JPH032989B2 - - 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. Tufted carpets lined with a resin layer of polyolefin or polyolefin containing an inorganic filler such as calcium carbonate are generally used as carpeting materials for automobile interiors. However, such carpets lack cushioning properties and are expensive. Further, in order to facilitate the installation of the carpet into a car, it is necessary to mold the carpet to match the shape of the recess in the car floor, but it lacks moldability. In order to improve these drawbacks, a carpet has been proposed in which needle punch carpet is impregnated with rubber latex or synthetic resin emulsion, water is removed, and the carpet is molded under heat and pressure to match the shape of the recess in an automobile. Ta. Carpets molded using the former rubber latex have good flexibility or elasticity, and have a good texture and texture, but have poor moldability and shape retention, and the carpet is in poor condition when laid inside a car. becomes. Carpets using resin emulsion with a glass transition point of 80°C or higher as a backing material are easy to install in automobile interiors, but they have high rigidity and lack elasticity, giving the carpet a strange feel to the touch and 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. As a measure to improve this, in order to impart moldability to raw rugs such as needle punch carpet base fabrics, an aqueous emulsion of a thermoplastic resin with a glass transition point of 80°C or higher, such as styrene (95% by weight)/ A method has been proposed and practiced in which an aqueous emulsion of n-butyl acrylate (5% by weight) copolymer is applied to the back side of the original rug, impregnated, and dried by heating to form a backing layer. This method is useful for imparting moldability to the original rug, but when bonding backing materials such as felt or resin foam sheets by heat, the adhesive strength between these backing materials and the backing layer may be reduced. It is weak, and the backing material often peels off when press molding to give a shape to the laying material. The present inventors investigated the possibility of improving thermal adhesion by blending thermoplastic resin powder such as polyethylene into this moldability-imparting resin emulsion and using this as a backing material. It was found that the surface of the powder was coated with an aqueous emulsion resin having a glass transition point higher than the melting point of the powder, making it difficult for the resin powder to function effectively. Next, an aqueous emulsion of a resin with a high glass transition point (80°C or higher) is used as the first backing material to impart moldability to the original rug, and an aqueous emulsion of an acrylic resin with a low glass transition point (10°C or lower) is used as the first backing material. When using this material as a second backing material that imparts thermal adhesive properties, the laying material could not be rolled up because the second backing layer was sticky at room temperature. It has been found that the laying material can only be rolled up after the second backing layer has been backed with felt, foam sheet, jute cloth, etc. The present invention has been made for the purpose of providing a laying material including 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 coating made of an aqueous resin emulsion (A) on the back side of an original rug.
A first backing material (A) that provides a method for manufacturing a laying material having moldability and thermal adhesiveness, characterized by providing a backing layer and a second backing layer having the following composition: Glass transition point 80 Resin aqueous emulsion second backing material whose main component is an aqueous dispersion of resin at a temperature of ℃ or higher: (a) having a melting point lower than the glass transition point of the resin in the aqueous emulsion of (A), and whose melting point is 60 to
(b) Thermoplastic resin particles with a particle size of 50 to 1000μ that have a melting point of 50 to 1000μ at 125℃ and have a melting point that is the same as or lower than the melting point of the resin particles in (a) above, and whose melting point is 50 to 125℃. Aqueous emulsion of resin with a size of 10 μm or less However, the resin particles (a) are blended in a proportion of 50 to 250 parts by weight based on 100 parts by weight of the solid resin content of the aqueous emulsion (b). 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, the glass transition point of component (A), which gives moldability to the carpet as a backing material
The emulsion whose main component (50 to 100% by weight) is an aqueous resin emulsion having a Tg) of 80°C or higher is (a).
