JPH0228458B2 - - Google Patents

Description

[Detailed description of the invention]

[Industrial Application Fields] The present invention is useful as automobile ceiling materials, door trims, rear shells, seat bags, trunk lids, trunk surrounding members, interior materials such as floors, ceiling materials for buildings, wall materials, and cosmetic container molding materials. The present invention relates to a method for manufacturing a laminated material that has deep-drawable rigidity, heat insulation properties, and shielding properties. [Prior Art] Conventionally, materials that can withstand temperatures of 100°C or higher have been used as interior materials for automobiles, such as resin felt made of phenol-aldehyde condensation resin filled with fibers, foamed synthetic resin, polypropylene composites, and polypropylene cardboard boxes. It is being Among these materials, resin felt has excellent rigidity, heat-resistant shape retention, dimensional stability, and shielding properties, but has the drawbacks of poor moldability, impact resistance, and lightness.
In addition, polypropylene cardboard has excellent rigidity and lightness, but on the other hand, it is difficult to deep draw,
Since corrugated material is used, the strength is directional. Furthermore, foamed synthetic resins such as polystyrene are excellent in lightness, but have the drawbacks of poor moldability and bending resistance, and also have problems with appearance after molding. Furthermore, although polypropylene composites have excellent rigidity, they have drawbacks in moldability, impact resistance, and dimensional stability. Required performance as an interior material: rigidity, appropriate flexibility, lightness, dimensional stability,
A material that satisfies both heat-resistant shape retention and moldability has not been obtained. On the other hand, fibers such as polyethylene, polypropylene, and low melting point (140°C) polyester are used as a fiber binder, and a fiber mat made of synthetic fibers is needled to temporarily bind the fibers of the upper and lower layers of the web, and then heated to Melt the fiber binder,
Methods for producing resilient nonwoven fabrics by bonding other synthetic fibers are known. Although this nonwoven fabric is lightweight and flexible, it lacks moldability and rigidity, so it is useful as an interior material for flat areas, but it is not useful as an interior material for areas with complex shapes. . In addition, needle punched cloth has a softening point of 100 to 130℃.
After coating or impregnating an aqueous emulsion of a thermoplastic resin, the nonwoven fabric is heat-dried to remove moisture, and the nonwoven fabric is further heated and press-molded to obtain an automobile interior material. be. This interior material has the advantage that it can be installed in places with complex shapes. The fixation of the fibers of this nonwoven fabric is due to the entanglement of the fibers by needle punching and the adhesion of the emulsion resin to the fibers, but the apparent density of the nonwoven fabric to which the emulsion is applied and impregnated is 0.08~
Since it is bulky at 0.13 g/cm ² , it has the disadvantage that the filling effect with emulsion resin is poor. Furthermore, since the filling effect is insufficient, there is a drawback that the shielding performance is inferior. The present inventor first developed a method for producing a nonwoven fabric using thermoplastic resin to overcome the drawbacks of poor dimensional stability and rigidity of the latter moldable nonwoven fabric without reducing its lightness, heat-resistant shape retention, and air permeability. After needling a fiber mat consisting of 15 to 50% by weight of binder fibers and 85 to 50% by weight of synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the thermoplastic resin, the mat is The thermoplastic resin binder fibers are heated at a temperature that melts the thermoplastic resin binder fibers but not the synthetic fibers or the natural fibers, and then the thermoplastic resin binder fibers are heated while the thermoplastic resin binder fibers remain in the molten state. Compress the fiber mat to reduce the apparent density of the mat
An aqueous emulsion of thermoplastic resin with a moldable temperature range of 80 to 180°C is adjusted to 0.15 to 0.50 g/cm ² and added to the compressed fiber mat in a proportion of the resin hardness of the emulsion to the fiber weight of the fiber mat. The type is
