JPS5810514B2 - Composition for carpet bagging - Google Patents

Description

[Detailed description of the invention] The present invention relates to carpet backing compositions.

More particularly, the present invention relates to carpet backing compositions having flame retardant properties that retard burn rate.

Since carpets are mainly composed of organic fibers, they are easily combustible, and are often considered to be dangerous as a cause of fire or a medium for fire spread.

Therefore, the flammability of carpets is often regulated by public authorities.

In particular, the flammability of carpets used in public places, places where large numbers of people gather such as on public transportation, and closed places is closely monitored.

The fibers that make up carpets, like wool, themselves
Some have excellent flame retardancy.

There is also a method of blending flame-retardant fibers such as vinyl chloride fibers and vinylidene chloride fibers to make carpets flame-retardant, but flame-retardant methods using these fibers are expensive and cause a decrease in fiber strength. However, it has the disadvantage of decreasing weather resistance and heat resistance.

Therefore, attempts have been made to make the carpet as a whole flame retardant by imparting flame retardancy to the carpet backing agent.

As a method of imparting flame retardancy to a backing agent, a method of adding a low molecular weight halogenated organic compound, a phosphorous organic compound, etc. to the backing agent is known.

Although this method is effective in imparting flame retardancy, it plasticizes the backing agent and significantly reduces strength and texture.
It often causes side effects of moisture absorption and rusting.

Furthermore, low molecular weight halogenated organic compounds are undesirable because they have the effect of degrading fibers under the action of heat and/or light.

JP-A No. 53-58096 discloses a carpet backing composition in which a vinyl chloride polymer is blended with rubber latex.

In this composition, the particle size of the vinyl chloride polymer used in the formulation is large, ranging from 10 to 350 microns, so the uniformity of the backing film is poor and the film tends to crack, resulting in insufficient flame retardancy. Furthermore, when this composition is applied to the back surface of a carpet using a roll, there is a drawback that the contact roll is easily stained.

As a result of research conducted by the present inventors to solve these drawbacks, the inventors of the present invention have developed a finely powdered polymer with a particle size of 1 micron or less produced by emulsion polymerization of vinyl chloride, or a finely powdered vinyl chloride polymer. The inventors discovered that it is sufficient to use the previous latex, and achieved the present invention.

That is, the present invention provides a carpet backing composition comprising a diene copolymer emulsion and/or a vinyl acetate copolymer emulsion and a vinyl chloride polymer, based on 100 parts by dry weight of the copolymer, 20 to 20% vinyl chloride polymer with an average particle size of 1 micron or less
A flame retardant carpet backing composition characterized by a composition containing 150% wood by weight is provided.

This composition is applied to the back side of the carpet using, for example, a rick-roll coater, and either by applying it as it is or after laminating a secondary base fabric, the backing agent is dried using a hot air dryer.

The film formed by drying contributes to its original purpose of fixing the carpet pile, adhering the secondary base fabric, and improving the feel of the carpet, and the polyvinyl chloride resin it contains significantly increases the burning speed upon ignition. delay.

Furthermore, since vinyl chloride resin has almost no hygroscopicity and is coated with a polymer emulsion film, it has no drawbacks such as rusting or fiber deterioration under normal usage conditions.

The simplest method for applying the backing agent composition of the present invention to the back surface of a raw carpet is to dry it using a drum dryer or hot air dryer to finish the carpet and use it.

This method is commonly called normal backing.

This method is most commonly used for sizing needle punch carpets.

After performing normal backing of the carpet with the backing agent composition of the present invention, mechanically foamed rubber latex foam is applied to the backing surface using a doctor roll,
There is also a method of performing foam backing processing by heat vulcanization.

Foam backing provides cushioning, soundproofing, and heat retention properties to carpets, significantly improving their functionality.

Further, after normal backing of a carpet with the backing agent composition of the present invention, polyethylene resin powder is sprinkled on the backing surface, and the backing surface is heated by melting with electric heat or a Schwank heater, or while extruding the polyethylene resin with an extruder. There is a method of applying it to the surface and then melting it with heat.

The backing agent composition of the present invention, which is applied to any of these processing methods such as normal backing, foam backing, and undercoating of polyethylene hot melt backing processing, imparts flame retardance to the carpet, and is suitable for each processing method. It can be carried out without prejudice to the other purposes of the law.

