JPH10276888A - Backing material for car floor carpet and car floor carpet mat using the same - Google Patents

Abstract

(57) [Problem] To provide an automobile floor highly blended with an inorganic filler, which has good formability in extruding a backing sheet and is excellent in durability, sound insulation and shape retention. An object of the present invention is to provide a carpet backing material and an automobile floor carpet mat obtained by covering the back surface of a carpet mat substrate with the backing material. SOLUTION: The present invention is obtained by copolymerizing 50% by weight or more of propylene with 50% by weight or less of ethylene, and has a melt viscosity at 190 ° C of 10 ² to 10 ⁵ centipoise. Backing material for automobile floor carpet, comprising an olefin, a copolymer of 70 to 99% by weight of ethylene and 1 to 30% by weight of butene-1 or octene-1, and an inorganic filler, and the use thereof Car floor mats.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a backing material for automobile floor carpets, which is highly blended with an inorganic filler, and has excellent moldability, sound insulation and shape retention properties, and a backing material coated on the back of a carpet mat substrate. And car floor mats obtained.

[0002]

2. Description of the Related Art Automobile floor carpets are made by coating a backing of a carpet base material with a composition sheet made of various materials, which is excellent not only in moldability but also in durability, sound insulation and mold retention. It is also necessary that the change in performance under various environments or over a wide temperature range of, for example, -30 to 80 ° C be small.
Since the sound insulating effect of the backing material is proportional to the weight per unit area of the backing material, the backing material is preferably a highly mixed inorganic filler. Conventionally, crystalline polyethylene, an ethylene-vinyl acetate copolymer, a synthetic rubber, or the like has been used as a backing material for carpets in order to impart the above-described specific and indispensable properties to the carpet base material.

[0003]

However, when these materials are used as a backing material for carpets, there have been problems in that the pile removal strength of the carpets is insufficient, and the carpet lacks durability and molding retention. Of these materials, crystalline polyethylene and ethylene-vinyl acetate copolymer are extremely difficult to mix inorganic fillers at a high level, and the hardness and brittleness increase with increasing filler loading. And the durability and low-temperature characteristics as a carpet backing material are deteriorated. Furthermore, synthetic rubber has the drawback that the processability at the time of kneading the backing material composition or the moldability at the time of sheet molding is inferior, and that economic efficiency is disadvantageous.

It is an object of the present invention to provide a backing material which satisfies the required performance as a backing material for an automobile floor carpet and which has improved the disadvantages of the conventional materials, and an automobile floor carpet mat using the same. Things.

[0005]

Means for Solving the Problems Accordingly, the present inventors have:
As a result of intensive studies on the backing material for car floor carpets to achieve the above object, as the backing material, amorphous poly-α-olefin obtained by copolymerizing propylene and ethylene, ethylene and butene-1 Alternatively, the present inventors have found that a composition containing a copolymer of octene-1 and an inorganic filler is suitable, and have completed the present invention.

That is, a first aspect of the present invention is to provide an amorphous poly-α-olefin obtained by copolymerizing propylene and ethylene;
The present invention relates to a backing composition for an automobile floor carpet, comprising a copolymer of ethylene and butene-1 or octene-1 and an inorganic filler. Further, the second aspect of the present invention
Is that the amorphous poly-α-olefin has a propylene content of 50% by weight or more, an ethylene content of 50% by weight or less, and a melt viscosity at 190 ° C. of 10%.
Relates ^{2-10 5} centipoise automobile floor carpet backing material according to the first invention, wherein the range of the third invention, a copolymer of ethylene and butene-1 or octene-1 Is obtained by copolymerizing 70 to 99% by weight of ethylene with 1 to 30% by weight of butene-1 or octene-1 (however, ethylene and butene-1 or octene-1 are 100 weight% in total). %) According to the first or second aspect of the invention.
A fourth aspect of the present invention is any one of the first to third aspects.
More particularly, the present invention relates to an automobile floor carpet mat obtained by covering the back surface of a carpet mat substrate with the automobile floor carpet backing material according to the invention.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail. The amorphous poly-α-olefin referred to in the present invention is obtained by copolymerizing propylene and ethylene using a special catalyst so that each monomer unit is randomly arranged. The amorphous poly-α-olefin has a crystallinity of 10% or less as measured by the DSC method and is very low in crystallinity as compared with a normal polyolefin, and has a number average molecular weight of less than 10%. 1,000 to 50,000
It has a relatively low molecular weight of 0, preferably in the range of 2,000 to 20,000. Therefore, since the amorphous poly-α-olefin has low crystallinity, the temperature dependence of the mechanical properties is small, the flexibility is high, and the loss elastic modulus (E ″) which is a measure of the vibration damping properties and the sound insulation properties is high. ) Has the characteristic that it is large among general-purpose plastic materials.Moreover, this amorphous poly-α-olefin has a propylene content of 50% by weight or more and an ethylene content of 50% by weight or less (however, propylene and ethylene are different from each other). Total 10
0 wt%) and a melt viscosity at 190 ° C of 10 ² to 10 ⁵ centipoise, preferably 200
Those having a range of ~ 20,000 centipoise are desirable.

