JPH0120260B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for lining carpets useful as interior materials for automobiles and rugs in homes.

[Prior art]

Non-woven fiber mats impregnated with an aqueous resin emulsion are used as floor carpets for automobiles, and non-woven webs made of mixed fibers of a thermoplastic resin composition with a high melting point and a resin fiber binder with a melting point of 100 to 170°C are used as resin in the emulsion. Alternatively, carpets that are heated to a temperature higher than the melting point of a resin fiber binder and then press-molded into the shape of an automobile floor are known.

These carpets lack luxury on their own, and also lack performance in terms of rigidity, elasticity, and moldability, so fibers are raised in a loop shape on a polypropylene flat sane cloth base fabric on the surface of the carpet. The tufted carpet for the surface layer is attached using a hot melt agent.

This tufted carpet is expensive and is used as an interior material for luxury cars, but for cars for the general public, the surface layer is plain needle-punch carpet, which is coated with high-melting point fibers and a resin fiber binder. The backing nonwoven fabric web made of mixed ^fibers of The fibers are sufficiently intertwined with the plain carpet for the surface layer and the web for the backing layer by performing needling to a depth of 100 mm).Then, the fibers are heated to melt the fiber binder and fix the fibers to form the plain carpet for the surface layer. A method has been proposed for manufacturing an inexpensive moldable multilayer carpet by integrating the PET and backing web.

This is not practical because the peel strength of the plain carpet A layer for the surface layer is weak at 0.25 kg/5 cm width, so after needling, a water-based resin emulsion is applied from the backing web side and squeezed to coat the emulsion close to the surface layer. A method has been implemented in which the surface layer and the backing web are integrated by heating and melting the binder and emulsion resin.

The peel strength of the fibers of Plain Carpet A is as high as about 5 kg/5 cm, which is sufficient for practical use.

[Problem that the invention seeks to solve]

This practical multi-layer carpet has a high needling density of about 70 to 90 needles/cm ² and a second
As the needle penetrates into the carpet up to the 2nd part of the 3rd to 4th barb (12 to 15 mm) shown in the figure, many thick needle marks remain on the surface of the plain type surface carpet, and many fibers of the carpet layer fall to the lower layer side. The carpet will be removed, and the carpet will become thinner and its appearance will be spoiled. However, this increases the bond (strength) between the upper and lower layers, making it more practical.

The present invention aims to improve this appearance, and
The present invention provides a multilayer carpet with practically sufficient fibers fixed therein.

[Specific measures to solve the problem]

In the present invention, the back surface of the nonwoven carpet A for the surface layer has a basis weight of 6 to 200 g/m ² and a melting point of 90 g/m2.
Water-permeable nonwoven fabric B made of a thermoplastic resin fiber binder with a temperature of ~200°C, followed by 15 to 50% by weight of a thermoplastic resin fiber binder with a melting point of 95 to 200°C, which is 40°C or more higher than the melting point of the fiber binder. A superimposed backing web C in which a fiber mat consisting of 85 to 50% by weight of synthetic fibers or natural fibers having a melting point is needled is needled from the nonwoven carpet A side for the surface layer to form a nonwoven carpet A, water permeable. After intertwining the fibers of each layer of the nonwoven fabric B and the backing web C, an aqueous emulsion of a thermoplastic resin with a glass transition point of 80°C or higher is applied from the backing web C side to form the surface carpet A layer. After the emulsion resin is impregnated to the extent that it does not penetrate, the fibers of the nonwoven carpet A for the surface layer do not melt in the solidified or unsolidified state of the emulsion resin, and the fiber binder of the nonwoven fabric B, the fiber binder of the web C, and the emulsion resin do not melt. The present invention provides a method for manufacturing a moldable multi-layer carpet, which is characterized in that the thermoplastic resin is heated to a temperature higher than the melting temperature and then compressed to bond and mold the respective layers.

Adhesion of facing carpet A and backing web C is as follows:
Conventionally, needle punching involves fiber entanglement between the upper and lower layers, which requires sufficient needle density and penetration (needling depth), and due to the needle structure,
70 to 100 needles/cm ² for alternating needling,
The depth is 12 to 15 mm, and a large amount of the fibers of the facing carpet are guided to the lower layer, and it is difficult to reduce the amount of fibers due to the loss of facing fibers, and there are needle holes and uneven surfaces due to needling on the surface. It lingers forever. For this reason, only the plain type was used, and the raised type could not be used.

In the present invention, in order to solve this problem, a nonwoven fabric B layer made of a thermoplastic resin fiber binder is placed between the facing carpet A and the backing web C.
Since C is used to bond C and C, temporary needling from the A side is sufficient until A and C are bonded by heat, so the needle density should be as low as possible to reduce fiber loss in the A layer. , and from the structure of the needle, it is sufficient that the first barb reaches the C layer.