Provided is a method for producing a moldable nonwoven fabric, characterized in that the nonwoven fabric is obtained by coating or impregnating it to a concentration of 15 to 300% by weight, and then heating and drying at 60 to 250°C to remove moisture. 1986-87353). This method uses a combination of a thermoplastic fiber binder and a resin emulsion to improve the rigidity of the nonwoven fabric, as well as bonding the fibers together to improve dimensional stability. A major feature of this method is that it compresses and expels a portion of the air, making it possible to increase the filling rate of the emulsion resin into the mat, thereby improving the rigidity of the nonwoven fabric. However, although this moldable nonwoven fabric has excellent moldability, dimensional stability, air permeability (sound absorption), and improved rigidity, it has poor water shielding properties due to the air permeability. Furthermore, depending on the application, higher rigidity,
Some require water impermeability. We previously proposed a carpet made of resin-backed nonwoven fabric with a foam sheet adhered to the back side as a material with excellent water impermeability and rigidity. (Akira Jigan
(See Nos. 57-170656 and 57-195731) However, this method requires a backing layer formation step and a foam sheet bonding step, and
In order to prevent the foam sheet from breaking due to bending, it is necessary to further laminate a non-foam sheet to the foam sheet. Furthermore, since the resin layer directly forms the surface layer, there are problems in terms of appearance. Separately, we applied a first backing material (A) an aqueous dispersion of a resin with a melting point of 80°C or higher containing the following (A) aqueous resin emulsion and (B) expandable polystyrene particles to the back side of the original rug. Resin aqueous emulsion as main component
(100 parts by weight in solid content) (B) After applying expandable polystyrene particles (10 to 100 parts by weight), the resin of the aqueous emulsion of (A) above is applied to the surface of the first backing material as a second backing material. An aqueous emulsion of a resin having a melting point lower than that of the particles and whose melting point is 50 to 125°C is applied, and then heated and dried to dry the emulsion to form a backing layer and foam the expandable polystyrene particles. proposed a method for manufacturing a laying material with moldability and thermal adhesiveness (Japanese Patent Application Laid-open No. 59176/1983). In this method, the amount of expandable polystyrene particles used is as small as 10 to 100 parts by weight per 100 parts by weight of the resin in the aqueous emulsion, and the foam layer does not form a continuous smooth layer, with spherical foam particles forming on the back side. The wall thickness of the laying material is not uniform due to the protruding adhesion, and in order to achieve uniform adhesion to other base materials such as metal or wood, it is necessary to fill in the gaps between the protruding foam particles and the original rug fabric. Therefore, it has the disadvantage of requiring a large amount of adhesive. Also, the appearance of the back side is poor. [Specific means for solving the problem] The present invention aims to improve the performance of the laying material proposed above, that is, to improve shielding properties, heat insulation properties and rigidity, improve appearance, and improve cracking prevention. It was made for this purpose, and uses expandable styrene resin particles and aqueous resin emulsion as the backing material.
This problem has been solved by making it possible to form a continuous and smooth foam layer by using a large amount of expandable resin particles, and by making this backing layer a laminated material with a structure in which the backing layer is sandwiched with a base fabric. . That is, in the present invention, on a base fabric (A) made of a material having a heat distortion temperature of 150° C. or higher, (a) 100 parts by weight of an aqueous resin emulsion (b) 150 to 700 parts by weight of expandable styrene resin particles. Apply a bucking coating agent mixed in parts by weight,
Then, on top of this applied bucking coating layer,
