JP2008142359A - Tile carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a tile carpet which attains excellent dimensional stability and warping performance and is economical, and to provide its manufacturing method. <P>SOLUTION: The tile carpet includes: a surface pile layer 2 composed of a pile fabric where piles are planted in a base fabric; and a backing layer 3 composed of a polyvinyl chloride resin and a filler. The backing layer is formed or three layers, i.e., an upper resin layer 4, a middle layer 5 composed of the nonwoven and woven fabrics made of glass fiber or polyester fiber, and a lower resin layer 6. The upper resin layer is constituted of a vinyl chloride-vinyl acetate copolymer, 200-500 pts.wt of the filler is contained with respect to 100 pts.wt of the copolymer. The lower resin layer is constituted of a polyvinyl chloride homopolymer, where 300-600 pts.wt of the filler is contained with respect to 100 pts.wt of the polyvinyl chloride homopolymer. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

The present invention relates to a tile carpet in which a backing material mainly composed of polyvinyl chloride resin is lined on the back surface of a carpet base material, and a manufacturing method thereof.

Conventionally, thermoplastic resins such as asphalt, polyolefin resin, and polyvinyl chloride (PVC) resin have been generally used as the backing layer of tile carpets. In particular, polyvinyl chloride resin is often used in terms of ease of processing and economy. Furthermore, although the polyvinyl chloride resin used is expensive among them, polyvinyl chloride made of a copolymer which has a low temperature to reach the maximum strength and can be processed even at a low temperature is used.

And as a structure of a backing layer, the nonwoven fabric and woven fabrics, such as glass fiber, are laminated | stacked in a backing layer, and the dimensional stability of a product is improved and curvature is also performed. In Japanese Patent Application Laid-Open No. 59-133503, a non-woven fabric such as glass fiber or a woven fabric is used as a boundary, and the backing layer has a two-layer structure of an upper layer and a lower layer, and the upper layer is 0 to 300 parts of filler relative to 100 parts of polyvinyl chloride. A tile carpet containing 300 to 800 parts of a filler for 100 parts of polyvinyl chloride as a lower layer is disclosed. This is mainly because when a tufted fabric to which a resin for fixing a pile is not applied is used as the surface pile layer, the pile of the tufted fabric is fixedly bonded to the first base fabric or the backing layer by the upper layer resin of the backing layer. In addition, if 300 parts or more of the filler is added to 100 parts of the resin, the viscosity of the resin is increased and the penetration into the pile or the like is deteriorated, and the fixing of the pile is insufficient.
JP 59-1335023

However, as described above, the processability of polyvinyl chloride made of a copolymer used for the backing layer of the tile carpet is excellent, but it is expensive in price and causes an increase in cost. Furthermore, when the resin used for the upper and lower layers of the tile carpet backing layer is composed of polyvinyl chloride made of a copolymer, and the filler is small, the pile of the surface pile layer is sufficiently fixed. Due to the flexibility of the resulting polyvinyl chloride, shrinkage and warping may occur after the tile carpet has been laid. As a result of diligent research, the present inventor has paid attention to the fact that it is effective to use polyvinyl chloride made of a homopolymer as the resin used in the lower layer in order to reduce the shrinkage and warpage. We completed a tile carpet and its manufacturing method that realized warpage performance and excellent economy.

In order to achieve the above object, the present invention provides the following means.

[1] A tile carpet composed of a surface pile layer made of a pile fabric in which a pile is planted on a base fabric and a backing layer made of a polyvinyl chloride resin and a filler, wherein the backing layer is an upper resin layer and glass It is formed of three layers of an intermediate layer made of a nonwoven fabric or a woven fabric of fibers or polyester fibers and a lower resin layer, and the upper resin layer is made of polyvinyl chloride made of a copolymer, and the polyvinyl chloride 100 The filler is contained in an amount of 200 to 500 parts by weight with respect to parts by weight, and the lower resin layer is composed of polyvinyl chloride made of a homopolymer, and the filler is 300 to 600 parts per 100 parts by weight of the polyvinyl chloride. A tile carpet characterized by containing parts by weight.

