and Comparative Examples were spun out of the hot melt thermoplastic resin in the cooling water bath below the spinning nozzle in the form of a strand made of a large number of yarns. A number of yarns swirled in relation to the cooling water just before the cooling water bath, respectively, turned into a loop shape, entered the cooling water bath, and wound up as a sheet in a state of forming a loop shape at random.

In the examples, the basis weight, thickness, fiber diameter, melt flow, air permeability, and peel strength were in accordance with the following.
(B) Mass per unit area (mass per unit g / m ² )
A size of 50 cm × 50 cm is cut out, the weight at that time is measured, and converted to a weight per 1 m ² .
(B) Thickness (mm)
A size of 15 cm × 15 cm is cut out, the initial load is 0.05 g / m ² , the heights of the four corners are measured, and the average value is shown.
(C) Fiber diameter (mm)
The diameter of the yarn was measured by enlarging the yarn 150 times with a microscope (manufactured by Keyence Corporation). The number of measurements is shown as an average value of n = 10. The unit is mm.
(D) Melt flow (MF)
According to JIS-K-6862. However, the measurement temperature is 160 ° C.
(E) Air permeability The air permeability was measured with a frangole type tester described in 6.27.1 of JIS L1096.
(F) Peel strength (N / 5cm)
The sample is a 5 × 20 cm sample piece, and the skin / nonwoven fabric is peeled from the short piece by about 5 cm in parallel to the long piece. The peeled skin and nonwoven fabric are attached to a Tensilon tensile tester and peeled off at a speed of 20 cm / min. The peel strength at this time is obtained.

Example 1
Polyester (PET) having a basis weight mass of fiber is polypropylene nonwoven 100g / m ² (PP) pile of fiber (mass per unit area weight 500 g / m ²⁾ and formed by tufting carpet material (basis weight mass 600 g / m ²⁾ An adhesive sheet (modified polyethylene (PE) resin, melting point 120 ° C., melt index 21, basis weight 200 g / m ² , random loop fiber diameter 0.5 mmφ) is placed on the opposite side with the pile surface of A non-woven fabric (polyester (PET) fiber, fineness 4.4 decitex) that has been processed with a heating device at a speed of 4 m / min and a processing temperature of 180 ° C. to melt the random loop-shaped fibers and then preheated (140 ° C.) in advance. , A weight per unit weight of 500 g / m ² ) which is needle punched with a fiber length of 52 mm is overlaid on the outlet at a pressure roller linear pressure of 10 kg. The adhesive was treated at / cm, cooled and wound up.

Example 2
Polyester (PET) carpet material basis weight mass of fiber is formed by tufting polypropylene (PP) pile of fiber (mass per unit area weight 500 g / m ²⁾ to the nonwoven fabric of 100 g / m ² (basis weight% by weight 600 g / m ² ) On the opposite surface with the pile surface facing down (ethylene vinyl acetate (EVA) resin, melting point 90 ° C., melt index 25, basis weight 200 g / m ² , random loop fiber diameter 0.9 mmφ) A non-woven fabric (polyester (PET) fiber, fineness of 4. 4 decitex, fiber length 52mm, needle punched mass per unit weight 500g / m ² The adhesive was treated at a pressure of 10 kg / cm, cooled and wound up.

Example 3
Polyester (PET) polyester basis weight mass of 100 g / m ² nonwoven fabric made of fibers (PET) pile of fiber (mass per unit area weight 500 g / m ²⁾ and formed by tufting carpet material (basis weight mass 600 g / m ²⁾ An adhesive sheet (modified polyethylene terephthalate (L-PET) resin, melting point 110 ° C., melt index 20, weight per unit area 200 g / m ²⁾ , random loop fiber diameter 0.4 mmφ ) On a non-woven fabric (polyester (PET) fiber, fineness 4) preheated (100 ° C.) by melting the random loop fiber by heating at a speed of 4 m / min and a processing temperature of 160 ° C. .4 dtex, overlying a basis weight mass 500 g / m ²⁾ was needle punched of fiber length 52mmφ at the exit pressure Wound by bonding treated and cooled in the roller line pressure 10 Kg / cm.

Comparative Example 1
Polyester (PET) having a basis weight mass of fiber is polypropylene nonwoven 100g / m ² (PP) pile of fiber (mass per unit area weight 500 g / m ²⁾ and formed by tufting carpet material (basis weight mass 600 g / m ²⁾ An adhesive sheet (modified polyethylene (PE) resin, melting point 120 ° C., melt index 21, basis weight 200 g / m ² , random loop fiber diameter 0.5 mmφ) is placed on the opposite side with the pile surface of Next, a non-woven fabric (polyester (PET) fiber, fineness 4.4 decitex, needle punched basis weight 500 g / m ² ) consisting of a fiber length of 52 mm is placed thereon and heated as a three-layer heating device (speed 2 m / min, treatment temperature) 180 ° C.) and heat treatment, and further, pressurizing treatment was continuously performed for adhesion treatment.