The compounding ratio of the amorphous poly-α-olefin to the backing material is 5 to 40% by weight, preferably 10 to 30% by weight.
% By weight. If the amount is less than 5% by weight, the melt viscosity of the backing material composition increases, so that the processability during kneading of the composition or the formability during sheet molding becomes difficult, and the flexibility and elasticity of the backing material are increased. Is reduced. Also, 40
If the content is more than 10% by weight, the melt viscosity of the backing material composition will be low, and the sheet formability will be reduced, and the backing material will be significantly distorted and deformed under high load conditions.

If the number average molecular weight of the amorphous poly-α-olefin is less than 1,000, the cohesive force of the polymer is too low, and the strength required for carpet backing is insufficient, and 50,000. If it is above, the melt viscosity is too high, and the workability at the time of kneading the backing material composition or the moldability at the time of sheet forming is reduced. Further, when the ethylene content in the amorphous poly-α-olefin is 50% by weight or more, the surface tackiness of the amorphous poly-α-olefin increases, and the handling workability at the time of forming the backing material is poor. Become.

Next, ethylene and butene-1 according to the present invention will be described.
Alternatively, the copolymer with octene-1 is obtained by copolymerizing 70 to 99% by weight of ethylene with 1 to 30% by weight of butene-1 or octene-1 (however, ethylene and butene-1). Or octene-1 is 100 in total
Wt.%) At a temperature of 230 ° C. and 2.16 k
Melt flow rate (MFR) under load of 1 to 1
Those having a range of 00 g / 10 minutes are preferable. Among these, for example, a copolymer of ethylene and butene-1 (EB
M) or ultra low density polyethylene (EOR) comprising a copolymer of ethylene and octene-1 is currently commercially available, and these can be suitably used in the present invention.

The mixing ratio of the copolymer of ethylene and butene-1 or octene-1 to the backing material is 5 to 40.
% By weight, preferably 10 to 30% by weight. 5% by weight
If the amount is less than the above, distortion or deformation accompanying the creep deformation of the backing material under a high load condition becomes remarkable, and if it is more than 40% by weight, the melt viscosity of the backing material composition extremely increases, and the moldability decreases. .

Further, as the inorganic filler of the present invention, for example, general-purpose plastics such as calcium carbonate, magnesium carbonate, magnesium sulfate, barium sulfate, magnesium hydroxide, aluminum hydroxide and glass powder can be used. . Of these, calcium carbonate is particularly preferred in terms of economy and moldability. In the present invention, the inorganic filler is preferably highly incorporated into the backing composition since the sound insulating effect of the backing is proportional to the weight per unit area of the backing.
The inorganic filler also has an additional effect of imparting appropriate stiffness and heat resistance to the backing material.

The inorganic filler has an average particle size of 5 to 50.
0 microns, preferably in the range of 10-100 microns. If the particle size is less than 5 microns, the melt viscosity of the backing composition will increase, making molding difficult. Particle size is 5
If it is larger than 00 microns, the surface of the backing material will be rough and the appearance will be poor. The mixing ratio of the inorganic filler to the backing material is 40 to 80% by weight, preferably 50 to 7% by weight.
0% by weight. If the amount is less than 40% by weight, the sound insulation of the backing material will be reduced, and the economic efficiency will be poor. Also, 80
If the amount is more than 10% by weight, the melt viscosity of the backing material composition increases, making molding difficult, and the strength or durability of the backing material decreases.

Furthermore, in the present invention, a crystalline olefin resin may be added to the backing material. The term "crystalline olefin resin" used herein includes general-purpose polyethylene such as low-density polyethylene (LDPE) and linear low-density polyethylene (LLDPE), homopolypropylene, and block- and random-type propylene copolymers. By adding these crystalline olefin resins, mechanical properties such as tensile strength and tear strength of the backing material can be improved. The compounding ratio of the crystalline olefin resin to the backing material is 10% by weight or less. If it is more than 10% by weight, the hardness of the backing material is increased, and the sound insulation is reduced.