[2] A polyvinyl chloride sol made of a homopolymer serving as a lower resin layer is continuously supplied onto the surface of a rotating releasable belt, and then an intermediate layer made of nonwoven fabric or woven fabric such as glass fiber. And then continuously supplying a polyvinyl chloride sol made of a copolymer that becomes an upper resin layer, and finally a surface pile layer made of a pile fabric is laminated, and then heat treatment is performed in a heated atmosphere to form upper and lower layers. In the manufacturing method of the tile carpet which gelatinizes a polyvinyl chloride sol, the temperature of the heat processing area | region which cures the polyvinyl chloride sol of each upper and lower layers in a heat processing area | region is set to 200-300 degreeC. Tile carpet manufacturing method.

According to the invention of [1], the tile carpet of the present invention is excellent in heat resistance because the backing layer is formed of polyvinyl chloride, and when laid on the floor in a tile shape, there is no change over time. Since the stability is excellent, there is no gap between tiles spread. In addition, since the upper resin layer is made of polyvinyl chloride made of a copolymer, it is excellent in penetration into the pile portion of the surface pile layer, so that it becomes a tile carpet having excellent yarn slippage prevention. Further, since the lower resin layer is made of polyvinyl chloride made of a homopolymer, the tile carpet is excellent in dimensional stability and warping performance, and is less likely to shrink or warp after laying the tile carpet. In addition, the manufacturing cost is lower than that of a conventional tile carpet in which a copolymer is used for both the upper layer and the lower layer.

Furthermore, the upper resin layer contains 200 to 500 parts by weight of filler with respect to 100 parts by weight of polyvinyl chloride, and the lower resin layer contains 300 to 600 parts by weight of filler with respect to 100 parts by weight of polyvinyl chloride. Therefore, the polyvinyl chloride of the resin layer can be kept in a sol state having an optimum viscosity during processing, and a necessary thickness for the tile carpet of the final product can be secured.

According to the invention of [2], in the conventional processing method, the temperature of the heat treatment region for curing the polyvinyl chloride sol of the backing layer is set to 150 to 200 ° C, but in the present invention, the temperature is set to 200 to 300 ° C. By setting it high, a stable gelation of polyvinyl chloride sol can be easily obtained as compared with the conventional method. This effect makes it possible to use polyvinyl chloride made of a homopolymer, which has been difficult to use in conventional low-temperature processing, and can produce a tile carpet at a lower manufacturing cost than conventional tile carpets.

Furthermore, by using polyvinyl chloride made of a homopolymer for the lower resin layer, a tile carpet with excellent dimensional stability and warping performance can be produced with an appropriate balance between the surface pile layer and the upper resin layer. can do.

Hereinafter, an embodiment of a tile carpet according to the present invention will be described with reference to the drawings. The tile carpet of this embodiment is a tile carpet in which a backing material mainly composed of polyvinyl chloride resin is lined on the back surface of a carpet base material. FIG. 1 is an enlarged schematic cross-sectional view showing a part of the tile carpet of the present embodiment.

The tile carpet (1) of the present invention comprises a surface pile layer (2) and a backing layer (3), and the backing layer (3) comprises an upper resin layer (4), an intermediate layer (5) and a lower layer. It consists of a resin layer (6).

The surface pile layer (2) in the present invention is preferably a tuft carpet in which a pile yarn is planted by tufting or the like on a base fabric, and a needle punch carpet in which a short fiber web is raised by a needle punch, A woven or knitted fabric, a three-dimensional woven fabric, or a normal woven or knitted fabric may be used.

As a pile material constituting the surface pile layer (2), a material generally used as a carpet material may be used. Natural fibers such as wool, hemp and cotton, polyamide fibers, polyester fibers, polyacrylic are used. And synthetic resin fibers such as polypropylene fibers and polypropylene fibers. Moreover, it is preferable to use the woven fabric and nonwoven fabric which consist of synthetic resin fibers, such as a polyester fiber and a polypropylene fiber, as the base fabric by which a pile is planted.

