JPS5878614A - Carpet - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a carpet that has excellent shape retention, flame retardancy, and heat resistance, and in particular provides a carpet that is useful as a floor covering material for automobiles.

Conventionally, carpets have been packed with rubber latex such as styrene/butadiene rubber or butadiene/acrylonitrile rubber to prevent the pile of the original rug from falling out and to stabilize the shape. When applying it to uneven areas, it is difficult to shape the rubber latex Bikinder material due to its high rebound elasticity, and even when it is shaped, its shape is not sharp and it does not retain its shape. is not enough.

In addition, melt extrusion lamination packing using thermoplastic resins such as polyethylene and ethylene/vinyl acetate copolymer resins has also been carried out. However, in this case, it is possible to form an uneven shape by heating, and this is a rubber-based latte. Compared to those using wood as a packing material, the shaped carpet has the advantage that it has better shape retention and has a sharper shape, but it is harder to the touch and has poor pile-type properties. It has the disadvantage of being inferior in its stopping effect. - As a method to compensate for the shortcomings of these packing materials, a rubber latex in which polyethylene powder is dispersed is used as a packing material, and this is applied to the original rug to impregnate it. After drying at high temperatures, heat and pressurize to form cannibals. was proposed. However, this packing material has the disadvantage that it is difficult to uniformly disperse polyethylene powder into the rubber laminate, and it is also difficult to uniformly impregnate the original rug with the powder.

In addition, a rubber-based latex packing material is applied to the back side of the original rug to impregnate it, and the moisture in the latex is removed by drying. Heating, tension,
Although methods of manufacturing carpets by molding are generally in practice, this method has the drawback of requiring two layers of packing and laminate for manufacturing.

Furthermore, in recent summers, the temperature inside closed automobile interiors has reached temperatures of over 80 degrees Celsius, so a test item has been added to the floor and trunk flooring materials to ensure that they do not deform even at temperatures of 10,0 degrees Celsius. Ta. As a result, a better alternative to rubber-based latex was being considered, and it was discovered that it could be used as a binder for molded silicon. Synthetic resin emulsions such as acrylic resins, vinyl chloride/vinyl acetate copolymers, and ethylene/vinyl acetate nonpolymers are increasingly being used as packing materials.Among these, acrylic resin emulsions are particularly popular. , is becoming more and more used because it has superior rigidity, moldability, and heat resistance compared to other copolymer materials and yarns.

This acrylic resin emulsion is a resin emulsion obtained by emulsion polymerization of a copolymer of so-called soft monomers such as butyl acrylate and acrylic 6-nitrile with so-called hard monomers such as styrene and methyl methacrylate bamboo. The softening temperature of this tree is approximately 100°C at most, which does not meet the regulation that carpets should retain their shape at 120°C according to JIS-D-0204, which requires even more severe heat resistance as an automobile interior design company. .

The present inventors have discovered that the shape of carpets obtained using conventional rubber latex and thermoplastic resin emulsions as packing materials is not perfect due to such shaping, and the heat resistance limit is due to the fact that the packing materials used are amorphous or non-crystalline. Based on the assumption that this is due to the low crystallinity of latex or emulsion of rubber or thermoplastic resin, when we used a highly crystalline e-nylidene chloride copolymer aqueous emulsion as a packing material, the shape due to shaping was It is possible to obtain a laying material that is fully exposed and has high heat resistance and elasticity.
In addition, they discovered that carpets have flame retardant properties and completed the present invention. , That is, the carpet characterized by the present invention has the following characteristics:
Vinylidene chloride 83-97% by weight as packing material
An aqueous emulsion of a crystalline vinylidene chloride copolymer obtained by emulsion polymerization of ・and 17 to 3% by weight of a vinyl monomer is coated, impregnated for one time, dried, and then heated and pressure molded. It is something.

Any material can be used as the carpet material for carpets in the present invention, and materials made from natural fibers, chemical fibers, and various fibers can be used. Generally, fibers such as wool, nylon, polyacrylonitrile, polyacetate, and polypropylene are used.
The tufted carpet kawara fabric is made by erecting piles on a primary base fabric knitted from 21 dollar punch or fugitive yarn obtained as a material, and the 21 dollar tufted carpet ridge fabric is used.

The aqueous emulsion of highly crystalline vinylidene chloride copolymer used as a packing material to be coated or impregnated on the back side of these raw rugs is 83 to 97% by weight of vinylidene chloride, preferably 85 to 97% by weight! 2% by weight and 17-3% by weight of vinyl monomer
, an aqueous emulsion obtained by emulsion polymerizing 15 to 8% by weight of a polymerizable monopoly mixture in the presence of a polymerization initiator, which penetrates into the original carpet rug and forms a bond with the fibers of the rug. The resin adheres to the rug, which has the effect of maintaining the processed shape of the original rug that has been molded and processed, and enhancing the locking effect of the pile.

The above vinyl monomer and sheath [chirume. Vinyls such as tacrylate, styrene, acrylonitrile, methacrylic acid, til, butyl acrylate, vinyl chloride, maleic anhydride, itaconic acid, acrylamide, and methacrylamide can be used. In addition, the resin solid content concentration in the resulting aqueous emulsion is usually 20 to 60% by weight, and the diameter of the dispersed resin particles is 10μ (.micron) or less.
Preferably it is 0.05 to 1.0μ. The softening temperature of highly crystalline pimolidene chloride copolymer is 140-1
The temperature is 90°C.

