JPS60167979A - Production of back-lining 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 method for manufacturing a carpet lining that has excellent shape retention, heat insulation, sound absorption, lightness, etc.

2. Description of the Related Art There has been a strong demand for improvements in the comfort of vehicles, mainly passenger cars, and this has led to the spread of interior materials with excellent interior decoration and soundproofing effects. As this type of interior material, for example, carpets such as tufted carpets and needle punch carpets, which are lined with a thermoplastic synthetic resin sheet made of ethylene/vinyl acetate copolymer containing inorganic fillers, etc., are in practical use. It is offered to However, in this case, if the content of the inorganic filler is increased in order to increase sound absorption and reduce material costs, there are disadvantages in that the suture removal strength decreases and hair removal tends to occur.

Also, the back side of the carpet is made of acrylic ester latex or styrene-butadiene copolymer (SBR).
Latex linings made of There are drawbacks.

In view of the above, an object of the present invention is to provide a method for producing a carpet lining that has excellent shape retention, heat insulation, sound absorption, lightness, etc.

The gist of this invention is (1) weight ratio, particle size 0°1~2
．． A foamed backing composition prepared by mixing and kneading 65 to 85% of foamable resin beads of 5.5% and 35 to 15% of polymer latex (solid content), or (2) a particle size of 0.1 to 2% by weight.
．． A foamable backing composition prepared by blending and kneading 5.5% of foamable resin beads, 35-15% of polymer latex (solid content), and 0.8-4% of short fibers is applied to at least the back side of the carpet. Apply it to a thickness of 0.2H and apply it to a thickness of 90~
This is after foaming treatment, for example free foaming or pressure foaming, in a temperature range of 150°C.

The foamable resin beads used in this invention include, for example, Styropol and Heatpol (trade names) manufactured by BASF.
This is expanded polystyrene containing a blowing agent such as an aliphatic hydrocarbon. In addition, polymer latex is an emulsion latex in which a dispersoid polymer is uniformly dispersed in water as a dispersion medium, and it functions to prevent carpet thread removal, tweezing, and as an adhesive for expanded polystyrene resin beads. It is. The short fibers include, for example, low melting point multi-branched fibers (SWP) having wood-loving properties, recycled fibers, and the like. By determining the appropriate blending ratio of these foamable resin beads, polymer latex, short fibers, etc. and the foaming treatment conditions after kneading them and applying them to the back side of the carpet, the shape retention and heat insulation properties of the backing carpet are improved. , sound absorption, lightweight, etc. can be adjusted depending on the application.

Next, the reasons for limiting the blended raw materials and manufacturing conditions in this invention will be explained.

(1) Particle size of expanded polystyrene resin beads When performing foaming treatment in the temperature range described below, small particles with a particle size of 0.1 mm or less have poor retention stability of the aliphatic hydrocarbon gas contained, and vice versa. If the particles are larger than 2.5H, the foamed polystyrene resin beads occupying the surface to which the foamed backing composition is applied will become rough, making the finished surface uneven and making it difficult to obtain a flat finished surface. ~2.5■.

(2) Mixing ratio of expanded polystyrene resin beads, polymer latex (solid content), and short fibers Out of several dozen basic experiments, Table 1 shows some examples: Experiment No. 11
,! '&), The overall results evaluated from the finish condition of the backing carpet belonging to Class 45 after pressure foaming treatment, the tendency of fine warp racks to occur in the backing foam layer when the rolled backing carpet is rolled out, etc. are excellent, and the experimental results are excellent. It
), 4. N.

, that of the backing carpet belonging to 18 is good, experiment Nb
, 26, Nb, and 38 were acceptable.

Table 1 According to the results of these basic experiments, if the blending ratio of expanded polystyrene resin beads is less than 65%, the foam backing layer becomes thin and the above functions are inferior, whereas if it exceeds 85%, the apparent viscosity decreases. It is set at 65% to 85% because it becomes difficult to mix wires and uniformly disperse the wires if it becomes high.

Also, the blending ratio of emulsion latex (solid content) is 3.
If it is more than 5%, the foam backing layer becomes thin and the above functions are inferior, and if it is less than 15%, the degree of bonding between the foamed polystyrene resin beads and the back side of the carpet becomes weak.
Next, 65 to 85% of the above expanded polystyrene resin beads and emulsion latex (solid content) are determined to be 5 to 15%.
If the above-mentioned short fibers are mixed in 35 to 15%, the tendency of cracks to occur is eliminated, but the mixing ratio is 0°8 to 4%.
(3) At low foaming treatment temperatures of 90°C or lower, the foaming of expanded polystyrene resin beads tends to become uneven, and at high temperatures over 150°C, carpets are adversely affected. The temperature was set at 90 to 150°C because the foamed lining layer would shrink.