The backing layer (3) in the present invention is composed of three layers of an upper resin layer (4), an intermediate layer (5) and a lower resin layer (6), and the upper resin layer (4) is polyvinyl chloride-acetic acid. It is composed of a copolymer of a vinyl copolymer having a medium polymerization degree (about 1300 to 1700), and is a mixture sol of a PVC sol composed of the vinyl chloride-vinyl acetate copolymer and a plasticizer such as DOP (dioctyl phthalate). It is a paste-like material in which required additives such as a filler, a stabilizer, and a pigment are blended, and is gelled by heating to form a homogeneous resin layer.

The melt viscosity at 190 ° C. of the PVC sol composed of the vinyl chloride-vinyl acetate copolymer is in the range of 300 to 30000 cP, and is sufficiently impregnated and impregnated into the surface pile layer (2), and has excellent yarn removal resistance. Become a tile carpet.

As the filler contained in the upper resin layer (4), calcium carbonate, magnesium carbonate, magnesium sulfate, barium sulfate, magnesium hydroxide, aluminum hydroxide, glass powder, or the like can be used. Of these, calcium carbonate is particularly preferable from the viewpoints of economy and processability. The average particle size of the filler is in the range of 5 to 500 microns, preferably 10 to 100 microns. If the particle size is smaller than 5 microns, the viscosity of the resin layer at the time of melting increases and processing becomes difficult. On the other hand, if the thickness is larger than 500 microns, the surface of the resin layer may become rough, resulting in poor appearance.

The filler contained in the upper resin layer (4) is blended for the economic effect of improving the dimensional stability and making the product inexpensive. Specifically, the content of the filler is 200 to 500 parts by weight, preferably 300 to 400% by weight, based on 100 parts by weight of polyvinyl chloride. If the amount is less than 200 parts by weight, the dimensional stability becomes unstable, and the economic effect of addition cannot be obtained. On the other hand, when the amount is more than 500 parts by weight, the viscosity becomes too high, so that the strength to prevent warpage cannot be obtained, and the surface pile layer (2) is not sufficiently impregnated with the coating, resulting in a tile carpet with poor thread slippage prevention.

The intermediate layer (5) of the present invention improves the shape and dimensional stability of the tile carpet, and examples thereof include non-woven fabrics, woven fabrics, braided fabrics of glass fibers or polyester fibers. As the woven fabric, a bundle of monofilaments woven, and as a braided fabric, a bundle of monofilaments arranged vertically and horizontally and fixed with a binder can be used.

From the viewpoints of shape and dimensional stability, glass or polyester-based nonwoven fabric is preferred, and the glass or polyester-based nonwoven fabric improves the shape stability of the carpet by inserting it between the upper and lower resin layers. That is, since the nonwoven fabric has a large contact area with the resin layer, it is possible to effectively stabilize the shape of the carpet. Basis weight from this point is preferably in the glass system nonwoven fabric in the range of 15 to 60 g / ^{m 2,} the range of 20 to 100 g / ^{m 2} in the polyester nonwoven fabric. In any case, if the basis weight is lower than this range, the effect of dimensional stability is insufficient, and if the basis weight is higher than this range, any peeling between the resin layer and the nonwoven fabric is likely to occur.

The lower resin layer (6) is made of a vinyl chloride homopolymer, and a mixture of a PVC sol made of a homopolymer of the polyvinyl chloride-vinyl acetate copolymer and a plasticizer such as DOP (dioctyl phthalate). It is a paste-like material in which required additives such as a filler, a stabilizer, and a pigment are blended with a sol, and is gelled by heating to form a homogeneous resin layer.

The PVC sol composed of the homopolymer of vinyl chloride-vinyl acetate copolymer has a melt viscosity at 190 ° C. in the range of 300 to 30000 cP, and is an excellent tile carpet in which shrinkage hardly occurs due to strong material strength. Furthermore, the tile carpet of the present invention has a slight amount so that it easily adheres to the floor surface due to the balance with the surface pile layer (2) having the uppermost layer elongation due to the presence of the resin layer that is unlikely to shrink in the lowermost layer. It has a practically preferable shape that has a warp toward the back side.

