JPH03786A - Adhesive composition for carpet backing - Google Patents

Abstract

PURPOSE:To obtain the title adhesive which can give a thermoformable carpet having thermoformability, hot shape retentivity, and rigidity well-balanced among each other at high levels by using a polymeric latex and a fluorocarbon surface active agent containing a specified group as constituents. CONSTITUTION:The title composition essentially comprises a polymeric latex (e.g. an acrylic copolymer latex or a vinyl chloride copolymer latex) and a fluoroalkylated fluorocarbon surface active agent [e.g. a perfluoroalkylcarboxylic acid salt (trade name: Surfron S-111) or a perfluoroalkyl phosphate (trade name: S-112)]. The thermoformable carpet obtained by using this composition has excellent rigidity, thermoformability, and hot shape retentivity well-balanced among each other and can be suitably utilized as an automobile carpet, interior finish material, etc.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to an adhesive composition for carpet lining, and more particularly to the production of thermoformed carpets obtained through a thermoforming process, such as automobile carpets and interior materials. For use in carpet backing adhesive compositions.

(Prior art) Needle-punch carpets or tufted carpets for automobile interiors have thermoformability and heat-resistant shape retention (ability to maintain their shape in a high-temperature atmosphere of about 80 to 95 degrees Celsius) on the back side of the carpet. Thermoplastic resin sheets are laminated using an adhesive mainly composed of butadiene-styrene copolymer latex, etc., then cut into desired shapes, thermoformed, and used in automobiles. Ru.

However, the above method requires a two-step process of applying or impregnating the backside of the carpet with adhesive and laminating a thermoplastic resin sheet to this, which complicates the manufacturing process, making it difficult to improve productivity and reduce costs. For this purpose, a so-called one-stage processing method has been proposed that does not use the thermoplastic resin sheet as described above, that is, provides the necessary performance only with an adhesive. The adhesive used in this one-step processing method is, for example, an adhesive composition prepared by blending a crosslinking agent reactive with carboxyl groups with a mixture of a synthetic resin emulsion and a synthetic rubber latex (Japanese Patent Laid-Open No. 178187/1987). Adhesive composition using a copolymer latex containing two types of copolymers having different glass transition temperature ranges in the same particle (Japanese Unexamined Patent Application Publication No. 1983-1999)
196779), an adhesive containing a polymer emulsion having a high glass transition temperature and a halogen-containing polymer emulsion as essential components (JP-A-63-3123)
Publication No. 76), etc. are known.

(Problems to be Solved by the Invention) As mentioned above, in the one-stage processing method, the rigidity, thermoformability, and heat-resistant shape retention required for thermoformed carpets are achieved using only adhesive without using a thermoplastic resin sheet. However, when trying to improve thermoformability and heat-resistant shape retention, problems arise such as a decrease in rigidity. None of the conventionally known adhesives described above has sufficient rigidity, and it is impossible to obtain a thermoformed carpet in which rigidity, thermoformability, and heat-resistant shape retention are simultaneously improved in a well-balanced manner.

Therefore, the present invention solves the above-mentioned conventional problems, improves the rigidity without impairing thermoformability and heat shape retention, and provides a heat molding material that has a well-balanced and high level of thermoformability, heat-resistant shape retention, and rigidity. It is an object of the present invention to provide an adhesive composition for carpet lining, which allows the production of molded carpets.

(Means for Solving the Problem) The present inventors have discovered that a thermoformed carpet obtained by using an adhesive containing a fluorosurfactant having a specific group for carpet lining has very good rigidity. It was found that the material exhibited the following properties and had the ability to maintain its shape even after being subjected to harsh conditions of 95° C., and based on this knowledge, the present invention was completed.

That is, the present invention relates to an adhesive composition for carpet lining, which contains a polymer latex and a fluorosurfactant having a fluoroalkyl group as essential components.

The present invention will be explained in detail below.

The fluorosurfactant having a fluoroalkyl group used in the present invention refers to a fluorosurfactant containing a linear or branched alkyl group having 5 to 30 carbon atoms containing at least one fluorine atom as a hydrophobic group. means an agent. These may be used alone or in combination of two or more. In the present invention, among the above-mentioned fluoroalkyl groups, a fluorine-based surfactant having a perfluoroalkyl group is particularly preferably used.