Comparative Example 2
Polyester (PET) having a basis weight mass of fiber is polypropylene nonwoven 100g / m ² (PP) pile of fiber (mass per unit area weight 500 g / m ²⁾ and formed by tufting carpet material (basis weight mass 600 g / m ²⁾ Thermoplastic resin (ethylene vinyl acetate (EVA) resin) between the back surface of the pile and the nonwoven fabric (polyester (PET) fiber, fineness 4.4 decitex, needle punched basis weight 500 g / m ² ) consisting of 52 mm fiber length) , Melting point 90 ° C., melt index 25) are melt extruded and are extruded and bonded in the form of 13 threads / 10 cm in the form of yarn (weight per unit area: 200 g / m ² , fiber diameter: 1.0 mmφ). After pressing and adhering (linear pressure: 10 kg / cm), it was cooled and wound up.

Comparative Example 3
Polyester (PET) having a basis weight mass of fiber is polypropylene nonwoven 100g / m ² (PP) pile of fiber (mass per unit area weight 500 g / m ²⁾ and formed by tufting carpet material (basis weight mass 600 g / m ²⁾ An adhesive film (modified polyethylene (PE) resin, melting point 90 ° C., melt index 70, mass per unit area 100 g / m ² , thickness 150 μ) is placed on the opposite surface with the pile surface of the heating device at a speed of 4 m / Min, a needle made of non-woven polyester (PET) fiber, fineness 4.4 decitex, fiber length 52 mm, which has been pre-heated (140 ° C.) by melting the adhesive film on the surface after treatment at 180 ° C. The punched mass per unit area (500 g / m ² ) is overlapped on the outlet and bonded with a pressure roller linear pressure of 10 kg / cm, cooled and wound. I scraped it.

  And each product obtained from the said Example and the comparative example evaluated each about the sound absorption performance, peeling strength, its peeling anisotropy, and the adhesive state of resin. The results are shown in Table 1 below. The state of adhesion between the layers was evaluated by peeling the adhered layers and evaluating the resin penetration state.

The resin penetrates into the surface fibers of both layers and is firmly bonded. ○
Resin bites into the surface fibers of both layers, but the amount of resin is small and adhesion is insufficient. △
The resin does not sufficiently penetrate the surface fibers of both layers and is not bonded. ×
In addition, since the sound absorption evaluation cannot actually be measured, it was replaced with an alternative evaluation.

In general, there is a literature that the sound absorbing performance can be expressed by the air permeability of the base material, and the effect is that the air permeability should be in the range of 1 to 50 cc / cm ² / sec. Therefore, the air permeability of the product was measured and evaluated as a substitute for the sound absorption performance.

上記表１より実施例１，２，３共に接着は良好で剥離強力は縦，横安定して高い値を示し、接着の状態も均一に繊維間に十分食い込んでいた。通気度も５０ｃｃ／ｃｍ²／ｓｅｃの範囲にあり、吸音性能は損なわれていないことが分かる。

From Table 1 above, Examples 1, 2 and 3 showed good adhesion, and the peel strength showed a high value stably in the vertical and horizontal directions, and the state of adhesion evenly penetrated between the fibers sufficiently. The air permeability is also in the range of 50 cc / cm ² / sec, and it can be seen that the sound absorption performance is not impaired.

  On the other hand, in Comparative Example 1, since the three layers were processed at a time, the processing speed was halved. However, heat was not sufficiently transferred to the adhesive sheet, the peel strength was weak, and the adhesion state was not soaked into the fiber surface. It was something.

  In Comparative Example 2, the adhesive resin was melt-extruded and discharged between the carpet layer and the non-woven fabric layer, and the two layers were bonded together, but the adhesion state was good, but the vertical and horizontal peel strength was anisotropic. Admitted. In Comparative Example 3, the adhesion between the carpet layer and the nonwoven fabric layer by the adhesive film caused width shrinkage when the adhesive film was heated, and good adhesion was not obtained. The adhesion state was not preferable because it hardly adhered to the fiber. Therefore, it can be said that the present invention is superior to the above comparison.

Claims (4)

It is a thick adhesive product formed by adhering two kinds of thick materials composed of fiber layered materials, each of which is a fiber layered material having a basis weight of 300 to 3000 g / m ² and a thickness of ² to 25 mm, in basis weight mass 80~1000g / m ² made of thermoplastic resin, the two thick ones by constituting the fiber diameter is melted random loop bonding sheet is 0.15~1.5mm is bonded In addition, a thick article adhesive having excellent adhesion, wherein the peel strength of the bonded product is 60 N / 50 cm or more, and the longitudinal and transverse peel strength ratio is 1.1 or less.   2. The thick adhesive product having excellent adhesiveness according to claim 1, wherein one of the thick materials A and B to be bonded is a carpet and the other is a nonwoven fabric for sound absorption and sound insulation. Thermoplastic resin is modified polyester constituting the adhesive sheet, modified polypropylene, polyethylene, EVA adhesion to claim 1 or 2, wherein the one or more hot-melt resin selected from (ethylene-vinyl acetate copolymer) Excellent thick adhesive. In basis weight mass ^{300g / m 2 ~3000g / m 2} , the basis weight mass composed of two kinds of heavy materials A and thick material B thickness is from fiber layered product 2mm~25mm thermoplastic resin is 80 g / m ² ~ in the range of 1000 g / m ^2, a method of constituting the fiber diameter is bonded with adhesive sheet formed in a random loop form is 0.15～1.5Mm, on the non-adhesive body, thick a put the adhesive sheet while heating and melting the sheet, after then sandwiched therebetween pressure bonding a roller topped with heavy materials B a heated該予separately preheating the adherends thickness was B on the molten sheet A method for producing a thick article having excellent adhesion, characterized by cooling.