JPH0130949B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for producing a floor covering material having moldability and thermal adhesive properties useful as an automobile floor covering material. Laying materials for automobile interiors are generally obtained by impregnating or coating a needle punch with rubber latex and then drying it. However, when this laying material is to be applied to uneven parts such as automobiles or buildings, it is difficult to shape the rubber latex backing material because of its high impact resilience. Melt extrusion lamination backing using thermoplastic resins such as polyethylene and ethylene/vinyl acetate copolymers has also been carried out. In this case, it is possible to mold the carpet into an uneven shape by heating, and compared to the carpet using rubber latex as the backing material, the shaped carpet has better shape retention and the shape is less sharp. Although it has the advantage of being a material, it has the disadvantage of being hard to the touch and being inferior in the effect of locking the pile yarn. In order to improve these drawbacks of bucking materials,
Substitutes for rubber-based latex have been studied, and synthetic resin emulsions with glass transition points of 80°C or higher, such as acrylic resins, vinyl chloride/vinyl acetate copolymers, and ethylene/vinyl acetate copolymers, have been developed as moldable backing materials. It is increasingly being used as a bucking material. Among these, acrylic resin emulsions are being used more frequently because they are superior in rigidity, moldability, and heat resistance compared to other copolymer emulsions. However, carpets using resin emulsions with a melting point of 80°C or higher as backing materials are easy to install in automobile interiors, but are highly rigid.
It lacks elasticity, feels like carpet, and feels strange underfoot. This is due to the fact that the resin emulsion is impregnated throughout the needle punch base layer. In order to provide a carpet with a good balance of elasticity and stiffness, low-density polyethylene, ethylene
A needle punch is impregnated with rubber latex in which powder of a thermoplastic resin with a low melting point such as vinyl acetate copolymer is dispersed, and after drying, it is molded under heat and pressure to provide shape retention with the thermoplastic resin, and to improve the elasticity of the rubber. A carpet with a good feel was proposed. However, it is difficult to impregnate the needle-punch carpet base layer with powder, and there is a drawback that more powder than necessary must be blended. One possible method of imparting moldability and cushioning properties to the laying material is to apply an aqueous emulsion of the above-mentioned resin with a melting point of 80°C or higher, and after drying, further backing with under felt or polystyrene foam sheet, but the melting point is high. When a water-based resin emulsion is used, and when backing materials such as felt and resin foam sheets are thermally bonded, the adhesive strength between these backing materials and the backing layer is weak, so press molding is required to give the laying material its shape. When doing so, it is observed that the backing material often peels off. We use an aqueous emulsion of a resin with a high melting point (80℃ or higher) as the first backing material to give moldability to the original rug, and a resin with a low melting point (10℃ or lower).
When we produced a laying material using an aqueous emulsion of acrylic resin as a second backing material that imparts thermal adhesive properties, we found that the second backing layer was sticky at room temperature, so the laying material could not be rolled up. First, it was found that the bedding material could only be rolled up after the second backing layer was lined with felt, foam sheet, jute cloth, etc. at the bedding material manufacturing site. The present invention has been made for the purpose of providing a laying material having a second backing layer having thermal adhesive properties that allows the laying material to be rolled up without such backing. That is, the present invention provides a first backing material (A) containing an aqueous resin emulsion as shown below and expandable polystyrene particles (B) on the back side of an original rug. Resin aqueous emulsion (B) whose main component is aqueous resin emulsion (B) After applying expandable polystyrene particles, a second backing material having a melting point lower than that of the resin particles of the aqueous emulsion (A) above is applied to the surface of the first backing material. A molding process characterized by coating an aqueous emulsion of a resin having a melting point of 50 to 125°C, and then drying the emulsion by heating to form a backing layer and foaming the expandable polystyrene particles. The present invention provides a method for manufacturing a laying material that has adhesive properties and thermal adhesive properties. Any material can be used as the rug raw material for the laying material in the present invention, and raw materials made from various fibers such as natural fibers, chemical fibers, and synthetic fibers can be used. In general, raw material for tufted carpet is prepared by erecting piles on a primary base fabric knitted from needle punch carpet or flat yarn obtained from fibers such as wool, nylon, polyacrylonitrile, polyacetate, polypropylene, etc.; A tufted carpet fabric is used, with a needle punch carpet as the primary base fabric and a pile erected thereon. Among these, inexpensive needle punch carpets are preferred for automobile interiors. Next, as a backing material, a resin aqueous emulsion having a melting point (glass transition point Tg) of component (A) of 80°C or higher is used as a main component (50 to 100% by weight) of the first backing material that imparts moldability to the carpet. Emulsion is (a). Polypropyl methacrylate (Tg 81°C), polystyrene (100°C), polyacrylonitrile (100°C), polymethyl methacrylate (105°C), polymethacrylic acid (130°C), polyitaconic acid (130°C), poly Acrylamide (153℃)
In addition to aqueous emulsions of homopolymers such as (b). 50 to 100% by weight, preferably 65 to 95% by weight of vinyl monomers, which are raw materials for these polymers, and other copolymerizable vinyl monomers, such as 2-ethylhexyl acrylate (Tg - 85°C), n-butyl acrylate (-54℃), ethyl acrylate (-22℃), isopropyl acrylate (-5℃), 2-methacrylate
Ethylhexyl (-5℃), n-propyl acrylate (8℃), n-butyl methacrylate (20℃),
Vinyl acetate (30℃), ethyl methacrylate (65
℃), vinyl chloride (79℃), etc. or vinylidene chloride (-18℃) 50% by weight or less, preferably 35-5%
Aqueous emulsion of the copolymer with wt% [this (b)
(c). Tg +80~155℃
50 to 97% by weight, preferably 55 to 95% by weight of a resin aqueous emulsion or rubber latex with a Tg of -85°C to less than +80°C.
