JPS6328980A - Backing composition of carpet - Google Patents

Abstract

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

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to high density carpet backing compositions highly loaded with inorganic fillers. More specifically, it consists of an unsaturated carboxylic acid-modified ethylene copolymer alone or a mixture of an unsaturated carboxylic acid-modified ethylene copolymer and an ethylene copolymer, an inorganic filler, a plasticizer, etc. with excellent kneading processability and compounding properties. The present invention relates to carpet backing compositions.

The present invention also relates to automobile carpets and tile carpets, which are lined with the above-mentioned composition in a heated and molten state.

[Prior Art and Problems to be Solved by the Invention] Automotive carpets are interior materials that provide interior decoration, heat retention, sound absorption, and sound insulation effects. Carpet backing materials for automobiles are basically required to have the following properties: carpet reinforcement, mold retention, prevention of pile handling, and prevention of shrinkage. Additionally, there is an increasing demand for improving indoor comfort by reducing noise from seedling pots, such as the sound of automobile engines, and this purpose requires a lining material with sound insulating properties. The sound insulation effect is determined by the quality of the lining material per unit area.
In order to be proportional to the amount received, the lining material needs to be dense and have a certain thickness. It would be desirable to be able to obtain a backing material that provides the original functions of a carpet and at the same time provides sound insulation properties without using expensive materials.

Carpet tiles are square, rectangular, diamond-shaped, or roughly multi-M in shape, and the area of one carpet is, for example, O, O.
It is a root-shaped carpet of about S to 2Tn, 3, and by using these in combination, it can be laid on the floor without creating any gaps. These tile carpets have the advantage of being easier to install than regular carpets by simply arranging them on the floor and fixing them, and can be made into carpets with a variety of textures by combining many shapes, colors, etc. It also has the advantage of being easy to repair. When these carpet tiles are laid on the floor,
It is necessary that it adheres well to the floor and that part of it does not come off when walking. Methods for this include using adhesives or adhesives, and fastening with nails or rivets, but these methods have drawbacks such as being troublesome to install and requiring time and effort to re-upholster. As an improvement over these shortcomings, a relatively thick backing material gives the tile carpet its own weight, and its own weight provides stability (placeability).
Tile carpets with

This backing material also serves the purpose of imparting various properties to the tile carpet, such as yarn handling resistance, dimensional stability, and elasticity. Therefore, the backing material for tile carpets must not only satisfy the required properties of general carpet lining materials, but also have the ability to be placed stably by simply placing it on a rough surface. Furthermore, this ease of placement must be provided without using expensive materials.

Conventionally, known carpet backing materials include rubber latex, elastomer, synthetic resin, and asphalt. For example, these are
It is disclosed in Japanese Patent Publication No. 839, Japanese Patent Publication No. 48-201991), Japanese Patent Publication No. 3455G of Sho 48, Japanese Patent Publication No. 17851 of Sho 52, and Japanese Patent Publication No. 4525 of Sho 53.

However, when these conventionally known backing materials are used as carpet base materials, they do not have sufficient preventive properties and tend to cause "fraying" in the pile fibers of the carpet. In addition, the backing material may not be thick enough, the color of the backing material may seep into the outer surface of the carpet, and the dimensional stability and placement of the tile carpet may be insufficient, and the reinforcement required for an automobile carpet may be insufficient. However, the properties such as properties such as durability, mold retention, and jointness are insufficient, and satisfactory results are not always obtained.

Furthermore, EV of Edylene-vinyl acetate copolymer
Also known are compositions in which an inorganic filler is blended with an olefin-polar supramid copolymer represented by (abbreviated as ^). However, as the amount of inorganic fillers added increases, it becomes difficult to obtain a uniform composition, and even if a uniform composition is obtained, the hardness increases and the composition becomes brittle.
Tensile properties and low temperature properties deteriorate. Furthermore, there were many other drawbacks, such as the softening temperature and flow temperature rising rapidly, resulting in lower workability and stricter conditions for lining carpets.

Therefore, such formulations were not preferred materials for carpet backing.

