JPH05201279A - Manufacture of molded carpet - Google Patents

Abstract

PURPOSE:To prevent polyurethane foaming material from seeping on the surface of a carpet to pollute it when forming a polyurethane foam material layer on the back of the carpet. CONSTITUTION:A prevention film 14 is formed by applying a polyurethane water dispersing material 14A to the back of a carpet 11 to be dried, or a prevention sheet consisting of nonwoven fabric 13 impregnated with the polyurethane water dispersing material 14A is bonded.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a molded carpet used, for example, for automobile floor coverings.

[0002]

2. Description of the Related Art For carpets for automobile floor coverings,
Carpet (1) molded as shown in FIG.
There is provided a method for providing the carpet (1) with soundproof and heat insulating properties by inserting the polyurethane foam layer (5) on the back surface of the carpet (1) by inserting it into the carpet (1).

Carpet (1) The carpet is on the back side
A backing layer (2) is formed to give moldability and dimensional stability to (1). The backing layer (2)
Is, for example, a polyethylene film, a styrene-butadiene latex coating layer, an acrylic resin emulsion coating layer, or the like.

However, the backing treatment layer (2) has many pinholes and cracks at the time of formation or molding of the carpet (1), especially in the deep drawing portion, and the polyurethane foam layer (5) is formed in the foaming mold (9). There is a problem that the polyurethane foam material exudes from the pinholes and cracks of the backing treated layer (2) when forming the above, and the carpet (1) surface is contaminated.

Therefore, conventionally, for example, a blocking film (4) which is excellent in spreadability and is unlikely to cause pinholes and cracks, such as a polyamide film, is adhered onto the backing treatment layer (2).

[0006]

However, in the above-mentioned conventional structure, the blocking film (4) is tensioned during the production, and is stretched in the tension direction and wound into a roll. The blocking film (4) wound up has a tension even when laminated on the carpet (1) side, and is stretched in the tension direction and heat-sealed. The laminated barrier film (4) shrinks after forming the carpet (1) by the stretched amount. This shrinkage is the carpet
(1) It is much larger than the shrinkage of the body. Due to the difference in shrinkage amount between the main body of the carpet (1) and the blocking film (4), a wavy deformation occurs in the molded article of the carpet (1). Further, when the backing layer (2) of the carpet (1) is a polyethylene film having poor adhesiveness, the polyamide film cannot be directly adhered, so the blocking film (4)
As a problem, for example, an expensive film having a two-layer or three-layer structure in which a polyethylene film is laminated on a polyamide film must be used.

[0007]

[Means for Solving the Problems] As a means for solving the above-mentioned conventional problems, the present invention provides a blocking film (14) by coating a backing-treated carpet (11) with a polyurethane water dispersion (14A) on the back surface and drying. ) Forming or non-woven
Step 1 of adhering the blocking sheet (13A) impregnated with the aqueous polyurethane dispersion (14A) to (13) Step 1 Step of shaping the carpet (11) into a predetermined shape 2 Step of molding the shaped carpet (11) with a foam mold (19 ), And the polyurethane foam layer (15) on the back surface of the carpet (11)
The present invention provides a method for producing a molded carpet comprising the above steps 1, 2, and 3, and when the backing layer (12) of the carpet (11) is a polyethylene film,
Adhesion of non-woven fabric (13) to the back side of carpet (11), application of polyurethane water dispersion (14A), drying and blocking film
Form (14).

In the present invention, the back surface of the carpet (11) is backed. The backing processing is performed by adhering a polyethylene film extruded from a T-die to the back surface of the carpet (11) in a heat-softened state, or by using styrene-butadiene It is carried out by applying latex or acrylic resin emulsion and drying.

The polyurethane water dispersion (14A) used in the present invention is mainly a urethane elastomer dispersed in water, and in order to improve the shape and dimensional stability or heat resistance of the carpet, the urethane elastomer is A crosslinked structure is desirable. As such a polyurethane aqueous dispersion, for example, Superflex 700, 900 (Daiichi Kogyo Seiyaku Co., Ltd., trademark) and the like are put on the market.

In step 1, the polyurethane aqueous dispersion (14A) is applied to the back surface of the carpet (11) which has been subjected to the backing treatment, and the amount of application is usually 30 to 9 as resin content.
The coating amount may be about 0 g / m ^2, and particularly, the backing layer (12) of the carpet (11) may be coated with a large amount of pinholes or cracks, for example, the deep-drawing portion of the carpet (11). Alternatively, only this portion may be applied. The polyurethane water dispersion (14A) is applied to the back surface of the carpet (11) and then dried by heating at 150 ° C. for about 2 to 3 minutes to form the blocking film (14) and at the same time melt the backing layer.

In the present invention, when the backing layer (12) of the carpet (11) is a polyethylene film, a non-woven fabric (13) is formed on the polyethylene film in order to obtain good adhesion with the blocking film (14). Is adhered, and then the polyurethane water dispersion (14A) is applied.

Further, in the present invention, instead of applying the polyurethane aqueous dispersion (14A), a blocking sheet (13A) made of a nonwoven fabric (13) impregnated with the polyurethane aqueous dispersion (14A) is applied to the carpet (11). You may attach it to the back side.

[0013]

In the present invention, the blocking film (14) is formed by applying the polyurethane aqueous dispersion (14A) and drying it. Therefore, when the blocking film (14) is formed, the blocking film (14) is not formed. No tension is exerted, and therefore no contraction force is generated due to the elongation due to the tension. Nonwoven fabric impregnated with polyurethane water dispersion (14A)
When the blocking sheet (13A) composed of (13) is used, the elongation deformation of the polyurethane tank is caused by the tension,
It is blocked by (13), so that contraction force is not generated due to the elongation.

