JPH0474471B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a molded material useful as an interior material for automobiles and a method for producing the same. [Prior art] Needle-punch carpets made of nonwoven fiber mat impregnated with SBR latex or resin aqueous emulsion as floor carpets for automobiles, and needle-punch carpets made of nonwoven fiber mats impregnated with SBR latex or resin aqueous emulsion, and thermoplastic resin fibers with a high melting point and resin fiber binders with a melting point of 100 to 130°C. A molding material is known in which a nonwoven mat needle punch carpet made of mixed fibers is heated to a temperature higher than the melting point of the resin or resin fiber binder in the emulsion, and then press-molded into the shape of an automobile floor. These molding materials alone lack performance in terms of rigidity, elasticity, and moldability (mold fidelity).
In addition, this molded material has excellent breathability, but this advantage has the disadvantage that it has water permeability, and rain (drops from an umbrella) can pass through the molded material, causing the car body to rust. Also,
There is a drawback that the engine noise can be heard through the gaps between the fiber mats. [Specific means for solving the problem] The present invention uses a molding material as a flexible surface carpet A and a molding material having a glass transition temperature of 80° C. or higher, which imparts moldability and provides a rigid film. 100~180
The present invention provides a molding material using a needle punch carpet impregnated with a resin emulsion at a temperature of .degree. [Surface Carpet] Carpet A may be needle punch carpet made from fibers such as wool, nylon, polyacrylonitrile, polyacetate, polypropylene, or polyethylene terephthalate, or a resin with a glass transition point of 35°C or lower. A raw fabric for tufted carpets, in which piles made of polyamide or polyethylene terephthalate are erected on a primary base fabric impregnated with emulsion and knitted with dried nonwoven fabric or flat yarn made of polypropylene, the needle punch carpet used as the primary base fabric; A tufted carpet material with erected piles on top is used. In addition, the melting point is 60 to 200℃ to provide rigidity.
15-50% by weight of thermoplastic fiber binder
and fibers with a bulk density of 0.5 g/m ³ or less obtained by needling pine into fibers consisting of 85 to 50% by weight of synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the thermoplastic resin. It is also possible to use a needle punch carpet, or a product obtained by impregnating this with an aqueous emulsion of a resin having a glass transition point of 35° C. or less or rubber latex and drying it. This latter material is manufactured by a known nonwoven fabric manufacturing method. i.e. 1.2-300 denier, fiber length 25-150
mm thermoplastic fiber binder 15-50% by weight
and 15 to 50% by weight of a thermoplastic resin fiber binder with a denier of 1.2 to 300 and a fiber length of 25 to 150 mm, and 1.2
~300 denier, 25-150 mm fiber length synthetic fibers and/or 85-50% by weight of natural fibers are sufficiently mixed and opened and supplied to a web forming device,
A web (fiber mat) obtained by stacking cards formed from the mixed fibers to a desired fiber weight 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. Similarly, the fiber apparent density is 0.5g/
Above cm ³ , the fiber layer becomes too dense and the texture of the fibers is impaired. [Needle punch carpet C] Needle punch carpet C before being coated with resin emulsion, impregnated and dried is made of fibers such as polypropylene, nylon, polyacrylonitrile, polyacetate, polyethylene terephthalate, wool, etc. It is manufactured by needling stacked fiber mats. As the fiber material, it is preferable to use polyamide or polyethylene terephthalate with a melting point of 200° C. or higher so that the fibers of the carpet on the surface layer do not melt when producing the multilayer molded material. In the carpet C on the back layer side, the fiber material may be any resin with a melting point of 200°C or higher, or a thermoplastic resin fiber binder such as polyester, polyethylene, polyamide, polypropylene, etc. with a melting point of 60 to 170°C.