In the present invention, the diene copolymer emulsions used include natural rubber latex, styrene-butadiene copolymer latex, acrylonitrile-butadiene copolymer latex, methyl methacrylate-butadiene copolymer latex, and acrylate-butadiene copolymer latex. latex and carboxyl-modified latex thereof.

Examples of the vinyl acetate copolymer emulsion include polyvinyl acetate emulsion and ethylene-vinyl acetate copolymer emulsion.

A small amount selected from the group consisting of carboxyl-modified styrene-butadiene copolymer latex, carboxyl-modified acrylonitrile-butadiene copolymer latex, and ethylene-vinyl acetate copolymer emulsion (if one type is used, it is particularly effective for flame retardancy) It's thick.

The backing composition of the present invention includes, if necessary,
Commonly used stabilizers, anti-aging agents, crosslinking agents, crosslinking accelerators, fillers, dispersants, thickeners, colorants, preservatives, flame retardants, antistatic agents and the like can be added.

These are usually added to the polymer emulsion in the form of powder, emulsion, slurry or aqueous solution.

The vinyl chloride polymers used in the present invention include a polymer consisting only of vinyl chloride monomers called straight vinyl chloride, and
About 30% or less of vinyl acetate monomer: Copolymerized vinylidene chloride monomer, etc. is included.

The vinyl chloride polymer used in the present invention has a particle size ranging from several hundredths of a micron to 1 micron.

These particulate polymers can be produced by emulsion polymerization.

A carpet backing composition containing a vinyl chloride polymer having a particle size larger than 5 microns has a reduced flame retardant effect.

The particle size of the copolymer that forms the main component of the composition is usually several microns or less.

By blending a large amount of vinyl chloride polymer with a significantly large particle size and performing carpet backing, it is possible to form a uniform film, and the formed film is prone to cracking and tearing. After applying a backing agent to the surface, the backing agent peels off and adheres to the wet roll and transport roll, which are in direct contact with the coated surface, causing so-called gum-up, which significantly impedes the backing work.
.

In addition, the final finish of the carpet coating deteriorates, and in extreme cases, the solids contained therein, such as fillers, become powdery and fall off.

Since the bulk specific gravity of vinyl chloride polymer fine powder is smaller than that of general fillers, it tends to float on the surface of the coating film, making the above phenomenon particularly likely.

The use of a flame retardant filler such as antimony trioxide, aluminum hydroxide, or zirconium oxide together with the vinyl chloride polymer is extremely effective in improving flame retardancy.

Copolymer emulsion 10 as a base for backing agent
The amount of vinyl chloride polymer added is from 20 parts by weight to 150 parts by weight relative to 0 parts by weight (dry weight).

More preferably, it is from 50 parts by weight to 120 parts by weight.

If the amount is less than 20 parts by weight, the flame retardancy will not be sufficiently imparted to the treated carpet (and a high degree of flame retardation cannot be achieved).

Moreover, if the amount is more than 150 parts by weight, the amount becomes unnecessary and excessive for flame retardation, which is uneconomical.

In addition, the total amount of the backing agent together with other fillers increases, which tends to cause gum-up during application of the backing agent, resulting in poor finish of the treated carpet and poor pile adhesion.

The vinyl chloride polymer is suitably added to the diene-based or vinyl acetate-based copolymer emulsion in the form of a powder, in the form of a latex, or after being made into an aqueous slurry.

Next, the present invention will be explained in more detail by showing Examples and Comparative Examples.

Examples 1 to 10, Comparative Examples 1 to 13 In these Examples and Comparative Examples, an experiment was carried out in which a so-called car mat backing process was applied inside a vehicle using a backing agent to which a predetermined amount of vinyl chloride polymer powder was added. I did it.

The backing agent was prepared by preparing a slurry of liquid A and then adding liquid B and stirring well according to the formulation shown in Table i.

All formulations have a total solids content of 25% and a viscosity of approximately 7000 cp.
s (BM type viscometer, 20°C).

These backing compounds were needle-punched using a needle rocker on polypropylene cotton, and the cotton basis weight was 3.
140gr (Dry)/m” uniformly on the surface of a 93gr/m2 raised type needle punched carpet raw material
The coating was applied at a ratio of 1, and dried for 15 minutes in a hot air dryer at 120°C.

The test results are shown on the second coat. Regarding the prepared samples, 1Federal Motor Vehicle 5 in the United States
Affection Standard (MYSS) No. 30
A combustion test was conducted according to 2j.

