JPH064935B2 - Backing method for laying materials - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to an interior material for automobiles, rugs inside and outside a house, and a method for lining carpets and woven fabrics useful as interior materials.

[Prior art]

Non-woven fiber mats impregnated with a resin aqueous emulsion as floor carpets for automobiles, or non-woven mats composed of mixed fibers of high melting point thermoplastic resin fibers and resin fiber binders having a melting point of 100 to 130 ° C are used as resins in emulsions. Alternatively, a carpet which is heated to a temperature equal to or higher than the melting point of the resin fiber binder and then press-molded to have a shape of an automobile floor is known.

These carpets lack luxury by themselves,
Also, because it lacks in one of rigidity, elasticity, and moldability,
On the surface of this carpet, a tufted carpet obtained by raising fibers in a loop shape to a polypropylene flat yarn cloth base fabric is adhered using a hot-melting agent, or the both carpets are overlapped and press-molded, or a foam is formed. It has been proposed that the sheet be lined on the carpet via a polyethylene film hotmelt agent.

Similarly, foamed polyethylene, urethane foam or under felt is also attached to the back of a polyvinyl chloride sheet or woven floor.

[Problems to be solved by the invention]

When a resin-based emulsion is used as the packing material, if this emulsion forms a foam, a small amount of the packing material is required, and the carpet is also lighter in weight.

For this reason, the foam coating method is used in the carpet, but in this method, the foam is broken after the coating. If the bubbles do not break and the initial shape can be maintained, the cushioning property of the carpet can be further improved. This can have the same effect as if a felt or foam sheet was attached to the back surface of the carpet.

As such a method, a high-foaming resin aqueous emulsion containing an ethylene / vinyl chloride / vinyl acetate copolymer aqueous emulsion, a thermally decomposable chemical foaming agent, and a decomposition accelerator (Japanese Patent Laid-Open Nos. 56-103229 and 56-103230). issue)
As a backing material, which is applied and impregnated on a woven fabric, and then at a temperature (60-1
(50 ° C) to evaporate the water to dry and then
It is conceivable that the chemical foaming agent is heated to a temperature (150 to 250 ° C.) at which it decomposes to cause foaming and backing.

This method requires heating in two steps and needs to be heated to a high temperature in order to reach foaming, which causes the carpet to be discolored, and the crystalline thermoplastic material that causes heat shrinkage as a carpet material. The use of resin fibers is limited.

Further, a method of mechanically stirring a resin aqueous emulsion to blow air into it to make it foam, applying this foamed emulsion to a laying material, and drying it to back it up is also performed, but in this method, The foamed resin emulsion has a defect that the bubbles become large or breaks with the passage of time, and stable and uniform bubbles cannot be obtained.

[Specific means for solving problems]

In the present invention, in the latter mechanical foaming method, by adding a silicone oil-based nonionic surfactant type heat-sensitive gelling agent to the resin water-based emulsion, a stable foaming emulsion is obtained, coarsening of the bubbles, and foam breaking. By using this foamed resin aqueous emulsion, a foamed resin backing layer having a foaming ratio of 2 to 10 can be obtained as a laying material.

That is, the present invention, a silicone oil-based water-soluble heat-sensitive gelling agent, and a resin aqueous emulsion containing a nonionic surfactant are mechanically agitated to foam, and then the foamed resin aqueous emulsion is used as a laying material. The present invention provides a backing method for a laying material, which comprises applying the coating to the back surface of the resin and heating it to gelate the resin aqueous emulsion to form a foamed resin backing layer on the laying material.

According to the method of the present invention, all or most of the backing material is present in a foamed state, so that the obtained laying material is excellent in cushioning property and shows a soft texture as a whole.

In the conventional method of coating and impregnating a non-foaming resin aqueous emulsion binder on a rug stock, the binder is likely to be non-uniformly impregnated in the fiber of the stock due to a capillary phenomenon. Especially when the rug is a needle punched carpet, the binder resin strongly adheres to the roots of needle traces and tufted pile raising, causing uneven binding of the binder resin, resulting in needle traces on the laying material and tufted pile parts. It gives a stiff feel and lacks a soft feel.

In the present invention, by coating the backing material with a foam, the viscosity of the backing material is increased to reduce the penetration rate of the backing material into the needle traces and the pile portion, so that the backing material (laying material) is evenly distributed over the entire surface. It was possible to carry out backing.