Here, in such a shape, when the carpet is hung down by picking up one side of the tile carpet and the state of the warp of the carpet is observed from above, a slight warp is recognized in the reverse direction of the carpet. means. Because of the slight warpage, when the carpet is placed on a flat floor surface, at least the corners and the peripheral portion of the carpet are sufficiently adhered to the floor surface by their own weight even when no load is applied.

As the filler mixed in the lower resin layer (6), as in the filler mixed in the upper resin layer (4), calcium carbonate, magnesium carbonate, magnesium sulfate, barium sulfate, magnesium hydroxide, hydroxide Aluminum or glass powder can be used. Of these, calcium carbonate is particularly preferable from the viewpoints of economy and processability. The average particle size of the filler is in the range of 5 to 500 microns, preferably 10 to 100 microns. If the particle size is smaller than 5 microns, the viscosity of the resin layer at the time of melting increases and processing becomes difficult. On the other hand, if the thickness is larger than 500 microns, the surface of the resin layer may become rough, resulting in poor appearance.

The filler contained in the lower resin layer (6) is blended for the economic effect of improving the dimensional stability and making the product inexpensive. Specifically, the content of the filler is 300 to 600 parts by weight, preferably 400 to 500% by weight, based on 100 parts by weight of polyvinyl chloride. When the amount is less than 300 parts by weight, the dimensional stability of the tile carpet is impaired. When the amount is more than 600 parts by weight, the material strength is lowered, and the viscosity of the lower resin layer (6) is increased when melted to prevent warpage. Cannot be obtained, and the processing time required for gelation by heating results.

The plasticizer is not particularly limited. For example, one or a mixture of di-2-ethylhexyl phthalate (DOP), dibutyl phthalate, dihexyl phthalate, diisononyl phthalate, phosphate ester, chlorinated paraffin, trimellitic acid ester, etc. Can be used. Among them, it is preferable to use di-2-ethylhexyl phthalate because of good workability. The plasticizer is blended in an amount of about 10 to 20% by weight based on the total amount of the resin composition.

In addition, known lubricants such as waxes, higher fatty acids, higher fatty acid salts, higher fatty acid esters, higher alcohols, oils and fats, phthalic acid esters and the like can be used as long as the effects of the present invention are not impaired. In addition, a pigment can be added to improve the appearance of the coated surface, and a conductive filler such as carbon fiber or metal fiber can be added to further impart conductivity. Furthermore, in order to impart an appropriate cushioning property, an appropriate amount of a foaming agent can be added to form a foamed backing layer.

Next, the manufacturing method of the tile carpet (1) of this invention is shown below. First, a composition constituting the upper resin layer (4) is prepared. The composition is a mixture sol of PVC sol composed of a copolymer of polyvinyl chloride-vinyl acetate copolymer and a plasticizer such as DOP (dioctyl phthalate) and predetermined additives such as a filler, a stabilizer and a pigment. Mix with the following formula. Furthermore, the composition which comprises the lower resin layer (6) is prepared. Its composition is a mixture sol of PVC sol composed of a homopolymer of polyvinyl chloride-vinyl acetate copolymer and a plasticizer such as DOP (dioctyl phthalate), and required additives such as fillers, stabilizers and pigments. Mix in the prescribed formulation.

And the composition which comprises the said lower resin layer (6) is 0.5-5.0 mm on the easy-release agent coating glass belt which moves at a predetermined | prescribed speed | rate as shown in FIG. It is applied to a thickness of 0 to 2.0 mm, a glass or polyester non-woven fabric is laminated thereon, and a composition constituting the upper resin layer (4) is further 0.1 to 5.0 mm, preferably 0. Applying to a thickness of 5 to 2.0 mm, laminating the surface pile layer (2), then roll-compressing and integrating, the lower resin layer (6) and the upper resin layer (4) After giving a temperature and time sufficient to achieve gelation for curing the constituent composition, after passing through a cooling step, and finally cutting into a predetermined shape, for example, a square of 500 mm square, the tile as the final product A carpet is obtained.

