JPS6059176A - Production of laying material having moldability and thermal bonding property - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

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 a floor covering material for automobiles.

Paving materials for automobile interiors are generally obtained by impregnating or coating a neat punch with rubber latex and then drying it. However, when this laying material is applied to uneven parts such as automobiles or furniture, it is difficult to shape the rubber latex backing material because of its high impact resilience. Additionally, melt extrusion laminate backing using thermoplastic resins such as polyethylene and ethylene/vinyl acetate copolymers is also used. In this case, it is possible to form an uneven shape by heating, and compared to a carpet using rubber latex as a backing material, the shaped carpet has better shape retention and has a sharper shape. Although the advantage 1 is that it has a certain disadvantage, it is hard to the touch and has a poor pile yarn locking effect.

In order to improve the shortcomings of these backing materials, alternatives to rubber latex have been investigated. Synthetic+i'J 717 emulsions with a glass transition point higher than SOC, such as coalescence, are increasingly being used as backing materials. Among them, acrylic resin emulsions are being used more frequently because they are significantly different from other copolymer emulsions in terms of rigidity, moldability, and heat resistance.

However, carpets made of Emulsicone, a resin with a melting point higher than this SOC, are easy to install in automobile interiors, but are highly rigid, lack elasticity, and have a strange feel to the touch and feel of the carpet. do.

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 elasticity, rubber latex in which powder of a thermoplastic resin with a low melting point such as low density polyethylene or ethylene/vinyl acetate copolymer is dispersed is made into m-dol punch. It is proposed that a carpet be impregnated with rubber, dried and then molded with heating power + IE to give it shape retention with a thermoplastic resin, and to have a good feel due to the elasticity of rubber. However, there is a drawback that it is difficult to impregnate the base layer of the needle-punched carpet with powder, and the required amount of powder must be blended.

As a method of imparting formability and cushioning properties to the laying material, 4r? It is conceivable to apply a water-based emulsion of fat and dry it, then further line it with an under felt or a polystyrene foam sheet. However, if a water-based resin emulsion with a high melting point is used, it can be further lined with felt, a resin foam sheet, etc. When the backing material is thermally bonded, the adhesive strength between the backing material and the backing layer is weak, and the backing material often peels off when press molding to give a shape to the laying material.

We use an aqueous emulsion of a resin with a high melting point (80°C or higher) as the first backing material to impart moldability to the original rug, and an aqueous emulsion of an acrylic resin with a low melting point (10°C or lower) to provide thermal adhesive properties. When the second backing layer was used as a second backing material to provide a coating material, 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 lined 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 an aqueous resin emulsion as described below (4) on the back side of an original rug, and a first resin containing tyrene particles (named for the foamable polyester of Isao).
After coating the backing material (4), an aqueous resin emulsion (B) mainly composed of an aqueous dispersion of a resin with a melting point of 80° C. or higher, expandable polystyrene particles each having a particle size of 1.5 W or less, The second bucking material on the surface of the bucking material has a melting point lower than that of the resin particles of the aqueous emulsion described in (5) above, and its melting point is 50 to 12
A moldable and heat-adhesive installation characterized by applying an aqueous emulsion of a resin that is chilled at 5°C and then heating and drying the emulsion to form a backing layer and foaming expandable polystyrene particles. The present invention provides a method for manufacturing the material.

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, needle punch carpets made from fibers such as wool, nylon, polyacrylonitrile, polyacetate, polypropylene, etc., or raw materials for tufted carpets with piles erected on a primary base fabric knitted with flat yarns. '62 - Beetle Punch Carpet Next, tufted carpet is used as a base fabric and piles are made to stand up on top of this.Among these, for car interiors (
- Inexpensive needle punch carpet is preferable.

