JPH06320994A - Auxiliary mat for transportation - Google Patents

Abstract

(57) [Abstract] [Purpose] To provide an auxiliary mat for transportation which has an appropriate weight, has good stability and shape retention, has no unpleasant odor, and produces no harmful substances even when incinerated. . [Structure] On a back surface side of a carpet-like mat base material 1, a first backing layer 2 having an ethylene-vinyl acetate copolymer and / or polyethylene as a main material is provided. Further, on the back surface side, a second backing layer 3 formed by crosslinking and foaming a resin composition containing linear low density polyethylene and an ethylene-vinyl acetate copolymer or an ethylene-ethyl acrylate copolymer is provided. Has been. An engaging piece 6 made of a linear rigid protrusion made of resin is preferably provided on the back surface of the second backing layer 3.
The sheet-like non-slip member 4 is planted in a group, and is attached.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is used by being removably laid on an interior carpet or the like which has been laid in advance in a driver's seat, a passenger's seat or a foot of a seat of a transportation such as an automobile or a train. The present invention relates to an auxiliary mat for transportation, which is a so-called second mat.

[0002]

2. Description of the Related Art As an auxiliary mat for transportation as described above, one having a carpet-like surface on which pile threads or the like are planted has been generally used. Such an auxiliary mat has a basic structure in which a backing layer for ensuring shape retention, weight stability, strength, etc. is provided on the back side of a carpet-like mat base material. As the layer, a layer formed of polyvinyl chloride resin (PVC) was used exclusively.

[0003]

However, in the backing layer made of polyvinyl chloride resin, the weight of the mat increases (usually the coating amount is 1300 to 3000 g / m ² ), which makes the handling at the time of laying and removal difficult. It is not always suitable as an auxiliary mat for transportation such as an automobile mat that is frequently removed to scrub off adhered sand, soil, mud and the like. Moreover, it has been one of the factors that prevent the weight reduction of vehicles and the like which have been recently required for improving fuel efficiency.

Further, since the interior of a car or train is highly airtight, there is a problem that the odor of the plasticizer added to the polyvinyl chloride resin or the resin odor causes discomfort.

Furthermore, since a large amount of toxic hydrogen chloride gas is generated during combustion, it is difficult to incinerate it. Therefore, at the present time, the scrap materials and unnecessary mats at the time of mat production are landfilled. There is also a problem that the disposal is concerned because of the saturation of the landfill.

The present invention has been made in view of the above circumstances, and has an appropriate weight, has good laying stability and shape retention, has no unpleasant odor, and is a harmful substance even when incinerated. The purpose is to provide an auxiliary mat for transportation that does not cause

[0007]

In order to achieve the above object, the present invention will be described with reference to the reference numerals in FIGS. 1 and 2. In the present invention, ethylene is formed on the back surface side of a carpet-like mat base material (1). A first backing layer (2) comprising a vinyl acetate copolymer and / or polyethylene as a main material is provided, and linear low density polyethylene and ethylene-vinyl acetate copolymer are further provided on the back side of the first backing layer. A secondary mat (A) for transportation, comprising a second backing layer (3) obtained by crosslinking and foaming a resin composition containing a polymer or an ethylene-ethyl acrylate copolymer. It is a summary.

The mat base material (1) is in the form of a carpet similar to the conventional one. For example, a tufted carpet in which a pile yarn (1a) is planted in a base cloth such as a woven cloth or a non-woven cloth made of polypropylene or polyester. Besides, it can be appropriately selected and used from among needle punch carpets, pile fabrics, pile knits and the like.