In the continuous production process of the tile carpet (1) of the present invention, by setting the temperature of the heat treatment region for curing the polyvinyl chloride sol of the upper and lower layers in the treatment region to 200 to 300 ° C, preferably 230 to 270 ° C, The temperature applied to the upper resin layer (4) sandwiched between the surface pile layer (2) and the lower resin layer (6) is 150 ° C. to 160 ° C., and the lower layer is directly on the easy-release agent-coated glass belt. The temperature applied to the resin layer (6) becomes 160 ° C. to 180 ° C., a stable gelation is performed, a homogeneous resin layer is obtained, and a tile carpet having high strength and high productivity can be manufactured.

When the temperature of the heat treatment region for curing the polyvinyl chloride sol of the upper and lower layers is lower than 200 ° C., the gelation of the upper and lower resin layers is insufficient and the strength to prevent warpage cannot be obtained. Further, the upper resin layer (4) does not easily penetrate into the pile portion of the surface pile layer, and becomes a tile carpet in which the pile yarn of the surface pile layer is easily removed. On the other hand, if the temperature of the heat treatment region for curing the polyvinyl chloride sol of the upper and lower layers exceeds 300 ° C., the resin composition will be thermally deteriorated and decomposed, so that the upper and lower resin layers are not sufficiently strong resin layers. Therefore, the dimensional stability of the tile carpet is impaired.

Examples of the present invention will be described below, but the present invention is not limited to the following examples.

<Example 1> On the easy-release agent-coated glass belt that moves at a predetermined speed, a composition that constitutes the lower resin layer mixed in the following formulation is applied to a thickness of 1.5 mm. Then, a glass nonwoven fabric having a basis weight of 35 g / m ² was laminated thereon, and a composition for a composition constituting the upper resin layer was applied in a similar manner to a thickness of 1.5 mm, and the pile was applied to the base fabric. Laminate the surface pile layer made of the planted pile fabric, and then roll-press, heat treat the temperature of the heat treatment area to cure the polyvinyl chloride sol of the upper and lower resin layers at 250 ℃, gel the polyvinyl chloride It was made to cool, and it cut | judged to the square of 500 mm square finally, and the tile carpet was manufactured. [Composition constituting lower resin layer] Polyvinyl chloride resin comprising homopolymer 100 parts by weight Dioctyl phthalate 100 parts by weight Calcium carbonate 450 parts by weight Stabilizer 2 parts by weight Pigment 2 parts by weight Antifoaming agent 5 parts by weight Composition constituting resin layer] Polyvinyl chloride resin comprising copolymer 100 parts by weight Dioctyl phthalate 100 parts by weight Calcium carbonate 370 parts by weight Stabilizer 2 parts by weight Pigment 2 parts by weight Antifoaming agent 5 parts by weight

<Example 2> Example 1 except that the upper resin layer contains 230 parts by weight of calcium carbonate, which is a filler contained in the upper resin layer and the lower resin layer, and 330 parts by weight of the lower resin layer. A tile carpet was obtained in exactly the same manner.

<Example 3> Example 1 except that the upper resin layer contains 470 parts by weight of calcium carbonate, which is a filler contained in the upper resin layer and the lower resin layer, and 570 parts by weight of the lower resin layer. A tile carpet was obtained in exactly the same manner.

<Example 4> A tile carpet was obtained in exactly the same manner as in Example 1 except that the heat treatment region for curing the polyvinyl chloride sol in the upper and lower resin layers was heat treated at 220 ° C.

<Example 5> A tile carpet was obtained in exactly the same manner as in Example 1 except that the temperature of the heat treatment region for curing the polyvinyl chloride sol of the upper and lower resin layers was 280 ° C.

<Comparative Example 1> A tile carpet was obtained in exactly the same manner as in Example 1 except that a polyvinyl chloride resin composed of the same copolymer as that of the upper resin layer was used as the composition constituting the lower resin layer.

<Comparative Example 2> Example 1 except that the upper resin layer contains 170 parts by weight of calcium carbonate, which is a filler contained in the upper resin layer and the lower resin layer, and 270 parts by weight of the lower resin layer. A tile carpet was obtained in exactly the same manner.