Polypropyl methacrylate (Tg81℃), polystyrene (100℃), polyacrylonitrile (100℃)
℃), polymethyl methacrylate (105℃), polymethacrylic acid (130℃), polyitaconic acid (130℃),
In addition to aqueous emulsions of homopolymers such as polyacrylamide (153°C), (b). 50 to 100% by weight of vinyl monomer, which is the raw material for these polymers, preferably
65-95% by weight and other copolymerizable vinyl monopolymers, such as 2-ethylhexyl acrylate (Tg
-85℃), n-butyl acrylate (-54℃), ethyl acrylate (-22℃), isopropyl acrylate (-5℃), 2-ethylhexyl methacrylate (-5℃), n-propyl acrylate (8°C), n-butyl methacrylate (20°C), vinyl acetate (30°C),
℃), ethyl methacrylate (65℃), vinyl chloride (79℃), etc. or vinylidene chloride (-18℃) 50
% by weight or less, preferably from 35 to 5% by weight [in this section (b), ( )
(c). Resin aqueous emulsion with Tg +80-155°C 50-97% by weight, preferably 55-95% by weight
and 50 to 3% by weight, preferably 45 to 5% by weight of an aqueous resin emulsion or rubber latex having a Tg of -85°C to less than +80°C. 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. 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 aqueous emulsion is applied to the fiber mat in an amount of 40 to 1000 g/m ² (solid content), preferably 100 to 400 g/m ² using a roll, spray, etc., impregnated with a Nippro roll, and then heated using an infrared heating machine and suction. The first backing layer is formed by heating and drying using a heating means such as a dryer or a hot air dryer at a temperature of 100 to 180°C that does not cause fiber deterioration. On the surface of the first backing layer thus formed, a second backing layer consisting of (a) thermoplastic resin particles having a melting point of 60 to 125°C and (b) an aqueous emulsion of a resin having a melting point of 50 to 125°C is applied. 20~200g/ ^m2
(solid content), preferably applied in an amount of 40 to 100 g/ ^m2 ,
A second backing layer is formed by heating and drying at a temperature higher than the film forming temperature of the aqueous emulsion (b). Alternatively, after applying the first backing material to the back side of the original rug, the second backing material is applied on top of the first backing material without drying, and then the aqueous resin (b) in the second backing layer is applied. The first backing material and the second backing material may be dried simultaneously by heating under conditions where the emulsion forms a film, preferably under conditions where the resin particles (a) are melted. The second backing layer is formed by first forming a film of the aqueous resin emulsion (b), and then dissolving the resin particles (a). Therefore, since the resin particles (a) are fixed by the previously formed film (b), the particles (a) are prevented from falling off even if the resin particles (a) are not sufficiently dissolved. It is rare for these (a) resin particles to dissolve and form a continuous film only with (a) resin particles, and due to the difference in specific gravity, on the (b) film (sea),
The resin particles of (a) may be partially agglomerated and dissolved, or may remain as they are, giving the appearance of scattered islands. In the practice of the present invention, the reason for using the hot melt resin particles (a) and the aqueous resin emulsion (b) as the second backing material is as follows. That is, the resin particles of the emulsion (b) have a particle size of 10
Since the resin particles are as fine as microns or less, the thickness of the first backing layer is very thick if used alone, and if they are not uniform, the resin particles will enter the voids between the fibers of the rug material, just like the resin of the first backing material. Therefore, unless the amount of second backing material applied is significantly increased, the adhesion to the backing material will deteriorate. In addition, when manufacturing paving materials continuously, the resin in (b) alone has a low heat capacity, so it cools quickly and the adhesive strength with the backing material is small, so the backing material may peel off due to stress etc. when the paving materials are taken off. There is a drawback that it can be damaged. When only the hot melt resin particles (a) with a large particle size are used as the second backing material, the adhesive force with the backing material is sufficient, but due to the large particle size, the adhesion to the rug side is not sufficient and it tends to fall off. There are drawbacks. Therefore, in the present invention, the above-mentioned effects are exhibited by using a second backing material that uses both resins (a) and (b) in combination. That is, we expect (a) adhesion to the backing material due to the large particle resin, and (b) adhesion effect to the laying material due to the fine particle resin. The resin particles of component (a) of the second backing material include low density polyethylene (melting point 105 to 121°C),
Atactic polypropylene (melting point 75-80℃),
Ethylene/vinyl acetate copolymer (melting point 70-100
°C), polyamide resin for hot melt materials (90~120
C) Other examples include resin particles having a melting point of 60 to 125 C, such as resins used as hot melts (petroleum resins, terpene resins, rosin resins, polyesters). The particle size of the resin particles is 50 to 1000 microns, which is larger than the particle size of the resin particles of the aqueous emulsion (b). For these resin particles, select a resin that has a film-forming temperature lower than the glass transition point (glass transition point) of the resin of the emulsion that is the first backing material (A), preferably 10°C or more lower (this book) In the invention, the glass transition point and melting point are