The first backing layer (2) has a function as a support member for supporting the mat base material (1) and an adhesive for adhering a second backing layer, which will be described later, and has a proper matte property. The weight of the laying stability,
It plays a role of ensuring shape retention. In the present invention, the first backing layer (2) is formed of a resin containing ethylene-vinyl acetate copolymer and / or polyethylene as a main material so as to satisfy such properties and to be incinerated. That is, the first backing layer may be formed of an ethylene-vinyl acetate copolymer alone or a resin containing the same as a main component, or may be formed of polyethylene alone or a resin containing a main component thereof, or ethylene. -A vinyl acetate copolymer and polyethylene may be mixed and used. Further, the powder filler may be mixed with the ethylene-vinyl acetate copolymer homopolymer, the polyethylene homopolymer, or the mixed resin of the ethylene-vinyl acetate copolymer and polyethylene. The type of filler is not particularly limited,
As an example, calcium carbonate, aluminum hydroxide, magnesium hydroxide, etc. can be mentioned. Such a powder filler is added for the purpose of increasing the softening point of the first backing layer, improving dimensional stability, improving rigidity, improving flame retardancy, imparting weight by increasing specific gravity, and reducing cost. However, if the amount of the filler with respect to the resin is too small, the above effect does not occur, and if the amount of the filler is too large, uniform coating cannot be performed and the composition becomes brittle.
Therefore, the content of the filler is 0 to 80% by weight, preferably 50 to 70% by weight, based on the ethylene-vinyl acetate copolymer, and 0 to polyethylene. 65% by weight, preferably 30-50% by weight
It is preferable to add such that the film forming property, processability, hardness, flexibility, etc.

When an ethylene-vinyl acetate copolymer is used as the resin for forming the first backing layer, one having a vinyl acetate content of 5 to 35% by weight is preferable in terms of hardness, flexibility and moldability. preferable. When polyethylene is used as the resin forming the first backing layer, it is desirable that the polyethylene has a low density. The first backing layer may be mixed with a small amount of olefin resin such as polypropylene, or may be mixed with stabilizers, pigments, oils, and other commonly used additives and auxiliaries. Of course, it is okay.

The coating amount of the first backing layer (2) on the mat substrate (1) is 500 to 120 by total weight including the filler in the case of ethylene-vinyl acetate copolymer.
0 g / m ² or so, particularly preferably 700 to 900 g / m
² is good, and in the case of polyethylene 200-8
00 g / m ² or so, particularly preferably 350 to 500 g /
It is good to use m ² . If both are too small, the laying stability and the shape retention are deteriorated due to insufficient weight, and the positional deviation easily occurs. On the other hand, if the amount is too large, the weight becomes excessive, which goes against the demand for weight reduction.

The first backing layer (2) may be applied directly to the back surface of the mat base material (1), or, although not shown, the pile yarn (1a) may be applied to the back surface of the mat base material. )
It is also possible to apply a precoat layer for removing the yarn and preventing play hair, and apply it to the back surface of the precoat layer. The precoat layer can be formed, for example, by applying a latex compound containing SBR, acrylic, EVA or a mixture thereof as a main component. The content of the filler in the latex compound is 0 to 70% by weight, preferably 0 to 30% by weight. The coating amount of the compound is, 50 to 500 g / m ² by solid content, and it is preferably a 100 to 200 g / m ^2.

The second backing layer (3) cooperates with the first backing layer (2) to provide the mat with appropriate hardness and suppleness as well as excellent mechanical strength. Is. The linear low-density polyethylene used for the second backing layer (3) means, for example, propylene, butene-1, penten-to ethylene by an ionic polymerization reaction under medium and low pressure.
1, hexene-1, octene-1, 4 methylpentene-
By copolymerizing a small amount (about 1 to 10 mol%) of an α-olefin such as 1 to introduce an appropriate number of short chain branches into a linear trunk polymer, the density can be reduced to that of a conventional high pressure low density polyethylene. It is a polymer reduced to a range, and preferably has a density of 0.915 to 0.94 g / cm ³ and a melt index of 0.5 to 50 g / 10 minutes, and more preferably a melt index of 1.0 to 10.0 g / 10
Minutes, such as Ultzex-3021F, 2
020L (Mitsui Petrochemical Co., Ltd.), DNGA734
2, CRSN 7345 (manufactured by Union Carbide) and the like.

The ethylene-vinyl acetate copolymer used for the second backing layer (3) has a vinyl acetate content of 5
From about 28% by weight is preferable from the viewpoint of the flexibility and moldability of the foam. If the vinyl acetate content is too low, the flexibility of the foam will be poor, and if it is too high, the moldability will be poor.

As the ethylene-ethyl acrylate copolymer used for the second backing layer (3), the one having an ethyl acrylate content of 7 to 25% by weight is the moldability of the foam,
It is preferable in terms of flexibility. If the content of ethyl acrylate is too low, the flexibility will be poor, and if it is too high, the moldability will be poor.