However, since a large needle mark remains when the needle penetration is large, the appearance of the needle penetration has a greater influence than the needle density. For this reason, the needle density is lower than the normal range, less than 100 needles/ ^cm2 , preferably 25 to 50 needles/cm2.
cm ² , the penetration is within the range where the first barb reaches the C layer and does not penetrate the C layer.
6mm + (A layer + B layer + C layer)
It is sufficient that the thickness does not exceed .

(Nonwoven fabric carpet for surface layer) The nonwoven fabric carpet A for the surface layer is mainly made of plain fibers obtained from fibers such as western wool, nylon, polyacrylonitrile, polyacetate, and polyethylene terephthalate, which have a higher melting point than the fiber binders of layers B and C. Although a type of needle punch carpet is used, a raised needle punch carpet can also be used in the present invention.

The basis weight of this needle punch type carpet A is 100 to 500 g/m ² . Generally 200g/m ²
However, in the present invention, since there is less migration from the facing layer to the lower layer due to needling, fewer fiber layers can be achieved than in the past.

(Nonwoven fabric of fiber binder) Nonwoven fabric B of thermoplastic resin fiber binder is made of fibers such as polyethylene, polypropylene, linear polyester, polyamide, polyethylene/polypropylene laminate fibers, etc., and has a melting point of 90 to 200°C, preferably 90 to 170°C. , 6~ obtained by intertwining 2~12 denier resin fibers by the spunpond method.
It is breathable and has a basis weight of 200 g/m ² , preferably 20 to 60 g/m ² , and a wall thickness of 5 to 500 microns.

In addition, this fiber binder is made by melting pellets of resin such as polypropylene, polyester, polyamide, etc. using an extruder and extruding them in a continuous shape through a die with many thin holes, which is then carried by the wind so that the individual fibers do not converge. It may also be produced by drawing it out, depositing it on a screen below the die, and pulling it off with a winder.

Such fiber binder nonwoven fabric B has many gaps through which water can pass, and is manufactured by Diabond Industries.
Mitsui Petrochemical Co., Ltd.'s Meltron W product name is PAY-200, PAS-200 for polyamide-based products, ES-500 for polyester-based products, and Y7 for ethylene-acetic acid copolymer-based products. Syntex PK is a polypropylene-based product from Kogyo Co., Ltd.
103, PK-106, PK-404, PK-408, etc. Polyethylene-based products are available under Admel's product names, and similar non-woven fabrics are available from Kureha Sen'i Co., Ltd.
DYNAC product name LNS-0000, LNS-2000,
It is sold with grade names such as ES-00, B-1000, B-2000, and B-3000.

Alternatively, polypropylene fibers may be made into a nonwoven fabric by needle punching or the like.

(Backing material) The backing material web C contains 15 to 50% by weight of a thermoplastic resin fiber binder with a melting point of 90 to 200°C, and synthetic or natural fibers having a melting point 40°C or more higher than the melting point of the thermoplastic resin. This web is obtained by needling a fiber mat consisting of 85 to 50% by weight of fibers, and is manufactured by a known nonwoven fabric manufacturing method. i.e. 1.2~300 denier, fiber length 25~
15-50% by weight of a 150 mm thermoplastic resin fiber binder; 15-50% by weight of a 1.2-300 denier thermoplastic resin fiber binder with a fiber length of 25-150 mm;
1.2 to 300 denier, fiber length 25 to 150 mm synthetic fibers and/or 85 to 50% by weight of natural fibers are sufficiently mixed and opened and supplied to a web forming device, and a card is formed from the mixed fibers. The web (fiber mat) is obtained by stacking the web (fiber mat) so that it has the desired fiber weight, and is temporarily fixed by needling in the vertical direction to entangle the fibers.

The fiber binder is used in a proportion of 15 to 50% by weight, preferably 20 to 40% by weight of the fiber mat weight. If it is less than 15% by weight, the contribution to improving the rigidity and dimensional stability of the carpet obtained by press molding will be small. On the other hand, if it exceeds 50% by weight, it becomes like resin felt, hard and brittle with impaired fiber texture.

In addition, the raw material for the synthetic fiber, which is the other fiber that substantially constitutes the fiber mat, has a melting point that is 40°C or more, preferably 70°C or more higher than the melting point of the thermoplastic resin fiber binder such as polyethylene terephthalate or polyamide. A thermoplastic resin having a Further, as natural fibers, cotton, linen, wool, etc. are used.

The fiber weight of the backing material web C is 300 to 2000 g/
m ² , preferably 500 to 1000 g/m ² . Since this backing material web C layer contains thermoplastic resin fibers, it exhibits thermoformability, but it is difficult to obtain a sharp shape and has insufficient rigidity.