Even if a mixed fiber containing 50% by weight and 85 to 50% by weight of a resin fiber having a melting point of 200°C or higher, such as polyamide or polyethylene terephthalate, which has a melting point 35°C or higher higher than the melting point of the emulsion resin and the melting point of the fiber binder, is used. good. This fiber binder is melted when the multilayer molding material is shaped using a press molding machine, and has the advantage of strengthening the bond between the fibers and improving mold fidelity. The fiber bulk density of the needle punch carpet impregnated with the resin emulsion and dried is 0.15 to 0.5 g/m ³ . Resin emulsion, rubber latex The resin emulsion or rubber latex, which is coated and impregnated as necessary on the nonwoven fabric for carpet A on the surface layer side, is used to strengthen the bond between the fibers and not to impair flexibility (cushionability). For this purpose, an aqueous resin emulsion or rubber latex with a glass transition point of 35°C or lower is used. Aqueous emulsion, latex resin (rubber)
The solid content concentration 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. Examples of the aqueous resin emulsion or rubber latex having a glass transition point of 35°C or lower include (i) 2-ethylhexyl acrylate, n-butyl acrylate, ethyl acrylate, isopropyl acrylate, 2-ethylhexyl methacrylate, n-acrylate; - Monomer selected from propyl, n-butyl methacrylate, vinylidene chloride, ethylene, butadiene 20-100% by weight (ii) Vinyl acetate, ethyl methacrylate, vinyl chloride, n-propyl methacrylate, styrene, acrylonitrile, Emulsion polymerization of 80% by weight or less of a monomer selected from methyl methacrylate, acrylic acid, itaconic acid, acrylamide, and methacrylamide (iii) 0 to 5% by weight of a monomer selected from diacetone acrylamide, maleic anhydride, and diethylene glycol acrylate Things can be given. Needle punch carpet C that gives moldability
The thermoplastic resin of the emulsion applied to and impregnated with the moldable temperature range is 80℃ or higher, preferably 100℃ or higher.
-180°C and particle size of 0.01-5 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℃), 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 aqueous emulsion with a temperature of -85℃ to less than +80℃
Examples include a mixture with 50 to 3% by weight, preferably 45 to 5% by weight. Fillers such as calcium carbonate, iron oxide, ferrite, barium sulfate, etc. may be added to this emulsion to give the obtained nonwoven fabric a sense of weight, and fillers such as low-density polyethylene, polystyrene, ethylene, etc. may be added to give moldability. - It is also possible to blend powder of low melting point resin such as vinyl acetate copolymer. Examples of means for applying or impregnating the emulsion onto the fiber mats of carpets A and C include a licker roll, a squeezing roll, a spray gun, and dipping. Generally, the applied emulsion is squeezed by squeezing rolls to completely impregnate the fiber mat with the emulsion. The emulsion can be applied from one or both sides of the fiber mat. The fiber mat coated and impregnated with the emulsion is heated to 60 to 250°C to remove moisture, and a needle punch carpet with bonded fibers is produced. During this heat-drying process, some of the resin particles in the emulsion exist in the resin mat in a particulate state, and some form a film, which strengthens the entanglement of the fibers and makes the fibers of the carpet C It gives the pine moldability and rigidity. Resin film The material resin for adhesive film B is a thermoplastic resin with a melting point of 80 to 170°C, such as ethylene.
Vinyl acetate copolymer, polyethylene, ethylene/
Acrylic acid copolymer or its metal salt (K, Li,
Na, Zn, Pb), polypropylene, etc. are used. This resin is melt-kneaded using an extruder, then melt-extruded from a die into a film, guided between both needle punch carpets A and C, and then compressed by a compression cooling roll to B and C are integrated. The thickness of the resin film is 20 to 2000 microns, preferably 35 to 300 microns. In addition to the above-mentioned method, A, B, and C can be integrated.
