JPH0318309A - Matting - Google Patents

Abstract

PURPOSE:To provide the matting having good moldability and shape holdability by using a net-like material consisting of hot melt adhesive conjugate monofilaments as a secondary base fabric and adhering the same with a binder or a thermoplastic resin having a low m.p. CONSTITUTION:The hot melt adhesive conjugate monofilaments to be used for the secondary base fabric are obtd. by the conjugate spinning of two kinds of the thermoplastic resins, which are different in m.p. by >=10 deg.C, to a parallel type or sheath and core type in such a manner that the thermoplastic resin of low m.p. continuously forms at least a part of the fiber surface. The fineness thereof is 150 to 5000d/f. These monofilaments are knitted or woven at 5 to 50 pieces/25mm picks to obtain the secondary base fabric. The combinations of the thermoplastic resins are exemplified by polypropylene/polyethylene, polyester/polyethylene, etc. The binder consisting of SBR latex, vinyl acetate, etc., is adhered to the rear surface of the raw fabric for the matting or the low melting thermoplastic resin, such as polyethylene or polypropylene, is laminated thereon and thereafter, the secondary base fabric is thermally adhered thereto. The matting is obtd. by a press molding at the temp. between the melting points of two kinds of the thermoplastic resins constituting the conjugate monofilaments.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a rug used as a flooring material for automobiles and the like. More specifically, the present invention relates to a rug that can be easily formed into a three-dimensional shape and can maintain a stable shape.

(Prior art) Conventionally, rugs for automobiles, etc. have been made using a rug fabric made by flocking pile yarns using the tufting or twenty-dollar punching method on a primary base fabric such as woven fabrics such as linen yarn or polypropylene slit yarn, or spunpond nonwoven fabrics. In addition, it is known that a secondary base fabric is attached to the back side with a binder such as latex to prevent hair pulling and for reinforcement, or that polyethylene is laminated instead of the secondary base fabric. As the secondary base fabric, the same woven or nonwoven fabric as used for the primary base fabric was used.

(Problem to be Solved by the Invention) In applications where the floor surface is uneven, such as in automobiles, the rug should also have an uneven shape that matches the floor surface in order to prevent sand, etc. from getting under the rug. It is desirable that

However, although it is easy to hot-press mold a rug using woven fabric as a secondary base fabric into a desired shape, the resulting rug (hereinafter referred to as a "molded rug") tends to lose its shape. Rugs laminated with polyethylene have the disadvantage of poor formability, such as the thickness of the polyethylene layer becoming extremely thin at sharp bends, exposing the base of the pile.

An object of the present invention is to eliminate the above-mentioned drawbacks of conventional rugs and to provide a rug that has good moldability and good shape retention.

(Means for Solving the Problems) In order to achieve the above object, the inventors of the present invention have conducted extensive research, and have found that they use a net-like material made of thermoadhesive composite monofilament as a secondary base fabric, and use a binder or a low melting point thermoplastic resin as a secondary base fabric. After discovering that the desired size could be achieved by gluing it together, he decided to give up on inventions altogether.

In the present invention, there are no particular restrictions on the primary base fabric and pile yarn used for the original rug, and any material can be used as long as it does not deteriorate or deform during hot press molding. The method of flocking the pile yarn to the primary base fabric is also a known method such as sewage threading or needle punching.

The thermoadhesive monofilament used for the secondary base fabric in the present invention has a melting point of 20°C or higher, preferably 20°C or higher, and is made by combining two different thermoplastic resins with a low melting point thermoplastic resin (hereinafter referred to as a low melting point component). ) is continuously formed on at least a part of the fiber surface, preferably 30% or more, in a parallel type or sheath-core type composite spinning, with a fineness of 150
~5, OOOd/f, preferably 200-4,000d
/t, Mono 7 Iramen 1. The number of such thermoadhesive monofilaments is 5 to 50/25
It is knitted or woven into a secondary base fabric. In order to prevent misalignment and fraying, this secondary base fabric may be heat-treated, if desired, using a hot air dryer or a thermal calendar roll to bond the intersection points of the Mono 7 filaments. If the melting point difference between the two types of thermoplastic resins constituting the thermoadhesive monofilament is 10°C or more, during the heat press forming described below, the secondary base fabric will have a high melting point component that will maintain its fiber shape while maintaining its fibrous shape. It is formed into an uneven shape, and the low melting point component fuses and fixes the intersections of the seven filaments forming the secondary base fabric. Such thermoplastic resin 3 4 combinations include polypropylene/polyethylene,
Examples include polyester/polyethylene, polyester/copolyester, and nylon 6/nylon 66. If the fineness of the thermoadhesive Mono 7 filament is less than 1506/f, the rigidity of the rug will be insufficient and the imposing rug will easily lose its shape. OOOcl
If it exceeds /f, the monofilament becomes hard and difficult to knit and weave, which is not preferable.

The method for adhering the secondary base fabric to the back side of the original rug is as follows: adhesion with a binder such as SBR latex, vinyl acetate latex, vinyl chloride latex, polyethylene, ethylene vinyl acetate copolymer, polypropylene. , laminating a thermoplastic resin with a low melting point such as low melting point polyester and then thermally bonding a secondary base fabric thereto; directly thermally bonding a secondary base fabric to the original rug and then bonding with a binder or laminate; Furthermore, a method such as using two or more layers of secondary base fabric can be used. The amount of binder or low melting point thermoplastic resin attached is usually 50 to 2
000 g/m", preferably 80 to 1000 g/m", the rug of the present invention thus obtained can be made into a rug by heating press molding.

