JPS6059183A - Manufacture of flooring material having cushioning property - Google Patents

Abstract

PURPOSE:To manufacture a flooring material having excellent cushioning property, and having a backing layer furnished with protruded foamed particles, by coating the back side of the raw fabric of a carpet with an aqueous emulsion of a resin containing expandable polystyrene particles, and heating the coated surface. CONSTITUTION:An aqueous emulsion of a resin containing expandable polystyrene particles having particle diameter of <=1.5mm., preferably 0.2-0.8mm. (containing 10-100pts.wt. of expandable particle based on 100pts.wt. of resin) is applied to the back surface of the raw fabric of a carpet at a rate of 600-1,000g/m<2>, preferably 80-300g/m<2> (solid basis). The coated surface is heated (preferably with hot air of 100-140 deg.C to effect the expansion of the expandable particles and the drying of the aqueous resin emulsion to obtain the backing layer having expanded polystyrene particles protruded from the surface.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a carpet that is superior to cushioning, and provides a carpet that is particularly useful as a floor covering material for automobiles.

Traditionally, carpets have been made using rubber latex such as styrene-butadiene rubber, butadiene-crylonitrile wrapper, vinyl chloride copolymer, styrene-butadiene rubber, etc. to prevent the pile threads of the original rug from coming off and to stabilize the shape. Resin aqueous emulsions such as acrylic acid alkyl ester copolymer, vinyl acetate/acrylic acid alkyl ester copolymer, vinylidene chloride copolymer, polyvinyl acetate, ethylene/vinyl acetate copolymer (hereinafter referred to as latex and φ1 fat aqueous emulsion) The backing is embroidered with [Resin aqueous emulsion =, -, 1].

As a method to further improve the cushioning properties of carpets backed with this resin aqueous emulsion, we previously proposed NoJ-Pet, which was created by bonding a foam sheet to the back side of this resin emulsion backing.
(See No. 170656 and No. 57-195731).

However, this method requires the steps of forming a backing layer and adhering the foam sheet, and in addition, in order to prevent the foam sheet from breaking due to bending, a non-foam sheet is added to the foam sheet. It is necessary to laminate.

The present invention was made for the purpose of performing the previously proposed manufacturing method of laying material, which requires many steps, in fewer steps, and by using an aqueous resin emulsion containing expandable polystyrene resin particles as a backing material. This problem has been solved.

That is, in the present invention, an aqueous resin emulsion containing expandable polystyrene particles having a particle size of 1.5" or less is applied to the back side of an original rug, and then the applied surface is heated to cause the expansion of the expandable polystyrene particles. The present invention provides a method for producing a laying material having cushioning properties, which comprises drying the aqueous resin emulsion to form a backing layer with protruding polystyrene foam particles on the back side of the original rug.

Any material can be used as the material for carpets and carpets in the present invention, and materials made from various fibers such as natural fibers, chemical fibers, and synthetic fibers can be used. In general, needle-punched carpets made from fibers such as wool, nylon, polyacrylonitrile, polyacetate, and polypropylene, tufted carpets with piles erected on a primary base fabric knitted with flat yarns, and the needle-punched A tufted carpet material is used, in which a carpet is used as a primary base fabric and a pile is made to stand up on top of the carpet.Among these, inexpensive needle punch carpets are preferred for automobile interiors.

Next, as a backing material, an aqueous resin emulsion that functions to secure the pile threads and adhere the polystyrene foam particles is an aqueous emulsion of a resin with a glass transition temperature of 165°C to +150°C, such as polyvinyl acetate, vinyl chloride, etc. Vinylidene chloride copolymer, styrene/butadiene copolymer rubber, styrene φ methyl methacrylate copolymer, styrene/n-butyl acrylate copolymer, ethylene/acetic acid IY'Z vinyl copolymer, styrene/acrylic acid n -Latices such as butyl/acrylic acid copolymer, vinylidene chloride/acrylonitrile/acrylic acid copolymer, and aqueous emulsions may be used alone or in mixtures.

In terms of formability and flexibility of the laying material, the glass transition point is 20.
Aqueous resin emulsions and latexes with a temperature below
An aqueous resin emulsion having a temperature of 0° C. or higher is preferred.