In order to improve these problems, compositions containing EVA, fillers, and plasticizers have been developed.
033, etc.), EVA, a filler, a plasticizer, and an elastomer (rubber) composition (Unexamined Japanese Patent Publication No. 56-1)
22847@publication, Japanese Unexamined Patent Publication No. 57-59942, etc.)
was devised, and the kneading properties, processability, and physical properties of the composition were improved to some extent. However, the physical properties of the blended plasticizer etc. are greatly reduced, that is, the tensile properties, tear properties, and heat resistance of the blend are reduced, and the carpet backed with this has poor reinforcing properties, mold retention properties, and dimensional stability. The strength and durability were insufficient, and further improvement of the '-layer was desired.

[Means for Solving the Problems] An object of the present invention is to provide a carpet backing material that satisfies the required properties of a carpet backing material and that improves the drawbacks of the conventional methods. In particular, it is an object of the present invention to provide a ceiling material suitable for the above-mentioned automobile carpets and tile carpets.

As a carpet backing composition, the tensile properties, tear properties,
However, as a result of intensive research into materials that would not cause the deterioration of the above items without removing these plasticizers, softeners, tackifier resins, and lubricants, we found that unsaturated It has been found that blending a carboxylic acid-modified ethylene copolymer is preferable. That is, the present invention comprises (a) 5-75% by weight of an ethylene copolymer modified with an unsaturated carboxylic acid and/or its derivative (b) 20-85% by weight of an inorganic filler (c) Plasticizer, softener This is a carpet backing composition comprising 1 to 20% by weight of a mixture of one or more of a tackifying resin, a tackifying resin, and a lubricant. Also, (a) 1 to 75% by weight of an ethylene copolymer modified with an unsaturated carboxylic acid and/or a derivative thereof (b) 75 to 1% by weight of an ethylene copolymer (c)
A carpet backing composition comprising 20 to 85% by weight of an inorganic filler (d) and 1 to 20% by weight of a mixture of one or more of two or more selected from plasticizers, softeners, tackifying resins, and lubricants. .

In the present invention, the ethylene copolymer refers to a copolymer of ethylene and an α-olefin such as propylene or butene (α-
Copolymerization ratio of olefin is 50% by weight or less), ethylene and vinyl acetate, methyl acrylate, ethyl acrylate,
It refers to acrylic acid, methyl methacrylate, ethyl methacrylate, methacrylic acid, carbon oxide, or a copolymer of two or more of these. A preferred copolymer is ethylene-
Vinyl acetate copolymer, ethylene-methyl acrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene-ethyl acrylate-acrylic acid copolymer, ethylene-
Acrylic-vinyl acetate copolymer, etc., especially ethylene-vinyl acetate copolymer (EVA) and ethylene-ethyl acrylate copolymer (hereinafter abbreviated as [E^)]
is preferred.

These copolymers preferably have a polar monomer content of 5 to 40% by weight, particularly 10 to 35% by weight. If the polar monomer content exceeds this range, it is not preferable because the hardness of the composition decreases, the tensile strength decreases, and the heat resistance deteriorates. If the content of the polar monomer is less than this range, the hardness of the composition increases, the composition becomes brittle, loses flexibility, and elongation decreases, and the embrittlement temperature of low-temperature properties increases, which is undesirable.

The melt index of these copolymers is 0.1-40
0, preferably 0.1-150, particularly preferably 0.2-50. If the melt index exceeds this range, physical properties such as heat resistance, tensile strength, and embrittlement temperature will be poor, which is not preferable. If the melt index is smaller than this range, blendability and processability will deteriorate, which is undesirable.

The ethylene copolymer modified with an unsaturated carboxylic acid and/or its derivative used in the present invention refers to the ethylene copolymer having 10 or less carbon atoms and at least one double bond. Suru j 2 group carvone! I
! (e.g. acrylic acid, methacrylic acid), carbon number 15
Hereinafter, diradical carboxylates 11i with at least one double bond (e.g. maleic acid) and those modified using dicarboxylic acid anhydrides (e.g. maleic anhydride, hymic anhydride) are used. Of these, ethylene copolymers modified with maleic anhydride are most preferably used.

The method for producing the unsaturated carboxylic acid-modified ethylene copolymer is generally obtained by reacting an ethylene copolymer with the unsaturated carboxylic acid in the presence of an organic peroxide, and includes a solution method, Known methods such as suspension method and melting method are used. The reaction rate of the unsaturated carboxylic acid (
content) is 0.01-10%, preferably 0.02
~5% by weight is used. If the reaction rate of this unsaturated carboxylic acid is less than 0.01% by weight, the effect of use is poor;
If it exceeds 10% by weight, discoloration will be significant and there will be a pungent odor due to residual bacteria and unreacted unsaturated carboxylic acid, which is not preferable.