The base fabric (B) made of a material with a heat deformation temperature of 150°C or higher is layered to form a laminate, and the laminate is compressed from one or both sides of the laminate to transfer a portion of the coating agent to the base fabric. After impregnating (B) with foamable styrene resin particles, the foamable styrene resin particles are heated at a temperature that is above the softening point of the resin of the foamable styrene resin particles and lower than the heat distortion temperature of the base fabrics (A) and (B). The present invention provides a method for producing a laminate, which comprises foaming particles and drying an aqueous resin emulsion to obtain a laminate having a foam layer between base fabrics (A, B). Base fabric (A) Base fabric (A) is a surface layer material, preferably one with cosmetic properties, and can be applied to tufted carpet, woven fabric, non-woven fabric such as needle punch carpet, synthetic leather, or non-woven fabric by screen printing. These base fabrics can be used with backing treatment. As the material for the base fabric, in addition to natural fibers such as wool and silk, resin fibers such as nylon, polyethylene terephthalate, polypropylene, and polyacrylonitrile are used. It is preferable that the thermal deformation temperature of the material for this base fabric (A) and the base fabric (B) described below is 40°C or more higher than the softening point of the material resin of the expandable styrene resin particles of the backing material, and such materials are selected. By doing so, thermal shrinkage during foaming can be prevented. When using needle punch carpet with poor appearance or spunbond nonwoven fabric obtained using scraps or regenerated fibers as the base fabric (A), carry out the present invention, obtain the laminate, and then use the base fabric (A). Decorate the surface of the fabric (A) by laminating artificial leather, printed or embossed synthetic paper, titanium paper, polyvinyl chloride decorative paper, woven fabric, or a composite material of these with foamed urethane, etc. . The basis weight of this base fabric (A) is 50 to 1000 g/m ² , preferably 80 to 500 g/m ² . Base Fabric (B) Since the base fabric (B) is used by adhering to the base material or used as the side that contacts the floor, that is, the back side of the interior material, the appearance is not important, and an inexpensive material is preferable. Therefore, rather than woven fabrics or artificial leather, woven fabrics or non-woven fabrics made from natural or resinous fibers such as wool, nylon, polyacrylonitrile, polyacetate, polypropylene, etc., such as needle punch carpets, spunbond fabrics, or inexpensive recycled fabrics are preferred. Felt is preferably used. Further, these base fabrics may be backed with phenol resin, synthetic resin emulsion, or latex, or may be glass fiber woven fabrics or nonwoven fabrics. The fibers may be recycled. This needle punch carpet is a web obtained by needling a fiber mat made of synthetic fibers and/or natural fibers, and is manufactured by a known nonwoven fabric manufacturing method. i.e. 1.2~300
Thoroughly mix fibers with denier and fiber length of 25 to 150 mm.
The opened fibers are fed to a web forming device, and the web (fiber mat and/or this web) obtained by stacking the cards formed from the mixed fibers to the desired fiber weight is vertically It is temporarily fixed by needling and intertwining the fibers. If some of these fibers (15 to 50% by weight of fibers based on the weight of the mat) are replaced with a resin fiber binder having a low melting point of 80 to 160°C, the strength of the resulting laminate will be further improved. As such a fiber binder, short fibers (15 to 40 mm in length) of resin such as polyethylene, polypropylene, linear polyester, and low molecular weight co-condensed polyamide are used. The raw materials for the synthetic resin constituting the fiber mat include polyethylene terephthalate, polyamide, etc., which have a melting point of 40% higher than the melting point of the thermoplastic resin fiber binder.
A thermoplastic resin having a melting point higher than 70°C, preferably 70°C or higher (specifically 200 to 280°C) is used. Further, as natural fibers, cotton, linen, wool, etc. are used. The basis weight of this base fabric (B) is 10 to 2000 g/ ^m2 ,
Although it varies depending on the application, it is preferably 10 to 10 when used simply for adhesion or to prevent the foam layer from cracking.
With a basis weight of 100g/ ^m2 , the laminated material has cushioning properties,
100 to 1000 g/m ² for the purpose of increasing the thickness.
Use at a ratio of Bucking Material The bucking material contains at least an aqueous resin emulsion and expandable styrene resin particles. The expandable styrenic resin particles are continuous and added to 100 parts by weight of the resin in the emulsion to obtain a smooth foam layer.