Examples of the fluorine-based surfactants having a perfluoroalkyl group include perfluoroalkyl sulfonates, perfluoroalkyl carboxylates, perfluoroalkyl phosphates, perfluoroalkyl-ethylene oxide adducts, and perfluoroalkylaminosulfonic acids. salts, perfluoroalkyltrimethylammonium salts, perfluoroalkylbetaines, and the like.

Note that the above salts also include ammonium salts of metal salts such as sodium and potassium.

In addition, oligomers containing a perfluoroalkyl group and a lipophilic group, and oligomers containing a perfluoroalkyl group and a hydrophilic group can also be used as the fluorosurfactant having a perfluoroalkyl group of the present invention. .

The perfluoroalkyl group has the following structural formula (% formula %), but in the present invention, in this structural formula, n
A fluorosurfactant having a perfluoroalkyl group of 3 to 11, particularly 4 to 7 is preferably used.

The above-mentioned fluorosurfactant having a perfluoroalkyl group is commercially available and can be easily obtained. For example, Surflon S-111 (perfluoroalkyl carboxylate), S-112 (perfluoroalkyl phosphate ester), S-113 (perfluoroalkyl carboxylate), S-121 (perfluoroalkyl trimethylammonium salt) ), S-131 (perfluoroalkyl betaine), S-145 (perfluoroalkyl-
Ethylene oxide adduct) (manufactured by Asahi Glass Co., Ltd.), Megafac F-110 (perfluoroalkyl sulfonate), F-120 (perfluoroalkyl carboxylate), F-142D (perfluoroalkyl-ethylene oxide adduct eIj) ), F-150 (perfluoroalkyltrimethylammonium salt), F-160 (perfluoroalkylaminosulfonate), F-171 (perfluoroalkyl group/hydrophilic group-containing oligomer), F
-177 (perfluoroalkyl group (hydrophilic group/lipophilic group)-containing oligomer) (manufactured by Dainippon Ink & Chemicals Co., Ltd.), and the like.

As the polymer latex used in the present invention, various polymer or copolymer latexes conventionally used in the production of thermoformed carpets can be used. For example, acrylic copolymer latex, vinyl chloride synthetic rubber latex such as polyisoprene, polybutadiene, styrene-butadiene rubber, cellulose derivative polymer latex, Examples include polyvinyl alcohol polymer latex. These polymer or copolymer latexes can be used alone or in combination of two or more. Also,
Patent application No. 63-26217, which was previously proposed by the applicant of this patent.
A copolymer latex composition comprising two types of copolymer latexes having different glass transition temperatures as described in the specification of No. 5, and a copolymer having different glass transition temperature ranges as described in the above-mentioned JP-A-63-196779. A copolymer latex containing in the same particle can also be used.

Among these, latexes having a glass transition temperature of 50° C. or higher, preferably 70° C. or higher are suitably used. In addition, in the case of a latex consisting of two or more types of polymers having different glass transition temperatures, the above-mentioned glass transition temperature means the glass transition temperature of the polymer having a higher glass transition temperature. Specific examples of these suitable copolymer latexes include:
For example, diene-based copolymer latex and (meth)acrylic acid ester, which are composed of a conjugated diene and a monomer copolymerizable with the diene and have a conjugated diene content in the range of about 0.5 to 99.5% by weight, are mainly used. An example of this is an acrylic copolymer latex containing as a component a monomer copolymerizable with the acrylic copolymer latex. Monomers used in the production of these copolymers include diene compounds such as butadiene, isoprene, 2-chloro-1,3-butadiene, styrene, α-styrene, p-methylstyrene, vinyltoluene, chlorvinyl Vinyl aromatic compounds, such as toluene (
(meth)acrylic acid esters such as methyl meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, glycidyl (meth)acrylate, and 2-ethylhexyl (meth)acrylate, vinyl chloride,
Vinyl compounds such as vinyl acetate, (meth)acrylic acid,
Examples include unsaturated carboxylic acids such as itaconic acid and fumaric acid, amide compounds such as (meth)acrylamide and N-methylol(meth)acrylamide, and vinylidene compounds such as vinylidene chloride.