As the inorganic filler used in the present invention, fillers used for rubber and plastics can be used. This filler is, for example, ``handbook, rubber, and plastic compounded chemicals.''
(Rubber Digest Co., Ltd., Mitsuyuki, 1972), Sections 11 and 12. Specifically, they include calcium carbonates, clays, silicas, aluminas, talcs, barium sulfate, calcium sulfate, sub-1aa12 calcium, zinc groups, carbon black, aluminum hydroxide, magnesium hydroxide, and the like. The blending amount of these non-porous fillers is 20 to 85,000 m%, preferably 40 to 85% by weight, and most preferably 50 to 85% by weight. If it exceeds this range, the hardness of the composition will become extremely large and it will become brittle and cannot be put to practical use. Further, if it is less than this range, it is not suitable for the purpose of the present invention, so it is preferable to keep it within the above range.

Furthermore, the plasticizers, softeners, tackifying resins, and lubricants used in the present invention are listed in the 8th section of the "Handbook of Rubber and Plastic Compounded Chemicals" above.
as described in Sections 9, 10 and 15. Specifically, phthalic acid derivatives, isophthalic acid derivatives, tetrahydrophthalic acid derivatives, adipic acid Lj 6, azelain Prt derivatives, sebacin!
Derivatives, maleic acid derivatives, fumar IS! 2 derivatives, trimellitic acid derivatives, Kuen 1!2 derivatives, oleic acid derivatives, stearic acid derivatives, ricinoleic acid derivatives, glycerin derivatives, epoxy derivatives, plasticizers such as polymeric plasticizers, softeners such as mineral oil and vegetable oil, Tackifying resins such as coumaron resin, phenolic resin, derubene resin, cyclopentadiene resin, petroleum resins consisting of aliphatic, alicyclic and aromatic hydrocarbons, rosin and rosin derivatives, hydrogenated resins of these, Lubricants such as paraffin wax, microcrystalline wax, polyethylene wax, amorphous polypropylene, and asphalt. The above-mentioned materials have the effect of improving the crosstalk property when mixing the composition of the present invention, improving the flow during the punching process on the bed, and improving the adhesion to the carpet. It also works to improve the flexibility of the carpet backing. The blending amount of these materials is 1 to 20% by weight, preferably 2 to 16% by weight. If it exceeds this range, the physical properties of the blend will deteriorate rather significantly, which is undesirable, and if it does not fall within this range, the blending effect will not appear.

In addition, 0.01 to 5.0% by weight of an antioxidant, an antistatic agent, a pigment, etc. may be added if necessary.

The composition of the present invention can be compounded using mixers such as kneaders, Brabenders, Banburys, rolls, and screw and twin-screw kneaders. For example, (a) ethylene copolymers modified with unsaturated carboxylic acids and/or derivatives thereof, (b) inorganic fillers, (c) plasticizers, softeners, tackifying resins, lubricants, and if necessary (d ) The required amount of each of the ethylene copolymers is added in the desired amount, but the order of addition is not restricted. Heating temperature is 100
~200℃, preferably 110~180℃, blending time 5
-40min, preferably 8-30min, to ensure sufficient uniformity of mixing. The compound is then extruded using an extruder at 100 to 220°C to form powder, pellet,
It can be formed into films, sheets, etc. Immediately after blending, it can be extruded into a film or sheet and can be directly lined onto a carpet substrate. A mixture prepared in advance in powder form can be applied uniformly to the back side of a carpet substrate and then heated and dipped for lining.

The pellet-formed compound can be extruded into a film or sheet using an extruder or the like to line a carpet substrate.

Further, the composition formed into a film or sheet can be lined by laminating the film, sheet, and carpet base material together by heating or using an adhesive. On the backing of the carpet base material in this way, woven fabric, non-woven fabric, plastic film, paper, felt, etc. can be laminated as necessary.

Carpet base materials for which the composition of the present invention can be used as a backing material include woven carpets, knitted carpets, tufted carpets, needle bunch carpets, artificial grass, etc., and it can be particularly preferably used for tufted carberas 1 to 1.