It is used in a proportion of 150 to 700 parts by weight, preferably 200 to 500 parts by weight. (Expansible styrene resin particles) As the expandable styrene resin particles, polystyrene, styrene/α-methylstyrene copolymer,
Styrene/α-methylstyrene/acrylonitrile copolymer, styrene/α-methylstyrene/acrylonitrile/butyl methacrylate copolymer,
Uses foamable resin particles (foaming agent content: 2-15% by weight) with a particle size of 0.1-1.5 mm made of styrene-based resin (softening point: 100-120°C) such as styrene/methyl methacrylate copolymer. It will be done. (Aqueous resin emulsion) As a backing material, an aqueous resin emulsion that functions as a anchor for fiber mats and an adhesive for foam particles is an aqueous emulsion of a resin with a glass transition point of -65°C to +150°C, such as polyvinyl acetate, Vinyl chloride/vinylidene chloride copolymer, styrene/
Butadiene copolymer rubber, styrene/methyl methacrylate copolymer, styrene/n-butyl acrylate copolymer, ethylene/vinyl acetate copolymer,
Latexes such as styrene/n-butyl acrylate/acrylic acid copolymer, vinylidene chloride/acrylonitrile/acrylic acid copolymer, and aqueous emulsions may be used alone or in mixtures. In terms of flexibility of the non-woven fabric layer of the laying material, aqueous resin emulsion or latex with a glass transition point of 20°C or lower is preferable; conversely, in order to impart rigidity and moldability to the non-woven fabric layer of the laying material, a glass transition point of 80°C is preferred. An aqueous resin emulsion having a temperature of 0.degree. C. or higher is preferred. Aqueous emulsions with a glass transition point of 80°C or higher include (a) polyn-propyl methacrylate (Tg81°C), polystyrene (100°C), polyacrylonitrile (100°C), polymethyl methacrylate (105°C), and In addition to an aqueous emulsion of a homopolymer such as methacrylic acid (130°C) or polyitaconic acid (130°C), (b) 50 to 100% by weight, preferably 65 to 95% by weight of vinyl monomer, which is a raw material for these polymers. weight% and
Other vinyl monomers, such as 2-ethylhexyl acrylate (Tg -85°C), n-butyl acrylate (-54°C), ethyl acrylate (-22°C), isopropyl acrylate (-5°C), methacrylate acid 2-
Ethylhexyl (-5℃), n-propyl acrylate (8℃), n-butyl methacrylate (20℃),
Vinyl acetate (30℃), ethyl methacrylate (65
℃), vinyl chloride (79℃), etc. or vinylidene chloride (-18℃) 50% by weight or less, preferably 35-5%
Aqueous emulsion of the copolymer with wt% [this (b)
(c) 50 to 97% by weight of an aqueous resin emulsion with a Tg of +80 to 155°C. ,Preferably
55 to 95% by weight and 50 to 3% by weight of a resin aqueous emulsion with a Tg of -85°C to less than +80°C, preferably 45
-5% by weight, and the like. The resin solid content concentration of aqueous emulsion is usually 20~
60% by weight, and the diameter of the dispersed resin particles is
It is 10μ (microns) or less, preferably 0.05 to 1.0μ. Examples of aqueous resin emulsions having a glass transition point of 20°C or lower include (i) 2-ethylhexyl acrylate, n-butyl acrylate, ethyl acrylate, isopropyl acrylate, 2-ethylhexyl methacrylate, n-propyl acrylate; , n-butyl methacrylate, vinylidene chloride, ethylene, butadiene 20-100% by weight (ii) Vinyl acetate, ethyl methacrylate, vinyl chloride, n-propyl methacrylate, styrene, acrylonitrile, methacrylic acid Monomer selected from methyl, acrylic acid, itaconic acid, acrylamide, methacrylamide 80% by weight or less (iii) Monomer selected from diacetone acrylamide, maleic anhydride, diethylene glycol diacrylate 0 to 5% by weight Examples include emulsion polymers. In order to impart a sense of weight to the resulting nonwoven fabric, inorganic fillers and pigments such as calcium carbonate, iron oxide, ferrite, and barium sulfate can also be blended into this emulsion. The film forming temperature of the resin of this aqueous emulsion is lower than the foaming temperature of the expandable styrene resin particles, and more preferably lower than the softening point of the expandable resin particles, so that the foam layer is continuous and smooth. It is also necessary for smooth foaming. The foam particles are adhered to each other with the emulsion resin acting as an adhesive to form a continuous foam layer. Application of the backing material to the base fabric (A) or (B) is performed using a spray, dipping, brush, foam coating machine, roll, or the like. The amount of bucking material applied is 100~
1700g/m ² (solid content), preferably 300-1300g/
^m2 . The coating is preferably a foam coating method. In particular, when the resin emulsion is expanded 3 to 7 times, coating workability, coating amount, and thickness can be easily adjusted. In addition to acting as an adhesive for the foam particles as described above, the aqueous resin emulsion also acts as a carrier when applying the foamable resin particles to the base fabric (A), and also acts as a carrier between the base fabrics (A) and (B) and foaming. A method for manufacturing a laminate material that serves as an adhesive to the body layer and also provides flexibility and rigidity to the base fabric. A bucking coating agent containing foamable resin particles is applied, and then a base fabric (B) or a base fabric (A) is stacked on the surface of this coating agent to obtain a laminate, and one side of this laminate is coated. Or, by squeezing from both sides with a squeeze roll, press machine, etc., the base fabric (A), (B)
The laminate is then impregnated with the emulsion at a temperature higher than the melting point of the foamable resin particles, and is then applied to the base fabric.