(Both refer to the maximum temperature that shows the peak in the figure obtained with a differential thermal analyzer.) (A) If the melting point of the resin particles in (a) is higher than the glass transition point of the resin in the emulsion of the first backing material, in order to obtain high adhesive strength to the backing material such as felt or foamed resin sheet, these When bonding the backing material, it is necessary to heat the backing material to a high temperature, and it takes a long time to cool it down. The aqueous emulsion of resin with a melting point of 50 to 125°C (JIS K-5903) in (b) above includes terpene resin, terpene-phenol copolymer, petroleum resin,
Examples include aqueous emulsions of resins such as rosin. This aqueous resin emulsion (b) contains toluene, xylene, ethyl cellosolve, mineral spirits, etc. so that the emulsion has a film-forming temperature lower (preferably 10°C or more lower) than the melting point of the resin particles (a). Film-forming aids such as organic solvents, plasticizers such as dibutyl octyl phthalate, etc. may also be blended. Addition of this film-forming aid improves the film-forming properties of the emulsion (b). Further, since this film-forming agent is volatile and the amount remaining in the formed film is extremely small, the adhesion between the second backing material and the backing material such as felt does not decrease. 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 longi, its water additives, 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. The method for producing emulsions of these petroleum resins, rosin resins, and terpene resins is
No. 78623, No. 56-87421, No. 56-159244, No. 57
- Since it is described in patent publications such as No. 125255,
The explanation will be omitted here. As for product names, petroleum resin emulsion is #75 emulsion, #90 emulsion, and ND-10 (all prototypes) manufactured by Toho Oil Resin Co., Ltd., and rosin resin emulsion is manufactured by Harima Kasei Kogyo Co., Ltd. Harrier Star DS-70L, same
DS-70E, DS-90E or Hersize EM-305,
Hercise EM-505 is a water-based emulsion of a terpene resin, and EMAX 800 (prototype) manufactured by Yasushi Oil Co., Ltd. is exemplified. And these petroleum resins,
In the aqueous emulsion of rosin resin, terpene resin, and the emulsion, the average particle size of the dispersed resin is 10 μm or less, generally 0.03 to 3 μm,
The solid content concentration is 20 to 65% by weight. It is important that the original melting point of the resin in the aqueous emulsion (b) is equal to or lower than the melting point of the resin particles in (a). When the melting point is higher than that of the resin in (a), the surface of the resin particles in (a) is coated with a film of the emulsion resin in (b), which has a higher melting point, so the hot melt adhesive cannot be used. The adhesive force that should be exerted by heating and melting the certain resin (a) does not effectively act on the backing material. In order to effectively exhibit the adhesive strength of the hot melt adhesive of the resin particles (a) to the laying material during continuous collection of the laying materials, the aqueous resin emulsion (b) must have its original melting point lower than that of the resin particles (a). It is necessary to have a melting point equal to or lower than that of Furthermore, in order to improve the adhesion of the resin particles (a) to the laying material, it is important that the film forming temperature of the resin emulsion (b) is at least 10°C lower than the melting point of the resin particles of (a). . Therefore, in the resin emulsion (b), the above-mentioned plasticizer or organic solvent is used as a film-forming agent, and the amount of 1 to 10
It is useful to lower the film-forming temperature by blending them in a proportion of % by weight. In the second backing material, the blending ratio of (a) resin particles and (b) resin aqueous emulsion is 50 to 250 parts by weight of (a) resin particles per 100 parts by weight of resin in the aqueous emulsion (b). parts, preferably 75 to 15 parts by weight. If the amount is less than 50 parts by weight, the effect of adding the resin particles to further improve the adhesion of the second backing layer to the backing material is small. vice versa,
If it exceeds 250 parts by weight, the storage stability of the second backing material will be poor, resin particles may float, or the second backing material may float.
After the backing material is applied, the proportion of resin particles (a) that fall off from the laying material increases until the backing layer is formed by heating and drying and afterward. The second backing material contains, like the first backing material, a film-forming aid, a thickener, a dispersant, an antifreeze agent, a coloring agent, a pigment, a wetting agent, an extender, an antifoaming agent, and a non-foaming agent. A fuel agent or the like may be added within a range that does not significantly change the original quality. The laying material produced in this way has good formability,
It has thermal adhesive properties, and can also be rolled up and stored before pasting 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 mold each layer simultaneously with adhesion. 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 recycled polyethylene terephthalate fiber waste with a fiber length of 75 to 125 mm and a denier of 15 denier, this (area weight: 650 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. Styrene (80% by weight) and n-butyl acrylate (20% by weight) were added to this needled fiber mat.