Layer carpet A, resin film B, and carpet C in this order using guide rolls, and then
A method in which the emulsion is dried by heating at 150 to 200°C and the emulsion resin and the above film are melted, and then press molding is performed to integrate the three parts A, B, and C and form the mold. The molten resin film B may be laminated onto the needle punch carpet, and then the other needle punch carpet C or A may be adhered using a pressure roll. Multi-layer molded material The wall thickness of the needle punch carpet A for the surface layer of the multi-layer molded material is 0.5 to 5 mm, and the wall thickness of the needle punch carpet C for the back surface is 1 to 10 mm. The wall thickness of this multilayer molded material is 1.5 to 15 mm. Needle punch carpet C of this multilayer molding material
If D such as under felt, foamed polystyrene sheet, polypropylene sheet, polyvinyl chloride sheet, nonwoven fabric, etc. is superimposed on the side and then heated and compression molded, a laying material whose back side is decorated with these can be obtained (see Figure 1). ). In addition, after heating the carpet side of C, if reinforcing materials such as plywood, resin felt, and cardboard are layered and bonded under pressure, these reinforcing materials can be bonded integrally to the laying material. It is useful as a cushioning material for rear bags and door trims. In particular, when underfelt is used as the backing material, raindrops that enter from the surface layer A are blocked by B, so that the underfelt does not become rotten or moldy. Example 1 80 g/m ² (solid content) of SBR latex was applied to a plain type needle punch carpet made of 350 g/m ² of polyester fibers and dried to obtain needle punch carpet A. Separately, 20% recycled polypropylene (melting point 164°C) fiber binder of 15 denier and approximately 100 mm fiber length,
A fiber mat (850
g/m ² ) using 15-18-32-3RB needles at a rate of 50 per square inch to create a needle carpet with a wall thickness of approximately 8.1 mm and an apparent density of 0.10 g/cm ³ . I got it. Styrene (85%) -
Methyl acrylate (12%) - acrylic acid (3%)
Aqueous emulsion of terpolymer [Resin average particle size
0.1 μ, solid content 50%, resin softening point approximately 120°C] to a resin content of 350 g/m ² , the entire web is impregnated with the emulsion using a nip roll, dried, and then processed using a needle punch car. PET C was obtained. Guide both carpets A and C with guide rolls,
Between these two, melt kneading is carried out using an extruder, and 190
A molten film B of ethylene/vinyl acetate copolymer extruded from die 1 with a thickness of 150 microns at ℃ is guided, and these three are superimposed with a nip roll.
It was compressed and integrated to obtain a molded material with a multilayer structure. In addition, after heating the needle punch carpet C side of this multilayer molding material at 190°C to melt the polypropylene fiber binder and emulsion resin, an under felt with a thickness of 10 mm was contacted, and this was then press molded. It was molded. The shaped product has a shape that is faithful to the mold cavity of the mold, and the wall thickness of the needle punch carpet of C is
It was 4.6mm. The physical properties of the multilayer molded materials A/B/C were evaluated by the method described later. The results are shown in Table 1. Waterproofness: After heating the nonwoven fabric to 190℃, compression molding is performed under conditions of 0.35Kg/cm ² G to form a tray-shaped container with a length and width of 200mm and a depth of 20mm, and when water is inserted into this container. , Water leaks quickly and continuously from the container as poor waterproofing (×), and water seeps into the container and drips discontinuously after that as normal waterproofing (△). Those that did not pass through were rated as good waterproofing (〇). Cushionability: The initial wall thickness when a load of 50 g/cm ² is applied to the laying material is t ₀ , then the wall thickness when a load of 400 g/m ² is applied for 1 minute is t ₁ , and this load is removed. , when the wall thickness after 1 minute is t ₂ , compression ratio = t ₀ - _{t 1} / t ₀ × 100 compression modulus = t ₂ - t ₁ / t ₀ - _{t 1} × 100 deformation ratio = ( It was calculated as 1-t ₂ /t ₀ )×100, and those with a small deformation rate and a small thickness change rate were considered to have good cushioning properties. [Bending strength] Fix one end of the sample piece (length 120 mm, width 30 mm),
The bending resistance value was measured when a deformation load was applied perpendicularly to the sample piece at a rate of 50 cm/min using an Instron type testing machine at a location 100 mm vertically from the fixed location. [Rigidity] A sample piece (length 300 mm, width 300 mm) is
Place it on a table with a width of 300mm x 300mm and a width of 250mm x 250mm.