<Comparative Example 3> Example 1 except that the upper resin layer contains 530 parts by weight of calcium carbonate, which is a filler contained in the upper resin layer and the lower resin layer, and 630 parts by weight of the lower resin layer. A tile carpet was obtained in exactly the same manner.

<Comparative Example 4> A tile carpet was obtained in exactly the same manner as in Example 1, except that the heat treatment region for curing the polyvinyl chloride sol of the upper and lower resin layers was heat treated at 180 ° C.

<Comparative Example 5> A tile carpet was obtained in exactly the same manner as in Example 1 except that the heat treatment region for curing the polyvinyl chloride sol of the upper and lower resin layers was heat treated at 320 ° C.

Each tile carpet obtained as described above was examined for dimensional stability test and warpage based on the following evaluation method. The results are shown in Table 1.

(Dimensional stability test) (A) According to JISL4406, each tile carpet was allowed to stand at 60 ° C. for 2 hours, then immersed in tap water for 2 hours, and then allowed to stand at 60 ° C. for 24 hours. Then, measurement was made for each of the vertical direction of the tile carpet and the horizontal direction of the tile carpet. Three samples were measured and the average value was obtained. (B) After rotating a chair caster with a load of 90 kg on the surface of one 500 mm square tile carpet for 2000 rotations, the vertical and horizontal dimensions were measured, and the values compared with the dimensions before rolling were the average values in the vertical and horizontal directions. Indicated.

(Warpage) In accordance with JIS-L-1904, each tile carpet is left in the standard state “20 ± 2 ° C., (65 ± 2) RH%” for 24 hours or more and then placed on a horizontal test bench. The length of the gap between the four corners of the carpet and the test bench was measured and shown as an average value.

As can be seen from Table 1, the tile carpets of Examples 1 to 5 were free of warpage, and a tile carpet that was excellent in dimensional stability and could be used sufficiently.

On the other hand, the tile carpet of Comparative Example 1 naturally has a problem in terms of economy, but good performance with respect to warpage could not be obtained. In Comparative Examples 2 and 5, good performance with respect to warpage was not obtained, and in Comparative Examples 3 and 4, good performance with respect to dimensional stability was not obtained.

It is sectional drawing of this invention tile carpet concerning one Embodiment of this invention. It is the schematic of the manufacturing apparatus of this invention tile carpet concerning one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ......... Tile carpet 2 ......... Pile layer 3 ...... Backing layer 4 ...... Upper resin layer 5 ... Intermediate layer 6 ......... Lower resin layer 7 ...... Heat treatment region

Claims (2)

A tile carpet comprising a surface pile layer made of a pile fabric in which a pile is planted on a base fabric and a backing layer made of a polyvinyl chloride resin and a filler, wherein the backing layer is an upper resin layer and glass fiber or polyester It is formed of three layers, an intermediate layer made of a nonwoven fabric or a woven fabric of fibers, and a lower resin layer, and the upper resin layer is made of polyvinyl chloride made of a copolymer, and is added to 100 parts by weight of the polyvinyl chloride. The filler is contained in an amount of 200 to 500 parts by weight, and the lower resin layer is made of a homopolymer polyvinyl chloride, and the filler is contained in an amount of 300 to 600 parts by weight with respect to 100 parts by weight of the polyvinyl chloride. A tile carpet characterized by A polyvinyl chloride sol made of a homopolymer as a lower resin layer is continuously supplied on the surface of a rotating releasable belt, and then an intermediate layer made of nonwoven fabric or woven fabric such as glass fiber is laminated thereon. Further, a polyvinyl chloride sol made of a copolymer that becomes an upper resin layer is continuously supplied, and finally a surface pile layer made of a pile fabric is laminated, and then heat treatment is performed in a heating atmosphere, and then the upper and lower resin layers are laminated. In the tile carpet manufacturing method for gelling vinyl chloride sol, the temperature of the heat treatment region for curing the polyvinyl chloride sol of the upper and lower resin layers in the heat treatment region is set to 200 to 300 ° C. The manufacturing method of the tile carpet as described.