(Thermoplastic resin aqueous emulsion) The thermoplastic resin used in the emulsion applied to and impregnated into the stacked carpets to provide molding and rigidity has a glass transition point of 80°C or higher, preferably 100°C or higher.
At 180°C, the particle size is between 0.01 and 5 microns.
Specifically, lower ester copolymers of styrene and acrylic acid (ester has 2 to 6 carbon atoms), lower ester copolymers of methacrylate and acrylic acid,
Vinylidene chloride copolymer (vinylidene chloride content is
85% by weight or more) and thermoplastic resins such as styrene/diene copolymers.

Optimally, (a) polyn-propyl methacrylate (Tg 81°C),
Polystyrene (100℃), polyacrylonitrile (100℃), polymethyl methacrylate (105℃),
In addition to aqueous emulsions of homopolymers such as polymethacrylic acid (130°C), polyitaconic acid (130°C), and polyacrylamide (153°C), (b) vinyl monomer 50, which is the raw material for these polymers.
-100% by weight, preferably 65-95% by weight, and other vinyl monomers such as 2-ethylhexyl acrylate (Tg 85°C), n-butyl acrylate (-54°C), ethyl acrylate (-22°C). ), isopropyl acrylate (-5℃), 2-ethylhexyl methacrylate (-5℃), n-propyl acrylate (8℃), n-butyl methacrylate (20℃), vinyl acetate (30℃), acrylic acid t
-Butyl (45℃), 2-hydroxyethyl methacrylate (55℃), ethyl methacrylate (65
), isobutyl methacrylate (67℃), vinyl chloride (79℃), etc. or vinylidene chloride (-18℃), etc.
°C) Aqueous emulsion of a copolymer with 50% by weight or less, preferably 35 to 5% by weight (c) Resin aqueous emulsion with Tg of +80 to 155°C 50
~97% by weight, preferably 55-95% by weight, Tg
Resin water-based emulsion 50 with a temperature of -85 to less than +80℃
-3% by weight, preferably 45-5% by weight, and the like. Fillers such as calcium carbon, iron oxide, ferrite, barium sulfate, etc. may be blended into this emulsion to give the obtained nonwoven fabric a sense of weight, and fillers such as low-density polyethylene or polystyrene may be added to give moldability. It is also possible to blend a powder of a low melting point resin such as ethylene/vinyl acetate copolymer.

The means for applying and impregnating the emulsion onto the fiber mat of the stacked carpet include a licker roll, a squeezing roll, a spray gun, dipping and the like. Generally, the applied emulsion is squeezed by squeezing rolls to completely impregnate the fiber mat with the emulsion. The emulsion is applied from the side of the fiber matte web C for backing. The fiber mats coated and impregnated with emulsion are heated to 80-250℃ to remove moisture.
A multilayer needle punch carpet with bonded fibers is produced. During this heating and drying process, some of the resin particles in the emulsion remain in the fiber mat in a particulate state, and some form a film that strengthens the intertwining of the fibers and also strengthens the fiber mat of the carpet. is given moldability and rigidity.

The aqueous thermoplastic resin emulsion contains 10 to 10 parts by weight of the resin solids in the emulsion, based on 100 parts by weight of the fibers in layer A, layer B, and layer C of the carpet.
It is used in a proportion of 100 parts by weight.

(Backing method) To back the carpet A with the web C, use the nonwoven fabric B made of resin fiber binder as an adhesive and overlap them between the two, and then use the needle 1 to apply the web C to the carpet A for the surface layer. 20-50
at a rate of 25 to 50 strands/cm ² , preferably from 25 to 50 strands/cm ² , and
The depth of the needle 1 is within the total thickness of each layer A, B, and C + 6 mm, for example, 7 to 9 mm (see Figure 1) to lightly entangle the fibers in each layer, and then The backing web C side is impregnated with a resin aqueous emulsion and heated to 90 to 220°C, preferably 100 to 160°C to dry the water, and the fiber binder resin of nonwoven fabric B, the fiber binder resin of web C, and the emulsion resin are is melted and compressed using a press molding machine or a pressure cooling roll, and the layers A, B, and C are bonded and integrated to complete the lining and are also molded.

In the case of this integration, it is also good to use B as a base when making a thin carpet A, and to first overlap the composite of A and B with C and join them by needling.

Alternatively, it is also possible to increase the amount of thermoplastic fibers on one side of the web layer C or to obtain a laminate of B and C in advance using B as a base, and then overlay A on this and perform needling bonding.

(Effects) The multilayer carpet of the present invention can be molded, has strong fiber fixation (peel strength approximately 7.5 kg/5 cm width), can be used with plain or brushed needle punch carpet, has an excellent appearance, and has excellent ventilation. It also has excellent strength and rigidity.