Next, a resin aqueous emulsion with a melting point (glass transition point 'rg) of 80°C or higher of component (4) of the first backing material that imparts moldability to the carpet is used as the main component (50 to 100% by weight). The emulsion to be prepared is (Topoly n-propyl methacrylate ('1''g8JC), polystyrene (100C), poly-1crylonitrile (1''g8JC),
00°C), polymethyl methacrylate (105C), polymethacrylic acid (130'C), Po'J (ri: 17fi!
(130C), PoIJ'Tcrylamide (153℃)
In addition to an aqueous emulsion of homopolymers such as (b), 50 to 100% by weight of vinyl monomer, which is the raw material for these polymers
, preferably 65 to 95% by weight, and other copolymerizable vinyl monomers, such as 2-ethylhexyl acrylate (T
g-85C), n'butyl acrylate (-54℃), ethyl acrylate (-220), inopropyl acrylate (-5℃), 2-ethylhexyl methacrylate (-5℃)
), n-propyl acrylate (8℃), butyl methacrylate (20℃), vinyl acetate (30℃), ethyl methacrylate (65C), vinyl chloride (79℃), etc. or vinylidene chloride (-18℃) ) 50% by weight or less, preferably 35 to 5% of copolymers [
In this section (b), the Tg shown in parentheses is the glass transition point of the vinyl monomer or the homopolymer of pinylyl chloride), (c), Tg is +80 to +15
Resin aqueous emulsion 50-97% by weight at 5°C, preferably 55-95% by weight and 'rg from 185C to +80
Resin aqueous emulsion or rubber latex below 5°C
0-3-reserve%, preferably 45-5
〇The concentration of resin DI type in the aqueous emulsion of these backing materials is usually 20 to 60.
The diameter of the dispersed resin particles is 10 μ (micron) or less, preferably 0.05 to 1.0 μ.
Hereinafter, preferably 0.2 to 0.8 ram of expandable polystyrene resin particles are blended at a ratio of 10 to 100 parts by weight to 100 parts by weight of resin in the emulsion.
Used as bucking material. If the particle size exceeds 1.5 mm, it is difficult to work with the emulsion, and the expandable polystyrene particles tend to move to the top of the emulsion and separate easily.In other words, the workability and storage stability of the backing material are affected. . Furthermore, if the particles are large, the coating properties during backing will be reduced, and furthermore, after the backing material is applied to the original rug, the expandable polystyrene particles are likely to fall off from the original rug.

Such expandable polyarene particles contain J
- styrene, if necessary methyl methacrylate - vinylbenzene - acrylic! Vinyl monomers such as styrene are emulsified in water and heated to polymerize vinyl monomers such as styrene.
Next, an expanding agent such as butane or heptane is injected into the suspension in which the polymer particles are dispersed, and the polymer particles are impregnated with the volatile group expanding agent at a ratio of 3 to 7% by weight. . In addition, vinyl monomers such as styrene can be
It can also be obtained by polymerizing while supplying the swelling agent to the suspension during ffi polymerization.

This aqueous emulsion, which is the first backing material, contains extender pigments such as calcium carbonate, aluminum hydroxide, clay, talc, barium sulfate, pigments such as red iron oxide, titanium oxide, flame retardants, dyes, iron powder, iron oxide, toluene, Coating aids such as mineral spirits, thickeners such as methyl ethyl cellulose and polyvinyl alcohol, antifreeze agents, antifoaming agents,
A dispersant, a foaming agent, a wetting agent, etc. are blended and the temperature is good.

The first bucking material is applied to the fiber mat at a rate of 60 to 1,000 f/n? using a roll, suggi, etc. c solid content),
Preferably 80-4009/rr? The membrane is coated on the skin, impregnated with nip rolls, and dried using a heating means such as an infrared heater, suction dryer, or hot air dryer.

At this point, it is necessary to dry at a low temperature to avoid foaming of the expandable polystyrene particles. For this reason, f,11
After applying the No. 1 backing material, while the No. 1 backing material is still in an undried state, a second backing material made of the aqueous emulsion of the resin having a melting point of 50 to 125° C. is applied to the surface of the first backing layer for 15 to 15 minutes. Apply 100 IF/m' (solid content), preferably 30 to 80 IF/m'. A temperature higher than the film forming temperature of the first backing material and the second backing material (50 to 150°C, preferably 100 to 140°C)
C.) to form the first backing layer and the second backing layer, and at the same time, it is preferable to foam the expandable polystyrene particles in the first backing material.

Due to this heating, the expandable polystyrene particles expand approximately 5 to 50 times and have a particle size of 0.5 to 4.5. , the foam (1) is adhered by the first backing material (z) formed by the resin emulsion (4), and the film (
2) Protrudes from the surface (see Figure 1). The second backing layer (3) has a rough surface due to the presence of the foam particles (1).

Therefore, due to the presence of the foam particles (1) in the laying material f4)++ of the present invention, the cushioning properties of the rug material (5) are significantly improved.

The FA midpoint of the resin of the second backing material is 50 to 12.
Aqueous emulsions of resins at 5° C. (JIS K-5903) include aqueous emulsions of resins such as terpene 4fft fats, terpene-phenol copolymers, petroleum resins, rosins, and ethylene-vinyl acetate copolymers.

