JPH0959879A - Mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a mat free from the generation of harmful gases in burning, stably keeping various physical properties such as elasticity, softness and non- slipperiness independent of the ambient temperature even under a severe temperature condition, exhibiting excellent water-permeation resistance and flexural recovery, easily producible at a low cost and suitable as a floor mat for automobile, leisure mat, etc. SOLUTION: A backing layer to be applied to the back of a textile cloth is produced by using a composition containing 30-90wt.% of a 1st blend component composed of a styrene-based thermoplastic elastomer containing 10-50wt.% of a styrene-based monomer and 1-3wt.% of a 2nd blend component composed of one or more polymers selected from ethylene-propylene-diene terpolymer, ethylene-vinyl acetate copolymer and olefinic polymer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mat that can be suitably used as a leisure sheet or the like in addition to a laid mat for an automobile, a mounting mat for an automobile, for example.

[0002]

2. Description of the Related Art In a vehicle, a piece-like laid mat may be laid at the feet of a driver or a passenger. Such a laid mat needs to have good flexibility and elasticity, especially for the backing layer so as to give comfort to the drivers, and in addition, to prevent unintentional displacement, A certain frictional force (slip resistance) is required for the laid surface. Furthermore, in order to avoid the adverse effect of absorption of water from the laid surface, it is also required to be water impermeable. However, cars are
Since the temperature inside the car changes more than expected depending on the parking position, etc.
Development is being carried out under severe conditions so that the above physical properties can be maintained under a severe temperature environment of about + 90 ° C.

Conventionally, as a resin composition for lining carpets and mats, synthetic rubber such as polyvinyl chloride and latex of styrene-butadiene rubber (SBR latex),
Those containing natural rubber, polyethylene, ethylene-vinyl acetate copolymer, etc. as main components are generally used.

Of these, the most widely used polyvinyl chloride composition produces a large amount of harmful hydrogen chloride gas when burned, and thus causes environmental pollution when burned in waste treatment, and has become a social problem these days. Not preferable in terms of environmental issues. Moreover, the elasticity and flexibility of this composition are relatively susceptible to the ambient temperature, and it is difficult to maintain good physical properties in high-temperature and low-temperature environments. Furthermore, volatilization of the plasticizer results in long-term stability. It is difficult to obtain the desired properties, and there is some concern about durability and weather resistance.

Further, in the case of using synthetic rubber such as SBR latex or natural rubber, it is necessary to carry out a crosslinking reaction in the step of forming the backing layer, which increases the number of steps and makes the production difficult. Incurring an increase in cost. Further SB
The R-latex is easily permeable to water and has a problem in terms of water impermeability.

Those using polyethylene or ethylene-vinyl acetate copolymer are inferior in flexibility, hard to follow the laying surface and poor in laying stability, and also have low frictional resistance against the laying surface and slip resistance. It has the disadvantage of being inferior.

The above description has been made on the laying mat for automobiles, but leisure mats (leisure sheets) used outdoors are rarely used under the severe temperature conditions as described above. There is no difference in that it is advantageous to be able to cope with a certain temperature change. In addition, in the leisure sheet, if the folds formed by folding during storage remain at the time of unfolding, good laying stability cannot be obtained, so in addition to the above characteristics, good folding recovery is strong. Required.

The present invention has been made in view of the above circumstances, and it is possible to prevent the generation of harmful gas during combustion, and further, the physical properties such as elasticity, flexibility and slip resistance are influenced by the ambient temperature. It is hard to receive and is maintained in a good condition even under a severe temperature environment, and it has excellent water impermeability and bending recovery,
An object of the present invention is to provide a mat that can be easily manufactured at low cost and that can be suitably used as, for example, a floor-standing mat for an automobile or a leisure mat.

[0009]

Means for Solving the Problems As a result of intensive studies, the present inventors have found that a mat capable of achieving the above object can be provided by blending specific components.

That is, in the mat of the present invention, the backing layer provided on the back surface of the fiber-based cloth is composed of the first blending component 30 to 30 consisting of the styrene-based thermoplastic elastomer containing 10 to 50% by weight of the styrene-based monomer. A second blend component consisting of 90% by weight and one or more selected from ethylene / propylene / diene terpolymer, ethylene / vinyl acetate copolymer, and olefin polymer. The gist is a composition comprising a composition containing 1 to 30% by weight.

In the present invention, the first blend component is one selected from polystyrene / polybutadiene / polystyrene block copolymers, polystyrene / polyisobrene / polystyrene block copolymers, and hydrogenated products thereof. It is advisable to adopt a configuration composed of two or more types.