In the present invention, additives such as an antiblocking agent and a coloring agent may be appropriately added to the backing material. The anti-adhesion agent has an effect of facilitating the handling of the carpet mat by reducing the adhesiveness of the backing material surface, and silicone oil, stearic acid and derivatives thereof can be used. As the coloring agent, any coloring pigment and dye can be used directly or as a master batch. Note that the usual backing material is black, and carbon black can be used in the form of a master batch.

In the present invention, the backing material for car floor carpets and the method of manufacturing car floor carpet mat products using the same are not particularly limited. For example, it can be manufactured as follows. First, the above-mentioned resins and inorganic filler, and further, if necessary, additives such as an antiblocking agent and a coloring agent are uniformly mixed by a mixer such as a Henschel mixer or a Banbury mixer, and then melt-compounded or a compound thereof. Make pellets or
Alternatively, the resin pellets and the additives are uniformly mixed with a stirrer such as a tumbler blender to produce dry blend pellets. Next, the above-mentioned raw material was heated at a temperature of 130 to 200 ° C. using a single-screw or twin-screw extruder equipped with a coat hanger die or the like at a temperature of 400 to 2,000.
Before cooling and solidifying the backing material sheet obtained by die extrusion molding as a sheet having a width of 0.1 to 3 mm and a thickness of 0.1 to 3 mm, a carpet mat is provided by a pressure roll or the like installed adjacent to the coat hanger die outlet. Continuously backing the back surface of the substrate, or after cooling and solidifying, by backing the backing sheet on the back surface of the carpet mat substrate with an adhesive or the like, an automobile floor carpet mat product is obtained. .

[0017]

The present invention will be described in more detail with reference to examples and comparative examples, but the present invention is not limited to these examples.

The materials used in the following examples and comparative examples are as follows. (1) Amorphous poly α-olefin (Ube Lexen,
(Trade name: UT2385, hereinafter abbreviated as "APAO") (2) Ethylene-butene-1 copolymer (manufactured by Mitsui Petrochemical Industry Co., Ltd., trade name: Tuffmer A-4090, hereinafter, referred to as "EB")
M) (3) Ethylene-octene-1 copolymer (manufactured by Dow Chemical Company, trade name: EG8150, hereinafter abbreviated as “EOR”) (4) Ethylene-propylene rubber (manufactured by Nippon Synthetic Rubber Co., Ltd.)
(Trade name: EP961, hereinafter abbreviated as “EPR”) (5) Low density polyethylene (manufactured by Ube Industries, trade name: F)
-022, hereinafter abbreviated as "PE") (6) Random type polypropylene (Ube Industries, Ltd.)
(7) Ethylene-vinyl acetate copolymer (manufactured by Du Pont-Toray Co., Ltd., trade name: “Evaflex” P-2805, hereinafter abbreviated as “EVA”) (8) Synthetic rubber: styrene-butadiene-based thermoplastic elastomer (trade name: TR2000, manufactured by Nippon Synthetic Rubber Co., Ltd.)
(Hereinafter abbreviated as "SBS") (9) Calcium carbonate (manufactured by Nitto Powder Co., Ltd., trade name: SS-
30, hereinafter abbreviated as "charcoal")

Examples 1 to 4 (Preparation of Resin Composition for Backing Material) Predetermined materials shown in Table 1 were prepared so that the resulting backing material had a composition (% by weight) as shown in Table 1. What was blended in the ratio of is mixed and stirred at 200 ° C. for 15 minutes in a kneader, and then
The obtained backing material composition is subjected to hot pressing at 200 ° C. for 2 hours.
It was formed into a sheet having a thickness of mm.

(Performance Evaluation Test) Next, the following performance evaluation tests were performed for each of Examples 1 to 4. The test results are as shown in Table 1. (1) Extrusion Formability The average required torque (kg · cm) when the backing material composition was kneaded and stirred at 200 ° C. for 10 minutes using a Labo Plastomill (manufactured by Toyo Seiki Co., Ltd.). Generally, 10kg
A composition with an excessive torque of not less than 1 cm cannot obtain a sufficient amount of extrusion during extrusion molding, and a composition with an excessive torque of 1 kgcm or less can maintain the shape of the molten sheet during extrusion. Becomes difficult. Therefore, in each embodiment, the required torque is 10 kg · cm or more or 1 kg · c
m, less than 1 kg · cm, 10 kg · c
Of those less than m, those relatively close to the lower and upper limits were evaluated as Δ, and the others were evaluated as ○.