In this resin aqueous emulsion, toluene, xylene,
Organic solvents such as ethylceronlube and mineral spirits,
Coating aids such as plasticizers such as dibutyl octyl phthalate may also be blended. Addition of this film-forming aid improves the film-forming properties of the emulsion.

The above-mentioned petroleum resin is obtained by heating and polymerizing an alkylstyrene indene resin, petroleum-based unsaturated hydrocarbon or/and cyclopentadiene in the presence of a catalyst such as sulfuric acid, anhydrous aluminum chloride, or boron fluoride. Resins and water additives thereof, etc. can be used. Examples of the rosin include processed rosins such as abietic acid rosin, water additives thereof, maleic acid adducts thereof, esterified products with alcohols such as gold lambda salt, glycerin, pentaerythritol, ethylene glycol, and diethylene glycol. In addition, as for terpene resin, the temperature is homopolymers such as α-pinene, β-pinene, dipentene, copolymers of these,
Terpene-phenol copolymers, α-pinene-phenol copolymers, water additives thereof, and the like are used.

Methods for producing emulsions of petroleum resins, rosin resins, terpene resins, and ethylene/vinyl acetate copolymers are described in JP-A-56-78623 and JP-A-56-87421.
Since it is described in patent publications such as No. 56-159244 and No. 57-125255, the explanation will be omitted here. As for the product names, the petroleum resin emulsions are Toho Oil Resin Gl Kiku:v 75 Emulsion, Na90 Emulsion, and the Narodine resin emulsions are Harinister DS-7OL, DS-70g, and Ds-9 from Harima Kasei Kogyo ■.
0g or bar size E ~ 305, bar size E
M-505 is an aqueous emulsion of terpene resin &[
[Ematax 800 (prototype) made of oil and fat ■ is ethylene/
Examples of the vinyl acetate copolymer emulsion include those manufactured by Mitsubishi Yuka Fine Men (prototype). In these aqueous emulsions and emulsions of petroleum resins, rosin resins, and terpene resins, the average particle size of the dispersed resin is 10i1 or less, generally 0.03 to 3 microns, and the solid content concentration is It is 20 to 65%.

The second backing material contains, like the first backing material, a film forming aid, a plasticizer, a thickener, a dispersant, an antifreeze agent, a coloring agent, a pigment, a wetting agent, a weight pigment, and an antifoaming agent. Agents, flame retardants, etc., wax emulsions, latexes, aqueous resin emulsions, etc. may be added within the range of not significantly changing the original quality.

The laying material produced in this way was
k +y厘h 空韮6 sito −慅ν← 子鉦7ヱg1r
← 6-1, 7 J- It is also possible to roll up and store the backing material before laminating it.

Examples of the backing material include felt, jute cloth, foamed polyurethane sheet, foamed polyvinyl chloride sheet, foamed polypropylene sheet, foamed ethylene/vinyl acetate copolymer sheet, foamed polystyrene sheet, and the like.

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 forming the laying material, the first backing layer, the second
After heating to a state where both resins of the backing layer are melted and softened, a backing material is laminated, and then a shape is given by compression molding using a press mold. 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.

Hereinafter, the present invention will be explained in detail using actual manufacturing examples.

M-shaped example of needle-punched non-woven fabric - 1 - - - - - - - - - - - 1 Random cards made of recovered polyethylene terephthalate fiber waste of cod with 15 denier and fiber length of 75 to 125 After stacking this (basis weight 400?/n?), 15-18-3
Needling was performed using 2-3RB (7) needles at a rate of 50 needles per square inch to obtain a fiber mat.

Example 1 A first backing material and L"C (
4) Aqueous emulsion obtained by emulsion polymerization of styrene (80% by weight) and acrylic + 'in-butyl (20% by weight) [average particle size of resin 0.2 microns, solid content 50%, softening point 120 C] ) 10 o', ftfitfNB, (
10 parts by weight of expandable polystyrene particles "Styroball IBE" (trade name manufactured by Yuka Hearties Co., Ltd., containing 5.8% butane) with an effective particle size of 0.5 M or less (average particle size 0.33 mm) were blended, and this The viscosity of 250 was increased to 3 by adding the thickener "2 Tecol" (product name) manufactured by Yuka Verdissier.
0 (10 cpa) was applied using a licker roller to give a solid content of 250?/t♂, and then the emulsion was impregnated into the fiber mat using a nip roll.