Further, in the present invention, the composition may be one selected from calcium carbonate, aluminum hydroxide, magnesium hydroxide, barium sulfate, calcium silicate, calcium sulfate, magnesium phosphate, and titanium oxide. It is preferable to adopt a constitution in which two or more kinds of inorganic compounds are contained in an amount of 70% by weight or less.

The backing layer of the mat of the present invention comprises a first blend component composed of a styrene thermoplastic elastomer, a resin composition constituting the backing layer, an ethylene / propylene / diene terpolymer and ethylene / vinyl acetate. It is a mixture of a copolymer and a second blend component composed of one or more selected from olefin polymers in a specific ratio. Since these blend components do not contain halogen, they do not generate a harmful gas when burning and have low smoke generation unlike those using conventional general-purpose vinyl chloride resins. Moreover, the combination of the first and second blending components imparts various suitable physical properties such as flexibility, elasticity and slip resistance to the mat.
Furthermore, those physical properties are not easily affected by the ambient temperature, are maintained even under a severe temperature environment, and are excellent in water impermeability and bending recovery. Moreover, since the above composition has excellent moldability by melt extrusion, it can be easily formed into a sheet by a general extrusion molding machine such as a T-die, and the formed sheet is used as a backing layer directly on the back surface of the textile fabric. By pressure bonding, an automobile floor mat or a leisure sheet can be easily manufactured.

In the present invention, as the styrene-based thermoplastic elastomer of the first blend component, specifically, polystyrene / polybutadiene / polystyrene block copolymer (SBS), polystyrene / polyisoprene /
Polystyrene block copolymer (SIS), SBS hydrogenated polystyrene / poly (ethylene / butylene) / polystyrene block copolymer (S)
EBS) and polystyrene / poly (ethylene / propylene) / polystyrene block copolymer (SEPS) obtained as a hydrogenated product of SIS can be mentioned as suitable examples. You may use it in combination of 2 or more types. Among these,
From the economical aspect, it is desirable to use SBS and / or SIS. Further, it is necessary to use the first blending component having a styrene-based monomer content of 10 to 50% by weight, among which the lower limit is 20% by weight or more and the upper limit is 4%.
Those of 0% by weight or less can be preferably used. If this content rate becomes low, the moldability by extrusion will deteriorate, and if it does not reach the above specified value, extrusion molding as a backing sheet will become difficult, and heat resistance will decrease and the surface of the extruded sheet will become rough, etc. Is generated, which is not preferable. On the contrary, if the content of the styrene-based monomer becomes high, the rigidity becomes high, and if it exceeds the specified values, it is not possible to obtain sufficient flexibility and elasticity as the backing layer, which is not preferable.

The first blending component must be contained in the composition for the backing layer in an amount of 30 to 90% by weight, and the one having a lower limit of 40% by weight or more and an upper limit of 70% by weight or less is preferable. Can be used. If this content is too small, the moldability as a backing sheet deteriorates and extrusion molding becomes difficult, which is not preferable. On the other hand, if the amount is too large, the extrusion molding becomes difficult, and the heat resistance is lowered, so that the surface of the extruded sheet may be roughened, which is not preferable.

On the other hand, in the present invention, as the second blend component, ethylene, propylene and a diene compound (1.
4-hexadiene, dicyclomentadiene, etc.) terpolymer (EPDM), ethylene-vinyl acetate copolymer (EVA), and one or more selected from olefin polymers. You need to use one.

Specific examples of suitable olefin polymers include crystalline polyethylene such as low density polyethylene (LDPE) and linear polyethylene (LLPE), crystalline polypropylene, and the like.

This second blend component must be contained in the composition in an amount of 1 to 30% by weight in order to improve moldability and heat resistance, and preferably the lower limit value is 2% by weight or more and the upper limit value is 2% by weight or more. Is preferably contained in an amount of 20% by weight or less.

More specifically, when EPDM is contained in the second blend component, the content of EPDM in the composition is 1 to 30% by weight, preferably the lower limit is 2% by weight or more and the upper limit is 20%. It is good to set it to the weight% or less. If this content is too low, due to the decrease in heat resistance, the extruded sheet may be rough, and if it is too large, as an extruded sheet, sufficient elasticity and flexibility cannot be obtained,
Not preferred.

