JP2008302051A - Tile carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the problem that the processability of polyvinyl chloride composed of a copolymer used for a lining layer of a tile carpet is excellent, however, is expensive to cause cost rise, and also its flexibility causes shrinkage or warpage after the tile carpet is spread. <P>SOLUTION: It is effective to compose the lining layer 3 of the tile carpet 1 of mixed polyvinyl chloride obtained by blending the polyvinyl chloride composed of the copolymer and polyvinyl chloride composed of homopolymer so as to reduce the shrinkage or warpage. On the basis of this, excellent dimensional stability or warpage performance is obtained, and the tile carpet 1 excellent in cost performance and its manufacturing method are achieved. <P>COPYRIGHT: (C)2009,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 been able to reduce the shrinkage and warpage by using a mixed vinyl chloride blended with a polyvinyl chloride made of a copolymer and a polyvinyl chloride made of a homopolymer as the resin used for the lower layer. Focusing on the effectiveness, it was an object to provide a tile carpet and a method for manufacturing the tile carpet that achieves excellent dimensional stability and warping performance, and is also excellent in economic efficiency.

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, wherein the backing layer is an upper resin layer and glass fiber or polyester It is composed of three layers: an intermediate layer made of non-woven fabric or woven fabric and a lower resin layer. The upper and lower resin layers are blended with a polyvinyl chloride made of a copolymer and a polyvinyl chloride made of a homopolymer. A tile carpet comprising: 300 to 500 parts by weight of a filler with respect to 100 parts by weight of the polyvinyl chloride.

[2] In the tile carpet, the mixed vinyl chloride constituting the upper and lower resin layers is blended at a ratio of 1: 2 to 2: 1 by mixing polyvinyl chloride made of a copolymer and polyvinyl chloride made of a homopolymer. 2. The tile carpet according to item 1 above.

[3] The mixed vinyl chloride sol serving as the lower resin layer is continuously supplied onto the surface of the releasable belt moving at a predetermined speed, and then an intermediate made of a nonwoven fabric or woven fabric such as glass fiber. After the layers are laminated, the mixed vinyl chloride sol that becomes the upper resin layer is continuously supplied, and finally the surface pile layer made of a pile fabric is laminated, and then heat treatment is performed in a heated atmosphere to perform upper and lower resin layers. In the tile carpet manufacturing method for gelling the mixed vinyl chloride sol, the temperature of the heat treatment region for curing the mixed vinyl chloride sol of the upper and lower resin layers in the heat treatment region is set to 150 to 200 ° C. 3. A method for producing a tile carpet according to item 1 or 2.

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 composed of mixed vinyl chloride blended with polyvinyl chloride made of a copolymer and polyvinyl chloride made of a homopolymer, it has excellent penetration into the pile portion of the surface pile layer. It becomes a tile carpet with excellent thread-release prevention. In addition, the lower resin layer is similarly composed of mixed vinyl chloride blended with polyvinyl chloride made of copolymer and polyvinyl chloride made of homopolymer, so shrinkage and warping occur after laying tile carpet. It becomes a tile carpet with excellent dimensional stability and warpage performance that is difficult.

Furthermore, since the resin layers of the upper and lower layers contain 300 to 500 parts by weight of filler with respect to 100 parts by weight of polyvinyl chloride, the polyvinyl chloride of the resin layer can be kept in a sol state with an optimum viscosity during processing. The thickness required for the tile carpet of the final product can be ensured.

According to the invention of [2], by adjusting the blend ratio of the polyvinyl chloride made of a copolymer and the polyvinyl chloride made of a homopolymer, it becomes possible to ensure the thread retaining property according to the material of the surface pile layer, Excellent dimensional stability and warping performance according to the environment in which the tile carpet is constructed can be ensured. In addition, the manufacturing cost is lower than that of a conventional tile carpet using 100% polyvinyl chloride made of a copolymer.

According to the invention of [3], 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 200 to 300 ° C, but in the present invention, the temperature is set to 150 to 200 ° C. It can be set low, and a stable gelation of the polyvinyl chloride sol can be easily obtained as compared with the conventional method. This effect can reduce energy costs and reduce damage to the surface pile layer due to heat.