Further, the backing layer (1) of the carpet (11)
When 2) is made of polyethylene film, a non-woven fabric (13) is adhered onto it, and the non-woven fabric (13) is dispersed in polyurethane water.
When the blocking film (14) is formed by applying (14A), the non-woven fabric (13) becomes a polyethylene film (12) and a blocking film (1).
Good adhesion to both 4).

[0015]

EXAMPLES The present invention will be described with reference to one example shown in FIGS. 1 to 4. As shown in FIG. 1, the backing of the carpet (11) extruded from the T die (22) in a heat-softened state. Polyethylene film (12) and non-woven fabric (13) that are treated layers
And are crimped by a crimping roll (23). The polyethylene film (12) usually has a basis weight of about 200 to 700 g / m ² , and the non-woven fabric (13) is a non-woven fabric such as polyester fiber or acetate fiber, and usually has a basis weight of 30 to 100 g / m ^2.
Something is used.

In step 1, as shown in FIG. 2, Superflex 700 (Daiichi Kogyo Seiyaku Co., Ltd.), which is a 30% by weight aqueous dispersion (14A) of polyurethane, is applied to the back surface of the carpet (11) by a roll coater (16). , Trademark) is 100
~ 250 g / m ² applied, then heating chamber (17)
Is dried at 150 ° C. for 3 minutes. Thus, as shown in FIG. 2, the non-woven fabric on the back side of the carpet (11)
A blocking film (14) is formed on (13).

In step 2, as shown in FIG. 3, the carpet (11) is press-molded by a molding die (18) into a predetermined shape. At this time, the polyethylene film (12) of the carpet (11) is in a softened state due to the heating in the heating chamber (17) of step 1.

In step 3, as shown in FIG. 4, the molded carpet (11) is inserted into the foaming mold (19), and the polyurethane foam material is injected into the foaming mold (19) to form the polyurethane foam. Form the layer (15). After that, the carpet (11) is taken out from the foaming mold (19) and used for automobile flooring.

In the present invention, as shown in FIG. 5, a non-woven fabric (13) is immersed in a polyurethane water dispersion (14A) in a dipping tank.
The nonwoven fabric (13) is impregnated with the polyurethane aqueous dispersion (14A) by immersing in the (20), and then the heating chamber (21)
Blocking sheet by heating and drying by (13A)
The blocking sheet (13A) may be adhered to the back surface of the carpet (11) through the backing layer (12).

[0020]

Therefore, in the present invention, when the polyurethane foam layer is formed on the back surface of the carpet, the adhesion of the blocking film or the blocking sheet for preventing the polyurethane foam material from leaching and contaminating the surface of the carpet to the carpet. It can be greatly improved and the carpet does not deform because the blocking film or sheet does not shrink.

[0021]

[Brief description of drawings]

 1 to 4 show an embodiment of the present invention.

FIG. 1 is an explanatory diagram of a carpet backing process.

FIG. 2 is an explanatory diagram of step 1

FIG. 3 is an explanatory diagram of step 2

FIG. 4 is an explanatory diagram of step 3

FIG. 5 is an explanatory diagram of another embodiment.

FIG. 6 is an explanatory diagram of a conventional example.

[Explanation of symbols]

 11 Carpet 12 Backing layer 13 Nonwoven fabric 13A Blocking sheet 14 Blocking film 14A Polyurethane water dispersion 15 Polyurethane foam layer

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[Procedure amendment]

[Submission date] July 24, 1992

[Procedure Amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0021

[Correction method] Delete

[Procedure Amendment 2]

[Document name to be amended] Statement

[Name of item to be corrected] Brief description of the drawing

[Correction method] Change

[Correction content]

BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1 to 4 show an embodiment of the present invention .

FIG. 1 is an explanatory diagram of a carpet backing process.

FIG. 2 is an explanatory diagram of step 1

FIG. 3 is an explanatory diagram of step 2

FIG. 4 is an explanatory diagram of step 3

FIG. 5 is an explanatory diagram of another embodiment.

FIG. 6 is an explanatory diagram of a conventional example.

[Explanation of symbols] 11 Carpet 12 Backing layer 13 Nonwoven fabric 13A Blocking sheet 14 Blocking film 14A Polyurethane water dispersion 15 Polyurethane foam layer

Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI Technical display area B29K 105: 04 B29L 9:00 4F

Claims (2)

[Claims] 1. A step of applying a water dispersion of polyurethane to the back surface of a backing-treated carpet and drying it to form a blocking film, or adhering a blocking sheet impregnated with a water dispersion of polyurethane to a non-woven fabric. Step 2 of molding into a step 2 of inserting the molded carpet into a foaming mold to form a polyurethane foam layer on the back surface of the carpet 3. A method of manufacturing a molded carpet comprising the above steps 1, 2 and 3. 2. A sheet obtained by adhering a non-woven fabric to the back surface of a carpet backed with a polyethylene film and then applying a polyurethane water dispersion and drying to form a film, or impregnating the non-woven fabric with the polyurethane water dispersion and drying. Step 1 of adhering the carpet to a predetermined shape Step 2 Step of inserting the molded carpet into a foaming mold to form a polyurethane foam layer on the back surface of the carpet 3 Steps 1, 2 and 3 above Molded carpet manufacturing method