This aqueous emulsion of highly crystalline vinylidene chloride copolymer is mixed with synthetic rubbers such as tyrene/putadiene copolymer, methacrylic acid ester/putadiene copolymer, latex such as natural rubber, and viral acetate. In order to further improve the stiffness of the resulting carpet, it is possible to blend an aqueous emulsion of a olefin resin, an olefin resin, a vinyl chloride resin, an acrylic resin, or a styrene resin in the same amount of solids to further improve the stiffness of the resulting carpet. In particular, styrene and acrylic ester copolymer emulsions obtained by emulsion polymerization of 50 to 95% by weight of styrene, 50 to 5% by weight of acrylic ester, and 0 to 5% by weight of other vinyl monomers are solidified. 10-50% by weight
If used together, heat resistance will decrease. In addition, calcium carbonate, aluminum hydroxide, clay 1
It is also possible to add toners such as talc and barium sulfate, toners and dyes such as red iron oxide, malachite green, and titanium oxide to these emulsions. , These emulsions are applied by a conventional method, generally using a roll coater, and the coating amount is usually 30 to 100% (solid weight) of the weight of the carpet material. The raw rug coated with emulsion can be heated and dried by any method.
For example, a heating cylinder, an infrared heating machine, a hot air dryer, a sweet dryer, etc. can be used, but it is preferable to use a hot air blower and a heating cylinder in combination. In addition, drying can be carried out at 100 to 200°C, but from the viewpoint of preventing fiber deterioration, the temperature is 110 to 1°C. It is preferable to carry out the reaction at θ°C. Then, water scum is removed and crystalline chloride 1=1
, De, Copolymer Ka E , < y #7 Kasareen Rug,
8" is obtained. This rug is preferably heated at 35 to 80°C.
The copolymer is highly crystallized by being stored in a thermostatic chamber at a temperature of be done.

This crystalline vinylidene chloride copolymer has a glass transition point of -20 to θ°C, and the heat resistance of the carpet with a lower softening point is significantly improved.

The carpet according to the present invention obtained as described above has a structure in which a packing layer 2 of vinylidene chloride copolymer is provided on the back side of a rug material 1 as shown in FIG. The carpet 3 has significantly improved flammability due to the vinylidene chloride copolymer in micron units impregnated into the interior of the carpet 1 during impregnation.

Examples I and ■ ゛Vinyl chloride 80 to
Aqueous emulsion of crystalline vinylidey chloride copolymer obtained by emulsion polymerization of 88% by weight and 20-12% by weight of methyl acrylate (resin particle size 0.5-1.3μ, solid content group weight) %) was applied using a licker roller to give a coating weight of 150.P- (solid fraction), and then a needle punch carpelt was impregnated with the emulsion using a nip roll.

Then, after heating the emulsion-impregnated twenty-one dollar punch carpet at 120-'C to remove moisture,
The resulting carpet was heated for ω seconds with a far-infrared heater with a surface temperature of 180°C to soften the vinyl chloride copolymer, and then pressed using a cooling press mold for 20 minutes for 5 minutes. molded and automatically manufactured indoor floor carpets.

゛For the carpets manufactured in Examples I and ①, the sharpness of the molding (■ is very excellent, O is excellent, Δ is average), the thermal shape retention (■ is no change at all, O is a slight change, Δ is a change, and X is a significant change), and the evaluation of the burning rate is shown in Table 1 in comparison with Comparative Examples I and ■.

Regarding heat-resistant shape retention, as shown in Fig. 2 (a), the carpet 4 based on the above Examples I and (2) was placed on a t = 45 10 type 5 and heated at 85°C for 100 hours or at 120°C. We observed the shape retention when stored for 20 hours, and the results shown in Figure 2 (
(b). Also, regarding the burning rate,
This method was updated based on the flammability test method for organic materials used in automobile interiors by J.Eng.S=D-1201-1977.

Comparative Example 2 shown in Table 1 above uses styrene/butyl acrylate copolymer (styrene/butyl acrylate) as the packing material instead of an aqueous emulsion of osteogenic pinylidene chloride copolymer
This is an evaluation of a carpet molded in the same manner as in Example 1, except that an aqueous emulsion containing acyl acrylate (80/20) was used.

Examples ■ and ■ As packing materials, the aqueous emulsion of vinylidene chloride/methyl acrylate copolymer (PVDC) used in Example I and the aqueous emulsion of acrylic resin (ACSM) used in Comparative Example ) was used to evaluate the carpet under the same conditions as in Example (2), together with Comparative Example (2), in the same manner as in Table 1 above, and the results are shown in Table 2 below.

[Brief explanation of the drawing]

FIG. 1 is a front sectional view showing an embodiment of the present invention, and FIGS. 2(a) and 2(b) are explanatory diagrams showing a method for measuring the heat-resistant shape retention of a carpet. In the figure, 1 is a rug material, 2 is a backing material including a rug material layer, and 3 is a carpet. Patent applicant Yuka Perdice Co., Ltd. Agent Patent Attorney Sadao Kikukawa 1

Claims (1)

[Claims] 1. Coating or impregnating the original rug with an aqueous emulsion of a crystalline vinylidene chloride copolymer obtained by emulsifying 83 to 97% by weight of vinylidene chloride as a packing material and 17 to 3% by weight of a vinyl monomer, Heat after drying,
Kabetsuko constructed by pressure molding. The carpet according to claim 1, wherein the crystalline vinylidene chloride copolymer has a softening temperature of 140 to 190°C and a particle size of 0.05 to 1.0 microns.