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 preferably uses a tuft carpet in which a pile yarn is planted on the base fabric by tufting or the like, and a needle punch carpet in which a short fiber web is raised by a needle punch. Alternatively, a woven or knitted fabric with a raised surface, 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 comprises three layers, an upper resin layer (4), an intermediate layer (5), and a lower resin layer (6), and the upper resin layer (4) and the lower resin layer ( 6) is a mixture of a polyvinyl chloride-vinyl acetate copolymer having a medium polymerization degree (about 1300 to 1700) and a vinyl chloride homopolymer, a PVC sol composed of vinyl chloride, and a plasticizer such as DOP (dioctyl phthalate). A paste-like product in which required additives such as a filler, a stabilizer, and a pigment are blended with a mixture sol and gelled by heating to form a homogeneous resin layer.

The mixed vinyl chloride is a blend of polyvinyl chloride made of a copolymer and polyvinyl chloride made of a homopolymer and blended in a ratio of 1: 2 to 2: 1. The ratio of 1: 1 is preferable in terms of securing the yarn removal preventing property, dimensional stability, economy, and the like.

Further, when the surface pile layer is a material that is easily damaged by heat such as polypropylene, the processing temperature can be set as low as 150 to 170 ° C. by blending at a ratio of 1.5: 1 to 2: 1. It becomes possible, and depending on the temperature transmitted to the fiber pile of the surface pile layer, the pile falls down and does not easily recover, and damage to the design properties of the product is reduced.

Furthermore, in a specific environment where tile carpet is actually installed, for example, in a cold district where the temperature difference between day and night is severe, a stronger ratio of dimensional stability is required. Therefore, a ratio of 1: 1.5 to 1: 2 is required. If blended with, strong material strength can be achieved.

The melt viscosity at 190 ° C. of the PVC-based sol composed of the salt-mixed vinyl chloride is in the range of 300 to 30000 cP, and the surface pile layer (2
) Is sufficiently impregnated and impregnated into a tile carpet with excellent thread-removal resistance. In addition, due to the strong material strength, it becomes an excellent tile carpet in which shrinkage hardly occurs.

The plasticizer to be mixed with the PVC-based sol composed of the mixed vinyl chloride is not particularly limited. For example, di-2-ethylhexyl phthalate (DOP), dibutyl phthalate, dihexyl phthalate, diisononyl phthalate, phosphate ester, chlorinated paraffin, tri One kind or a mixture of merit acid esters 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.

As the filler contained in the upper resin layer (4) and the lower resin layer (6), 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 is blended for the economic effect of improving dimensional stability and making the product inexpensive. Specifically, the content of the filler is 300 to 500 parts by weight, preferably 400 to 450% by weight, based on 100 parts by weight of polyvinyl chloride. When the amount is less than 300 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 in the upper resin layer (4), the surface pile layer (2) is not sufficiently impregnated and the tile carpet is inferior in thread-removal resistance. Further, in the lower resin layer (6), the viscosity at the time of melting increases, the strength for preventing warpage cannot be obtained, and the processing time for gelation by heating is required.

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.

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 the 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.

Furthermore, in the configuration of the tile carpet (1) of the present invention, the balance between the uppermost surface pile layer (2) and the lower resin layer (6) with the intermediate layer (5) as a boundary is the present invention. The tile carpet has a practically preferable shape that has a slight warpage toward the back side so as to easily adhere to the floor surface.

The shape having a slight warping toward the back side means that when a tile carpet is picked up, the tile carpet is hung downward, and the state of warping of the tile carpet is observed from above, a slight warp in the back direction of the carpet. It means being accepted. When the tile carpet is placed on a flat floor surface due to slight warping, at least the corners and the peripheral portion of the tile carpet are sufficiently adhered to the floor surface by their own weight even when no load is applied. To do.

Next, the manufacturing method of the tile carpet (1) of this invention is shown below. First, a composition constituting the upper resin layer (4) and the lower resin layer (6) is prepared. The composition is a mixture sol in which a copolymer of a polyvinyl chloride-vinyl acetate copolymer having a degree of polymerization (about 1300 to 1700), a homopolymer of vinyl chloride, and a plasticizer such as DOP (dioctyl phthalate) are mixed by a blender machine. The required additives such as fillers, stabilizers and pigments are mixed in a predetermined composition.