The foamable resin particles are foamed by heating at a temperature lower than the heat distortion temperature of the materials (A) and (B), and the foam layer (E) is formed by drying to dissipate the moisture in the resin aqueous emulsion. A laminate material (S) is produced in which a base fabric (A) and a base fabric (B) are integrally bonded to the front and back surfaces of the laminate (S) (see Fig. 1). At this time, a method may be used in which water is removed at a temperature at which the expandable resin particles do not foam, for example around 90° C., and then the temperature is raised to a temperature at which foaming occurs. Using expandable polystyrene particles (Tg104℃),
When the base fabric is made of polyester (melting point is approximately 240℃) or polypropylene (melting point is 164℃),
The drying temperature is set at 110 to 140°C. The heating drying of the applied emulsion and the foaming of the expandable resin particles can be carried out by any method. For example, a heating cylinder, an infrared heater, a hot air dryer, a suction dryer, etc. can be used, but it is preferable to use a hot air dryer. By this heating, the foamable resin particles are expanded by about 2 to 50 times, and the foam particles or parts of the particles having a particle size of 0.5 to 4.5 mm are fused together to form a foam sheet. Of course,
The foam particles also form a continuous foam (E) due to the resin coating of the emulsion. This foam layer provides insulation, formability, rigidity, and barrier properties to the laminate. (Effects) Due to the presence of such continuous foam layers, the laminate material of the present invention is a laminate material with significantly improved rigidity, heat insulation properties, and shielding properties. Further, by heating the laminated material to a temperature at which the foam softens and melts and press-molding the laminated material, the laminated material can be shaped into a desired shape and thickness. Furthermore, since both sides of the foam layer are covered with the base fabric, the sound of the foam layer rubbing is not generated, and the durability of the foam layer when it is broken is improved. Furthermore, it has excellent compatibility with other materials. Furthermore, during the production of the laminated material, the bucking coating agent is sandwiched between the base fabrics (A) and (B) and compressed to form a smooth foam layer. Hereinafter, the present invention will be explained in more detail with reference to Examples. Manufacturing example of needle punch carpet Example of nonwoven fabric for base fabric (A) 1 Polyester fiber and polypropylene fiber 200
A plain type needle punch carpet (80% polyester fiber) made of g/m ² was used and screen printing was performed on the surface. Example 2 Artificial leather Ecsaine (trade name) manufactured by Toray Industries, Inc. was used (heat resistance 160°C or higher). Example 3 A tufted carpet with nylon pile applied to a primary base fabric of polyester nonwoven fabric was used (basis weight: 450 g/m ² ). Example 4 Aqueous resin emulsion Acronal 295DN (product name: 50% solids content, MFT 20°C) from Mitsubishi Yuka Verdice Co., Ltd. was applied to a plain type needle punch carpet made of polyester fiber (basis weight 300 g/m ² ). 100 g/m ² (dry solid content) was used. Example of nonwoven fabric for base fabric (B) 5 A fiber mat (150 g/m ² ) made by randomly stacking 15 denier polyester fiber waste with a fiber length of about 100 mm and polypropylene (melting point 164°C) fibers,
