JPH0474472B2 - - Google Patents

Description

[Detailed description of the invention]

[Industrial Field of Application] The present invention relates to a laying material useful as an interior material for automobiles and a method for manufacturing the same. [Prior art] Needle-punch carpets made of non-woven fiber mat impregnated with SBR latex or thermoplastic resin aqueous emulsion as floor carpets for automobiles, and thermoplastic resin fibers with a high melting point and resin fibers with a melting point of 100 to 130°C. A molding material is known in which a needle-punch carpet of non-woven mat made of mixed fibers with a binder is heated to a temperature higher than the melting point of the resin in the emulsion or the resin fiber binder, and then press-molded into the shape of an automobile floor. be. These molding materials by themselves lack performance in terms of rigidity, elasticity, and moldability (mold fidelity).
In addition, this molded material has excellent breathability, but this advantage has the disadvantage that it has water permeability, and rain (drops from an umbrella) can pass through the molded material, causing the car body to rust. Also,
There is a drawback that the engine noise can be heard through the gaps between the fiber mats. [Specific means for solving the problem] The present invention uses a flexible surface carpet A as a molding material, and thermoplastic resin fibers with a melting point of 60 to 200°C to provide moldability and rigidity. The binder
15-50% by weight and above the melting point of the fiber binder
Using Needle Punch Carpet C, which is made by needling a fiber mat consisting of 85 to 50% by weight of synthetic fibers or natural fibers with a melting point higher than 40°C,
The present invention also provides a molded material in which both carpets are bonded together with a water-impermeable resin film, and a method for manufacturing the same. [Surface Carpet] Carpet A may be needle punch carpet made from fibers such as wool, nylon, polyacrylonitrile, polypropylene, polyacetate, polyethylene terephthalate, or a resin emulsion with a glass transition point of 35°C or lower. An original fabric for tufted carpet, which has piles made of polyamide or polyethylene terephthalate erected on a primary base fabric knitted with a non-woven fabric or flat yarn made of polypropylene impregnated and dried; A tufted carpet material with erected piles is used. In addition, the melting point is 60~60 to provide further rigidity.
Thermoplastic resin fiber binder at 200℃ is 15~50
% by weight, and synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the thermoplastic resin 85~
A needle-punched carpet with a fiber bulk density of 0.5 g/cm ³ or less obtained by needling a fiber mat consisting of 50% by weight, laminating it with a carpet of C in the future, heating it, and melting the fiber binder. Alternatively, it may be impregnated with an aqueous emulsion of a resin having a glass transition point of 35° C. or less or rubber latex and dried. This latter material is manufactured by a known nonwoven fabric manufacturing method.
That is, 15 to 50% by weight of a thermoplastic resin fiber binder having a denier of 1.2 to 300 and a fiber length of 25 to 150 mm;
1.2 to 300 denier, 15 to 50% by weight of thermoplastic resin fiber binder with fiber length of 25 to 150 mm, and 1.2 to 300 denier
Denier, fiber length 25-150mm synthetic fiber and/
Alternatively, a material in which 85 to 50% by weight of natural fibers are sufficiently mixed and opened is supplied to a web forming device, and cards formed from the mixed fibers are stacked to obtain the desired fiber weight. The web (fiber mat) is temporarily fixed by needling in the vertical direction to entangle the fibers. The fiber binder is used in a proportion of 15 to 50% by weight, preferably 20 to 40% by weight of the fiber mat weight. If it is less than 15% by weight, the contribution to improving the rigidity and dimensional stability of the carpet obtained by press molding will be small. On the other hand, if it exceeds 50% by weight, it becomes like resin felt, hard and brittle with impaired fiber texture. Similarly, when the bulk density is higher than 0.5 g/cm ³ , the fiber layer becomes dense, and although the rigidity is improved, the texture of the fibers is impaired. [Needle Punch Carpet C] Carpet C is composed of 15 to 50% by weight of a thermoplastic resin fiber binder with a melting point of 60 to 200°C, and a synthetic fiber or synthetic fiber having a melting point 40°C or more higher than the melting point of the thermoplastic resin. This web is obtained by needling a fiber mat consisting of 85 to 50% by weight of natural fibers, and is manufactured by a known nonwoven fabric manufacturing method. i.e. 1.2-300 denier, fiber length 25-150
mm thermoplastic fiber binder 15-50% by weight
and 15 to 50% by weight of a thermoplastic resin fiber binder with a denier of 1.2 to 300 and a fiber length of 25 to 150 mm, and 1.2
~300 denier, 25-150 mm fiber length synthetic fibers and/or 85-50% by weight of natural fibers are sufficiently mixed and opened and supplied to a web forming device,
A web (fiber mat) obtained by stacking cards formed from the mixed fibers to a desired fiber weight is temporarily fixed by needling in the vertical direction to entangle the fibers,
Bulk density is 0.15~0.5g/cm ³ , area weight is 300~2000g/
^m2 is preferred. The fiber binder is used in a proportion of 15 to 50% by weight, preferably 20 to 40% by weight of the fiber mat weight. If it is less than 15% by weight, the contribution to improving the rigidity and dimensional stability of the carpet obtained by press molding will be small. On the other hand, if it exceeds 50% by weight, it becomes like resin felt, hard and brittle with impaired fiber texture. Similarly, when the fiber bulk density exceeds 0.5 g/cm ³ , the stiffness improves, but the carpet becomes resinous and the feel is impaired. On the other hand, the fiber density is 0.15g/
If it is less than cm ³ , rigidity is insufficient and shape retention (formability)
It's bad. Examples of the fiber binder include polyethylene, linear polyester, polypropylene, low melting point polyamide, etc., and examples of the high melting point fiber include polyamide, polyethylene terephthalate, wool, etc. Resin film The material resin for adhesive film B is a thermoplastic resin with a melting point of 80 to 170°C, such as ethylene.
Vinyl acetate copolymer, polyethylene, ethylene/
