JPS61227025A - Manufacture of formed carpet mat - Google Patents

Abstract

PURPOSE:To obtain a formed carpet mat lined with shape-retaining foam by a structure wherein soft polyurethane foam formed by spraying expandable composition onto the inner surface of a mold and mounting material are pasted by curing in the mold into an integral body. CONSTITUTION:Firstly, resin liquid, the main component of which is polyol mixed with expanding agent and which is stored in one raw material tank of a spray expanding device, and crude diphenylmethane diisocyanate stored on the other raw material tank are thinly uniformly sprayed through a spray gun 5 onto the inner surface of the bottom half 2 of a mold with a resin liquid-to-diphenylmethane diisocyanate ratio by weight of 2:1. On the other hand, the raw fabric 7 of carpet is attached onto the inner surface of the top half 1 of the mold in such a manner that the back 8 of the raw fabric 7 can be visible. Before the polyurethane foam stock liquid mixture 6 sprayed onto the bottom half 2 cures, the top half 1 is put on the bottom half 2 so as to close the mold to clamp both the halves together with each other and to maintain them at normal temperature in order to completely cure the urethane foam. After the curing of the urethane foam, the top half 1 is removed to open the mold in order to take the product out of the mold. The non-flat carpet mat manufactured as mentioned above retains its shape even after the long-term use on the floor of a passenger car.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a method for producing molded articles of 7 ohm bonded carpet, particularly carpet mats lined with flexible polyurethane foam.

(Prior Art) Carpets, which have an elastic material such as rubber or thermoplastic resin attached to the back side of a covering material such as a textile, have been used for floor coverings, wall materials, etc. These products were generally flat, but recently they have come to be used as car floor mats, door linings, chair cushions, etc. For this purpose, carpets must be shaped three-dimensionally to fit and fit into the shape of automobile floors, chair seats, etc. For molding, carpets lined with thermoplastic resin are thermoformed indoors into the desired shape.

(Problem to be solved by the invention) In such molded products, the residual stress generated during thermoforming is released during use, causing the molded carpet mat to deform, resulting in car floors and chair seats. It floats up from a base structure like . In such a situation, people's movements become more easily deviated, which poses a danger.

(Means for solving the problem) In order to remove such residual stress, the raw material mixture of flexible polyurethane foam is poured into a mold, and after foaming, a facing material is immediately applied under pressure. In this method, the raw material mixture accumulates in the recesses of the mold, resulting in an extreme difference in thickness of the lining foam, making it impractical. As a result of various studies on methods for attaching a layer of flexible polyurethane foam of uniform thickness to the back surface of a carpet having a complex curved surface in a manner that prevents the formation of residual stress, the present invention was arrived at.

That is, the present invention is as follows.

(1) A foamable composition consisting of polyol, organic polyisocyanate, and other auxiliary agents is sprayed onto the inner surface of a mold, and the flexible polyurethane foam and surface material are cured and adhered in the mold to be integrated. Features: A manufacturing method for molded carpet mats.

The foamable composition of the present invention includes, for example, JP-A-57-1987
The stock solution for soft, highly elastic sprayed polyurethane foam described in No. 22 is used.

When a foamable composition adheres to the inner surface of a mold (made of aluminum, etc.), it immediately starts foaming and loses its fluidity in a short period of time.
A foam layer with a uniform thickness can be formed on the inner surface of the mold, and no internal stress remains in the cured foam. Before foaming is completed, close the upper mold attached to the entire inside of the facing material, or place the facing material on the uncured foam in alignment with the mold, close the upper mold, and tighten it to complete foaming. Glue the ohm and the facing material. In this case, the upper and lower molds may be placed in opposite positions during the work, if necessary. In these cases, the back side of the facing material should be in contact with 7 ohms.

Surface materials include floor coverings such as woven carpets and woven carpets; textiles made of natural and synthetic fibers; interior materials such as upholstery fabrics, laminated fabrics, pile fabrics, and covering fabrics; soft plastic sheets and films. can.

After foaming is completed, the product is left at room temperature for several minutes to one hour, and then removed from the mold. In addition, if it is necessary to heat set the facing material to the shape of the mold, 80 to 150 CKI 0 to 30
After heating for several minutes, the product is cooled and removed from the mold.