Needle punch carpet with a thickness of about 1 mm (polyester fiber is 80 %) was obtained. Resin aqueous emulsion (1) Acronal S-886: Cross-linked styrene/acrylic acid ester copolymer aqueous emulsion manufactured by Mitsubishi Yuka Verdice Co., Ltd. (film forming temperature 20°C, Tg of cross-linked resin
(approx. 110℃, solid content concentration 50% by weight) (2) Acronal YJ-1100D: Mitsubishi Yuka Verdice Co., Ltd.'s styrene/acrylic acid ester copolymer aqueous emulsion (Tg 55℃, solid content concentration 46% by weight) ) (3) Deiofan 192D: Vinylidene chloride copolymer aqueous emulsion (Tg 20°C, solids concentration 55% by weight) manufactured by Mitsubishi Yuka Verdice Co., Ltd. Example 1 Needle punch carpet obtained in Example 1 (fabric weight
(200 g/m ² ) on the opposite side from the printed surface, (a) 200 parts by weight of Acronal 5-886 (b) From 400 parts by weight of expandable polystyrene particles with an average particle size of 0.33 mm (containing 5.5% by weight of butane) 700g solid amount of Naru Batsuking coating agent
After coating to give a thickness of m ² , the needle punch carpet obtained in Example 5 was immediately laminated as a base fabric (B), and then the nonwoven fabric layers on both sides were compressed with rolls to impregnate the emulsion on both sides. Then, the needle-punch carpet laminate impregnated with the emulsion was heated with hot air at 130°C for 15 minutes from the needle-punch carpet side obtained in Example 5 to remove moisture and expand the expandable polystyrene particles to increase bulk. A laminate was prepared comprising layers of continuous polystyrene foam particles having a density of approximately 0.14 g/cm ³ and a particle size of less than 1.0 mm. The thickness of the base fabric of the laminate material (Example 1) is approximately 2 mm, the thickness of the foam layer is approximately 5 mm, and the thickness of the base fabric (Example 4) is approximately 1 mm.
It was hot. Furthermore, this laminated material was heated for 60 seconds in a far-infrared oven at 180°C to sufficiently soften the backing material resin and polystyrene foam, and then heated at a pressure of 20 kg/cm ² for 1 minute using a cooling press mold. This was then molded to produce a carpet for the interior floor of an automobile. Comparative Example 1 In Example 1, a resin emulsion was used between the upper and lower nonwoven fabric layers, but the expandable polystyrene particles were not sandwiched (not used). layer 1
mm) was further molded to obtain a carpet for the interior floor of an automobile. Note that the evaluation of the laminate carpet is based on the following method. Three-point bending strength: A test piece (length 150 mm, width 50 mm) is supported with a span of 100 mm, and a deformation load is applied perpendicularly to the sample piece at a rate of 50 mm/min at the center point of the sample using an Instron type testing machine. The maximum bending resistance value was measured when a load was applied. Impermeability: Conforms to JIS A-6910 water permeability test. The water head is set to 250mm, and the judgment is made after 12 hours. ×: Water did not penetrate through the back surface and remain. △: Water bleeding is observed on the back side. ○: No water bleed is observed on the back side. Adhesive strength: Sample piece (length 150 mm, width 30 mm) Measure the peeling strength of the foam layer and base fabric (A) using an Instron type tester at a speed of 50 mm/min.