(2) Thermal degradation during melt-kneading As in the case of the evaluation of the extrudability described in the above item (1), the backing material composition was subjected to a pressure kneader (manufactured by Irie Seisakusho) for 20 minutes.
After mixing and stirring at 0 ° C. for 1 hour, yellowing and coloring of the backing material were observed to determine the presence or absence of thermal deterioration. In each of the examples, those having yellowing were evaluated as x, and those without coloring were evaluated as ○. In general, olefin resins such as amorphous poly-α-olefins and copolymers of ethylene and butene-1 or octene-1 have excellent heat resistance, similarly to crystalline polyolefins.

(3) Strength The tensile strength at 23 ° C. of a sheet having a thickness of 2 mm obtained by hot press molding at 200 ° C. was measured in accordance with JIS K7113 “Plastic tensile test method”. Generally, those having a tensile strength of more than 40 kg / cm ² have excellent carpet durability and a tensile strength of 30 kg / c.
Those having m ² or less are not preferred in terms of durability. Therefore,
In each example, those having a tensile strength of more than 40 kg / cm ² were evaluated as ○, and those having a tensile strength of 30 kg / cm ² or less were evaluated as x.

(4) Surface Hardness Similar to the strength evaluation described in the above item (3), for a sheet having a thickness of 2 mm, a “spring type hardness test (type A)” in JIS K6301 “Vulcanized Rubber Physical Test Method” was used. ) 』
The surface hardness at 23 ° C. was measured in accordance with. In general, those with low surface hardness are rich in flexibility, but JIS A
If the hardness is less than 70, shape retention is poor, and JIS
If the A hardness exceeds 90, the carpet becomes rigid,
Not preferred. Therefore, in each embodiment, JIS A
Those with a hardness of less than 70 or more than 90 were evaluated as x, and those with a hardness of 70 or more and 90 or less were evaluated as ○.

[0024]

[Table 1]

Comparative Examples 1 to 7 Comparative Examples 1 to 7 were repeated except that the specified materials shown in Table 2 were used and the resulting backing materials had compositions (% by weight) shown in Table 2, respectively. A sheet having a thickness of 2 mm was prepared in exactly the same manner, and each performance evaluation test was performed. Table 2 shows the test results.

[0026]

[Table 2]

Examples 5 to 8 In Examples 5 to 8, one side of the 2 mm-thick sheet obtained in Examples 1 to 4 was again
After placing on a hot plate at 5 ° C. for 5 minutes and heating and melting, a polyester fiber carpet mat substrate was bonded, and then cooled and solidified to obtain a carpet mat.

Comparative Examples 8 to 14 In Comparative Examples 8 to 14, the 2 mm thick sheets obtained in Comparative Examples 1 to 7 were used instead of the 2 mm thick sheets obtained in Example 1. Except for the above, a carpet mat was obtained in exactly the same manner as in Example 5. As is clear from Tables 1 and 2, the carpet mats of Examples 5 to 8 related to the present invention are excellent in any property as a car floor carpet mat product. The deviating carpet mats of Comparative Examples 8 to 14 are inferior in any of the properties.

[0029]

According to the present invention, an automobile floor comprising an amorphous poly-α-olefin obtained by copolymerizing propylene and ethylene, a copolymer of ethylene and butene-1 or octene-1, and an inorganic filler. The backing material for carpets can provide an automobile floor carpet mat that has good formability during backing sheet extrusion and is excellent in durability, sound insulation, and shape retention.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Yoshitaka Okada 3-1 Chikko Shinmachi, Sakai-shi, Osaka Ube Industries, Ltd. Inside the Sakai Plant (72) Inventor Takaya Sakaguchi 3-1 Chikushinmachi, Sakai-shi, Osaka Ube Industries, Ltd. Sakai factory

Claims (4)

[Claims] 1. An automobile floor carpet comprising an amorphous poly-α-olefin obtained by copolymerizing propylene and ethylene, a copolymer of ethylene and butene-1 or octene-1, and an inorganic filler. Backing material. 2. The amorphous poly-α-olefin has a propylene content of 50% by weight or more, an ethylene content of 50% by weight or less, and a melt viscosity at 190 ° C. of 10 ² to 10 ⁵ centipoise. The backing material for an automobile floor carpet according to claim 1, wherein: 3. A copolymer of ethylene and butene-1 or octene-1 containing 70 to 99% by weight of ethylene,
To 30% by weight of butene-1 or octene-1 (provided that ethylene and butene-
1 or octene-1 is 100% by weight in total)
The backing material for an automobile floor carpet according to claim 1 or 2, wherein: 4. An automobile floor carpet mat obtained by coating the underside of a carpet mat substrate with the backing material for an automobile floor carpet according to any one of claims 1 to 3.