(4) Application thickness of foamable backing composition When applying a foamable backing composition consisting of foamed polystyrene resin beads and emulsion latex, or foamed polystyrene resin beads, emulsion latex, and short fibers to the back side of the carpet, If the coating thickness is too thin, shape retention, heat insulation, sound absorption, lightness, etc. after foaming treatment will be poor, so it is necessary to apply the coating to a thickness of at least 0.2 mm.

Preferred embodiments of this invention will be described below.

That is, after preparing a foamable backing composition kneaded in the proportions shown in Table 2, it is applied to the back surface of the carpet to a thickness of about 1.5+ai+ by means not shown. Next, a carpet 1 with a pile layer 2 on the surface side as shown in FIG. Foam layer 3 on the back side
manufactured a carpet lining formed by:

Table 2 □-≦ □□□□□□□" Table 3 shows the results of the investigation on shape retention, heat insulation, sound absorption, etc. of the carpet lining shown in Table 2 above.

Table 3 Next, the heat insulation property of the sample taken from the backing carpet belonging to the continuous production period code When the carpet lining according to the present invention was thin, it was found to have an excellent heat insulating effect, as shown in FIG. 2.

Furthermore, when we measured the sound absorption coefficient (spatial distance between the installation position and the measurement position: 80m+*) of the sample taken from the backing carpet belonging to the continuous manufacturing period code YA shown in Table 2, we found that it was the same as the conventional material as shown in Figure 3. (SBR backing material with a thickness of about 2.0H, the above spatial distance = 4°■)
It was found that the sound absorption properties (soundproofing properties) in the region of 1 hertz or less are excellent. Although the reason for this has not been investigated in detail, it is presumed that it is due to the countless closed cells formed within the foam lining layer.

As described above, according to the present invention, the foamed backing layer made of foamed resin is firmly fixed to the back surface of the carpet, so it has better shape retention, heat insulation, sound absorption, etc. than the conventional backing layer described above. It has excellent properties and eliminates the need for secondary lining with polyethylene film or the like. In addition, the foamable resin beads are not foamed during the next lining process; in other words, the unfoamed lining foam layer is heated and foamed during the molding process (see Figure 4).
It is also possible to simplify the process to make full use of various functions. The carpet lining thus obtained has a large deformation recovery force due to repeated external stress and can be used as an interior member with excellent cushioning properties. Therefore, it is suitable not only for vehicle interior materials such as floor materials, door side materials, ceiling materials, etc. of automobiles, mainly passenger cars, but also for architectural interior materials.

[Brief explanation of the drawing]

The figures show an embodiment of the present invention, and FIG.
Figures 3 and 3 are graphs comparing the thermal insulation and sound absorption properties of conventional materials and the foam-backed carpet according to the present invention, and Figure 4 shows the state in which the unfoamed foam backing layer is heated and foamed during molding. FIG. l...back side of carpet, 3...backing foam layer. jll Figure No. 2 Figure 0 10 20 Thickness (Cm), drawing 1! F (No change in content) Zhou * & (Hertz) Figure 4 Self-amended Amendment Procedures Amendment 1, Indication of the case 1982 Patent Application No. 21479 2, Name of invention Method for manufacturing lining carpet 3, Amendment Relationship with the case filed by the person filing the patent application Name and address of the person Daikyoku Boseki Co., Ltd. 4, Agent 5, Column of “Detailed Description of the Invention” in the specification to be amended, drawings and reference materials 6, Contents of the amendment (1) Note 4111 of Table 2 on page 9 of the specification is amended as follows. [1] No. 10 (60°C), No. 20 (80°C)
), No. 30 (100°C), No. 40 (110°C)
), 50th-rule (110"C) in 3.5 minutes." (2) Figure 3 of the drawing is supplemented as shown in the attached sheet. (3) Delete "(loop polymer latex)" from the explanation of reference photo 2.

Claims (2)

[Claims] (1) Weight ratio: 65-85% foamable resin beads with a particle size of 0.1-2.5H and 35% polymer latex (solid content)
After preparing the foamable backing composition by kneading ~15%,
The intumescent backing composition is applied to the underside of the carpet to a thickness of at least 0.2 mm and heated to 90-150''C.
A method for producing a carpet lining, characterized by performing foaming treatment in a temperature range of . (2) Weight ratio: 65-85% foamable resin beads with a particle size of 0.1-2.5mm and 3% polymer latex (solid content)
After preparing a foamable backing composition by kneading 5% to 15% and 0.8% to 4% short fibers, the foamable backing composition is applied to the back side of the carpet to a thickness of at least 0.2 mm. death,
A method for manufacturing a carpet lining, which comprises foaming the carpet in a temperature range of 90 to 150°C.