The second backing layer (3) is a mixture of a linear low density polyethylene and an ethylene-vinyl acetate copolymer or an ethylene-ethyl acrylate copolymer, or an ordinary low density polyethylene. The mixture is obtained by cross-linking and foaming, and is specifically as follows. That is, a foaming agent is added to the above resin mixture, and the mixture is uniformly mixed using a ribbon blender or the like, and the mixture is kneaded and melted at a temperature and pressure at which the foaming agent is not substantially decomposed by an extruder or a calender roll into a sheet form. Molded into
The sheet-shaped molded product is crosslinked by irradiation with ionizing radiation, and then heated to a temperature above the decomposition temperature of the foaming agent to obtain a crosslinked foamed product, or a foaming agent and a crosslinking agent are added to the resin composition. A mixture obtained by uniformly mixing this is kneaded and melted by an extruder or a calender roll at a temperature and pressure at which the foaming agent and the cross-linking agent are not substantially decomposed to form a sheet, which is heated to a temperature at which the cross-linking agent decomposes. A method of obtaining a crosslinked foamed body by crosslinking by heating and further heating at a temperature not lower than the decomposition temperature of the foaming agent.

As the foaming agent, a chemical foaming agent such as azodicarbonamide or N-N'-dinitrosopentamethylenetetramine, which generates a decomposition gas upon heating, is preferable because it requires no special equipment in use.

The ionizing radiation that crosslinks the resin is β
Rays, γ rays, neutrons, electron rays and the like are used, and the irradiation amount thereof is preferably in the range of 0.5 to 20 Mrad.
When a cross-linking agent is used as a means for cross-linking the resin, dicumyl peroxide, 2,5-dimethyl-
Organic peroxides such as 2,5-ditertiary peroxyhexane and ditertiary butyl perterephthalate are used.

As a weight mixing ratio of the linear low density polyethylene and the ethylene-vinyl acetate copolymer or the ethylene-ethyl acrylate copolymer, the mechanical strength of the foam is in the range of 1: 1 to 4: 1. It is preferable in terms of flexibility, moldability and the like. If the linear low density polyethylene is too small, the mechanical strength will be insufficient, and if it is too large, the flexibility will be insufficient. In the above mixture, the ethylene-vinyl acetate copolymer and the ethylene-ethyl acrylate copolymer may be used together, and the mixture may further contain a conventional low density polyethylene, high density polyethylene, ethylene-propylene copolymer. It is also possible to add a resin such as polypropylene. For example, when ordinary low density polyethylene is added, its density is 0.
91 to 0.93 g / cm ³ , melt index 1 to 1
0 g / 10 min is preferable, and 5% of the total resin mixture
It can be suitably added up to 0% by weight.

In the production of the second backing layer made of the above crosslinked foam, additives which are usually used, such as stabilizers, ultraviolet absorbers, lubricants, pigments, antistatic agents, fillers and reinforcing materials. Needless to say, auxiliary agents may be mixed.

The amount of the second backing layer (3) as described above is
50 to 400 g / m ² or so, particularly preferably 100 to 2
It is good to set it to 00 g / m ² . Too little, flexibility,
The cushioning property is inferior, and if the amount is too large, the weight increases. The thickness depends on the expansion ratio, but is 0.8-3.
It is set to 0 mm, preferably about 1.0 to 2.0 mm. The expansion ratio is 5 to 20 times, preferably 8 to 15 times.

In order to manufacture the automobile mat according to the present invention, the resin constituting the first backing layer (2) is treated with, for example, T
While extruding in a molten state at about 200 ° C. from the die, the back surface of the carpet base material (1) was coated to a predetermined thickness, and then a separately manufactured foam sheet for forming the second backing layer (3) was coated. Just wear it.

As a preferred embodiment of the present invention, the non-slip members (4) may be provided on the entire lower surface of the mat or on required portions (in the illustrated embodiment, a total of four on the front, rear, left and right of the mat). This non-slip member (4) is
When the mat is laid on the carpet-like interior material of the car floor, the mat is prevented from slipping further.

The non-slip member (4) comprises a sheet-like base cloth (5) and an engaging piece (6) made of a linear rigid protrusion made of resin, which is planted in a group. is there. The base fabric (5) is made of nylon in this example, but other fibers such as polyester, polypropylene,
You may comprise by the cotton mixed spinning or the mixed weaving.

