JPS61252378A - Forming material of multilayer structure and its production - Google Patents

Abstract

PURPOSE:A carpet for the surface layer is integrally adhered to a needle-punched carpet of a specific fiber mat through a melt-extruded film to give the titled forming material of high toughness, elasticity and good formability. CONSTITUTION:(A) A carpet for the surface layer such as a needle punched carpet of wool or a synthetic fiber, e.g., nylon, which is impregnated with a resin emulsion or rubber latex with a glass transition point lower than 35 deg.C and dried, or tufted carpet with piles is subjected to press-adhesion to (C) a needle-punched carpet of a fiber mat which is composed of 15-50% of a fibrous binder of a thermoplastic resin melting at 60-200 deg.C and 85-50% of synthetic fiber melting at a temperature more than 40 deg.C higher than the melting point of the fibrous binder, through (B) a moisture-impermeable, 20-200mu thick melt- extruded film to give the objective multilayered forming material containing layers A, B and C, integrated.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a laying material useful as an interior material for an automobile and a method for producing the same.

[Prior art]

Needle-punch carpets of non-woven fiber mats impregnated with SBR latex or thermoplastic resin aqueous emulsion as automobile floor carpets, and mixed fibers of thermoplastic resin fibers with a high melting point and resin fiber binders with a melting point of 100 to 130°C. A molding material is known in which a needle-punch carpet of a Yoshinaru nonwoven fabric mat is heated to a temperature higher than the melting point of the resin or resin fiber binder in the emulsion, and then press-molded into the shape of an automobile floor.

These molding materials by themselves lack performance in terms of rigidity, elasticity, and moldability (mold fidelity). In addition, this molded material has excellent breathability, but this advantage has the disadvantage that it has water permeability, and rain (drops from an umbrella) can pass through the molded material, causing the car body to rust. Another disadvantage is that the engine noise can be heard through the gaps in the fiber mat.

[Specific measures to solve the problem]

The present invention uses a molded material as a flexible Table 1 carpet (
A) and a melting point of 60 to provide moldability and rigidity.
200℃ thermoplastic resin fiber binder is 15-50
A needle bunch carpet (C) is used, which is obtained by needling a fiber mat made of 85 to 50% synthetic fibers and natural fibers having a melting point of 40°C or more higher than the melting point of the fiber binder. , and both powers-
The present invention provides a molded material in which a pet is bonded with a non-water permeable resin film, and a method for producing the same.

(Surface carpet) Carpets (A) include needle punch carpets made from fibers such as wool, nylon, polyacrylonitrile, polypropylene, polyacetate, and polyethylene terephthalate, and carpets with a glass transition point of 35°C.
A raw fabric for tufted carpets made of a primary base fabric impregnated with the following resin emulsion and knitted with dried nonwoven fabric or polypropylene flat yarn, with piles made of polyamide or polyethylene terephthalate erected, and the above needle-punched carpet used as the primary base fabric. A raw tufted carpet with piles erected thereon is used.

In addition, in order to further provide rigidity, the melting point is 60 to 200.
℃ thermoplastic resin fiber binder is 15-50% by weight
Then, a fiber mat consisting of 85 to 50% by weight of synthetic fibers or natural fibers having a melting point 40°C or more higher than that of the thermoplastic resin is needled, and this is later laminated with a zero carpet and heated. Needle punch carpet obtained by melting the fiber binder and having a fiber bulk density of o, sr/cd or less, or a glass transition point of 3
An aqueous emulsion of a resin or a rubber fax impregnated and dried at a temperature of 5°C or less can also be used.

This latter material is manufactured by a known nonwoven fabric manufacturing method. That is, 1.2-300 denier, fiber length 25-15
0m heat 1liT plastic resin pear fiber binder 15~50
Weight%, 1.2-300 denier, fiber length 25-15
A thermoplastic resin fiber binder of 1.2 to 300 denier and a fiber length of 25 to 150 cm and a synthetic fiber and/or a natural fiber of 85 to 50 weight are thoroughly mixed and opened. The mixed fibers are fed to a web forming device, and the cards formed from the mixed fibers are stacked to the desired fiber weight, and the resulting web (fiber mat) is vertically needled to entangle the fibers. They are temporarily fixed by matching them together.

The fiber binder is 15 to 50% by weight of the fiber mat weight.
, preferably in a proportion of 20 to 40 7o by weight.

When the amount is less than 15% by weight, the contribution to improving the rigidity and dimensional stability of the carpet obtained by press molding is small. On the contrary, 5
If the weight exceeds 0, it becomes like resin felt, hard and brittle with impaired fiber texture. Similarly, when the bulk density is higher than 0.5 f/-, the fiber layer becomes dense, and although the rigidity is improved, the texture of the fibers is impaired.