Polyols used in the present invention include monomeric polyols such as ethylene glycol, propylene glycol, diethylene glycol, triethylene glycol, diethylene glycol, trimethylene glycol, 1,3- and 1,4-butanediol, and triethanol. amines, alkanolamines such as jetanolamine, aliphatic polyamines such as ethylenediamine, diethylenetriamine, triethylenetetramine, methylene orthochloroaniline, 4,4'-diphenylmethanediamine, aniline, 2.4-)lylenediamine, 2.6 - Aromatic polyamines such as tolylene diamine, also water, ethylene glycol, propylene glycol, diethylene glycol, 11 ethylene glycol, diethylene glycol, trimethylene glycol, 1,3- and 1,4-butanediol, 1. 5-bentanediol, 1.2-hexylene glycol, 1.10-decanediol, 1.2-cyclohexanediol, 2-butene-1,4-diol, 3-cyclohexane-1,1-dimetatool, 4-methine 3-Cyclohexane-1,1-dimetatool, 3-
Methylene-1,5-bentanediol, (2-hydroxyethoxy)-1-propanol, 4-(2-hydroxyethoxy)-1-butanol, 5-(2-hydroxypropoxy)-1-pentanol, 1- (2-hydroxypropoxy)-2-octatool, 3-allyloxy-1,5-bentanediol, 2-allyloxymethyl-
2-methyl-1°3-bentanediol ((4,4-benteloxy)-methyl)-1,3-propanediol,
3-(.

-propenylphenoxy)-1,2-7'ropanediol, 2,2'-diisopropylidenebis(p-7enyleneoxy)jethanol, glycerin, 1°2,6-hexanetriol, 1,1,1-trimethylolethane , 1,1.1-)limethylolpropane, 3-(2-hydroxyethoxy)-1,2-propanediol, 3-
(2-hydroxypropyl)-1,2-propanediol, 2,4-dimethyl-2-(2-hydroxyethoxy)-methylpentanediol-1.5.1.1.1-tris[(2-hydroxy ) Methyl]・ethane, 1,1.
1-Tris[(2-hydroxypropoxy)-methyl]
Propane, pentaerythritol, nruvit, sucrose,
Lactose, α-methyl glucoside, a-hydroxyalkyl glucoside, novolac resin, phosphoric acid, benzenesic acid, poly-D phosphoric acid (e.g. tripolyphosphoric acid and tetrahydronic acid), phenol-aniline-formaldehyde ternary condensation product, aniline-formaldehyde condensation product,
caprolactone, etc., aliphatic polyamines such as ethylenediamine, diethylenetriamine, triethylenetetramine, methyleneorunchlor, aniline, 4.4'-diphenylmethanediamine, 2.4-)lylenediamine, 2
．． Obtained by adding one or more of aromatic polyamines such as 6-tolylene diamine, alkanolamines such as triethanolamine and jetanolamine with ethylene oxide, propylene oxide, butylene oxide, tetrahydrofuran, styrene oxide, etc. Polyether polyols, or polytetramethylene ether glycol, also ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, diethylene glycol, trimethylene glycol% 1.3- and 1.4-butanediol, tetramethylene glycol, One or more compounds having at least two hydroxyl groups such as neopentyl glycol, hexamethylene glycol, decamethylene glycol-A/, chrycerin, trimethylolpropane, pentaerythritol, sorbitol, etc., and malon Acid, one of the compounds having at least 42 carboxyl groups such as maleic acid, succinic acid, adipic acid, tartaric acid, pimelic acid, sebacic acid, sheracic acid, 7-tar acid, terephthalic acid, trimellitic acid, hemimellitic acid, etc. Polyester polyols from one species or two or more species, ring-opening polymers of cyclic esters such as polycarbonate, and Japanese Patent Publication No. 39-247
37, Special Publication No. 41-3473, Special Publication No. 43-22108
, JP 44-8230% JP 47-47597, JP 47-47999, JP 48-34991, JP 51-50398, JP 51-70286, JP 52-11249, JP 53-4092, Japanese Unexamined Patent Publication No. 1983
-13700, JP-A-54-64264, JP-A-53-
78297% Japanese Patent Publication No. 54-133599. Japanese Unexamined Patent Publication 1973-
There is a so-called polymer polyol composition obtained by graft polymerizing an ethylenically unsaturated compound in a polyether polyol and/or polyester polyol described in Japanese Patent No. 5988, etc. Saturated compounds include acrylonitrile, styrene, etc. Furthermore, 1,2-polybutadiene polyol and 1,4-polybutadiene polyol are used.