[Table] Examples 2 to 3 The bending strength, water impermeability, and shape were evaluated in the same manner as in Example except that the artificial leather of Example 2 and the tufted carpet of Example 3 were used instead of the needle punch carpet of Example 1. A laminated material with excellent fidelity and rigidity was obtained. In addition, in the case of artificial leather, it was pressed from both sides of the laminate. Examples 4 to 5 In Example 1, the mixing ratio of Acronal S-886 and expandable polystyrene particles (EPS) was 100 parts to 200 parts (Example 4) and 100 parts to 700 parts (Example 4). 5) in the same manner except that Table 2
A laminated material with the physical properties shown below was obtained. Examples 6-7 Acronal S as resin aqueous emulsion
A laminate having the physical properties shown in Table 2 was obtained in the same manner as in Example 1, except that Acronal 1100 or Diofan 192 was used in place of -866. Example 8 200 parts by weight of Acronal "S-886S" as a resin aqueous emulsion, as a nonwoven fabric for base fabric (A),
Obtained in Example 4, under felt 1000 using phenol used for vehicles as non-woven fabric for base fabric (B)
g/m ² as foamable resin and foamable styrene α-
Methylstyrene copolymer particles, Heatpole manufactured by Mitsubishi Yuka Verditz Co., Ltd. (Tg≒115℃, particle size 0.5
200 parts by weight of particles less than mm and particles with a particle size of 1.0 mm.
Using a mixture of 100 parts by weight (300 parts as foam layer)
A floor carpet (the thickness of the foamed layer was 1.5 mm) was obtained in the same manner as in Example ¹ except that the procedure was the same as in Example 1. The bending strength was 0.68 kg/5 cm width, but the moldability, water impermeability, shrinkage rate at 100°C, and adhesion to both nonwoven fabrics were good.

【table】

[Table] Example 9 In Example 1, the drying temperature was set to 95°C for 20 minutes, water was removed, and then foaming treatment was performed by heating at 130°C for 50 seconds in a hot air oven. As a result, as in Example 1, a foam layer with a thickness of about 5 mm was obtained. No differences were observed in moldability, water impermeability, rigidity, etc. Example 10 A floor carpet was molded in the same manner as in Example 8, except that the coating amount of the coating agent consisting of Acronal S-886S and expandable styrene/α-methylstyrene copolymer particles was changed to 700 g/ ^m2 . (The thickness of the foamed layer was approximately 5 mm). The bending strength of the carpet was 2.67 kg/5 cm width. Comparative Example 2 The same procedure as in Example 1 was made except that the base fabric (B) was not used, but the smoothness of the back surface was poor, so during drying and foaming,
It became non-uniformly foamed and curled significantly toward the base fabric (A). Also, because the foaming is random, the surface is uneven,
Smoothness could not be obtained. Three-point bending strength is 0.26 without immediate breakage (cracking).
Kg/5cm wide and low.

[Brief explanation of drawings]

FIG. 1 is a plan view showing the manufacturing process of the laminated material.

Claims (1)

[Claims] 1. Base fabric made of a material with a heat distortion temperature of 150°C or higher
On top of (A), apply a bucking coating agent containing (a) 100 parts by weight of aqueous resin emulsion (b) 150 to 700 parts by weight of expandable styrene resin particles,
Then, on top of this applied bucking coating layer,
The base fabric (B) made of a material with a heat deformation temperature of 150°C or higher is layered to form a laminate, and the laminate is compressed from one or both sides of the laminate to add a portion of the coating agent to the base. After impregnating the fabric (B), the base fabric (A), (B)
The foamable styrene resin particles are foamed by heating at a temperature lower than the heat distortion temperature of the material, and the aqueous resin emulsion is dried to obtain a laminate having a foam layer between the base fabrics (A, B). A method for manufacturing a laminated material, characterized by: 2. The manufacturing method according to claim 1, wherein the base fabric (A) is selected from tufted carpet, nonwoven fabric, and woven fabric. 3. Claim 1, wherein the resin aqueous emulsion is a styrene/acrylic acid lower alkyl ester copolymer aqueous emulsion.
Manufacturing method described in section. 4 The thickness of the base fabric (A) of the laminated material is 0.5 to 10 mm,
2. The manufacturing method according to claim 1, wherein the foam layer has a thickness of 1.0 to 20 mm, and the base fabric (B) has a thickness of 0.1 to 10 mm. 5. The fabric according to claim 1, characterized in that the basis weight of the base fabric (A) is 50 to 1000 g/ ^m2 , and the basis weight of the base fabric (B) is 10 to 2000 g/ ^m2 . Production method.