[Needle Punch Carpet 0] Carpela (C) is a synthetic carpet containing 15 to 50% by weight of a fiber binder made of a thermoplastic resin with a melting point of 60 to 200°C and a melting point 40°C or more higher than the melting point of the thermoplastic resin. This is a web obtained by needling a fiber mat consisting of 85 to 50% by weight of fibers or natural fibers, and is manufactured by a known nonwoven fabric manufacturing method. That is, 1,2~
300 denier, thermoplastic resin throat fiber binder with fiber length 25-150 mm, weight 15-50 mm, 1.2-300 mm
15 to 50% by weight of a thermoplastic resin fiber binder with a denier and a fiber length of 25 to 150 square meters, and 85 to 50 weight% of synthetic fibers and/or natural fibers with a denier of 1.2 to 300 square meters and a fiber length of 25 to 150 square meters. The mixed fibers are sufficiently mixed and opened, and the resulting web (fiber mat) is stacked vertically so that the card formed from the mixed fibers has the desired fiber weight. It is temporarily fixed by needling to entangle the fibers, preferably having a bulk density of 0.15 to 0°st/cA and a basis weight of 300 to 2.000 f/-.

The fiber binder is 15 to 50% by weight of the fiber mat weight.
, preferably in a proportion of 20 to 40% by weight.

When the amount is less than 15% by weight and t%, the contribution to improving the rigidity and dimensional stability of the carpet obtained by press molding is small. On the contrary, 5
If it exceeds 0% by weight, it becomes hard and brittle, like resin felt9, with impaired fiber texture. Similarly, when the fiber bulk density exceeds 0.5 f/al, the stiffness improves, but the carpet becomes resinous and the feel is impaired. On the other hand, if the fiber density is less than o,1s t/-, the rigidity is insufficient and shape retention (moldability) is poor.

Examples of the fiber binder include polyethylene, linear polyester, polypropylene, low melting point polyamide, etc., and examples of the high melting point fiber include polyamide, polyethylene terephthalate, wool, etc.

Resin film adhesive film (T3 material resin has a melting point of 8
0 to 170°C thermoplastic resin, such as ethylene/vinyl acetate copolymer, polyethylene, ethylene/acrylic acid copolymer or its metal salt (K.

Li% Na-, Znz Pb), polypropylene, etc. are used.

This resin is melt-kneaded using an extruder, then melt-extruded from a die into a film, guided between both needle punch carpets (A) and (C'1), and then compressed with a compression cooling roll. Champion (A), (B),
(Q is integrated.

The thickness of the resin film is 20 to 2.000 microns, preferably 35 to 300 microns.

(4), (B), and C) can be integrated in addition to the method described above.
■Carpet captured by guide roll, resin film @),
Layer carpet 0 in this order, 150-20
A method of drying the emulsion and dissolving the emulsion resin and the above film by heating at 0°C, and then press molding to integrate and shape the champions (4), (6), and C); Alternatively, the molten resin film (B) may be laminated onto the needle punch carpet 0 or 0, and then another needle punch carpet 0 or (AI) may be adhered using a pressure roll.

The wall thickness of multi-layer molded material (Curbera for the surface layer of multi-layer molded material) (A) is 0.5~
The wall thickness of the needle punch carpet for the back side is 1 to 10 m, preferably 2 to 5 m.

The overall thickness of the multilayer molded material is 1.5 to 15 cm, preferably 3 to 5 cages.

On the needle punch carpet C) side of this multilayer molded material,
If under felt, foamed polystyrene sheet, polypropylene sheet, polyvinyl chloride sheet, nonwoven fabric, etc. are layered and heated and compression molded, a laying material whose back side is decorated with these materials can be obtained (see Figure 1). .

In addition, after heating the carpet side of (0), reinforcing materials such as plywood, resin felt, and cardboard are layered,
By applying pressure and bonding, these reinforcing materials can be integrally bonded to a molding material, which is useful as a molding material for rear bags and various trims.

In particular, when underfelt is used as the backing material, raindrops that seep into the surface layer (on the surface side) may cause the underfelt to deteriorate as it is blocked by the sun.
Does not cause mold.

Example 1 A plain tights needle punch carpet Ic made of polyester fiber 3509/m'' was coated with SBR latex 80?/yr/(solid content) to obtain a dried sasse needle punch carpet ■.

Separately, 20% of recovered polypropylene (melting point 164°C) fiber binder of 15 denier and about 100 fiber lengths and 15
Fiber mat (8509/lr/
) was needled using a 15-18-32-3RB needle at a rate of 50 needles per square inch to obtain a wall thickness of 8.1
A needle carpet with an apparent density of 0.105 f/cd (Q was obtained).

Both forces - PET (4) and Q are guided by guide rolls, and between them, ethylene-vinyl acetate copolymer is melt-kneaded by an extruder and extruded from a die (1) at 190°C to a thickness of 150 microns. The combined molten film (■) was guided, and this king was layered with nip rolls, compressed and integrated to obtain a molded material with a multilayer structure.

In addition, after heating the needle punch carpet Ω side of this multi-layer molded material at 190°C to melt the polypropylene fiber binder, a 10 m thick under felt was brought into contact with it, and then this was press-molded to form the multi-layer molded material. I got it.

This product shows a shape that is faithful to the mold cavity of the mold, the thickness of the 0 layer is 4.7 g, and the fiber bulk density is 0.188 f/cII
Met.