Further, although the engaging piece (6) is formed of polypropylene monofilament in this embodiment, it is formed of nylon, polyester, vinylidene chloride, or a blend of one or more of these. Is also good. The anti-slip member (4) is attached to the second backing layer (3) via a heat-resistant acrylic pressure-sensitive adhesive applied to the back surface of the base cloth (5). The anti-slip member (4) may be manufactured by the same method as the pile woven or knitted fabric.

The engaging piece (6) prevents displacement of the mat by digging into the surface of an interior carpet or the like laid inside an automobile. Are arranged in a plurality of rows so as to generate a larger drag force against them, and in each row, they are alternately arranged in an oblique or parallel protruding state so as to form an inverted V shape or an inverted U shape in a side view. ing. It is to be noted that the tip of each engaging piece (6) is bulged or hooked for better retaining effect, but in the present invention, the first and second
Due to the effect of the backing layers (2) and (3), the laying stability is excellent, curling and curling are not generated, and therefore it is not necessary to consider the retaining by the engagement piece (6). Rather, when the tip of the engaging piece (6) is formed to be bulged, the surface raised portion of the interior carpet is caught by the bulging portion when the mat is removed, which causes damage to the raised portion, which is prevented. Therefore, the engagement piece (6) is formed in a substantially linear shape with the same diameter up to the tip thereof.

[0027]

EXAMPLES Examples of the present invention will be described below.

[0028]

[Table 1]

[Table 2] Examples 1 to 8 Sumitomo Textile Co., Ltd. in which pile threads are planted while extruding a first backing layer forming resin composition having four types of compositions A to D shown in Table 1 above from a T-die in a molten state of about 200 ° C. Mat base material made of company-made tufted carpet (base cloth:
Polyester non-woven fabric, pile thread: nylon, thickness: 8m
After coating on the back surface of m), while the first backing layer is still in a molten state, separately manufactured three kinds of foam sheets for forming the second backing layer shown in Table 2, A, B and C are coated. By wearing it, an automobile mat was produced. The combination of the resin composition for forming the first backing layer and the foam sheet for forming the second backing layer is as shown in Table 3 below, and the coating amount of the first backing layer is 800 g / m ² , Thickness is 1.2
mm, the amount was 120 g / m ^2, and the total thickness of the backing layer was 2 mm.

The foam sheet for forming the second backing layer was prepared by mixing the resins shown in Table 2 and extruding it into a sheet with an extruder, and then using an electron beam irradiator to obtain 2.5 Mrad.
It is produced by irradiating with an electron beam of (1) to crosslink, and then continuously passing through an oven at 250 ° C. for heat-foaming, which has uniformly dispersed closed cells.
The specific gravity was about 0.1 times.

Comparative Example 1 On the back surface of the same mat base material as in the above example, a latex compound containing 50 PHR of calcium carbonate as a filler and containing an acrylic latex as a main component was used.
The foam sheet for forming the second backing layer (a) shown in Table 2 was laminated. The amount of latex applied is 250 g / m in terms of solid content.
² , the amount of the second backing layer was 120 g / m ² , and the total thickness of the backing layer was 1.2 mm.

Comparative Example 2 On the back surface of the same carpet base material as in the above-mentioned example, the foam sheet for forming the second backing layer (a) shown in Table 2 was stuck via the SBR solvent adhesive. The amount of the adhesive applied is 200 g / m ^{2 in} solid content, and the amount of the second backing layer is 120 g / m ² .
m ^2, and the total thickness of the backing layer was 1.2 mm.

Conventional Example A conventional automobile mat is coated on the back surface of the same mat base material as in the above example with a reclaimed vinyl chloride resin containing a plasticizer made of dioctyl phthalate (DOP) and a filler as a backing layer. I made it. The coating amount of vinyl chloride resin is 18
Was 00g / m ^2, the thickness of the backing layer was 1.0 mm.

With respect to the various types of automobile mats obtained as described above, the weight feeling of the mats, the presence or absence of unpleasant odor, and the fitability to the vehicle floor were examined.