The adhesive composition for carpet lining of the present invention (hereinafter simply referred to as "adhesive composition") contains the above-mentioned fluoroalkyl group-containing fluorosurfactant and polymer latex as essential components. The amount of activator used is preferably 0.01 to 5% by weight, preferably 0.05 to 0.5% by weight of the total adhesive composition (solids).

If the amount used is less than 0.01% by weight, sufficient rigidity will not be exhibited, and if it exceeds 5% by weight, the surface tension of the adhesive composition will decrease significantly and the adhesive composition will seep onto the front side of the carpet. and cause surface contamination, resulting in poor appearance of the product carpet.

The reason why rigidity is improved by the addition of fluorosurfactants having fluoroalkyl groups is not necessarily clear, but it is said that fluorosurfactants exhibit an extremely low surface tension that cannot be reached by general hydrocarbon surfactants. Due to the inherent properties of the fluorosurfactant, when the adhesive composition is applied to or impregnated into the fiber base fabric, the penetration of the polymer latex into the fiber base fabric is promoted, and the polymer latex is absorbed onto the fiber surface or at fiber intersections. This is thought to be due to the fact that it is stuck to the surface.

In addition, the surface tension of the adhesive composition of the present invention is 20 to 35
It is preferably in the range of dyne/Cm. If the surface tension of the adhesive composition is too low, as described above, the adhesive composition will seep onto the front side of the carpet, causing surface staining, resulting in poor appearance of the product carpet. On the other hand, if the surface tension is too high, the polymer latex will not penetrate much into the fiber base fabric, making it difficult for the polymer latex to adhere to the fiber surface or fiber intersections.

There is no particular restriction on the method of adding the fluorosurfactant having a fluoroalkyl group to the adhesive composition of the present invention, and the fluorosurfactant may be added to the polymer latex or added to the polymer latex. It can also be used as an emulsifier during production and blended as is.

Fillers, pigments, antifoaming agents, anti-aging agents, crosslinking agents, flame retardants, thickeners, and the like can be appropriately blended into the adhesive composition of the present invention, if necessary.

Specific examples of the above-mentioned fillers include calcium carbonate, aluminum hydroxide, magnesium hydroxide, inorganic fillers such as glass fibers and metal #A fibers, plastic pigments and hollow particles such as polystyrene particles, synthetic fibers, natural fibers, etc. Mention may be made of organic fillers.

The adhesive composition of the present invention can be applied to carpets such as needle punch carpets and tufted carpets using synthetic fibers or natural fibers such as polyester, polypropylene, acrylic, and nylon, and the resulting thermoformed carpets are It can be used as carpets and interior materials for automobiles, etc.

(Example) Hereinafter, the present invention will be described in more detail with reference to Examples. Note that "part r" means "part by weight."

Example 1 4 parts of butadiene, 79 parts of styrene, 1 part of acrylonitrile
Part 5, acrylic W! 2 parts, t-dodecyl mercaptan 0.2 parts, potassium persulfate 0.3 parts, ion exchange water 15
0 parts and sodium dodecylbenzenesulfonate2.
0 parts of the mixture was placed in an IOR autoclave and incubated at 60"C for 25 hours without stirring to obtain a monomer composition of butadiene: styrene: acrylonitrile: acrylic acid.
A copolymer latex of 9:15:2 (weight ratio) was obtained. There was no formation of aggregates during the production of this copolymer latex, and the polymerizability was good. In addition, the 1-go conversion rate is 9
It was 8.8% by weight.

Surflon S-113 (trade name, Asahi Glass Co., Ltd.>a1 fluorooctylic acid ammonium salt) as a surfactant having a fluoroalkyl group is 0.1 to the above copolymer latex 10 (parts by weight (based on solid content)) An adhesive composition was prepared by blending the following parts.

This was whipped to three times its volume using a multipurpose mixer, and then applied to the back of a polyester needle punch carpet with a striped area of 450 g/m2 to a dry weight of 200 g/m2, impregnated, and heated at 150°C. A thermoformed carpet was obtained after drying for 10 minutes.

The rigidity, thermoformability, and heat-resistant shape retention of this thermoformed carpet were evaluated using the following test methods.

(Rigidity) The thermoformed carpet was cut into a size of 2 cm x 10 cm, and the stiffness of the obtained test piece was measured when it was bent at an angle of 30'' using an Olsen stiffness tester.

The larger the number, the higher the rigidity. It is preferable that the value is in the range of 40 to 50.