Acrylic acid copolymer or its metal salt (K, Li,
Na, Zn, Pb), polypropylene, etc. are used. This resin is melt-kneaded using an extruder, then melt-extruded from a die into a film, guided between both needle punch carpets A and C, and then compressed by a compression cooling roll to B and C are integrated. The thickness of the resin film is 20 to 2000 microns, preferably 35 to 300 microns. In addition to the above-mentioned method, A, B, and C can be integrated.
Lay carpet A, resin film B, and carpet C in this order using the guide roll, and then
A method in which the emulsion is dried by heating at 150 to 200°C and the emulsion resin and the above film are dissolved, and then press molding is performed to integrate and shape the three parts A, B, and C. The molten resin film B may be laminated onto the needle punch carpet, and then another needle punch carpet C or A may be adhered using a pressure roll. Multi-layer molded material The wall thickness of carpet A for the surface layer of multi-layer molded material is 0.5
5 mm, and the wall thickness of the needle punch carpet for the back side is 1 to 10 mm, preferably 2 to 5 mm.
The overall thickness of the multilayer molded material is 1.5 to 15 mm, preferably 3 to 5 mm. Needle punch carpet C of this multilayer molding material
If D such as under felt, foamed polystyrene sheet, polypropylene sheet, polyvinyl chloride sheet, nonwoven fabric, etc. is superimposed on the side and then heated and compression molded, a laying material whose back side is decorated with these can be obtained (see Figure 1). ). In addition, after heating the carpet side of C, if reinforcing materials such as plywood, resin felt, or cardboard are layered and bonded under pressure, these reinforcing materials can be integrally bonded to the molding material. It is useful as a molding material for rear bags and various trims. In particular, when underfelt is used as the backing material, raindrops that seep in from the surface layer A are blocked by the film B, so that the underfelt does not become rotten or moldy. Example 1 80 g/m ² (solid content) of SBR latex was applied to a plain type needle punch carpet made of 350 g/m ² of polyester fibers and dried to obtain needle punch carpet A. Separately, 20% recycled polypropylene (melting point 164°C) fiber binder of 15 denier and approximately 100 mm fiber length,
A fiber mat (850
g/m ² ) with a 15-18-32-3RB needle at a rate of 50 needles per square inch to create a needle carpet with a wall thickness of approximately 8.1 mm and an apparent density of 0.105 g/cm ³ . I got a C. Guide both carpets A and C with guide rolls,
Between these two, melt kneading is carried out using an extruder, and 190
A molten film B of ethylene/vinyl acetate copolymer extruded from die 1 with a thickness of 150 microns at ℃ is guided, and these three are superimposed with a nip roll.
It was compressed and integrated to obtain a molded material with a multilayer structure. In addition, after heating the needle punch carpet C side of this multilayer molding material at 190°C to melt the polypropylene fiber binder, an under felt with a thickness of 10 mm was brought into contact, and this was then press molded to form a multilayer molding material. Obtained the mold material. This item shows a shape that is faithful to the mold cavity of the mold, and C
The layer thickness is 4.7mm, and its fiber bulk density is 0.188g/cm ³
It was hot. The physical properties of the multilayer molded materials A/B/C were evaluated by the method described later. The results are shown in Table 1. Waterproofness: After heating the multilayer molding material to 190℃, compression molding is performed under the conditions of 0.35Kg/cm ² G to a length and width of 200mm and depth of 20mm.
When a tray-shaped container of If water drips discontinuously, the waterproofness is fair (△), and if water does not permeate at all, the waterproofness is good (◯). Cushionability: The initial wall thickness when a load of 50 g/cm ² is applied to a multilayer molded material is t ₀ , and the wall thickness when a load of 400 g/m ² is applied for 1 minute is t ₁ . is removed and the wall thickness after 1 minute has passed is t _2. Compression rate = t ₀ - _{t 1} / t ₀ × 100 Compressive modulus = t ₂ - _{t 1} / t ₀ - t ₁ × 100 Deformation rate It was calculated as = (1- _t2 / _t0 ) x 100, and those with a small deformation rate and a small thickness change rate were considered to have good cushioning properties. [Adhesive strength] Surface carpet A and needle punch carpet C at one end of the sample piece (length 50 mm, width 200 mm) were each fixed to an Instron type testing machine, and the 200 mm/
A 180 degree peel test was conducted at a speed of 10 minutes. Example 2 As a non-woven fiber mat, 15 denier, fiber length
Fiber Mat C' (fabric weight 850
A molded material in which three layers were integrated was obtained in the same manner as in Example 1, except that the molding material was used (g/cm ³ ). Table 1 shows the physical properties of this molding material. Comparative Example 1 In Example 1, a nonwoven fabric B "Syntex PK-" made of polypropylene fiber binder manufactured by Mitsui Petrochemical Industries, Ltd. was applied to the back side of needle punch carpet A.
110” (product name, basis weight 50g/m ² , fiber diameter 3 denier)
Layer three sheets of non-woven fabric B, then layer needle carpet C under this non-woven fabric B, and then apply this laminate to 190 mm.
After heating to ℃ to melt the polypropylene fiber binder of nonwoven fabric B and needle punch carpet C, pressure molding is performed using a press molding machine, and the thickness of layer C is determined by integrating each layer faithfully to the mold. A 4.5 mm molded material was obtained. Example 3 In Example 1, needle punch carpet A was made of 350 g of a mixed fiber of 20% by weight of recovered polypropylene fiber binder with a 15 denier and a fiber length of about 100 mm and 80% polyethylene terephthalate fiber with a 15 denier and a fiber length of 75 to 125 mm. / ^m2 plain type needle punch carpet,
A molded material with a multilayer structure was obtained in the same manner as in Example 1, except that 80 g/m ² (solid content) of SBR latex was applied and dried. Table 1 shows the physical properties of this molding material. Reference Example Table 1 shows the physical properties of molded materials obtained by individually molding Carpet A and Carpet C used in Example 1.