In addition, a nonionic surfactant, which is a silicone oil-based water-soluble heat-sensitive gelling agent, was included in the backing material in order to prevent foam breakage during foam coating.

(Laying material) As the laying material, needle punched carpet obtained from fibers such as wool, nylon, polyacrylonitrile, polyacetate, polyethylene terephthalate, spunbonded non-woven fabric and polypropylene on the primary base fabric woven with polypropylene flat yarn , A polyethylene terephthalate pile upright tufted carpet fabric, a woven fabric, a needle punched carpet or a spunbond nonwoven fabric as a primary base fabric, and a pile upright tufted carpet etc. used.

(Resin water emulsion) The resin water emulsion is the glass transition point (Tg) of the resin in the emulsion when the moldability and rigidity of the new material are increased.
Of 80 to 180 ° C. is used. On the contrary, when the purpose is not to impair the flexibility, a resin emulsion having Tg of 30 ° C. or lower, preferably 20 ° C. or lower is used. Of course, Tg of 30 to 80 ° C. may be used in consideration of the balance between rigidity and flexibility.

Further, a plasticizer may be added to the emulsion.

Examples of emulsions having a Tg of 80 to 180 ° C. are lower esters of styrene / acrylic acid (the number of ester carbons is 2 to 2).
6) Thermoplastic resins such as copolymers, lower ester copolymers of methacrylate / acrylic acid, vinylidene chloride copolymers (vinylidene chloride content is 85% by weight or more), and styrene / diene copolymers.

Optimally, (a). Poly (n-propyl methacrylate) (Tg 81 ℃), polystyrene (100 ℃), polyacrylonitrile (10
0 ° C.), polymethylmethacrylate (105 ° C.), polymethacrylic acid (130 ° C.), polyitaconic acid (130 ° C.) polyacrylamide (153 ° C.), and other aqueous emulsions of homopolymers (b). Vinyl monomers, which are the raw materials of these polymers, 50-
100% by weight, preferably 65 to 95% by weight, and other vinyl monomers such as 2-ethylhexyl acrylate Tg-
85 ° C), n-butyl acrylate (-54 ° C), ethyl acrylate (-22 ° C), isopropyl acrylate (-
50), 2-ethylhexyl methacrylate (-5 ° C),
N-propyl acrylate (8 ° C), n-butyl methacrylate (20 ° C), vinyl acetate (30 ° C), acrylic acid t
-Butyl (45 ° C), 2-hydroxyethyl methacrylate (55 ° C), ethyl methacrylate (65 ° C) isobutyl methacrylate (67 ° C), vinyl chloride (79 ° C), etc. or vinylidene chloride (-18 ° C) 50 wt. % Or less, preferably 35 to 5% by weight, of an aqueous emulsion of a copolymer [Tg shown in () in this item (b) is a glass of a homopolymer of these vinyl monomers or vinylidene chloride]. It is a transition point], (c). Resin aqueous emulsion 5 with Tg of + 80-155 ℃
0-97% by weight, preferably 55-95% by weight, and a resin aqueous emulsion having a Tg of -85 ° C to less than + 80 ° C 50-
3% by weight, preferably a mixture with 45 to 5% by weight, and the like.

In the case of these resin aqueous emulsions having a high Tg, a small amount of binder is used to make the liquid even, and the permeation of the liquid into the laying material is reduced.

For those having a Tg of 30 ° C. or lower, the type and amount of the vinyl monomer are determined with reference to the Tg of the homopolymer of the vinyl monomer, and the Tg of the resin aqueous emulsion resin obtained is 30.
Keep it below ℃.

The resin aqueous emulsion is a cross-linking type resin aqueous emulsion (Japanese Patent Laid-Open Nos. 57-3850 and 57-3857,
Japanese Patent Application Nos. 60-2014437 and 60-201438
No. 60-201439), and examples thereof include Acronal YJ-2740, YJ-2741, YJ-272 manufactured by Mitsubishi Petrochemical Verditsie Co., Ltd.
0, YJ-2716 (both are trade names), Sumitomo Chemical Co., Ltd.'s SUMIKAPLEX 900, 751 (both are trade names).

The aqueous resin emulsion of the present invention must be obtained by emulsion polymerization of the vinyl monomer in the presence of a nonionic surfactant.