Further, when EVA is contained in the second blend component, the content of EVA in the composition is 1 to 30% by weight,
Preferably, the lower limit is 2% by weight or more and the upper limit is 20% by weight.
The following is good. If this content is too small, the molding processability may deteriorate, and extrusion molding may be difficult,
On the other hand, if the amount is too large, the extruded sheet may be roughened due to deterioration in heat resistance, which is not preferable.

When the second blend component further contains an olefin polymer, the content thereof in the composition is 1 to 3.
0% by weight, preferably the lower limit is 2% by weight or more and the upper limit is 20% by weight or less. If this content is too small, due to the decrease in heat resistance, the extruded sheet may be rough, and conversely, if the content is too large, as an extruded sheet, sufficient elasticity and flexibility cannot be obtained, Not preferable. Among the olefin-based polymers, when polypropylene-based ones are used, flexibility is inferior to polyethylene-based ones, but good heat resistance can be obtained.

In addition to the above-mentioned first and second blend components, the composition of the present invention may contain an inorganic compound, if necessary, for the purpose of improving economy, rigidity, and increasing effect. good. As the inorganic compound, for example, calcium carbonate, aluminum hydroxide, magnesium hydroxide, barium sulfate, calcium silicate, calcium sulfate, magnesium phosphate, titanium oxide, and the like used in ordinary plastic molding techniques can be used. Particularly, it is recommended to use calcium carbonate as a main component from the viewpoints of economy and molding processability.

The content of this inorganic compound in the composition is 7
It is good to set it to 0% by weight or less, preferably 60% by weight or less.

When the composition of the present invention is used as a backing material for a leisure sheet, it is desirable that the content of the above-mentioned inorganic compound is small in order to reduce the weight.

The composition of the present invention may optionally contain a plasticizer such as DOP in order to obtain good moldability.
You may contain in the range of 0 weight% or less.

Further, in the present invention, various additives used in general plastic molding techniques such as lubricants, softening agents, colorants, antistatic agents, etc. can be appropriately blended if necessary. Is.

On the other hand, the fibrous fabric in the present invention is not particularly limited, and any kind can be used. For example, in addition to fabrics made by weaving and weaving yarns made of polyester fibers, nylon fibers, polypropylene fibers, acrylic fibers, etc., various fibers and yarns are mechanically knotted by needle punching or chemically bonded by an adhesive or the like. A non-woven fabric or the like bound to can be used.

Further, the cloth may be a pile cloth having a pile layer formed on the surface thereof, or may be a flat cloth having no pile layer formed thereon. In the case of forming a pile layer, the pile material is not particularly limited, and those made of the above fibers can be preferably used. The means for forming the pile layer is also not particularly limited, but for example, means for forming the pile layer by weaving such as warp pile weft, weft pile weave, such as moquette, and tufting of pile yarn by a tufting machine. Examples thereof include a means for forming a pile layer, a means for forming a pile layer by adhering pile yarns with an adhesive.

When the present invention is applied to a leisure mat, as the cloth, there is no directionality and has good folding recovery so that folding storage can be performed without trouble, for example, a needle-punched nonwoven fabric made of polyester fiber. It is preferable to use, among others, the thickness is 1 to 5
It is even more preferable to use one having a unit weight of 100 mm and a basis weight of about 100 to 500 g / m ² .

A thin non-woven fabric having a basis weight of 5 to 70 g / m ² may be attached to the backing layer to improve the appearance of the backing resin and to protect and reinforce the resin layer.

In the present invention, a mat is obtained, for example, by the following method using a composition comprising the above-mentioned first and second blend components and an inorganic compound, a plasticizer and an additive which are blended if necessary. . That is, the above composition is mixed with an appropriate mixer such as a Henschel mixer or a Banbury mixer, and the mixture is used as a molding material, or the mixture is pelletized to be a molding material. Alternatively, the above composition is used as it is as a molding material (direct blending method), or the above composition is mixed by a mixer such as a tumbler blender and the mixture (dry blend pellets) is used as a molding material.

Subsequently, the molding material for backing is extruded using a single-screw or twin-screw extruder equipped with a T-die or the like, and the T-die outlet is formed before the sheet is cooled and solidified. A back surface of the fiber-based fabric is continuously coated as a backing layer with a pressure-bonding roll or the like installed adjacent to the mat to obtain a mat (extrusion laminating method). Alternatively, the extruded backing sheet is cooled and solidified, and then one surface of the sheet is melted and heated to bond the melted surface to the back surface of the fiber-based fabric to obtain a mat.

