JPS649341B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a composition for backing rugs.
More specifically, the present invention relates to a backing composition for rugs comprising an emulsion containing a vinyl ester-ethylene-vinyl chloride copolymer and a basic inorganic filler. Traditionally, carpets with various textures and structures have been used, and in recent years, carpets with piles embedded in the base fabric called tufted carpets and webs have been used for reasons such as simplicity and economy in the manufacturing process. Needle punch carpets that are mechanically entangled using the needle punching method are often used. Such rugs have piles or webs that are merely mechanically intertwined, so the shape is unstable and cannot be put to practical use as is. Therefore, natural rubber, synthetic rubber latex, or synthetic resin emulsion is usually applied to the front or back surface of the rug, either alone or in the form of a mixture, and then dried to give the rug strength and dimensional stability. These rugs are used for a variety of purposes, including homes, vehicles, aircraft, and ships, but in recent years, flame-retardant regulations have been tightened for such rugs to prevent fire accidents. For this reason, various methods are being considered, such as making the fiber itself flame retardant and making it flame retardant with a backing agent, but flame retardant using a backing agent is currently the mainstream from the economical and technical aspects. . Among these uses, flame retardant regulations have been applied to carpets, which have been recently installed as materials for vehicles, especially for the interior of automobiles, and in addition, standards for heat and light resistance have recently been further strengthened, making them particularly difficult to use. In addition to flammability, it is also necessary to address heat and light resistance. The fibers used to make needle punch carpets, which are often used for automobile interiors, have traditionally been a blend of vinyl chloride, vinylidene chloride fibers, and other fibers, but due to the need to reduce weight, The reason for the switch to polypropylene fibers is that polypropylene is a highly combustible material, and in response to the need for increased flame retardancy in these fields, performance improvements with backing agents are required more than ever before. It's summery. For this reason, in the conventional synthetic rubber latex used as a backing agent, such as styrene-butadiene copolymer latex, it is necessary to increase the amount of flame retardant added, but even though this method is effective for flame retardation, it inherently causes backing. The disadvantage is that the reinforcing effect is significantly impaired in terms of stabilizing the shape of the pile to prevent thread removal, which is the purpose of this method. Under these circumstances, beer ester-ethylene-vinyl chloride copolymer emulsions have recently been increasingly used in place of conventional synthetic rubber latexes. Vinyl ester-ethylene-vinyl chloride copolymer emulsion has many halogens in its molecules, and especially when a copolymer with a high halogen content is used as a backing agent, the copolymer itself is self-extinguishing. Therefore, it is easy to make flame retardant with a backing agent, and the purpose can be achieved even with a small amount of flame retardant. It is possible to not only provide the original suture removal strength and maintain stable shape, but also provide excellent water resistance due to the fact that the copolymer is a hydrophobic polymer. Furthermore, among the necessary performances for automobile rugs, good performance is required not only in terms of flame retardancy, thread removal strength, shape stability, and water resistance, but also in terms of light resistance. For example, there is a need for a backing agent that does not cause deterioration in performance, such as loss of shape due to a decrease in the strength of the rug, especially when exposed to axial heat or light from the sun through window glass. Therefore, in recent years, the test standards have been strengthened to test under even more severe conditions than the conventional test method using an ultraviolet fade meter to accelerate the light resistance of the rug. For example, the temperature conditions for testing have become stricter, increasing from 63°C to 83°C. Even in this strict test standard, a backing agent that does not cause deterioration, loss of shape, discoloration or fading of the fibers of the rug itself is required. For these reasons, the present inventors have conducted various studies to further improve the light resistance of the vinyl ester-ethylene-vinyl chloride copolymer without impairing its original performance for rugs. By adding , flame retardancy, suture removal strength,
The present inventors have discovered a backing composition that maintains properties such as shape stability and water resistance, and has significantly superior light resistance, thereby completing the present invention. That is, the present invention comprises a vinyl ester-ethylene-vinyl chloride copolymer emulsion and a basic inorganic filler as essential components, and if necessary, a flame retardant,
The present invention provides a composition for backing a rug, which has excellent light resistance and is blended with a dispersant, a thickener, and the like. The main binder used in the bucking composition of the present invention is a vinyl ester-ethylene-vinyl chloride copolymer emulsion, and the constituent monomer composition ratio of the copolymer is vinyl ester: ethylene: vinyl chloride = 10 to 55. :5-30:30-75 weight ratio. The vinyl ester is preferably vinyl acetate. Vinyl esters include vinyl propionate and vinyl versatate. Furthermore, part of the vinyl ester may be replaced with an acrylic ester or a methacrylic ester, and the vinyl ester may be used in combination with vinyl acetate, particularly preferably. Additionally, a small amount of a functional vinyl monomer such as (meth)acrylic acid, maleic acid monoester, N-methylol acrylamide, N-butoxymethyl acrylamide, acrylamide, glycidyl methacrylate, or hydroxyethyl acrylate is copolymerized with the copolymer. A copolymer emulsion may also be used. All of these copolymer emulsions can be obtained by conventional emulsion manufacturing methods. Basic inorganic fillers used in the present invention include metal oxides, hydroxides, and carbonates such as calcium carbonate, aluminum hydroxide, magnesium oxide, talc, zinc white, and calcium hydroxide, which are commonly commercially available. The amount used is 30 to 160 parts by weight, preferably 60 to 100 parts by weight, based on 100 parts by weight of the solid content of the vinyl ester-ethylene-vinyl chloride copolymer emulsion. The basic inorganic filler may be used alone or in combination of two or more. In this case, if the amount of the basic inorganic filler used is less than the above range, it will be difficult to obtain excellent light resistance, and if it is more than the above range, the physical strength will decrease. The emulsion used in the backing composition is required to be stable so that it will not thicken or coagulate when a basic substance is added. Therefore, it is necessary to sufficiently impart the above-mentioned properties, particularly light resistance, to the carpet obtained by backing, maintain the stability of the copolymer emulsion, and balance the performance and workability of the backing composition. For this reason, the basic inorganic filler used in the present invention is specifically prepared by dispersing 10 g of the filler in 40 g of ion-exchanged water, and the pH of the supernatant is 8 to 9.