3% by weight, preferably 45 to 5% by weight, and the like. The resin solid content concentration in the aqueous emulsion of these backing materials is usually 20 to 60% by weight, and the diameter of the dispersed resin particles is 10 microns or less, preferably 0.05 to 1.0 microns. This aqueous resin emulsion (A) has a particle size of 1.5
Expandable polystyrene resin particles with a diameter of 0.2 mm or less, preferably 0.2 to 0.8 mm, are blended in an amount of 10 to 100 parts by weight based on 100 parts by weight of the resin in the emulsion, and used as the first backing material. If the particle size exceeds 1.5 mm, the workability of mixing with the emulsion is poor, and the expandable polystyrene particles move to the upper part of the emulsion and are likely to separate. In other words, the workability and storage stability of the bucking material are poor. Furthermore, if the particles are large, the coating properties during backing will be reduced, and furthermore, after the backing material is applied to the original rug, the expandable polystyrene particles are likely to fall off from the original rug. Such expandable polystyrene particles are produced by emulsifying styrene containing a polymerization initiator and, if necessary, vinyl monomers such as methyl methacrylate, vinylbenzene, and acrylic acid in water, and heating the mixture to polymerize the vinyl monomers such as styrene. Then, an expanding agent such as butane or heptane is injected into the suspension in which the polymer particles are dispersed, and the volatile expanding agent is impregnated into the polymer particles at a ratio of 3 to 7% by weight. It will be done. Moreover, when carrying out suspension polymerization of a vinyl monomer such as styrene, it can also be obtained by carrying out the polymerization while supplying the above-mentioned swelling agent to the suspension. To this aqueous emulsion, which is the first backing material, extender pigments such as calcium carbonate, aluminum hydroxide, clay, talc, barium sulfate, pigments such as red iron oxide and titanium oxide, flame retardants, dyes, iron powder, etc.
Coating aids such as iron oxide, toluene, and mineral spirits, thickeners such as methyl ethyl cellulose and polyvinyl alcohol, antifreeze agents, antifoaming agents, dispersants, foaming agents, and wetting agents may be added. . The first backing material is applied to the fiber mat in an amount of 60 to 1000 g/m ² (solid content), preferably 80 to 400 g/m ² using a roll, spray, etc., impregnated with a nip roll, and then heated using an infrared heating device. It is dried using heating means such as a suction dryer or a hot air dryer. At this point, it is necessary to dry at a low temperature to avoid foaming of the expandable polystyrene particles. For this reason, after applying the first backing material, while the first backing material is still in an undried state, a second backing layer made of the aqueous emulsion of the resin having a melting point of 50 to 125° C. is applied to the surface of the first backing layer. 15-100g/ ^m2 (solid content), preferably 30-80g/m2
Apply in an amount of g/m ² . A temperature higher than the film forming temperature of the first backing material and the second backing material (50~
It is preferable to form the first backing layer and the second backing layer by heating and drying at 150°C, preferably 100 to 140°C, and to foam the expandable polystyrene particles in the first backing material. This heating causes the expandable polystyrene particles to
It is expanded by ~50 times to form a foam 1 with a particle size of 0.5 to 4.5 mm, which is adhered by a film 2 formed by the resin emulsion of (A) of the first backing material, and which protrudes from the film 2 surface. (See Figure 1). The second backing layer 3 has a rough surface due to the presence of the foam particles 1. Therefore, the laying material 4 of the present invention is a laying material in which the cushioning properties of the rug material 5 are greatly improved due to the presence of such foam particles 1. The melting point of the resin of the second backing material is 50~
Examples of aqueous emulsions of resins at 125°C (JIS K-5903) include aqueous emulsions of resins such as terpene resins, terpene/phenol copolymers, petroleum resins, rosins, and ethylene/vinyl acetate copolymers. This aqueous resin emulsion may contain film-forming aids such as organic solvents such as toluene, xylene, ethyl cellosolve, and mineral spirits, and plasticizers such as dibutyl octyl phthalate. Addition of this film-forming aid improves the film-forming properties of the emulsion. The above-mentioned petroleum resins include alkylstyrene indene resins, resins obtained by heating and polymerizing petroleum-based unsaturated hydrocarbons and/or cyclopentadiene in the presence of catalysts such as sulfuric acid, anhydrous aluminum chloride, and boron fluoride; water additives etc. can be used. Examples of the rosin include processed rosins such as abietic acid rosin, water additives thereof, maleic acid adducts thereof, metal salts, and esterified products with alcohols such as glycerin, pentaerythritol, ethylene glycol, and diethylene glycol. In addition, as terpene resins, homopolymers such as α-pinene, β-pinene, and dipentene or copolymers thereof, terpene/phenol copolymers, α-pinene/phenol copolymers, and water-added things are used. Methods for producing emulsions of petroleum resins, rosin resins, terpene resins, and ethylene/vinyl acetate copolymers are described in JP-A-56-78623 and JP-A-56-78623.