A pressure of 2.0 Kg/cm ² is applied to the center of the sample piece at O/15 mm, and if the sinking distance of the center position of the sample piece is within the wall thickness of the sample piece, the rigidity is considered to be good. Those exceeding the thickness were considered to have poor rigidity. [Adhesive strength] Cut out a sample piece with a width of 50 mm and a length of 200 mm, fix the carpet A and the nonwoven fiber mat C at one end to an Instron type testing machine, and measure the 180 degree peel strength at a speed of 200 mm/min. Ta. Example 2 A nonwoven fiber mat before being impregnated with emulsion is a fiber mat C' obtained by needling a web randomly stacked with recycled polyethylene terephthalate (melting point 264°C) fiber waste of 15 denier and fiber length 75 to 125 mm. A molded material in which three layers were integrated was obtained in the same manner as in Example 1, except that a molded material having a basis weight of 850 g/cm ² was used. Table 1 shows the physical properties of this molding material. Comparative Example 1 In Example 1, a nonwoven fabric B "Syntex PK-" made of polypropylene fiber binder manufactured by Mitsui Petrochemical Industries, Ltd. was applied to the back side of needle punch carpet A.
110” (product name, basis weight 50g/m ² , fiber diameter 3 denier)
Layer three sheets of non-woven fabric B, then layer needle carpet C under this non-woven fabric B, and then apply this laminate to 190 mm.
After drying the emulsion by heating to ℃ and melting the polypropylene fiber binder of the nonwoven fabric B and the needle punch carpet C, the layers were pressure-molded using a press molding machine, and each layer faithful to the mold was integrated. A molded material with a layer thickness of 4.5 mm was obtained. Example 3 In Example 1, needle punch carpet A was made of 350 g of a mixed fiber of 20% by weight of recovered polypropylene fiber binder with a 15 denier and a fiber length of about 100 mm and 80% polyethylene terephthalate fiber with a 15 denier and a fiber length of 75 to 125 mm. / ^m2 plain type needle punch carpet,
A molded material having a multilayer structure was obtained in the same manner as in Example 1, except that 80 g/m ² (solid content) of SBR latex was applied and dried. Table 1 shows the physical properties of this laying material. Reference Example Table 1 shows the physical properties of molded materials obtained by individually molding Carpet A and Carpet C used in Example 1. 【table】

[Brief explanation of the drawing]

FIG. 1 is a perspective view of a multilayer molded material obtained by carrying out the present invention, and FIG. 2 is a front view showing a manufacturing apparatus. In the figure, A is a carpet, B is a film, and C is a carpet.

Claims (1)

[Claims] 1 Carpet A for the surface layer and a glass transition point of 80
A method for producing a multilayer molded material, which comprises adhering a needle punch carpet C impregnated with a thermoplastic resin emulsion at a temperature of 0.degree. C. or higher and dried, using a melt extrusion film B. 2. The manufacturing method according to claim 1, wherein the facing carpet A is a needle punch carpet impregnated with a resin emulsion or rubber latex having a glass transition point of 35° C. or less and dried. 3 Carpet A for the surface layer contains fiber binder 15~
50% by weight and a resin fiber having a melting point at least 35°C higher than the melting point of the resin of the fiber binder.
The manufacturing method according to claim 1, characterized in that the needle punch carpet is made of 85 to 50% by weight of mixed fibers. 4. Claims characterized in that the blending amount of the resin emulsion having a glass transition point of 80° C. or higher based on 100 parts by weight of the fibers of the needle punch carpet C is 15 to 300% by weight of the resin solid content of the emulsion. The manufacturing method according to item 1. 5 The material fiber of needle punch carpet C is
50 to 85% by weight of thermoplastic resin fibers whose melting point is 35°C or more higher than the melting point of the emulsion resin and whose melting point is 200°C or more;
The manufacturing method according to claim 1, characterized in that it is composed of 50 to 15% by weight of thermoplastic resin binder fibers at 170°C. 6. The manufacturing method according to claim 1, wherein the thickness of the film B is 20 to 2000 microns. 7 Carpet A for surface layer and glass transition point of 80℃
A multilayer molded material characterized in that a needle punch carpet C impregnated with the above resin emulsion and dried is integrated with a resin film B as an adhesive layer.