It is also possible to use these carpet base materials that have been precoated with latex, EVA hot-melt adhesive, low-density polyethylene film, or the like.

The composition of the present invention can be used as a backing material for automobile carpets and tile carpets.

[Examples] Hereinafter, the present invention will be explained in detail with reference to Examples, but the present invention is not limited to these Examples unless it departs from the gist of the present invention.

Throughout this specification, temperatures are expressed in °C, and parts and percentages are by weight unless otherwise specified.

Examples 1 to 3 Maleic anhydride-modified ethylene-vinyl acetate copolymer produced by a melting method (hereinafter referred to as HAn [abbreviated as ■^)]
, EVA, calcium carbonate, a plasticizer, and a softener were kneaded in an electrically heated pressure kneader at 150° C. for 30 minutes to obtain a blend. This was roll sheeted while hot, cooled, and shredded using a sheet cutter. This was extruded into a sheet at 200° C. through a T-die using an extruder, spread on the back side of a tufted carpet base material, and passed between water-cooled nip rolls for lining. The physical properties of the resulting blend and backing carpet were good as shown in Table 1.

Comparative Examples 1 to 2 Predetermined amounts of EVA, calcium carbonate, and plasticizer were kneaded at 150° C. for 30 minutes in an electrically heated pressure kneader, immediately cooled by roll sheeting, and shredded with a sheet cutter. This was extruded into a sheet at 200° C. from a T-die using an extruder and lined with a carpet. As shown in Table 1, the physical properties were poor in tensile strength, elongation, tear strength, and bendability.

Examples 4 to 7 A maleic anhydride-modified edylene-ethyl acrylate copolymer (HAn-based EE^) prepared by a melting method was prepared using [E, calcium carbonate, a plasticizer, and a softening agent in specified amounts. It was carried out in the same manner as in 1, and the results were good as shown in Table 2.

Comparative Example 3 The same procedure as in Comparative Example 1 was performed except that EEA was used instead of EVA. The results are shown in Table 2. It was inferior in tensile strength, elongation, tear strength, and bendability.

Examples 8 to 9 It was carried out in the same manner as in Example 1 using predetermined amounts of HAnified EE^, EvA, calcium carbonate, and tackifying resin prepared by the melting method, and as shown in Table 3, the results were good. .

Comparative Example 4 Comparative Example 1 was carried out in the same manner as in Comparative Example 1, except that EEA was used instead of EVA and a predetermined amount of tackifying resin was used instead of the plasticizer. The results are shown in Table 3. It was inferior in tensile strength, tear strength, and bendability.

Example 10 Maleic anhydride-modified ethylene produced by melting method
The experiment was carried out in the same manner as in Example 1 using the predetermined amounts of propylene copolymer (HAnized EP), [:E^, calcium carbonate, and plasticizer, and the results were good as shown in Table 3.

Comparative Example 5 The same method as in Comparative Example 1 was conducted using ethylene-propylene copolymer (EP), EEA, calcium carbonate, and a specified ♀ plasticizer, and the results are shown in Table 3.

It was inferior in tensile strength, elongation, tear strength, and bendability.

[Effects of the Invention 1] The carpet backing composition of the present invention has improved tensile strength and
In addition to improving elongation, tear strength, and bendability,
In some cases, the softening point and embrittlement temperature are also improved, and when carpet is lined with this material, the removal strength, tensile strength, and moldability properties of automotive carpets are improved.
A similar effect can be obtained with carpet tiles.

Claims (2)

[Claims] (1) (a) 5-75% by weight of ethylene copolymer modified with unsaturated carboxylic acid and/or its derivatives (b) 20-85% by weight of inorganic filler (c) Plasticizer, softener, tackifier A carpet lining composition comprising 1 to 20% by weight of one or more mixtures of resins and lubricants. (2) (a) 1 to 75% by weight of ethylene copolymer modified with unsaturated carboxylic acid and/or its derivatives (b) 75 to 1% by weight of ethylene copolymer (c) 20 to 85% by weight of inorganic filler % (d) A carpet backing composition comprising 1 to 20% by weight of one or a mixture of two or more selected from plasticizers, softeners, tackifying resins, and lubricants.