Generally, nonionic surfactants have a cloud point (35 to 80 ° C.) and are usually heat-sensitive, and examples thereof include aliphatic alcohol / ethylene oxide adducts such as Texofor V27 (cloud point 55 by ABM Chemical Co.). ℃),
Same as T95 (cloud point 55 ℃), Plurafac D25 (cloud point 57 by Pakiney Eugene Coolman)
° C); alkylphenol / ethylene oxide adduct,
For example, ICI's Synperonic N
P9 (cloud point 54 ° C.), Texhohol FN11 (cloud point 39 ° C.) from ABM Chemicals; propylene oxide / ethylene oxide copolymer, eg Spronik B50 (cloud point 41 ° C.) from ABM Chemicals; polyoxyethylene glycol, polypropylene glycol Etc. can be used.

By the way, the nonionic surfactant used for emulsion polymerization does not exhibit heat sensitivity in the temperature range of emulsion polymerization, and therefore cannot act effectively as a heat sensitive agent. In addition, the post-added nonionic surfactant has almost no effect on the stabilization of the resin aqueous emulsion even if the nonionic surfactant itself exhibits a cloud point.

The nonionic surfactant of the resin aqueous emulsion used in the present invention has a cloud point of 80 ° C. or higher, and specifically, polyoxyethylene lauryl ether, polyoxyethylene cetyl ether, polyoxyethylene stearyl ether, polyoxyethylene. Oleyl ether, polyoxyethylene higher alcohol ether, polyoxyethylene nonylphenyl ether and the like are sold by Kao Corporation under the brand name of Emulgen.

This nonionic surfactant is used in the resin aqueous dispersion obtained in an amount of 0.1 to 5% by weight, preferably 0.5 to 3% by weight.

(Heat-sensitive gelling agent) As the water-soluble silicone-based heat-sensitive gelling agent that imparts the effect of heat-sensitive coagulation of the resin aqueous emulsion, TPA-4380, SF-8427, SH-of Toshiba Silicone Co., Ltd.
3746, SH-3748, SH-3749, and Coagrant WS (all trade names) of Bayer AG of West Germany can be used.

Natural rubber latex and artificial rubber latex (SB
R, NBR) as a heat-sensitive gelling agent, polyvinyl methyl alcohol, polypropylene glycol, polyether polyformal, a nonionic surfactant having a low cloud point,
Inorganic or organic zinc ammonium complex salts and nitroparaffin that exhibit gelling action in the presence of zinc oxide are known, but these are heat-sensitive gels for aqueous emulsions such as acrylic resins and ethylene-vinyl acetate copolymers. It does not have the function of making it practical, or it is small at all, and it is suitable for practical use.

By the way, NUC Silicone FZ-2107 (cloud point 53.5 ° C., trade name) made by Nippon Unicar Co., which is composed of polyoxyalkylene glycol, which is a water-soluble silicone-based heat-sensitive gelling agent and also a nonionic surfactant, and silicone, is sold. There is.

The combination of this water-soluble silicone heat-sensitive gelling agent having a polyoxyalkylene glycol chain and the nonionic surfactant having a polyoxyalkylene glycol chain is a gel of an acrylic resin or an aqueous emulsion of ethylene / vinyl acetate copolymer. It is particularly effective for the use of one of them, or when only one of them is used, or when another heat-sensitive gelling agent or other surfactant, for example, anionic surfactant such as potassium laurate and castor oil potassium soap is used. , The gelling function is impaired.

(Optional component) In order to give a feeling of weight to the laying material in this emulsion, it is also possible to add a filler or a coloring agent such as calcium carbonate, iron oxide, ferrite, barium sulfate or Portland cement to impart moldability. Therefore, it is possible to mix powder of low melting point resin such as low density polyethylene, polystyrene, ethylene-vinyl acetate copolymer and the like, and natural rubber latex or reversible agent for imparting flexibility.
Other thickeners, flame retardants, fungicides, surfactants as foaming agents, foam stabilizers (San Nopco's Nopco DC-100
A) may be blended.

(Baking material component) In the backing material component, the heat-sensitive gelling agent has a solid content of 0.4 to 100 parts by weight of the resin solid content in the aqueous emulsion.
It is used in a proportion of 20 parts by weight, preferably 2 to 5 parts by weight.

When the addition amount of the heat-sensitive gelling agent is 0.4 parts by weight, the gelling effect is small, and even if the addition amount is increased, it is difficult to amplify the heat-sensitive effect,
A large amount of addition reduces the deposition thickness of the foaming resin which is the backing layer.

The amount of the nonionic surfactant blended is such that the resin water emulsion stabilizes at room temperature and during mechanical stirring.

(Backing method of laying material) The backing is performed by stirring a resin aqueous emulsion containing a preliminarily heat-sensitive gelling agent and a nonionic surfactant with a super mixer, a homogenizer, etc., and entraining air to generate 2 to 10 times bubbles. And then the foamed resin aqueous emulsion is applied or impregnated on the back surface of the laying material, and then heated to a temperature above the gelation temperature of the emulsion to cause gelation and remove water. And then dried.

The foamed emulsion is applied in the fiber layer or on the back surface to a certain thickness by using a roll or bar coater spraying method. The coating amount is optional, but usually the solid content is 40
Performed as a to 300 g / m ^2.

A measure of the gelling temperature is the cloud point of the heat-sensitive gelling agent. Usually, the cloud point is the gelling temperature, but depending on the formulation it may be slightly (± 1
It shifts about 5 ° C. Usually, a temperature higher by 30 ° C. or more than the heat-sensitive temperature of the heat-sensitive gelling agent is preferable.

(Another embodiment) Rigidity of a non-woven fabric carpet using a resin emulsion having a Tg of 80 ° C. or more as a resinous aqueous emulsion to be foamed,
When imparting moldability, the foaming agent layer, which is a backing layer, has a high rigidity, and therefore, when the laying material is rolled, a crack occurs in the backing layer. Therefore, the laying material backed to an appropriate length is cut and pressed.

When obtaining a laying material that has moldability and is wound by a roll, the laying material has a low-melting point fiber binder of 15 to 50% by weight, and 40 ° C. higher than the fiber binder.
A needle punched non-woven fabric made of a mixture of synthetic resin fiber or natural fiber having a high melting point as described above is used, and a Tg containing a heat-sensitive gelling agent and a nonionic surfactant
Form an aqueous resin emulsion having a temperature of 30 ° C. or less to form the present invention, or use a laying material having a pre-determined Tg of 80 ° C.
The above moldable resin water emulsion has a solid content of 70-
After coating so as to be 400 g / m ² , a Tg of 30 including a heat-sensitive gelling agent and a nonionic surfactant is further applied.
An aqueous emulsion of a resin having a temperature of not higher than ℃ is applied by a foam coating, dried, and heated and heated to cause gelation.

(Effect) The laying material obtained by backing up the foamed resin layer obtained by the method of the present invention has a good cushioning property and a feeling without lumpiness. In addition, since the backing layer is foamed, the amount of resin emulsion used can be reduced, which is economical.

Hereinafter, the present invention will be described in more detail with reference to Examples. The parts and% in the examples are based on weight.

Example of production of needle carpets 15 denier, 20% recovered polypropylene (melting point 164 ° C.) with a fiber length of about 100 mm and 15 denier, mixed polyethylene terephthalate with a fiber length of 75-125 mm (melting point 264 ° C.) mixed fiber waste with 80% fiber Fiber mats (850 g / m ² ) in which the
5 per square inch with -18-32-3RB needle
Needling at a rate of 0, wall thickness of about 8.1 mm, apparent density
A needle carpet of 0.10 g / cm ³ was obtained.

The needle carpet used in the following examples is this carpet.

Example-1 Acrylic resin aqueous emulsion "Acronal YJ-"
2720D "(trade name, manufactured by Mitsubishi Yuka Verditsie Co., Ltd., solid content 48%, MFT 6 ° C) 100 parts, 3 parts NUC Silicone FZ-2107 manufactured by Nippon Unicar Co., Ltd. was added, and about 4 times the mechanical foaming was performed. To form a film having a thickness of about 2 mm on the release paper.

This was heated in a hot air oven at 130 ° C. for 20 minutes to obtain a dry film. The density of the film was 0.36, and the appearance was a white film due to the fine foam.

The results of measuring the cushioning property and elongation recovery rate of this film by the methods described below are shown in Table 1.

Further, the composition was applied to the back surface of the needle punched carpet obtained in the above-mentioned example so that the foamed resin aqueous emulsion was applied at a solid content of 200 g / m ² and heated to 130 ° C.
A laying material having a foamed resin layer was obtained by gelling and drying.

With this laying material, the fibers were sufficiently fixed (the backing effect) by the foamed resin layer without the surface raised portion coming off. It had a soft texture with no lumpy feeling when touched from the surface side.

Cushioning property: The initial thickness of the foamed sheet (5.0 × 5.0 cm size) is t _0, and the thickness when a load of 500 g is applied for 5 minutes is t ₁ , and when this load is removed and 5 minutes have elapsed When the wall thickness of is t ₂ , The deformation ratio was small and the thickness change ratio was small, and the cushioning property was good.

Elongation recovery rate: 10 mm width, distance between chucks 20 mm, set to 250% elongation with an Instron type tensile tester, and check the elongation recovery rate after 5 minutes excluding the load.

Comparative Example-1 A laying material having a backing layer was obtained in the same manner as in Example-1, except that the acrylic resin water-based emulsion "Acronal YJ2720D" containing no NUC silicone FZ-2107 manufactured by Nippon Unicar was used.

This product has poor bubble stability and a bubble size of 1-5.
It was a coarse one of mm. Also, NUC Silicone F
When Z-2107 is not added and no foaming treatment is applied, a transparent film is formed, which is deeply impregnated into the raised root of the needle punch carpet, and the ruggedness is strongly felt on the surface side of the laying material (carpet). Tonatsuta.

Examples 2-7, Comparative Examples 2-4 The blending components of the emulsion mixture were changed as shown in Table-1,
A foamed sheet was obtained in the same manner as in Example 1 except that heating was performed as shown in the table. The abbreviations on the surface are as follows.

Resin water-based emulsion EVA: Sumitomo Chemical Co., Ltd. ethylene-vinyl acetate copolymer water-based emulsion "Sumika Flex 900"
(Brand name, solid content 50%, Tg = -20 ° C.) DI φ232D: Mitsubishi Yuka Verditsie, trade name, vinylidene chloride copolymer aqueous emulsion (solid content 55
%, MFT 11 ° C) Acronal S-400: Mitsubishi Yuka Verdice, solid content 57
%, MFT <0 ° C Acronal YJ-7082D: Mitsubishi Yuka Verdice, solid content 5
0%, MFT = 30 ° C., Tg> 80 ° C. Thermosensitive gelling agent FZ-2107: Nihon Unicar Co., Ltd. silicone oil-based nonionic surfactant PPG: Sannopco's polypropylene glycol-based liponox NCI: Lion Oil & Fat Co., Ltd. Oxyethylene Nonionic Surfactant (Cloud Point 55 ° C.) Comparative Example-3 The same operation was performed as in Example-1 except that the drying temperature was 50 ° C.-40 minutes. The size was 1-3 mm and it became coarse.

Continuation of front page (51) Int.Cl. ⁵ Identification code Office reference number FI Technical display location D06M 15/643 23/04 D06M 15/643

Claims (6)

[Claims] 1. A silicone oil-based water-soluble heat-sensitive gelling agent and a resin aqueous emulsion containing a nonionic surfactant are mechanically agitated to foam, and then the foamed resin aqueous emulsion is used as a laying material. A method for backing a laying material, which comprises coating and impregnating the back surface and then heating to gel the resin aqueous emulsion to form a foamed resin backing layer on the laying material. 2. The heat-sensitive gelling agent is used in a proportion of 0.4 to 20 parts by weight based on 100 parts by weight of the resin solid content in the aqueous emulsion. Method described in section. 3. A vinyl monomer is emulsion-polymerized by using an emulsifier contained in a resin aqueous emulsion in a proportion of 0.1 to 5% by weight of a nonionic surfactant (content relative to the resin solid content in the aqueous emulsion composition). The method according to claim 1, which is an aqueous resin emulsion obtained as described above. 4. The resin aqueous emulsion is selected from acrylic resin aqueous emulsion, ethylene-vinyl acetate copolymer emulsion, and vinylidene chloride resin aqueous emulsion. The method described. 5. The nonionic surfactant is selected from polyoxyethylene glycol, propylene oxide / ethylene oxide copolymers, and ethylene oxide adducts of aliphatic alcohols. Method described in section. 6. The cloud point of the silicone oil-based water-soluble heat-sensitive gelling agent is 45 to 95 ° C., which is lower than the cloud point of the nonionic surfactant by 15 ° C. or more. The method according to claim 1.