It is preferable to have a medium basicity within the range of 10 to 10. In this case, if the PH is low, the effect of imparting light resistance will be insufficient, and if it is high, the composition containing the filler will thicken and gel. It becomes easier. From this point of view, it is preferable to use calcium carbonate alone or in combination with calcium carbonate and aluminum hydroxide. The bucking composition of the present invention basically consists of a vinyl ester-ethylene-vinyl chloride copolymer emulsion and a basic inorganic filler, but a flame retardant may be added depending on the intended use conditions. I can do it. For example, as the flame retardant, conventionally known flame retardants such as phosphoric acid ester compounds, halogen-containing phosphoric acid ester compounds, ammonium polyphosphate, antimony trioxide, zinc borate, barium metaborate, etc. may be used. In addition, other known thickeners, dispersants, colorants, etc. other than flame retardants may be appropriately blended as necessary. Furthermore, the vinyl ester-ethylene-vinyl chloride copolymer emulsion used in the present invention may be blended with conventionally commonly used styrene-butadiene copolymer latex or vinyl acetate-ethylene copolymer emulsion. good. As the fiber material for the rug using the bucking composition of the present invention, natural or synthetic fibers such as rayon, wool, nylon, polypropylene, polyester, and polyacrylonitrile can be used. There are no particular restrictions on the weaving structure of the rug, and it can generally be used for tufted carpets, needle punch carpets, and automobile seats. Methods for applying the bucking composition of the present invention to a rug include a roll coater, a flow coater,
A known device such as a sprayer may be used, and after application, it is dried using hot air, infrared rays, etc. Later, in automobile carpets, polyethylene hot melt coating and felt were sometimes integrally molded. There is no particular limit to the amount of application, but in order to obtain stable results, the solid content should be 1.
0.1 to 2.0 kg per m ³ is suitable. Further, if necessary, the backing composition can be foamed appropriately and then applied. The thus obtained rug has sufficiently excellent flame retardancy, water resistance, suture removal strength, shape stability, and water resistance. The present invention will be explained below using examples. Examples 1 to 9 and Comparative Examples 1 to 6 Vinyl acetate-ethylene-vinyl chloride copolymer emulsion was used as the main binder, and packing compositions were prepared using the formulations shown in Tables 1 and 2, respectively. created something. The backing compositions obtained in Examples 1 to 9 and Comparative Examples 1 to 6 were transferred onto the back side of a needle punch carpet made of 100% polypropylene fibers with a basis weight of approximately 560 g/m ³ as a solid content of 150 g/m ^{3 .} Apply it so that it looks like this and dry it for 20 minutes at 110℃. Cut this bucking material to the specified size, apply approximately 10 mm thick felt to the buckling surface, and use a high-temperature ultraviolet fade meter (Suga Test Instruments KK) to 83℃±3.
The polypropylene fibers on the irradiated surface of the carpet were irradiated with ultraviolet rays at ℃ for 300 hours, and thermal deterioration, deformation, and discoloration were investigated. The results are shown in Tables 1 and 2, respectively. (Lightfastness test evaluation method) ○: No fiber deterioration, deformation, discoloration or fading on the carpet surface. ○-△: Slight deterioration of fibers is observed. No discoloration or fading. △: Significant deterioration and deformation of fibers are observed. No discoloration or fading. : Severe fiber deterioration and considerable deformation observed. No discoloration or fading.

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Claims (1)

[Claims] 1. 30 to 160 parts by weight of a basic inorganic filler is blended with 100 parts by weight of the solid content of a vinyl ester-ethylene-vinyl chloride copolymer emulsion,
and the composition of the vinyl ester-ethylene-vinyl chloride copolymer emulsion is 10 to 55% by weight of vinyl ester, 5 to 30% by weight of ethylene, and 30 to 75% by weight of vinyl chloride, and the basic inorganic filler is 10g of the filler to 40g
The pH of the supernatant liquid dispersed in ion-exchanged water is 8.
9. A composition for rug bucking, characterized in that the composition is