JPH10314005A - Molded carpet backing for vehicles - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate easy corporation into the inside of a vehicle by compounding α-olefin resin with a specific value of crystallinity to copolymerize with ethylene, ethylene α-olefin resin to copolymerize with α-olefin and a filler, in respective compositional percentage by weight to satisfy specific formulas. SOLUTION: A barking material is formed of the following (A) component, (B) component and (C) component and each component of the three (A), (B) and (C) is compounded in a proportion to satisfy formula I, formula II, and formula III simultaneously. (A) component consists of α-olefin resin having a degree of crystallinity of less than 10% which is formed by copolymerizing more than 50% by weight of propylene with ethylene. (B) component consists of ethylene α-olefin resin which is formed by copolymerizing more than 50% by weight but less than 99% by weight of ethylene with α-olefin selected from propylene, butene 1, hexene 1, methylpentene 1, or octene 1 and (C) component consists of a filler. However, [A], [B], [C] shows respective percentage by weight of (A) component, (B) component and (C) component and [a], [b] shows respective average crystallinity of (A) component and (B) component.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a composition suitable as a backing material for a molded carpet for a vehicle.

[0002]

2. Description of the Related Art Conventionally, tuft carpets, needle punch carpets and the like have been used as carpets laid on floor panels of vehicles. Of such carpets, a molded carpet that requires molding in accordance with the laying position is provided with a backing mainly composed of a thermoplastic resin on the back surface. Heat the carpet from the side with the backing material,
When the backing material is plasticized, the carpet is squeezed and formed into a required shape, and after forming, the formed shape can be fixed by cooling the backing material. As the thermoplastic resin for the backing material, a polyethylene resin and an ethylene-vinyl acetate copolymer resin are suitable and often used. Outside noise (road noise, etc.) that enters the cabin through the floor panel
To reduce noise, carpets laid on floor panels are also required to have sound insulation. According to the mass law, the heavier carpet is more advantageous in sound insulation, so that a luxury car tends to have a larger weight per unit of the backing material. (Often mix heavy filler in backing)

[0003] Increasing the basis weight of the backing material makes the carpet harder, causing the following problems. The carpet is folded to incorporate a large floor carpet across the vehicle floor panel into the cabin through a narrow door opening. In a carpet provided with a large amount of backing material, the carpet becomes hard and difficult to bend. In particular, when the backing material is a relatively high melting point resin such as a polyethylene resin, if the basis weight exceeds 800 g / m ² , the difficulty of bending becomes remarkable, and the backing material may sometimes crack.

When the backing material is a resin having a relatively low melting point such as an ethylene-vinyl acetate resin, the carpet can be bent up to a weight per unit area of 1000 g / m ² because of the softness of the resin itself. Further, since the melting point of the resin is low, the time required for heating and cooling the backing material is short, and the molding tact can be shortened. However, when a resin having a low melting point, such as an ethylene-vinyl acetate resin, is used for the backing material, there is a problem in recycling the carpet. 2. Description of the Related Art Today, molded carpets for vehicles are often recycled by integrally melting the carpet and the backing material. Since high melting point fibers such as polyester and nylon are used for the pile yarn of the carpet, 250 wt.
A heat treatment at a temperature of at least ℃ is required. At the same time, if a backing material such as an ethylene-vinyl acetate resin having a considerably low melting point (compared to a pile yarn) is to be melt-processed, decomposition will occur on the low melting point resin side, thereby hindering this type of recycling.

[0005]

SUMMARY OF THE INVENTION The present invention provides a molded carpet backing material for vehicles which can simultaneously solve the above-mentioned problems.

[0006]