Since it is described in patent publications such as No. 87421, No. 56-159244, and No. 57-125255, the explanation will be omitted here. As for product names, the petroleum resin emulsions are #75 emulsion and #90 from Toho Oil Resin Co., Ltd.
Emulsions, ND-10 and ND-12 (both prototypes) are used as rosin resin emulsions such as Hariestar DS-70L and DS- from Harima Kasei Kogyo Co., Ltd.
70E, DS-90E or Hersize EM-305, Hersize EM-505, but the aqueous emulsion of terpene resin is Ematux 800 (prototype) manufactured by Yasushi Oil Co., Ltd.
However, examples of ethylene/vinyl acetate copolymer emulsion include the one manufactured by Mitsubishi Yuka Fine Co., Ltd. (prototype). In these aqueous emulsions and emulsions of petroleum resins, rosin resins, and terpene resins, the average particle diameter of the dispersed resin is 10 μm or less, generally 0.03 to 3 μm, and the solid content concentration is 20 to 3 μm. 65% by weight. The second backing material contains, like the first backing material, a film-forming agent, a plasticizer, a thickener, a dispersant, an antifreeze agent, a coloring agent, a pigment, a wetting agent, an extender, and an antifoaming agent. Agents, flame retardants, etc., wax emulsions, latexes, aqueous resin emulsions, etc. may be added to the extent that the original quality is not significantly altered. The thus-manufactured laying material has excellent cushioning properties, moldability, rigidity, and thermal adhesion, and can also be rolled up and stored before bonding with the backing material. Backing materials include felt, jute cloth, foamed polyethylene sheet, foamed polyvinyl chloride sheet, foamed polypropylene sheet, and foamed ethylene/foamed polyethylene sheet.
Examples include vinyl acetate copolymer sheets and expanded polystyrene sheets. After heating and melting the second backing layer, these backing materials are pressed and bonded to the second backing layer with a roll. When press-molding the laying material, the resin of both the first backing layer and the second backing layer is heated until it melts and softens, then the backing material is laminated, and then compression molding is performed using a press mold. and give it shape. Furthermore, adhesion of the backing material and the second backing material and shaping of the laying material can be performed simultaneously in the press mold. The thus-manufactured multi-layered laying material is bent, cut, and sewn as necessary to give it a shape suitable for laying. Further, it is also possible to perform molding at the same time as adhering each layer. The present invention will be explained in more detail below using actual manufacturing examples. Manufacturing example of needle-punched nonwoven fabric After randomly stacking cards made of recovered polyethylene terephthalate fiber waste with a fiber length of 75 to 125 mm and a denier of 15 denier, this fabric (basis weight: 400 g/m ² ) was produced.
was needled using 15-18-32-3RB needles at a rate of 50 needles per square inch to obtain a fiber mat. Example 1 An aqueous emulsion obtained by emulsion polymerization of (A) styrene (80% by weight) and n-butyl acrylate (20% by weight) as the first backing material [average particle size of resin] was applied to the back side of the above fiber mat. 0.2 micron, solid content 50
%, softening point 120℃] 100 parts by weight, (B) particle size 0.5 mm
Expandable polystyrene particles “Styropol IBE” with the following (average particle size: 0.33 mm) [Yuka Bardatessie Co., Ltd.]
Product name: Contains 5.8% butane] 10 parts by weight,
Furthermore, a thickener "Latechol" (trade name) manufactured by Yuka Verdice Co., Ltd. is added to this to achieve a viscosity of 25℃.