The molding conditions were a temperature between the melting points of the two types of thermoplastic resins constituting the thermoadhesive composite monofilament, a press pressure range of 1-10 kg/cm'', and a press time of about 10 seconds to 15 minutes.

(Effect of the invention) In the rug of the present invention, the low melting point component of the net-like material made of heat-adhesive composite seven filaments used as the secondary base fabric melts during hot press molding, and the In addition to adhesively fixing the base fabric and the binder layer or the secondary base fabric and the laminate layer, the high melting point component maintains the network shape and prevents the binder layer or laminate layer from moving.
The base of the pile is not exposed on the back side of the rug, and the reinforcing effect of the high melting point component makes it possible to stably maintain the shape given by hot press molding.

(Example) 5 6 The present invention will be explained in more detail with reference to Examples and Comparative Examples. The rug (molded rug) was evaluated by the following method.

Shapeability: Using a female mold with a groove with an inverted trapezoid cross section of 60 mm on the base, 220 mm on the top, and 200 mm in depth, and a corresponding male mold, the surface of the rug is convex and the back side is concave. The back side of the resulting molded rug was observed, and those where the pile base was exposed or the binder layer or laminate layer was thinned were judged to be defective, and those that were not were judged to be good. judge.

Shape retention: Measure the width of the upper side of the groove of the molded rug used to evaluate moldability, and calculate the difference (
A mm) to deformation rate (Y = IOOA /220)
Y is less than 10%, good, 10% or more20
% was determined to be acceptable, and 20% or more was determined to be poor.

Example 1 Polypropylene bulk yarn (2, OOOd /'00 f) was tufted into a lube pile shape using a ]/10 gauge to a polyester ether (PET) primary base fabric (fabric weight 100 g/m2) by the spunpond method. A raw rug of 430 g/m2 was obtained. On the back side of this original rug, a secondary base fabric (see Table 1) was prepared by plain weaving polypropylene/polyethylene (sheath-core type) heat-adhesive composite monofilament (1.oOQd/f) with 18 filaments/25 mm each in the vertical and horizontal directions. A) was laminated and heated to 154°C only on the secondary base fabric side using a thermal calendar roll at a linear pressure of 15 kg/cm and a speed of 3 m/m i.
Adhesion was carried out under the conditions of 1.
The rug of the present invention was obtained by drying in a hot air dryer at 10°C.

Next, this rug was heated from the back side with a far infrared heater at 130°C for 40 seconds, and then heated to 5kg/cm"G with a mold at room temperature.
, and pressed for 50 seconds to form a shaped rug.

The composition of the secondary base fabric used is shown in Table 1, and the test results are shown in Table 2.

Example 2 The original rug fabric used in Example 1 and the secondary base fabric shown as B in Table 1 were laminated and bonded in the same manner as in Example 1, and then polyethylene was melted at 200 g/m'' on the back side. 7 8 Lamino-1-L An inventive rug was obtained.

Next, this rug was press-molded in the same manner as in Example 1, except that the heating conditions were 135° C. for 50 seconds. The test results are shown in Table 2.

Example 3 Using the same original rug as in Example 1, melt-laminate polyethylene at 130 g/m" on the back side, and after cooling, apply C in Table 1.
The secondary base fabric shown in 17 is laminated, and polyethylene is further layered.
A rug of the present invention whose back surface was reinforced to 3199 was obtained by melt laminating at 30 g/rn2. This rug was press-molded in the same manner as in Example 1 to obtain a molded rug of the present invention. The test results are shown in Table 2.

Example 4 An uninvented rug was obtained in the same manner as in Example 3, except that D in Table 2 was used as the secondary base fabric. This rug was heated and pressed under the same conditions as in Example 2 to obtain a molded rug of the present invention.

The test results are shown in Table 2.

Comparative Example 1 The back side of the original rug used in Example 1 was directly coated with 100 g/m2 of pure SBR latex without laminating a secondary base fabric, and dried for 15 minutes in a hot air dryer at 110°C. and obtained a prior art rug. This rug was heat press molded in the same manner as in Example 1 to obtain a conventional molded rug. The test results are shown in Table 2.

Comparative Example 2 In Comparative Example 1, after coating the SBR latex and before drying, a polypropylene spunpond nonwoven fabric (fabric weight 102 g/m'') shown in E in Table 1 was laminated and dried with hot air at 110°C for 15 minutes. The rug of Comparative Example 2 was prepared by hot press molding in the same manner as in Example 1. The test results are shown in Table 2.

Comparative Example 3 On the back side of the original rug used in Example 1, 200 g/m2 of polyethicine was melt-laminated directly without laminating a secondary base fabric, and after cooling, it was heated with a press in the same manner as in Example 1. The test results are shown in Table 2.

9 10 As is clear from the results shown in the table, the rugs and rugs of the present invention have excellent shapeability and shape retention, and are very suitable as rugs for use on uneven areas such as car floors. be.

that's all

Claims (2)

[Claims] (1) On the back side of the primary base fabric (hereinafter sometimes referred to as rug material) on which pile threads are flocked, the melting point of the secondary base fabric is 10
Two types of thermoplastic resins that differ by more than ℃ are combined in a parallel type or sheath-core type so that the low melting point thermoplastic resin (hereinafter simply referred to as the low melting point component) forms at least a continuous portion of the fiber surface. fineness of 150~ obtained by composite spinning
A rug characterized in that net-like materials made of thermoadhesive composite monofilaments of 5000 d/f are laminated and adhered with a binder or a low-melting thermoplastic resin. (2) A molded rug obtained by heat press-molding the rug according to claim (1) at a temperature between the melting point of the low melting point component and the melting point of the high melting point component of the composite monofilament constituting the secondary base fabric.