In the case of manufacturing a piled mat such as a car laying mat for covering the backing layer, it is necessary to secure sufficient flexibility and elasticity and to surely perform sealing. In addition, the coating amount of the backing layer should be relatively thick, specifically 800 to 2000 g /
m ² , preferably the lower limit is 1000 g / m ² or more and the upper limit is 1800 g / m ² or less. When manufacturing a mat without piles such as a leisure sheet, while ensuring good flexibility and elasticity,
The coating amount of the backing material may be the minimum necessary amount so as not to impair the lightness, specifically, 200 g / m ² or more, preferably 300 g / m ² or more as the lower limit and 800 as the upper limit.
It is preferable to set it to g / m ² or less.

On the other hand, in the present invention, it is also possible to obtain a mat by cooling and solidifying the backing sheet extruded as described above, and then bonding the sheet to the back surface of the fiber type fabric by hot pressing. . However,
In this method, the fibrous fabric may be thermally deteriorated during reheating (hot pressing). Therefore, it is preferable to adopt the extrusion laminating method.

[0035]

EXAMPLES Examples of the present invention and comparative examples for deriving the effects thereof will be described below. In the following description, "%" means "% by weight".

<Materials used> In carrying out the examples, etc.,
The following materials were prepared.

1. First blend component: SBS ... polystyrene / polybutadiene / polystyrene block copolymer (styrene content 35%)-SIS ... polystyrene / polyisobrene / polystyrene block copolymer (styrene content 17%)-SEBS ... polystyrene / poly ( Block copolymer of ethylene / butylene) / polystyrene (styrene content 30%) 1. Second blending component: EPDM: ethylene content 20%, propylene content 40
% Ethylene, propylene and a diene compound random terpolymer EVA-ethylene 72% ethylene-vinyl acetate copolymer PE-low density polyethylene 3. 3. Plasticizer and inorganic compound-DOP ... di-2 ethylhexyl phthalate-Calcium charcoal ... Calcium carbonate (average particle diameter 7.41 μm) 4. Other backing materials-PVC ... Polyvinyl chloride-SBR ... Styrene-butadiene rubber latex <Fiber-based fabrics used> Needle punched nonwoven fabric made of polyester fiber (thickness 1
mm, on the surface of the basis weight 100 g / m ^2), and flocking the polyester yarn by the tufting machine, it was prepared loop pile type of mat base member pile weight per unit area 400 g / m ² (fiber based fabric).

<Example 1>

[Table 1] As shown in Table 1 above, SBS 64%, EPDM 16%,
Using a twin-screw extruder equipped with a T-die, a composition containing 20% calcium carbide was used to obtain a thickness of 0.5 mm and a width of 2000 mm.
The extruded molded sheet for backing, and before the sheet is cooled and solidified, the back surface of the fabric is continuously coated with a basis weight of 500 g / m ² by a pressure roll installed adjacent to the die exit. Then, a continuous mat was obtained, which was cut to obtain a sample as a leisure mat (leisure sheet) having a size of 600 mm × 900 mm.

<Example 2> SBS 64%, EPDM8
%, PE 8%, calcium carbide 20%,
A sample as a leisure mat was obtained in the same manner as above.

Example 3 SBS 67%, EPDM8
%, EVA 10%, DOP 5% and calcium carbonate 10% were used to obtain a sample as a leisure mat in the same manner.

Example 4 SBS 46%, EPDM10
%, DOP 4%, 40% charcoal 40% by the same method using a composition (automatic mat)
As a sample was obtained.

<Example 5> SBS 45%, EVA 10
%, PE 5%, DOP 5% and calcium carbonate 35% were used to obtain a sample as an automobile mat in the same manner.

<Example 6> SBS 50%, EVA 5%,
Using a composition containing 10% PE and 35% calcium charcoal, a sample as an automobile mat was similarly obtained.

Example 7 SIS 70%, EVA 5%,
Using a composition containing 5% PE and 20% calcium charcoal, a sample as a leisure mat was similarly obtained.

<Example 8> SIS 40%, EPDM25
% And 35% charcoal were used to obtain a sample as an automobile mat in the same manner.

Example 9 SEBS 45%, EPDM2
Using a composition containing 0%, 5% DOP, and 30% calcium carbonate, a sample as an automobile mat was similarly obtained.

<Comparative Example 1> SBS 60%, calcium carbonate 40%
A sample as an automobile mat was obtained in the same manner as in the above-mentioned examples by using the composition containing the above.