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 nonwoven fabric is laminated thereon as an intermediate layer (5), and a composition constituting the upper resin layer (4) is further added to 0.1 to 5 Is applied to a thickness of 0.0 mm, preferably 0.5 to 2.0 mm, the surface pile layer (2) is laminated, and then roll-pressed and integrated to form the lower resin layer (6) and the upper layer. After giving a temperature and time sufficient to achieve gelation for curing the composition constituting the resin layer (4), a cooling step is performed, and finally a predetermined shape, for example, a square of 500 mm square is cut. , Tile carpet as the final product 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 each upper and lower layers in the treatment region to 150 to 200 ° C, preferably 150 to 180 ° C, The temperature applied to the upper resin layer (4) sandwiched between the surface pile layer (2) and the lower resin layer (6) is 120 ° C to 130 ° C, and the lower layer is directly on the easy-release agent-coated glass belt The temperature applied to the resin layer (6) becomes 130 ° C. to 160 ° C., a stable gelation is performed, a homogeneous resin layer is obtained, and a tile carpet with 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 150 ° C., the upper and lower resin layers are not sufficiently gelled and the strength for preventing 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 in the upper and lower layers exceeds 200 ° C., the resin composition will be thermally deteriorated and decomposed, and the upper and lower resin layers are not sufficiently strong. 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. A surface pile layer made of an embedded pile fabric is laminated, then roll-bonded, and heat treatment is performed at a temperature of 170 ° C. in the heat treatment region for curing the polyvinyl chloride sol of the upper and lower resin layers. 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 the upper and lower resin layers] Polyvinyl chloride resin mixed at 1: 1 blend ratio of copolymer and homopolymer 100 parts by weight Dioctyl phthalate 100 parts by weight Calcium carbonate 400 parts by weight Stabilizer 2 parts by weight Pigment 2 parts by weight anti-bubble agent 5 parts by weight

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

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

<Example 4> A tile carpet was obtained in exactly the same manner as in Example 1, except that the blend ratio of the copolymer and homopolymer used in the upper resin layer and the lower resin layer was 1: 1.5. .

<Example 5> A tile carpet was obtained in exactly the same manner as in Example 1, except that the blend ratio of the copolymer and homopolymer used in the upper resin layer and the lower resin layer was mixed at 1.5: 1. .

<Example 6> 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 150 ° C.

<Example 7> 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 190 ° C.

<Comparative Example 1> A tile carpet was obtained in exactly the same manner as in Example 1 except that 100% of a polyvinyl chloride resin made of a copolymer was used as the composition constituting the upper and lower resin layers.

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

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

<Comparative Example 4> A tile carpet was obtained in exactly the same manner as in Example 1 except that the blend ratio of the copolymer and homopolymer used in the upper resin layer and the lower resin layer was 1: 2.5. .

<Comparative Example 5> A tile carpet was obtained in exactly the same manner as in Example 1 except that the blend ratio of the copolymer and homopolymer used in the upper resin layer and lower resin layer was 2.5: 1. .

<Comparative Example 6> 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 130 ° C.

<Comparative Example 7> 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 230 ° 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 Tables 1 and 2.

(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. If both (A) and (B) have a value of less than ± 0.100 mm, the tile carpet can withstand actual use.

(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. If the value is less than 0.3 mm, the tile carpet can withstand actual use.

As can be seen from Table 1, the tile carpets of Examples 1 to 7 were free of warpage, and obtained tile carpets that were excellent in dimensional stability and could be fully used.

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. Also, in Comparative Examples 2 to 7, good performance satisfying both warpage and 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 (3)

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, wherein the backing layer is an upper layer resin layer and a nonwoven fabric of glass fiber or polyester fiber In addition, the resin layer of each of the upper and lower layers is a mixed chloride mixed with polyvinyl chloride made of copolymer and polyvinyl chloride made of homopolymer. A tile carpet comprising vinyl and containing 300 to 500 parts by weight of a filler with respect to 100 parts by weight of the polyvinyl chloride. In the tile carpet, the mixed vinyl chloride constituting the upper and lower resin layers is blended at a ratio of 1: 2 to 2: 1 by mixing polyvinyl chloride made of a copolymer and polyvinyl chloride made of a homopolymer. The tile carpet according to claim 1. The mixed vinyl chloride sol that becomes the lower resin layer is continuously supplied on the surface of the releasable belt that moves at a predetermined speed, and then an intermediate layer made of nonwoven fabric or woven fabric such as glass fiber is laminated thereon. Further, the mixed vinyl chloride sol as the 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 heated atmosphere to mix the upper and lower resin layers. In the tile carpet manufacturing method for gelling vinyl chloride sol, the temperature of the heat treatment region for curing the mixed vinyl chloride sol in each of the upper and lower resin layers in the heat treatment region is set to 150 to 200 ° C. Or the manufacturing method of the tile carpet of 2.