Aqueous emulsion obtained by emulsion polymerization [Resin average particle size 0.2 microns, solid content 50%, glass transition point]
120℃] with a Ritzker roller to 250g/m ² (solid content)
Then, the entire fiber mat was impregnated with the emulsion using Nipprol. Next, heat this at 140℃ to remove moisture,
A first backing layer was formed. On top of this first backing layer, a second backing material with the following composition (film forming temperature: 20°C) is applied at a solid content of 60°C.
g/m ² and heated and dried in a hot air dryer at 140° C. for 10 minutes to form a second backing layer to obtain a laying material. (a) Melt index is 20g/10min, melting point is
100 parts by weight of low-density polyethylene particles passed through a 60-mesh sieve at 108°C (“Frozen MG-801”, trade name of Seitetsu Kagaku Kogyo) (b) Petroleum resin aqueous emulsion “ND-10” manufactured by Toho Oil Resins Co., Ltd. (product) Name, glass transition point of resin 80
C, solid content concentration 57% by weight, average particle size 1 micron) 100 parts by weight (c) Toluene 3 parts by weight This second backing layer did not exhibit any tackiness at 20°C. Using a heater, heat the laying material at 180°C from the second backing layer side to melt the resin of the first backing layer and the second backing layer.
A piece of felt with a diameter of mm was brought into contact with the second backing layer with a roll, and then compression molded using a press mold to obtain a laid part with the desired shape (ⓓ). The shaped laying material was evaluated for shape retention, adhesive strength between the felt and the second backing layer, and prevention of powder (a) from falling off by 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 (〇), and those with deviations of 2 mm or more were evaluated as poor (x). (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 out only the felt side across the width, then fix one end of the non-woven fabric side with your hand, grab the felt with the other hand, and peel off the felt. Good adhesion (〇) if the felt layer peels off.
Peeling between the felt and nonwoven fabric interface was defined as poor adhesion (×). Also, when both cases occurred, it was marked as normal (△). (3) Preventing powder from falling off When adhesive tape “Cello Tape” (trade name manufactured by Nichiban) is attached to the second backing layer of the laying material before press molding and then peeled off, the powder adhering to the adhesive tape is removed. I evaluated it somewhat. ◎ Almost none 〇 Some (10 pieces/cm ² or less) △ Somewhat many × Very many Examples 2 Instead of the needled fiber mat, nylon-based fabric was used as a primary fabric made of polypropylene flat yarn knitted in a lattice pattern. A laying material was obtained in the same manner as in Example 1, except that the flat drag rug original fabric obtained by embroidering was used, and the second backing material was applied using a foam coating method to prevent impregnation of the first backing material. . Table 1 shows the performance of this laying material. Examples 3 to 7, Comparative Examples 1 to 7 Laying materials having the performance shown in Table 1 were obtained in the same manner as in Example 1, except that the material shown in Table 1 was used as the second backing material.

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Claims (1)

[Claims] 1. Aqueous resin emulsion (A) on the back side of the original rug.
1. A method for manufacturing a laying material having moldability and thermal adhesiveness, which comprises providing a first backing layer having the following composition and a second backing layer having the following composition. First backing material (A): Resin aqueous emulsion whose main component is an aqueous dispersion of a resin with a glass transition point of 80°C or higher Second backing material: (a) Lower than the glass transition point of the resin in the aqueous emulsion of (A) has a melting point, and the melting point is 60~
Thermoplastic resin particles with a particle size of 50 to 1000μ at 125°C (b) Particles with a melting point that is the same as or lower than the melting point of the resin particles in (a) above, and whose melting point is 50 to 125°C An aqueous emulsion of a resin having a diameter of 10 μm or less. However, the resin particles (a) are blended in an amount of 50 to 250 parts by weight based on 100 parts by weight of the solid resin in the aqueous emulsion (b). 2. The aqueous resin emulsion in (A) is a resin aqueous emulsion with a glass transition point of +80°C to +155°C.
95% by weight and a resin aqueous emulsion or rubber latex with a glass transition temperature of -85°C to less than +80°C45
5. The method for producing a laying material according to claim 1, wherein the material is a mixture of .about.5% by weight. 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 20 to 200 g/ ^m2 . Method of manufacturing the described laying material.