On top of this first backing 1-, a petroleum resin aqueous emulsion "N1)-1z" (product name,
The softening point of the resin is 80C1, the solid content concentration is 60%, the average particle size is 1 micron), and the solid content is 6of/rr? It was coated to give the following properties, and was heat-dried by 1° in a 140C hot air dryer to foam the expandable polystyrene particles and form resin films for the first and second winter backing layers to obtain a laying material.

This second backing layer did not exhibit any tackiness at 20°C.

Polystyrene in the first backing layer of this laying material
The it-form particles have a bulk density of about 0.15 mm/d and a particle size of 0.15 mm/d.
It was 5-1.51. The cushion quality of this laying material was measured using the following method, and a good result was obtained. Measurement method: The initial thickness when a load of soy/di was applied to the laying material was taken as to, and then the maximum weight of 400y/aA was measured. load 1
The thickness at 1 minute/'C is 1 degree, the thickness of the iron after this load is removed is t2, and t.

2 Deformation rate = (--)X100 t.

When calculated, those with a small deformation rate and a small change in thickness were considered to have good cushioning properties.

In addition, from the second backing layer 1Iill of this laying material,
Using a heater, heat at 180°C (17), and then apply felt with a thickness of 10#I to the second banking layer with a roll, which is made by melting the wood H'tf of the first and second backing layers, and then The shape-retaining property and the adhesive force between the felt and the second backing layer were evaluated by the following method for the laying material that was compression molded using a press mold.

The results are shown in Table 1.

Evaluation method (1) Shape 1 Sustainability The molded paving material was placed on a model with the same shape as the male mold of the press mold, and this was left in a room at 85°C for one day to check for any misalignment between the model and the paving material. The presence or absence of 0 was observed. Those with no deviation were evaluated as good (○), and those with deviations of 2 or more were evaluated as poor (x).

(2) Adhesive strength to felt Cut out 5 sample pieces with a width of 30+m and a length of 250m from the molded laying material, and then cut out only the felt surface from one end, each 2m wide, and then cut out one end of the non-woven fabric surface. After fixing with your hand, grab the felt with your other hand and peel it off. If the felt layer peels off, it is considered good adhesion (0), and if it separates between the felt and nonwoven fabric interface, the adhesion is good. It was marked as defective (×). Further, when both cases occurred, it was defined as normal (Δ).

Examples 2-3, Comparative Examples 1-2 i: [2 A felt-backed laying material was obtained in the same manner as in Example 1, except that the emulsion shown in Table 2 was used as the backing material.

The shape retention properties of this material and the P>a force with felt are shown in the same table.

(Hereinafter, blank spaces) Examples 4 to 5, Comparative Example 3 A laying material was obtained in the same manner as in Example 1, except that a material having the composition shown in Table 3 was used as the first backing material.

The cushioning properties of this laying material are shown in the same table.

Table 3

[Brief explanation of drawings]

Figure 1 shows the laying material obtained by carrying out the present invention.
are polystyrene foam particles, 2 is the first backing layer, 3 is the polystyrene foam particle;
is the second backing layer, 4 is the laying material, and 5 is the original rug fabric. Patent Applicant Yuka Bardatesier Co., Ltd. Agent Patent Attorney Hidetoshi Furukawa Agent Patent Attorney Masahisa Hase Figure 1

Claims (1)

[Scope of Claims]), a self-contained aqueous resin emulsion placed on the back side of the original rug, a first backing material (2) containing expandable polystyrene particles (B), and a resin having a melting point of 80°C or higher. After applying the resin aqueous emulsion (B), whose main component is an aqueous dispersion, expandable polystyrene particles each having a particle size of 1.5 mm or less, the aqueous resin emulsion (B) containing the above-mentioned aqueous dispersion as a second backing material is applied to the surface of the first backing material. has a melting point lower than that of the resin particles of the emulsion, and its melting point is 50-125
A laying material having moldability and thermal adhesion properties, characterized in that an aqueous emulsion of a resin is applied at a temperature of °C, and then heated and dried to dry the emulsion to form a backing layer and to foam expandable polystyrene particles. manufacturing method. 2) The first bucking material is characterized by being a composition in which expandable polystyrene particles are blended at a ratio of 10 to 100 parts by weight per 100 parts by weight of the resin content in the aqueous resin emulsion. A method for manufacturing a laying material according to claim 1. 3) The first backing layer is 60 ~ ooof? /-
The second backing layer has a weight ratio of 15 to 100 f
42. The method of manufacturing a laying material according to claim 41, wherein the laying material is provided at a weight ratio of /d.