The various polyols mentioned above can be used alone or in combination.

The organic polyisocyanates used in the present invention are known ones, and are not particularly limited, but examples include 2.4-tolylene diisocyanate), 2.6-) lylene diisocyanate, 2.
．． The isomer ratio of 4-toluene diisocyanate and 2.6-tolylene diisocyanate is 80/20 (TDI-80
), mixture of 65/35 (TDI-65), crude tolylene diisocyanate, diphenylmethane-4,4'-diisocyanate, polyphenylmethylene polyinsyanate (known as crude MDI, regardless of its manufacturing method), carbodiimide group Various known modified diphenylmethane-4,4'-diisocyanate, dianisidine diisocyanate, toluidine diisocyanate, xylylene diisocyanate, bis(2-incyanatoethyl) fumarate, bis(2-incyanatoethyl)malate, bis(2-incyanatoethyl)fumarate, etc. (2-incyanatoethyl) carbonate, bis(2-incyanatoethyl) carbonate)
, 1.6-hexylylene diisocyanate isocyanate, 1.10-decamethylene diisocyanate, cumene-2,4-diisocyanate, 4-methoxy-1,3-7enylene diisocyanate, 4-bromo-1,3-phenylene Diisocyanate, 4-ethoxy-1,3-phenylene diisocyanate, 2,4'-diisocyanat diphenyl ether, 5,6-dimethyl-1,3-phenylene diisocyanate, 2,4-dimethyl-1,3-7 di-2 diisocyanate , 4.4'-
Diisocyanatodiphenyl ether, bis5.6-(2
-incyanatoethyl)bicyclol:2,2.1:lhept-2-ene, benzidine diisocyanate, 4.6
-Simethyl-1,3-phenylene diisocyanate, 9
．． 10-anthracene diisocyanate, 4,4'-diisocyanatodibenzyl, 3,3'-dimethyl-4,4
'-diynecyanatodiphenylmethane, 2,6-dimethyl-4,4'-diynecyanatodiphenyl, 2,4-diisocyanatostilbene, 3,3'-dimethyl-4,4
'-diisocyanatodiphenyl, 3,3'-dimethyl-
4,4'-diisocyanatodiphenyl, 1,4-anthracene diisocyanate, 2,5-fluorene diisocyanate, 1,8-naphthalene diisocyanate, 2.
6-diynetobenzfuran, 2,4.6-) luent isocyanate, dimers and dimers of these organic polyisocyanates, and NCO from these organic polyincyanate compounds and the above-mentioned active hydrogen-containing compounds. These are group-terminated prepolymers, which can be used alone or in combination.

The amount of organic polyisocyanate used is such that NCO/H (active hydrogen) (equivalent ratio) is 0.70 to 1.40.

Catalysts that can be used in the present invention are conventionally known and are not particularly limited, but include, for example, amine-based urethanation catalysts (triethylamine, tripropylamine, triimpropaturamine, tributylamine, trioctylamine, hexadecyldimethylamine, N-methylmorpholine, N-ethylmorpholine, N-octadecylmorpholine, monoethanolamine, jetanolamine, triethanolamine, N-methylgetanolamine, N, N-dimethylethanolamine, diethylenetriamine, N, N
, N', N'-tetramethylethylenediamine, N
.

N, N', N'-tetramethylpropylene diamine, N.

N, N', N'-f) 5 mufflelln) 7 min, N, N
,N? N'-tetramethyl-1,3-butanediamine,
N, N.

N1. N/-tetramethylhexamethylene diamine,
Bi
N'-pentamethyldiethylenetriamine, triethylenediamine, formates and other salts of triethylenediamine, oxyalkylene adducts of amino groups of primary and secondary amines, azacyclic compounds such as N,N-dialkylpiperazines, various N, N: N'-to'J alkylaminoalkylhexahydrotriazines, Japanese Patent Publication No. 52-435
17 l-aminocarbonyl catalyst, Japanese Patent Publication No. 53-142
79 β-amino nitrile catalyst, etc.), organometallic urethanation catalysts (tin acetate, tin octylate, tin oleate, tin laurate, dibutyltin diacetate, diptyltin dilaurate, diptyltin dichloride, lead octoate, naphthenic acid) lead, nickel naphthenate, cobalt naphthenate, etc.)
etc. These catalysts are used alone or in combination, and the amount used is 0.0001 to 10.0 parts by weight per 100 parts by weight of the compound having active hydrogen (in the present invention, parts indicate parts by weight).
Department.

