JP3160965B2 - Resin composition for tile carpet backing and its tile carpet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tile carpet in which a backing material is lined with a carpet substrate and a resin composition for the backing.

[0002]

2. Description of the Related Art In recent years, mainly in office buildings, in order to provide pile fixing, cushioning and laying properties to the back of a carpet base material, a square with a backing material is laminated.
Plate-shaped tile carpets of cut shapes such as rectangles and rhombuses have become widespread. This tile carpet has better workability and maintainability than rolled carpet,
It has the advantage that carpets of various atmospheres can be made by combinations of shapes and color tones. As a backing material for this tile carpet, a material obtained by blending an inorganic filler with an asphalt-based material or a polyvinyl chloride-based material has been widely used because it is suitable from the viewpoint of performance and cost.

[0003]

However, tile carpets using asphalt-based materials are inexpensive but produce bad smells during processing, stain white walls during construction, and are not suitable for construction on cold days or sudden deformation. Has the disadvantages of cracking and poor heat resistance. On the other hand, a tile carpet using a polyvinyl chloride-based material covers the above-mentioned disadvantages as compared with an asphalt-based tile carpet, but has a problem in the gas and smoke generated at the time of disposal and fire. That is, when the polyvinyl chloride tile carpet is incinerated for the purpose of disposal, hydrogen chloride gas and chlorine gas are generated, which causes acid rain and other environmental destruction.

[0004] Further, in the case of burning in a fire, a large amount of smoke is generated, and the above-mentioned toxic gas is also generated. Although asphalt tile carpets also do not generate hydrogen chloride gas, there is a problem with the large amount of smoke generated. Therefore, as a material in consideration of the absence of these environmental pollutions and safety, as an inorganic filler, a resin component containing olefin-based polymers such as ethylene-vinyl acetate copolymer and amorphous polyolefin as main components is used. An attempt has been made to use a material containing calcium carbonate for a tile carpet as a backing material excellent in cost, pile fixing, layability and dimensional stability.
72878 and JP-A-3-124888. However, these materials have the advantage that they do not generate toxic gas compared to the above-mentioned asphalt-based materials and polyvinyl chloride-based materials, and that they emit relatively little smoke. There is a need for tile carpets with reduced quantities.

Accordingly, a first object of the present invention is to provide a tile carpet backing resin composition which emits a small amount of smoke during combustion and does not generate toxic gas, and a tile carpet using the composition. Further, a second object of the present invention is to provide a resin composition for lining a tile carpet, which has a cost advantage, and is excellent in cold resistance, heat resistance, dimensional stability, pile fixing property, and layability, and a composition thereof. Is to provide a tile carpet using the same. The present inventors have conducted intensive studies for the above purpose, and as a result, a resin component comprising an amorphous polyolefin and a tackifier, a composition comprising an inorganic filler containing a carbonate of crystalline polypropylene and magnesium, The present inventors have found that the present invention is suitable for the purpose and completed the present invention.

[0006]

According to the present invention, there is provided a resin comprising (a) 50 to 90% by weight of an amorphous polyolefin and (b) 10 to 50% by weight of a petroleum resin tackifier. parts relative to 100 parts by weight, (c) 0 to 30 parts by weight of crystalline polypropylene, and (d) Ri inorganic filler 25-900 parts by weight Na are formulations comprising a carbonate of magnesium, amount of smoke during combustion
(Ds value, maximum value) backing resin composition der Ru Carpet Tile 95-124, and carpet tiles having a backing layer made of composition. After heating and melting and mixing the resin composition for a backing of the present invention compounded as described above, the backing is laminated on a carpet substrate to a thickness of 0.5 to 20 mm, and then cut or punched into a predetermined shape after cooling. The tile carpet produced has a cost advantage and is excellent in cold resistance, heat resistance, dimensional stability, pile fixing property, and layability.