Using an emulsion adjusted to 3000 cps, it was coated with a Ritzker roller at a concentration of 250 g/m ² (solid content), and then the fiber mat was impregnated with the emulsion using a nip roll. On top of this first bucking layer, Toho Oil Resin Co., Ltd.
Aqueous emulsion made from petroleum resin "ND-12" (trade name, resin softening point 80℃, solid content concentration 60% by weight, average particle size 1 micron) was applied to a solid content of 60g/ ^m2 . The foamed polystyrene particles were heated and dried in a hot air dryer at 140° C. for 10 minutes to foam them, and resin films of the first and second backing layers were formed to obtain a laying material. This second backing layer did not exhibit any tackiness at 20°C. The polystyrene foam particles in the first backing layer of this laying material have a bulk density of approximately 0.15 g/cm ³ and a particle size of
It was 0.5 to 1.5 mm. When the cushioning properties of this laying material were measured using the following method, good results were obtained. Measurement method: The initial thickness when a load of 50 g/cm ² is applied to the laying material is t ₀ , then the thickness when a maximum load of 400 g/cm ² is applied for 1 minute is t ₁ , and this load is Let the wall thickness after removal be t ₂ , compressive elastic modulus = t ₂ − _{t 1} / t ₀ − t ₁ × 100 Compression rate = t ₀ − t ₁ / t ₀ × 100 Deformation rate = (−t ₂ /t ₀ )×100, the cushioning property was determined to be good if the deformation rate was small and the thickness change was small. Also, from the second bucking layer measurement of this laying material,
After heating at 180°C using a heater to melt the resin of the first backing layer and the second backing layer,
Felt with a wall thickness of 10 mm was brought into contact with the second backing layer using a roll, and then compression molded using a press mold to obtain a laying material with a desired shape (ⓓ). This shaped laying material was evaluated for shape retention and adhesive strength between the felt and the second backing layer using the following methods. The results are shown in Table 1. Evaluation method (1) Shape retention: Place the molded laying material on a model with the same shape as the male press mold, leave it in a room at 85℃ for one day, and check whether there is any misalignment between the model and the laying material. observed. Those with no deviation were evaluated as good (○), and those with deviations of 2 mm or more were evaluated as poor (×). (2) Adhesive strength to felt Cut out 5 sample pieces with a width of 30 mm and a length of 250 mm from the molded laying material, and then cut out 5 sample pieces of 2 cm each from one end.
Cut only the felt side across the width, then fix one end of the nonwoven fabric side with your hand, grab the felt with your other hand, and peel off the felt. If the felt layer peels off, the adhesion is good (○).
Peeling between the felt and nonwoven fabric interface was defined as poor adhesion (×). Also, when both cases occurred, it was marked as normal (△). Examples 2-3, Comparative Examples 1-2 Felt-lined laying materials were obtained in the same manner as in Example 1, except that the emulsion shown in Table 2 was used as the second backing material. The shape retention and adhesive strength of this material with felt are shown in the same table.

【table】

[Table] Examples 4 to 5, Comparative Example 3 A laying material was obtained in the same manner as in Example 1, except that a material having the composition shown in Table 3 was used as the first backing material. The cushioning properties of this laying material are shown in the same table.

【table】 [Brief explanation of drawings]

FIG. 1 is a sectional view of a laying material obtained by implementing the present invention. In the figure, 1 is a polystyrene foam particle, 2 is a first
The backing layer 3 is a second backing layer, 4 is a laying material, and 5 is a rug material.

Claims (1)

[Claims] 1. A first backing material containing the following (A) aqueous resin emulsion and (B) expandable polystyrene particles on the back side of the original rug: (A) an aqueous resin having a melting point of 80°C or higher; Resin aqueous emulsion (B) whose main component is a dispersion liquid After applying expandable polystyrene particles, a second backing material having a melting point lower than that of the resin particles of the aqueous emulsion (A) above is applied to the surface of the first backing material. and applying an aqueous emulsion of a resin having a melting point of 50 to 125°C, and then heating and drying the emulsion to form a backing layer and foaming the expandable polystyrene particles. A method for manufacturing a laying material having moldability and thermal adhesiveness. 2. A patent characterized in that the first backing material is a composition in which expandable polystyrene particles are blended in a ratio of 10 to 100 parts by weight based on 100 parts by weight of the resin content in the aqueous resin emulsion of (A). A method for manufacturing a laying material according to claim 1. 3. Claim 1, characterized in that the first backing layer is provided at a weight ratio of 60 to 1000 g/ ^m2 , and the second backing layer is provided at a weight ratio of 15 to 100 g/ ^m2 . Method of manufacturing the described laying material.