(Thermoformability) The thermoformed carpet was heated in a hot air dryer at 170° C. for 6 minutes, and then molded using a convex-concave press molding machine, and moldability was evaluated according to the following criteria.

O: Good Δ: Unsatisfactory X: Poor heat-resistant shape retention) The above molded carpet was
The sample was left in a hot air dryer at ℃ for 8 hours, and changes in shape at each temperature were evaluated based on the following criteria.

O: No deformation Δ: Slight deformation ×: Large loss of shape The results are shown in Table 1.

Example 2 100 parts (solid content) of the same copolymer latex used in Example 1 was mixed with Surflon S-112 (trade name, Asahi Glass Co., Ltd.) as a fluorosurfactant having a fluoroalkyl group. O alkyl phosphate ester)
A thermoformed carpet was produced in the same manner as in Example 1.

This thermoformed carpet was evaluated in the same manner as in Example 1, and the results are shown in Table 1.

Example 3 In Example 1, the monomer composition was butadiene: styrene: acrylic nitrile: acrylic acid = 4, 9:15
Example 1 except that an acrylic copolymer latex with a monomer composition of methyl methacrylate: acrylonitrile: acrylic acid = 78:20:2 (ffiil ratio) was used instead of a copolymer latex with a Xltfl ratio of 78:20:2 (Xltfl ratio). A thermoformed carpet was produced in a similar manner.

This thermoformed carpet was evaluated in the same manner as in Example 1, and the results are shown in Table 1.

Example 4 50 parts of a copolymer latex with a monomer composition of butadiene: styrene: methyl methacrylate: acrylic acid = 22:66:l O:2 (weight ratio) obtained by polymerization in the same manner as in Example 1 ( solid content) and 50 parts (solid content) of the copolymer latex obtained in Example 1, and 0.1 part of Surflon S-113 as a fluorosurfactant having a fluoroalkyl group was mixed therewith. Thereafter, a thermoformed carpet was obtained in the same manner as in Example 1.

This thermoformed carpet was evaluated in the same manner as in Example 1, and the results are shown in Table 1.

Comparative Example 1 In Example 1, Blysurf A-212C, which is a non-fluorine surfactant, was used instead of Surflon S-1'13.
A thermoformed carpet was produced in the same manner as in Example 1, except that (trade name, hydrocarbon alkyl phosphate ester manufactured by Nippon Oil & Fats Co., Ltd.) was used.

20 The thermoformed carpet was evaluated in the same manner as in Example 1, and the results are shown in Table 1.

Comparative Example 2 A thermoformed carpet was produced in the same manner as in Example 1 except that Surflon S-113 was not used.

This thermoformed carpet was evaluated in the same manner as in Example], and the results are shown in Table 1.

Comparative Example 3 In Example 1, except that Perex 0T-P (trade name, sodium dialkyl sulfosuccinate manufactured by Kao Seki Im Co., Ltd.), which is a non-fluorine surfactant, was used instead of Surflon S-113, A thermoformed carbant was produced in the same manner as in Example f51].

This thermoformed carpet was evaluated in the same manner as in Example 1, and the results are shown in Table 1.

Comparative Example 4 In Comparative Example 3, the amount of Pellex 0T-P used was 0.
A thermoformed carpet was produced in the same manner as Comparative Example 3 except that the amount was changed from 1 part to 1 part.

This thermoformed carpet was evaluated in the same manner as in Example 1, and the results are shown in Table 1.

Table 1 From the results in Table 1, it can be seen that when the fluorine-based surfactant having a fluoroalkyl group of the present invention was not used, or when a non-fluorine-based surfactant was used, the rigidity and heat-resistant shape retention were inferior. , it is understood that the performance is unbalanced.

(Effects of the Invention) The thermoformed carpet obtained using the carpet lining adhesive composition of the present invention has well-balanced rigidity, thermoformability, and heat-resistant shape retention, and can be used as an automobile carpet, interior material, etc. It can be suitably used.

Patent consultant: Japan Synthetic Rubber Co., Ltd. Agent: Patent Attorney Yuzo Nakai

Claims (1)

[Claims] (1) An adhesive composition for carpet lining, which contains a polymer latex and a fluorosurfactant having a fluoroalkyl group as essential components.