According to the present invention, there is provided an α-olefin resin having a propylene content of at least 50% by weight and copolymerized with ethylene and having a crystallinity of at most 10%. A) As the component, the ethylene content is 5
An ethylene α-olefin resin obtained by copolymerizing with an α-olefin selected from propylene, butene 1, hexene 1, methyl pentene 1, and octene 1 as 0 to less than 99% by weight as a component (B), and Using the material as component (C), component (A), component (B), and component (C) are blended in a ratio that simultaneously satisfies the following (formula 1), (formula 2), and (formula 3). A molded carpet backing material for vehicles, comprising: Equation 1: 0.10 <[A] / ([A] + [B]) <0.40 Equation 2: [C] <0.85 Equation 3: ([a] · [A] + [b] · [B]) / ([A] + [B]) <0.25 where [A], [B], and [C] are the (A) component, (B) component, and (C ) Indicates the weight fraction of the component, and [a] and [b] are the component (A),
The average crystallization fraction of the component (B) is shown. The component (A) of the present invention has a very low crystallinity as compared with a conventional thermoplastic resin (eg, polyethylene), so that the flexibility of the backing material is secured by the component (A) and the basis weight is 1200 g / m 2. ^The carpet can be bent even if it becomes ² . Also (A)
The components have a melt viscosity of 10 ² to 10 ⁵ centipoise (190
° C), the sheeting properties are excellent, and the backing material can contain a large amount of the component (C) filler.
The component (B) of the present invention is an ethylene α-olefin copolymer resin, and specifically, an ethylene-propylene copolymer,
Ethylene-butene copolymer, ethylene-octene copolymer and the like correspond to this. The component (B) is a flexible resin similarly to the component (A), but has a higher crystallinity than the component (A), and has an effect of maintaining a molded shape of a carpet with a certain rigidity. Therefore, the physical properties of the backing material are controlled by the blending balance with the component (A). The weight fraction of the component (A) is 1 to the sum of the components (A) and (B).
Suitably, it is in the range of more than 0% and less than 60%.
If the proportion of the component (A) is too small, the melt viscosity of the backing material increases, and sheeting with an extruder becomes difficult. In addition, the dispersibility of the component (C) deteriorates, and the amount of the component (C) cannot be increased. Conversely, if the ratio of the component (A) is too large, the backing material becomes too soft, and the molded shape of the carpet cannot be maintained. The more the component (C) is added, the more the sound insulation effect increases. In the present invention, the blending amount can be 50% by weight or more, but if it exceeds 85% by weight, elongation of the backing material is lost and cracks and tears are generated, which is not preferable. Further, it is preferable that the average of the crystallization fractions of the components (A) and (B) does not exceed 25%. If it exceeds 25%, the backing material becomes hard, and if the basis weight is 1000 g / m ² or more, it becomes difficult to bend the carpet and the assemblability to the vehicle is reduced.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION

(Examples and Comparative Examples)
-Backing materials of Example 5 and Comparative Examples 1 and 2 were produced.
These backing materials were actually applied to the back surface of the carpet for vehicles and evaluated. The basis weight of the backing material is 1000g
/ M ² and the conditions for sheeting the backing material from the extruder were set so that the temperature would be the most suitable for each resin.

[Table 1]

(A) Component Amorphous polypropylene resin: Ube Lexen Co., Ltd. (trade name: APAO-UT2385), crystallization fraction 4% (B) Component (B-1) Ethylene propylene rubber: Nippon Synthetic Rubber Co., Ltd. (B-2) ethylene-butene 1 copolymer resin: manufactured by Mitsui Petrochemical Co., Ltd. (trade name: Tuffmer A), crystallized fraction 18% (B-3) ethylene-octene 1 copolymer Polymeric resin: Dow Chemical Co., Ltd. (trade name Engage), crystallization fraction 15
% (B-4) Linear low-density polyethylene resin: manufactured by Idemitsu Co., Ltd. (trade name: Mooretec), crystallization fraction: 25% (B-5) Ethylene-octene copolymer resin: manufactured by Dow Chemical Co., Ltd. (trade name: Affinity) ), Crystallization fraction 30
% (B-6) Low-density polyethylene resin: manufactured by Asahi Kasei Corporation, crystallization fraction 33% (C) component Calcium carbonate: manufactured by Nitto Powder Co., Ltd.

The evaluation of each of Examples and Comparative Examples is that the sheeting from the extruder is not hindered, the formability of the carpet provided with the backing material is good, the carpet can be bent, and the recyclability is high. This was done due to the fact that no decomposition occurred during recycling. In Examples 1 to 5, each of the above evaluations was good, and the material was suitable as a backing material for molded carpet for vehicles. On the other hand, in Comparative Example 1, the viscosity of the resin was high at the time of sheeting and backing was difficult, and the carpet provided with the backing material was hard and could not be bent. Comparative Example 2
In addition, the moldability of the carpet was also poor (the molded shape could not be maintained).

According to the backing material of the present invention, even if the basis weight is increased, the carpet is extremely hard and does not become impossible to bend, so that it can be easily incorporated into the interior of a car. It is a backing material that does not impair the recyclability of carpet.

Claims (1)

[Claims] 1. An α-olefin resin having a propylene content of at least 50% by weight and copolymerized with ethylene and having a crystallinity of 10% or less is used as the component (A), and the ethylene content is at least 50% by weight. Less than 99% by weight, an ethylene α-olefin resin copolymerized with an α-olefin selected from propylene, butene 1, hexene 1, methyl pentene 1, and octene 1 is used as the component (B), and the filler is (C) As component (A), component (B) and component (C) are blended in a ratio that simultaneously satisfies the following (formula 1), (formula 2) and (formula 3). Characterized molded carpet backing material for vehicles. Equation 1: 0.10 <[A] / ([A] + [B]) <0.40 Equation 2: [C] <0.85 Equation 3: ([a] · [A] + [b] · [B]) / ([A] + [B]) <0.25 where [A], [B], and [C] are the (A) component, (B) component, and (C ) Indicates the weight fraction of the component, and [a] and [b] are the component (A),
The average crystallization fraction of the component (B) is shown.