As the aqueous emulsion having a glass transition point of 80°C or higher, (a) polymethacrylic city n-globil (Tg81C
), polystyrene (100°C), polyacrylonitrile (100°C), polymethyl methacrylate (105°C),
Polymethacrylic acid (130°C), polyitaconic acid (13
In addition to water 1'JE emulsions of homopolymers such as (0°C) and polyacrylamide (153°C), (b) 50 to 100% by weight of vinyl monomers, which are raw materials for these polymers, preferably 65 to 95% by weight. % and vinyl monomers such as 2-ethylhexyl acrylate (Tg -85°C), n-butyl acrylate (-54'C), ethyl acrylate (-22°C), isopropyl acrylate ( -5℃), 2-ethylhexyl methacrylate (-5℃), Acrylic-
n-propyl acid (8℃), n-butyl methacrylate (2
0℃), vinyl acetate (30℃), ethyl methacrylate (
65°C), vinyl chloride (79°C), etc. or vinylidene chloride (-18°C) 50% by weight or less, preferably 35-5%
[In this (b) section, 'vg' shown in parentheses is the glass transition point of the vinyl monomer or vinylidene chloride homopolymer], (c ), Pg is 50-97% in aqueous resin emulsion at 80-155°C, preferably 55-97%
Resin aqueous emulsion with 95% heavy bone and l'g of 185°C to less than +80°C 50-3% by weight, preferably 45-5%
% by weight, etc.

Resin solid content of aqueous emulsion NU Ikawa 20~
60% by weight and dispersed (fft diameter of fat particles) 0 μ (micron) or less, preferably 0.05 to 1.0
μ.

Examples of aqueous resin emulsions having a glass transition point of 20'C or lower include (1), 2-ethylhexyl acrylate, n-acrylic acid;
- Monomer selected from butyl, ethyl acrylate, inglovir acrylate, 2-ethylhexyl methacrylate, n-propyl acrylate, n-butyl methacrylate, vinylidene chloride, ethylene, butadiene 20-100% (I Weight, 80% by weight or less selected from vinyl acetate, ethyl methacrylate, vinyl chloride, methacryl rffn-flovir, styrene, acrylonitrile, methyl methacrylate, acufunolic acid, itaconic acid, acrylamide, methacrylamide (Il+)-diacetone acrylamide Examples include emulsion polymers containing 0 to 5 weight η% of monomers selected from , maleic anhydride, and diethylene glycol diacrylate.

This aqueous resin emulsion has a particle size of 1.5. Hereinafter, preferably 0.2 to 0.8 particles of expandable polystyrene resin are added per 100 g of resin in the emulsion.
It is blended at a ratio of 0 to 100 Ji Keibu and used as a backing material. If the particle size exceeds 1.5r+Im, the workability of mixing with the emulsion will be poor, and the expandable polystyrene particles will trap and move to the upper part of the emulsion and easily separate. In other words, the workability and storage stability of the backing material are poor. In addition, if the particles are large, the coating properties of the backing material will deteriorate, and furthermore, after the backing material is applied to the original rug, the IF')-prone polystyrene particles will easily fall off from the original rug.

Such expandable polystyrene particles are produced by emulsifying styrene containing a polymerization initiator, optionally methyl methacrylate, vinylbenzene, and 1% vinyl monomer of acrylic K in water, and heating the mixture to polymerize the vinyl monomer such as styrene. Then, butane,
It is obtained by injecting an expanding agent such as heptane under pressure and impregnating the volatile expanding agent into the polymer particles at a ratio of 3 to 7% by weight. In addition, vinyl monomers such as styrene can be suspended + I
It can also be obtained by polymerizing while supplying the swelling agent to the ltf and m liquids during the polymerization.

Extender pigments such as calcium carbonate, aluminum hydroxide, clay, talc, barium sulfate, perlite, pigments and dyes such as red iron oxide, malachite green, and titanium oxide can also be blended with this banking material.

The viscosity of the backing material at 20℃ is 500-8, +)
OO centipoise is preferable from the viewpoint of coating.

The backing material can be applied to the original rug by spraying, brushing,
This is carried out using a foam coating machine, rolls, etc., generally a roll coater. The month of application of the backing material is 6
0~1,1) OOt/rr? (solid content), preferably 80 to 3 oop/m''.

Generally, the total weight of the backing material is 30% of the weight of the original rug.
It is used so that it becomes ~100% by weight (solid content weight).

Heat drying of the applied emulsion and foaming of the expandable resin particles can be carried out by any method.For example, a heating cylinder, infrared heating, hot air dryer, suction dryer, etc. can be used, but hot air dryer It is preferable to use Although drying can be carried out at 80 to 180°C, it is preferable to dry with hot air at 100 to 140°C in order to prevent fiber deterioration and to ensure sufficient foaming.