Comparative examples using vinyl chloride polymers with particle sizes larger than 10μ have inferior flame retardancy compared to examples with particle sizes smaller than 1μ.

Comparative examples that do not contain resin powder also have poor flame resistance.

In addition, in roll coating work, we tested the uniformity of coating and the contamination (gum-up) of the contact roll. Comparative examples using vinyl chloride polymer powder with a particle size of more than 10μ and cases where the particle size was smaller than 1μ were tested. Comparative examples, in which the content exceeds the range of the present invention, are significantly inferior to the examples and cannot be put to practical use.

The treated surface after coating and drying of the blended composition was tested. Comparative examples that did not contain vinyl chloride polymer were excellent, but other comparative examples were inferior to Examples.

In particular, in cases where a large amount of vinyl chloride polymer is added, powder falling off (peeling off of vinyl chloride polymer powder) is significant.

However, there is no significant difference in the tensile strength of the finished carpets between the Examples and Comparative Examples.

Examples 11 to 14, Comparative Examples 14 to 18 In these Examples and Comparative Examples, a backing agent containing a predetermined amount of vinyl chloride polymer powder and aluminum hydroxide powder, which is a flame retardant filler, was used. We conducted an experiment on backing processing of needle punch carpet used as general flooring material.

The backing agent was added and mixed in order from above with stirring according to the formulation shown in the third coating to prepare a sample.

All prepared formulations had a total solids content of 50% and a viscosity of approximately 110.
000 cps (B-type viscometer, 20°C).

These backing compounds were needle-punched using a needle locker on polypropylene cotton, and the cotton basis weight was 5.
Apply it evenly on the back side of a 00gr/m2 needle-punched carpet material at a rate of 350gr(Dry)/m2,
Drying was performed for 15 minutes in a hot air dryer at 120°C.

Observation of the condition of the coating process and of the finished sample, observation of the condition of the coated surface, and flame retardancy (tested using JIS L1091-1973B method with a gap of 2 mm between the sample and the asbestos vanillite plate)
A test was conducted.

The test results are shown in the fourth column.

Flame retardancy in this test was reduced by using too little or too much vinyl chloride polymer powder.

Furthermore, it is shown that vinyl chloride polymer powder with a large particle size has inferior flame retardant effect.

Coatability and surface finish deteriorate significantly with the use of vinyl chloride polymers with large particle sizes, and even with small particle sizes, if the amount added is significantly large (this indicates that the finish condition will deteriorate). .

Examples 15 to 17, Comparative Examples 19 to 23 In these Examples and Comparative Examples, a backing agent containing a predetermined amount of vinyl chloride polymer powder and aluminum hydroxide powder, which is a flame retardant filler, was used. We conducted an experiment to undercoat tufted carpet, which is used as a general flooring material.

Next, a rubber foam backing was applied, and a flame retardant test was performed on the sample.

The backing agent was added and mixed in order from above with stirring according to the formulation shown in the fifth coating to prepare a sample.

All formulations made had a total solids content of 70% and a viscosity of approximately 28
000 cps (BM viscometer, 20°C).

These backing compositions were uniformly applied at a rate of 700 gr (Dry) 7 m to the back side of a raw tufted carpet with a cotton area weight of approximately 500 gr/m2, which was made by tufting nylon pile in a loop shape onto a polypropylene primary base fabric. The coating was dried in a hot air dryer at 120° C. for 15 minutes, and the coating process and finished state were observed.

Subsequently, over this undercoat, a rubber foam made of styrene-butadiene rubber latex was foamed 3 times to a thickness of 3 m/m.

This sample was tested for flame retardancy.

(According to JIS L1091-1973B method.

) The test results are shown in Figure 6. Comparative Examples 21-23 in formulations with high filler content and high solids content, such as these examples.
When a vinyl chloride polymer powder with a large particle size is used, the coating method and treated surface finish are extremely poor.

Claims (1)

[Scope of Claims] 1. A carpet backing composition comprising a diene copolymer emulsion and/or a vinyl acetate copolymer emulsion and a vinyl chloride polymer, based on 100 parts by dry weight of the copolymer. A flame-retardant carpet backing composition comprising 20 to 150 parts by weight of a vinyl chloride polymer having an average particle size of 1 micron or less. 2. The composition according to item 1, wherein the diene copolymer is a carboxy-modified styrene-butadiene copolymer and/or a carboxy-modified acrylonitrile-butadiene copolymer.