The blowing agent in the present invention is a mixture of one or more of water, trichloromonofluoromethane, dichlorodifluoromethane, methylene chloride, trichlorotrifluoroethane, dibromotetrafluoroethane, trichloroethane, pentane, n-hexane, and the like.

The foam stabilizer in the present invention is a conventionally known organosilicon surfactant, such as L-520 manufactured by Nippon Unicar Co., Ltd.
L-532, L-540, L-544, L-550, L
-3550, L-5305, L-3600, L-360
1, L-5305, L-5307, L-5309, L-
5710, L-5720, L-5740M, L-620
2 etc., 5H-190 manufactured by Toray Silicone Co., Ltd.
゜5H-192, 5H-194, 5H-200, 5RX
-253,5RX-274C,5F-2961,5F-
2962, 5RX-28OA, 5RX-294A, etc. manufactured by Shin-Etsu Silicone f7) F-114, F-12
1, F-122, F-220°F-230, F-258
, F-260B, F-317, F-341, F-601
%F-606, X-20-200%
TFA-4202, etc.

The amount of these foam stabilizers to be used is 0.1 to 20 parts per loo part of the compound having active hydrogen and the organic polyisocyanate.
Department.

According to the present invention, dyes, coloring agents, etc. can be contained as necessary.

The molded carpet mat of the present invention adheres closely to the surface of a substrate having a complex shape, and does not deform or float away from the substrate during use.

(Example) Polymer polyol POP36 manufactured by Mitsui Nisso Urethane Co., Ltd.
20 parts of -42, 80 parts of polyoxyethylene polyoxybrobylene glycerol manufactured by Mitsui Nisso Urethane Co., Ltd., 2 parts of water
5 parts, catalyst triethylenediamine 1.0 part, manufactured by Union Carbide, delayed catalyst NIAX A-1070,
5 parts, manufactured by Nippon Unicar Co., Ltd., silicone foam stabilizer L-36
00 and 3.0 parts of a trichloromonofluoromethane blowing agent were mixed to prepare a resin.

This embodiment will be explained with reference to the drawings.

The above resin liquid and crude diphenylmethane diincyanate were separately charged into the raw material tank of the spray foaming device, and then thinly applied to the inner surface of the lower mold 2 in FIG. 2 or 4 through the sprayer 15 at a weight ratio of 2:1. Sprayed evenly.

Separately, an original carpet 7' is attached to the inner surface of the upper mold shown in FIG. 1 so that its back surface can be seen as shown in FIG. Before doing so, as shown in FIG. 5, the upper mold 1 was closed, tightened, and left at room temperature to completely cure the urethane foam, and then the upper mold 1 was opened and the product was taken out.

This molded carpet was left in a constant temperature room at 70° C. for one month, but no deformation occurred.

(Effects of the Invention) The particularly non-flat carpet mat produced does not take on a T-shape even when left to warm, so it does not lose its shape even when placed on the floor of a passenger car and used for a long period of time.

[Brief explanation of the drawing]

Figures 1 to 4 are perspective views illustrating the mold and other parts of the present invention;
FIG. 5 is a cross-sectional view of the apparatus in which the invention is practiced. 1st
In Figures to Figures 5, 1 is the upper mold, 2 is the lower mold, 3 is the recess, and 4
is a convex part, 5 is a polyurethane foam spray gun, 6 is
7 is the polyurethane foam layer, 7 is the original carpet, 8 is the back surface thereof, and 9 is the gap provided on the lower mold 2.

Claims (1)

[Claims] (1) A flexible polyurethane foam made by spraying a foamable composition comprising a polyol, an organic polyisocyanate, and other auxiliary agents onto the inner surface of a mold and a surface material are cured and adhered in the mold to be integrated. Features: A manufacturing method for molded carpet mats.