As a result of this heating, the expandable polystyrene particles expand approximately 5 to 50 times, forming an expanded i-envelope (1) with a particle size of 5 to 4.5 mm, and a film (2) formed by the resin emulsion forms a rug material. 3) and protrudes from the surface of the membrane (2) (see Figure 1).

Therefore, the laying material (4) of the present invention has such foamed monolithic particles (
Due to the presence of 1), the cushioning properties have been greatly improved 4, (
It is used as a teaching material.

In addition, when using a resin emulsion with a glass transition point of 80°C or higher, the laying material has moldability, so it is heated to a temperature at which 1(' and 2) of the panogging layer melts. By press-molding the laying material, the laying material can be shaped into a desired shape.

Hereinafter, the present invention will be explained in more detail with reference to Examples.O Manufacture example of needle punch carpet 15 denier, fiber length 100cm polypropylene (melting point 164°C) fibers randomly stacked together to form a fiber mat (
400 f/m') was needled at a rate of 50 needles per square inch using 15-18-32-3RB needles to obtain a needle punch carpet with a thickness of about 3 cm.

The raw carpet material used in the following Examples and Comparative Examples is this needle punch carpet.

Example 1 Styrene (49% by weight)/n-butyl acrylate (
49% by weight) and acrylic acid (2% by weight) copolymer aqueous emulsion (resin particle size 0.1 to 0.2 microns, solid content 50 parts, film forming temperature 20°C), By blending 10 times more expandable polystyrene particles (containing 5.5% butane) with an average particle size of 0.33 m, and further blending the thickener "Latechol D" (trade name) manufactured by Yuka Verdissier ■, 25% The viscosity at ℃ was adjusted to 3.000 cps, and it was rolled at 150 f/- with a licker roller.
(solid content), and then the needle punch carpet was impregnated with the emulsion using a nip roll. Then, the needle punch carpet impregnated with the emulsion was heated with hot air at 130°C for 10 minutes to remove moisture and foam the expandable polystyrene particles, with a bulk density of about 0.15 f/cd and a particle size of 0.5 ~1.
A laying material was obtained in which five-fin polystyrene foam particles were adhered to the back side of a needle punch carpet via a resin film.

The cushioning properties of this product were evaluated using the following method.
It was good.

Evaluation method: The initial wall thickness when a load of 5of/ltl is applied to the laying material is to, then the load is 400f/crr? Let tl be the wall thickness when the load is applied for 1 minute, and let t2 be the wall thickness after 1 minute has passed after this load is removed. 2 Deformation rate = (1--)X100 t.

Binding temperature was calculated, and those with a small deformation rate and a small thickness change rate were considered to have good cushioning properties @Examples 2 to 3, Comparative Example 1 Actual I! A laying material was obtained and shaped in the same manner as in FU51J1, except that the blending ratio of the aqueous resin emulsion and expandable polystyrene particles in the backing material was changed as shown in Table 1. The performance of the laying materials is shown in the same table.

For reference, needle felt "Ango Felt" 651111P/rr? manufactured by Company A is used. The table shows the cushioning properties based on the basis weight.

Example 4 In Example 1, styrene (80%
1RJt%)/n-butyl acrylate (20% by weight) copolymer aqueous emulsion (width 114t particle size approximately 0.2 microns, solid content 50%) 100 parts by weight is blended with 10 parts by weight of expandable polystyrene particles. A laying material with poor cushioning properties was obtained in the same manner, except that the same material was used.

In addition, this laying material was heated to 120°C to soften the resin film of the backing layer, and then 5
A pressure of Kg/rfA was applied for 5 minutes to form a carpet for an automobile interior floor.

[Brief explanation of drawings]

FIG. 1 is a sectional view of a laying material obtained by implementing the present invention. In the figure, 1 is a polystyrene foam particle, 2 is a resin film, 3 is a rug material, and 4 is a laying material. Patent Applicant Yuka Birdinocie Co., Ltd. Agent Patent Attorney Hidetoshi Utsukawa Agent Patent Attorney Tadashi Hase Kusei 1 Figure 4

Claims (1)

[Scope of Claims] 1) An aqueous resin emulsion containing expandable polystyrene particles with a particle size of 1.5 or less is applied to the back side of the original rug, and then the applied surface is heated to remove the expanded polystyrene particles. A method for manufacturing a laying material having cushioning properties, which comprises foaming the particles and drying the aqueous resin emulsion to form a backing layer in which polystyrene foam particles protrude on the back side of an original rug. 2), 4fi (the ratio of expandable polystyrene particles to 100 parts by weight of the resin content of the fat-aqueous emulsion is 10 to
The method for manufacturing a laying material according to claim 1, characterized in that the amount is 100 parts by weight.