[0034]

[Table 3] As can be seen from Table 3 above, Examples 1 to 7 of the present invention have appropriate weight, hardness, and suppleness, and fit snugly to the vehicle floor, and Example 8 is Example 1
Although it is slightly lighter and less supple than Nos. 7 to 7, it can be used without any problem in a floor shape having less unevenness, and all are odorless and have no unpleasant odor. On the other hand, Comparative Products 1 and 2 in which the second backing layer was laminated via a latex compound or a solvent-based adhesive were odorless but lacked in weight and hardness, and lacked in installation stability. there were.

Further, in order to examine the surface strength of the second backing layer according to the present invention, foamed sheets having various foaming ratios were prepared by using the resins shown in Table 2a and general low density polyethylene, and each of them was manufactured. The skin strength was examined. The skin strength was measured under the following conditions. That is, a vinyl cloth tape (manufactured by Sekisui Chemical Co., Ltd.) was attached to a foamed sheet, and a pressure roll (4 kg) was reciprocated twice on the foamed sheet for adhesion, and then 15
It was left in the standard state for more than a minute. Then, each test piece was attached to a tensile tester and pulled at a speed of 200 mm / min until the epidermis was completely peeled off, and the strength at that time was measured. Then, this was repeated several times, and the average value was evaluated. The results are shown in Table 4.

[0036]

[Table 4] From the results in Table 4 above, the foamed sheet for the second backing layer that satisfies the composition of the present invention has excellent skin strength, and therefore the mat according to the present invention has a risk of peeling the skin of the second backing layer. It was confirmed that it could be reduced.

[0037]

According to the present invention, according to the above, the backing layer of the carpet-like mat base material is mainly composed of an ethylene-vinyl acetate copolymer and / or perylene.
Since it is composed of a backing layer, a linear low density polyethylene, and a second backing layer obtained by crosslinking and foaming a resin composition containing an ethylene-vinyl acetate copolymer or an ethylene-ethyl acrylate copolymer. It has an appropriate weight and flexibility, is excellent in laying stability and shape retention, and can be suitable as an auxiliary mat for automobiles and other transportation means that is frequently laid and removed. Moreover, since the second backing layer is excellent in surface strength, even if the back surface of the mat, that is, the surface of the second backing layer, comes into contact with the floor or other parts, is rubbed, or is caught, The risk of skin peeling can be reduced, and a mat with excellent strength and durability can be obtained.

Moreover, there is no unpleasant odor like polyvinyl chloride resin, and since the backing layer does not contain chlorine, harmful substances such as chlorine gas are not generated even when incinerated, and therefore, incineration-friendly environmental destruction is possible. It can be made with a mat that is not afraid of.

When the first backing layer contains a powder filler, the softening point, the dimensional stability, the rigidity, and the flame retardancy of the first backing layer and the entire mat are increased. It is possible to provide the effects of improving the property, imparting weight by increasing the specific gravity, and reducing the price.

In the case where a sheet-like non-slip member in which engaging pieces made of resinous linear protrusions are planted in a group is attached to the back surface of the second backing layer, The mating piece bites into the carpet-like interior material that has been laid in advance on the floor surface, whereby the lateral displacement of the mat can be further prevented.

[Brief description of drawings]

FIG. 1 is a perspective view showing a state in which the present invention is applied to an automobile mat.

FIG. 2 is a sectional view taken along line I-I of FIG.

[Explanation of symbols]

 A ... Mat 1 ... Mat base material 2 ... First backing layer 3 ... Second backing layer 4 ... Anti-slip member 6 ... Engaging piece

Claims (3)

[Claims] 1. A first backing layer (2) comprising an ethylene-vinyl acetate copolymer and / or polyethylene as a main material is provided on the back surface side of a carpet-like mat substrate (1), and the first backing layer (2) is further provided. A second backing layer (3) obtained by crosslinking and foaming a resin composition containing linear low-density polyethylene and an ethylene-vinyl acetate copolymer or an ethylene-ethyl acrylate copolymer on the back side of the backing layer. ) Is provided, an auxiliary mat for transportation. 2. The auxiliary mat for transportation means according to claim 1, wherein the first backing layer (2) contains a powder filler. 3. A sheet-like non-slip member (4) in which engaging pieces (6) made of a linear rigid protrusion made of resin are planted in a group in a group on the back surface of the second backing layer (3). The auxiliary mat for transportation according to claim 1 or 2, which is affixed.