【table】

【table】 [Brief explanation of the drawing]

FIG. 1 is a perspective view of a multilayer molded material obtained by carrying out the present invention, and FIG. 2 is a front view showing a manufacturing apparatus. In the figure, A is a carpet, B is a film, and C is a carpet.

Claims (1)

[Claims] 1 Carpet A for the surface layer and a melting point of 60 to 200°C.
15-50% by weight of thermoplastic fiber binder
and a needle-punch carpet C obtained by needling a fiber mat consisting of 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 fiber binder, and bonding them with a melt-extruded film B. A method for producing a multilayer molded material characterized by: 2. Claim 1, wherein the carpet A for the surface layer is a needle punch carpet impregnated with a resin emulsion or rubber latex having a glass transition point of 35° C. or lower and dried.
Manufacturing method described in section. 3. The manufacturing method according to claim 1, wherein the carpet A for the surface layer is a tufted carpet. 4 Carpet A for the surface layer has a fiber binder of 15 to 50
% by weight, and a resin fiber having a melting point at least 35°C higher than the melting point of the resin material of the fiber binder.
The manufacturing method according to claim 1, characterized in that the needle punch carpet is made of 85 to 50% by weight of mixed fibers and has a fiber bulk density of 0.5 g/cm ³ or less. 5. The manufacturing method according to claim 1, wherein the thickness of the film B is 20 to 2000 microns. 6 Carpet A for the surface layer and 15 to 50% by weight of a thermoplastic resin fiber binder with a melting point of 60 to 200°C
and a needle-punch carpet C made by needling a fiber mat made of 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 fiber binder are integrated with a resin film B as an adhesive layer. A multi-layer molded material characterized by: