JPH09220156A - Backing structure of carpet for forming - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable to form a forming carpet and simultaneously adhere felt by anchoring effect, by laminating a first layer made of thermoplastic resin added with a nuclear forming agent on the back face of a carpet and a second layer made of thermoplastic resin of a same kind with that of the first layer. SOLUTION: Felt 16 is adhered on the back face of a carpet 11 of this carpet for forming 10 via first and second layers of thermoplastic resin 14 and 15. A tufted carpet which is made by tufting foundation cloth 12 to form piles 13 or a needle punched carpet is used as the carpet. Low density polyethylene resin, etc., are used as first and second thermoplastic resin layers 14 and 15. Each of organic and inorganic components including recycled resin containing polyethylene resin can be used as a nuclear forming agent 17 to be added to the first layer. Olefinic thermoplastic resin is preferable among various kinds of resin waste of automobiles and household electric appliances.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a backing structure for a molding carpet, and more particularly to a structure suitable for backing an automobile floor carpet.

[0002]

2. Description of the Related Art Conventionally, tufted carpets or needle punched carpets have been used as floor carpets for automobiles, and they have been laid in a shape suitable for the floor panel of automobiles. In order to impart moldability to the carpet, a backing material of a thermoplastic resin is applied to the back surface of the carpet, the backing material is softened by heating, and then drawn by a press-molding die having a required shape. Conventionally used as a backing material is a low-density polyethylene resin, a thermoplastic resin having a relatively low melting point such as ethylene-vinyl acetate resin, which is extruded into a sheet with a thickness of several millimeters by a sheet extruder to make a carpet. It was common to provide a laminate on the back surface. When used as an automobile floor carpet, a laying mode in which felts are arranged as a cushioning material between the floor carpet and the floor panel is generally used.
This felt is for the purpose of cushioning, soundproofing, etc., and it is necessary to attach the felt to the back surface of the carpet in order to improve the feeling of laying the carpet. It is reasonable to attach the felt to the back surface of the carpet with the anchor effect (without using an adhesive) by utilizing the fact that the carpet backing material is heated and softened for drawing. . Felt to be pasted is arranged in advance in the carpet press molding die, and when the carpet is molded, the felt fluff is backed by pressing the felt between the softened carpet backing material and the molding die. It can get in and stick with the anchor effect. (For example, Japanese Examined Patent Publication No. S60-6053) Thus, in order for the felt to be fixed to the backing material by the anchor effect without using an adhesive, the backing material is sufficient for fixing the felt (at least at the surface in contact with the felt). It is necessary to maintain a softened state. On the other hand, the temperature of the backing material cannot be made too high when considering the drawing of the carpet at the same time when the felt is attached, which needs to be close to the melting point. If the temperature of the backing material is too high, that heat will be transferred to the fiber pile of the carpet. When the pile is subjected to the effects of high heat and pressure at the same time, it falls down and is not easily recovered, and the design of the product is significantly impaired. Therefore, it is necessary to limit the heating of the backing material in consideration of this, and the backing material cannot be sufficiently heated depending on the type of carpet fiber, the backing material, and the weight per unit area, softening is insufficient, and the felt is attached by the anchor effect. Sometimes I couldn't wear it. There has been no suitable method for solving the contradiction of the heating conditions. For example,
As one solution, it is conceivable that two kinds of resins having different melting points are used for backing. However, the difference in heat shrinkage ratio depending on the backing material causes deformation of the carpet after molding, which is not preferable.

[0003]

SUMMARY OF THE INVENTION The present invention is to solve the above problems and provides a backing structure for a molding carpet suitable for simultaneously forming a molding carpet and attaching a felt with an anchor effect.

[0004]

[Means for Solving the Problems] The means for solving the problems according to the present invention include a first layer of a thermoplastic resin having a nucleating agent added to the back surface of a carpet, and a first layer of a thermoplastic resin of the same system as the first layer. Due to the backing structure of the molding carpet formed by stacking two layers, the thermoplastic resin of the first layer and the second layer is a low-density polyethylene resin, and nucleation is added to the thermoplastic resin of the first layer. A backing structure for a molding carpet in which the agent is a recycled resin containing a polyethylene resin is preferable.

[0005]

In the present invention, the first and second thermoplastic resins of the same series are laminated on the back surface of the carpet, but since the first thermoplastic resin layer contains the nucleating agent, Compared to the second layer that does not contain a nucleating agent, the crystallization temperature is higher at the stage of solidifying from the molten state, and solidification starts at a higher temperature, so the resin temperature tends to decrease and By doing so, it is possible to reduce the amount of heat transmitted to the pile of the carpet, while the second layer to which the nucleating agent is not added has a delayed crystallization and is sufficiently soft even at the same temperature, so by arranging it on the felt side, It can be easily attached by the anchor effect with the felt. First layer, second layer
Since the thermoplastic resin of the layer is a resin of the same system, it has good compatibility, and the interfaces are welded and integrated without a gap. Further, since the heat shrinkage rate is close, deformation of the carpet after molding is not induced. As a result of the experiment, when the thermoplastic resin of the first layer and the second layer is a low-density polyethylene resin and a recycled resin containing ethylene resin is introduced as a nucleating agent to be added to the first layer, the compatibility of both is good and the physical properties are good. It was found that the effect of being stable and increasing the crystallization temperature of the first layer is remarkable.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a cross-sectional view of a molding carpet 10 having a backing structure according to the present invention and a felt 16 (attached by an anchor effect). A felt 16 is attached to the back surface of the carpet 11 via the first layer and the second layer of the thermoplastic resins 14 and 15. In the figure, the carpet is a tufted carpet in which piles 13 (standing fibers) are formed on the base cloth 12 by tufting, but there is also a needle punch carpet.
In any case, a known structure can be used for this purpose. As the thermoplastic resin 14, 15 for the first layer and the second layer, low density polyethylene resin, linear low density polyethylene resin, high density polyethylene resin, ethylene-vinyl acetate copolymer resin, and other low melting point thermoplastic resin A resin can be used. The preferred basis weight is 200 to 3000
g / m ² . The nucleating agent 17 to be added to the first layer may be organic or inorganic components, but a recycled resin containing ethylene resin is particularly preferable. Among the various resin waste materials for automobiles, home appliances, etc., those obtained by pulverizing and recovering olefinic thermoplastic resin waste materials are preferable as the recycled resin. 70 to 20% by weight of this waste material is mixed with 30 to 80% by weight of a pure thermoplastic resin, or 2.5 to 15% by weight of a compatibilizing agent which further promotes the compatibility of both, and is kneaded and re-pelletized. Those that are suitable are preferred. The compatibilizer preferably has a functional unit that reacts with the waste material component and the pure resin component in the opposite direction. For example, when the waste material is a nylon carpet waste material, there are styrene elastomer, maleic anhydride modified olefin, unsaturated carboxylic acid, etc. . The felt 16 preferably has a fluffy surface such as a cotton felt, a synthetic fiber felt, a material containing a thermoplastic or thermosetting binder therein, a non-woven fabric, or a crushed product of a foam. The heating conditions for forming the carpet are preferably from the side to which the backing material of the carpet is applied, with a far-infrared heater, etc., and the resin temperature of the first layer is 100 to 160 ° C. and the resin temperature of the second layer is 120 to 120 ° C. It is preferably 180 ° C. Pressing when molding carpet (pressing between felt and backing material)
0.3 to 2.0 kg / cm ² is suitable.

【Example】

(Carpet) Nylon tufted carpet (base polyester) Basis weight 650 g / m ² (thermoplastic resin for the first layer) Low density polyethylene resin (J351 manufactured by Ube Industries, Ltd.)
9) Density = 0.919 g / cm ³ Melting point = 104 ° C. Crystallinity = 95% Nucleating agent (addition rate to first layer resin = 50% by weight) Nylon carpet recycled resin (polyamide: polyester: polyethylene = 400: 120: 400) Recycling conditions are melting process at 270 ° C. and re-pelletizing. (Thermoplastic resin for the second layer) Low-density polyethylene resin (same as the first layer) The temperature characteristics of the thermoplastic resin for the first layer are shown in FIG. 3 with a nucleating agent added by DSC (differential thermal analyzer). It is shown in comparison with the thermoplastic resin of the second layer which is not provided. The heat flow rate was measured while cooling the sample resin once heated to 200 ° C. at a cooling rate of 20 ° C./min. As a result, the crystallization start temperature and the crystallization peak of the resin of the first layer to which the nucleating agent was added were measured. It can be seen that the crystallization end temperature and the like are higher (earlier) by 5 to 15 ° C. than the second layer resin, and crystallization starts (and ends). (Felt) Phenolic resin binder 10 to 3 on cotton wool
Resin felt mixed with 0% by weight, density 0.05 g / c
m ³ and thickness 15 mm were used. (Process) Backing: The backing process will be described with reference to FIG. 2. The carpet 10 wound on the roll a is woven with the base cloth 1 at a constant speed.
While feeding the two surfaces upward, the first resin layer 14 containing the nucleating agent 17 extruded in a sheet form from the first extruder 21 is applied onto the base cloth and pressed by the pressing roll bb '. Add. Next, the second resin layer 15 extruded in a sheet shape from the second extruder 22 is applied onto the first resin layer in an overlapping manner, and pressure is applied by the pressure roll cc '. The resin temperatures of the first and second layers at this time were 250 ° C. and 230 ° C., respectively, and the basis weight was 400 g / m ² and 200 ° C., respectively.
g / m ² . Heating at the time of molding: Heater = infra type heater, heating for 60 seconds Actual temperature, 1st layer = 120 ° C, 2nd layer = 140 ° C Molding: The felt is placed in the lower mold in advance by the upper and lower press molds. , Pressure 1.0kg / cm
^{At 2} , the carpet was molded. (Evaluation) The peel strength between the carpet molded according to this example and the felt was sufficiently high, at least the material breaking strength of the felt, and the collapse of the carpet pile was extremely small, and the design of the carpet surface was good. . In the comparative example in which the nucleating agent was not added to the first layer under the same molding conditions, although the felt could be stuck, the pile of the pile fell due to heat transfer to the carpet surface, impairing the design of the product. .

According to the present invention, the felt can be attached by the anchor effect simultaneously with the molding of the molded carpet of the automobile, and at this time, the pile of the carpet can be prevented from falling due to heat and pressure.

[Brief description of drawings]

[Fig. 1] Sectional view of carpet

[Fig. 2] Backing material application process

FIG. 3 shows temperature characteristics of each layer resin.

[Explanation of symbols]

 10 ... Carpet for molding 11 ... Carpet 14 ... Thermoplastic resin for first layer 15 ... Thermoplastic resin for second layer 16 ... Felt 17 ... Nucleating agent

Claims (2)

[Claims] 1. A laminate of a first layer of a thermoplastic resin containing a nucleating agent and a second layer of a thermoplastic resin of the same system as the first layer, which are laminated on the back surface of the carpet. Molding carpet lining structure. 2. The thermoplastic resin according to claim 1, wherein the thermoplastic resin of the first layer and the second layer is a low density polyethylene resin.
A backing structure for a molding carpet, wherein the nucleating agent added to the thermoplastic resin of the layer is a recycled resin containing a polyethylene resin.