Example 1 Mitsui Oil Co., Ltd. was applied to the back side of a plain type needle punch carpet A made of fiber mat 150 g/m ² randomly stacked with polyethylene terephthalate (melting point 264°C) fiber cards of 15 denier and fiber length 85 to 120 mm. Polypropylene fiber binder nonwoven fabric B “Syntex PK” manufactured by Kagaku Kogyo Co., Ltd.
100 (Product name, basis weight 30g/m ² , fiber diameter 3 denier)
A web C made of a needle carpet produced as described below was further superimposed on the nonwoven fabric B to obtain a three-layer laminate having an apparent thickness of about 12 mm.

Then, needling was carried out from the surface carpet A side of this laminate at a rate of 25 fibers per cm ² and a penetration depth of 8 mm into the laminate to entangle the fibers in each layer.

Then, from the backing web C side of this laminate,
An aqueous emulsion of styrene-butyl acrylate copolymer with a glass transition point of 90°C is applied at a rate of 130g/m ² (solid content) and squeezed to impregnate the web C to a depth of 1/2. After drying at ℃ to remove moisture, this laminate was further heated to 190℃ to melt the polypropylene fiber binder of nonwoven fabric B and web C, and the copolymer resin of the emulsion, and then using a press molding machine. By pressure molding, we obtained a laying material with a thickness of approximately 9.5 mm in which each layer was integrated, faithful to the mold.

The needle holes in the surface layer agent of this laying material are not noticeable, it is smooth and has a good appearance, and the peel strength of the surface layer fiber is 7.5 kg/
It was 5cm wide. Even when a 500g load was placed on this product and an abrasion test was performed, no peeling occurred.

Manufacturing method for Needle Carpet C A mixed fiber of 20% recycled polypropylene (melting point 164°C) fiber binder of 15 denier and approximately 100 mm fiber length and 80% recycled polyethylene terephthalate (melting point 264°C) fiber of 15 denier and fiber length 75 to 125 mm. Fiber mat (700g/m ² ) made by stacking waste randomly
was needled using 15-18-32-3RB needles at a rate of 100 needles per square centimeter, and the wall thickness was approximately 7.1 mm.
mm, needle carpet C with apparent density 0.10g/ ^cm3
I got it.

Comparative Example 1 In Example 1, fiber binder nonwoven fabric B
The physical properties of the laying material obtained in the same manner were as follows, except that the laminates [A and C] were needled at a rate of 70 needles/cm ² and at a depth of 14 mm.

Appearance - Needle marks are clearly visible on the surface of plain carpet A.

Peel strength of layer A - 0.25Kg/5cm width [When not impregnated with water-based emulsion] -5.5Kg/5cm width [When impregnated with water-based emulsion] Resistance - resistance test with a 500g load Peeling occurs easily.

[Brief explanation of drawings]

FIG. 1 is a sectional view showing the needling state of the present invention, and FIG. 2 is a plan view of the needle.

Claims (1)

[Claims] 1. On the back side of the nonwoven carpet A for the surface layer, a water permeable nonwoven fabric B having a basis weight of 6 to 200 g/m ² and a thermoplastic resin fiber binder having a melting point of 90 to 200°C.
, followed by 15-50% by weight of a thermoplastic resin fiber binder with a melting point of 95-200°C, and 85-50% by weight of synthetic or natural fibers having a melting point 40°C or more higher than the melting point of the fiber binder. The backing web C, which is made by needling fiber mats, is needled from the surface nonwoven carpet A side to entangle the fibers in each layer of the nonwoven carpet A, the water-permeable nonwoven fabric B, and the backing web C. After laminating, an aqueous emulsion of a thermoplastic resin with a glass transition point of 80°C or higher is applied from the backing web C side, and the emulsion resin is impregnated to the extent that it does not penetrate the surface carpet A layer. When the resin is in a solidified or unsolidified state, the fibers of nonwoven carpet A for the surface layer do not melt, and the fiber binder of nonwoven fabric B, the fiber binder of web C, and the thermoplastic resin of the emulsion are heated to a temperature higher than that at which they are melted, and then compressed. A method for producing a moldable multi-layer carpet, which comprises bonding and molding each layer. 2. The manufacturing method according to claim 1, wherein the needle density during needling is 20 to 100 needles/cm ² . 3 The depth of penetration of the needle tip into the overlapped carpet exceeds the thickness of layer A, layer B, and layer C plus 6 mm plus the thickness of layer A, layer B, and layer C. 2. The manufacturing method according to claim 1, wherein the thickness is less than or equal to . 4. The aqueous thermoplastic resin emulsion has a resin solid content of 10 parts by weight per 100 parts by weight of the fibers in layer A, layer B, and layer C of the carpet.
2. The manufacturing method according to claim 1, wherein the amount is 100 parts by weight. 5 The fiber weight of nonwoven carpet A for the surface layer is
100 to 500 g/m ² , and the fiber basis weight of the backing web C is 300 to 2000 g/m ² .