The physical properties of this multilayer molded material (A)/(9/(C')) were evaluated by the method described later. The results are shown in Table 1.

Waterproofing: 0.35 after heating the multi-layer molded material to 190℃! l/-G
Compression molded under the following conditions: length and width 200mm, depth 20mm
When a 1m tray-shaped container is molded and water is inserted into the container, water immediately and continuously leaks out of the container, which is considered poor waterproofing (X).Water seeps into the container and bleeds. ,
If water drips discontinuously, the waterproofness is fair (Δ), and if no water passes through it, the waterproofness is good (○).

Cushioning properties: The initial wall thickness when a load of 50 f/cd is applied to the multilayer molded material is taken as tx, then the wall thickness when a load of 400 t/- is applied for 1 minute is taken as tx, and this load is removed. When the wall thickness after 1 minute has passed is t2, compression ratio = -xio.

It was calculated as 悌to -tx, and those with a small deformation rate and a small thickness change rate were considered to have good cushioning properties.

[Adhesive strength]

The surface carpet (A) and needle punch carpet 0 at one end of the sample piece (50 mm long, 200 mm wide) were each fixed in an Instron type testing machine, and a 180 degree peel test was performed at a speed of 200-7 minutes. Ta.

Example 2 As a nonwoven fiber mat, 15 denier, fiber length 75~
125 ■ recovered polyethylene terephthalate (melting point 26
A molded material with three layers integrated was obtained in the same manner as in Example f111, except that a fiber mat c) (basis weight 5 sor/i) obtained by needling a web of randomly stacked fiber waste (4°C) was used. .

Table 1 shows the physical properties of this molding material.

Comparative Example In Example 1, a nonwoven fabric made of polypropylene fiber binder manufactured by Mitsui Petrochemical Industries Ltd. (9" Syntex PK-110" (trade name, basis weight 50 f/nl, fiber diameter 3 denier) was used on the back side of the needle punch carpet (4). ) to 3
Layer the carpet (150r/W?), then layer the needle carpet 0 under this non-woven fabric ■, and then add this laminate to the layer 1.
After heating to 90℃ to melt the nonwoven fabric ■ and the polypropylene fiber binder of the needle punch carpet Ω,
Pressure molding was performed using a press molding machine, and a molded material was obtained in which each layer faithful to the mold was integrated (the thickness of the 0th layer was 4.5 layers).

Example 3 In Example 1, the needle punch carpet (4) was a mixed fiber of 20% by weight of recovered polypropylene fiber binder of 15 denier and fiber length of 100 m and 80% of polyethylene terephthalate fiber of 15 denier and fiber length of 75 to 125 m. 350? /- SBR latex go on Yoshinaru plain type needle punch carpet
A molded material with a multilayer structure was obtained in the same manner as in Example gAJ1, except that f/m' (solid content) was applied and dried.

Table 1 shows the physical properties of this molding material.

Reference Example Carpet (A) used in Example 1 and Carpet 0
Table 1 shows the physical properties of molded materials molded individually.

(Margin below)

[Brief explanation of drawings]

FIG. 1 is a perspective view of a multilayer molded material obtained by carrying out the present invention, and FIG. 2 is a front view showing a mounting device. In the diagram, (A) is carpet, (g) is film, and (o is carpet. Patent applicant: Mitsubishi Yuka Berdische Co., Ltd. Patent attorney: Hidetoshi Furukawa Patent attorney: Masahisa Hase Figure 1 Figure 2

Claims (1)

[Claims] 1) A carpet for the surface layer (A) and a carpet with a melting point of 60 to 20
15 to 50% by weight of a thermoplastic resin fiber binder at 0°C, and 85 to 50% by weight of synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the fiber binder.
A method for producing a multi-layer molded material, which comprises adhering a needle-punched carpet (C) obtained by needling a fiber mat consisting of a fiber mat with a melt-extruded film (B). 2) A claim characterized in that the carpet for the surface layer (A) is a needle punch carpet (C) impregnated with a resin emulsion or rubber facsimile having a glass transition point of 35° C. or lower and dried. The manufacturing method according to item 1. 3) The manufacturing method according to claim 1, wherein the surface layer carpet (A) is a tufted carpet. 4) Surface layer carpet (A) contains fiber binder 15~
50% by weight of resin fibers having a melting point that is at least 35°C higher than the melting point of the material resin of the fiber binder 85~
Fiber bulk density made from 50% by weight mixed fiber is 0.5
2. The manufacturing method according to claim 1, wherein the carpet is a needle punch carpet having a particle diameter of 3 g/cm^3 or less. 5) The manufacturing method according to claim 1, wherein the film (B) has a wall thickness of 20 to 2,000 microns. 6) Surface carpet (A) with a melting point of 60 to 200
15-50% by weight of thermoplastic resin fiber binder at °C
and a needle-punched carpet (C), which is obtained by needling a fiber mat made of 85 to 50% by weight of synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the fiber binder, adheres the resin film (B). A multi-layer molded material characterized by being integrated into layers.