<Comparative Example 2> EVA 60%, calcium carbonate 40%
A sample as an automobile mat was obtained in the same manner using the above composition.

<Comparative Example 3> Using a composition of PE 60% and calcium carbonate 40%, a sample as an automobile mat was similarly obtained.

Comparative Example 4 PVC50%, DOP30
%, And a composition of 20% calcium charcoal was used to similarly obtain a sample as a leisure mat.

<Comparative Example 5> A composition comprising SBR 60% (solid content) and calcium carbonate 40% was applied to the back surface of the above-mentioned fiber type cloth by a roll coater at a coating amount of 400 g / m ² (solid content). As a result, a sample as a leisure mat was obtained.

<Evaluation> In each of the above samples, the following measurements were carried out to evaluate each characteristic.

1. Flammability The amount of hydrogen chloride gas generated was measured by the NBS (National Bureau of Standards) flammability test method, and those that did not occur were evaluated as “◯” and those that occurred were evaluated as “x”.

2. Elasticity The tensile elastic modulus is measured according to JIS K 6301,
"○" for 200kgf / cm ² or less, over 200f / cm ² 1
Those having a value of 000 f / cm ² or less were evaluated as “Δ”, and those having a value of more than 1000 f / cm ² were evaluated as “x”.

3. Flexibility A flexibility test is conducted in accordance with JIS L 1096, and the measured value at that time is 4.0 kgf / cm ² or less is “◯”,
4.0f / cm ² ultra-5f / cm ² or less of the things "△", 5f / cm ²
The super thing was evaluated as "x".

4. Anti-slip property The friction coefficient was measured according to the friction coefficient test of the plastic film and sheet of JIS K 7125 to 7.0.
Those having a kgf or more were evaluated as “◯”, those having a weight less than 7.0 kgf and 5.0 kgf were evaluated as “Δ”, and those less than 5.0 kgf were evaluated as “x”.

5. Non-water permeable A water resistance test was conducted in accordance with JIS L 1092, in which water did not drip "○", and when drip "X"
Evaluated as.

6. Bending recovery property The rebound rate was measured according to JIS L 1096, and was 40
% Or more was evaluated as “◯”, less than 40% as 20% or more as “Δ”, and less than 20% as “x”.

The results of the above evaluations are shown in Table 2 below. In addition,
Among the evaluation results, those with “◯” are acceptable, and those with other results (“Δ” and “×”) are unacceptable.

[0060]

[Table 2] As is clear from Table 2 above, the examples related to the present invention have good evaluations for all characteristics, and are particularly suitable for a floor-standing mat for automobiles, leisure sheets and the like. I understand. On the other hand, the comparative examples that deviate from the gist of the present invention are inferior in any of the characteristics, and are not suitable for those used under harsh conditions, such as a laying mat for automobiles and a leisure sheet. I find it unsuitable.

[0061]

As described above, according to the mat of the present invention, it is possible to prevent the generation of harmful gas at the time of combustion, and further, the physical properties such as elasticity, flexibility and slip resistance are controlled by the ambient temperature. It is not easily affected and is maintained in a good condition even under harsh temperature environment, and it has excellent water impermeability and bending recovery.
The effect that it can be easily manufactured at low cost and can be suitably used, for example, as a laying mat for automobiles or as a leisure sheet, and especially when used as a laying mat for automobiles, it can be post-processed according to the shape of the laid face Is obtained.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Taro Hattori 634, Kubota, Azai-cho, Ikoma-gun, Nara 1 Sumie Textile Co., Ltd. Nara Works

Claims (3)

[Claims] 1. The backing layer provided on the back surface of the fiber-based fabric comprises 30 to 90% by weight of a first blend component composed of a styrene-based thermoplastic elastomer having a styrene-based monomer content of 10 to 50% by weight. A second blend component 1 to 30 wt% consisting of one or more selected from ethylene, propylene diene terpolymer, ethylene vinyl acetate copolymer, and olefin polymer %, A mat comprising a composition containing 2. The first blend component is a polystyrene / polybutadiene / polystyrene block copolymer,
The mat according to claim 1, which comprises one or more selected from polystyrene / polyisobrene / polystyrene block copolymers and hydrogenated products thereof. 3. The composition containing calcium carbonate, aluminum hydroxide, magnesium hydroxide, barium sulfate, calcium silicate, calcium sulfate, magnesium phosphate,
The mat according to claim 1 or 2, which comprises 70% by weight or less of one or more inorganic compounds selected from the group consisting of titanium oxide and titanium oxide.