Hereinafter, the present invention will be described in detail. In the present invention, the amorphous polyolefin which is the component (a) includes a homopolymer, a binary copolymer, a terpolymer, and a multipolymer of olefins such as ethylene, propylene, butene-1, pentene, hexene, and octene. It is a copolymer and a substantially amorphous polymer. Here, the term "substantially amorphous" refers to a substance having a boiling n-heptane insoluble content, that is, a Soxhlet-extracted insoluble content of 60 wt% or less due to boiling n-heptane.
If the boiling n-heptane insoluble content is more than 60% by weight, the crystallinity is high, and the dimensional stability is poor, which is not preferable.

Examples of the amorphous polyolefin include very low density polyethylene, ethylene / propylene rubber, atactic polypropylene, propylene / ethylene random copolymer, propylene / butene-1 random copolymer, and propylene / hexene-1 random copolymer. Coalescence, etc., from the viewpoint of heat resistance at the time of post-processing such as dyeing of tile carpet or at the time of use, atactic polypropylene having a propylene component of 50% or more, propylene / ethylene random copolymer, propylene / butene-1 Random copolymer,
Propylene / ethylene / butene-1 random copolymer,
A propylene / hexene-1 random copolymer is preferred.

As the atactic polypropylene and the propylene / ethylene random copolymer, by-products produced as by-products during the production of crystalline isotactic polypropylene may be used, or the objective production of polymerization from raw materials may be performed. . In the case of the intended production, it can be obtained, for example, by polymerizing the raw material monomer in the presence of hydrogen or in the absence of hydrogen using a titanium-supported catalyst supported on magnesium chloride and triethylaluminum. From the viewpoints of supply stability and quality stability, it is preferable to use a predetermined amorphous polyolefin produced for the purpose. In addition, if there is a corresponding suitable commercial product, it can be appropriately selected and used as a commercial product.

When the amorphous polyolefin is a propylene / ethylene copolymer, the ethylene component content is 0 to 3
0% by weight, preferably 0 to 20% by weight is desirable. If the content of the ethylene component is more than 30% by weight, the obtained resin composition becomes too soft and the surface tackiness becomes large, which is not preferable because of inconvenience in handling. When the amorphous polyolefin is a propylene / butene-1 copolymer, the content of the butene-1 component is 0 to 0.
50% by weight, preferably 5 to 45% by weight is desirable. If the butene-1 component content is greater than 50% by weight, the resulting resin composition has an undesirably low softening point.

The amorphous polyolefin used in the present invention has a number average molecular weight in the range of 1,000 to 20,000 and / or
Alternatively, the melt viscosity at 190 ° C. is preferably 100 to 100,000 cps. If the number average molecular weight is 1,000 or less or the melt viscosity at 190 ° C is 100 cps or less, the mechanical strength such as tension and bending is poor, and the viscosity is too low when the backing material is laminated on the tile carpet base material. Tile carpets with good finish cannot be obtained. Conversely, the number average molecular weight is 20,0
When the melt viscosity at 00 or more or 190 ° C. is 100,000 cps or more, the mechanical properties are good, but when the backing material is laminated on the tile carpet base material, the viscosity is too high to obtain a good finished tile carpet. It becomes difficult.

[0012] tackifier component (b) in the present invention can be used aliphatic petroleum resin, petroleum resin and their hydrogenated products such as alicyclic petroleum resin. In addition, acid-modified products obtained by acid-modifying them can also be used. Among them, petroleum resins are preferable because they have good compatibility with the amorphous polyolefin, are inexpensive, and emit a small amount of smoke during combustion.
Further, alicyclic petroleum resins are preferred. The amount of tackifier used in the present invention, the amorphous polyolefin 50
It is 10 to 50 % by weight to 90% by weight. If the amount of the tackifier is less than 10% by weight, the adhesiveness with a reinforcing material such as a nonwoven fabric of glass inserted into the backing material layer as a carpet base material or a core material becomes insufficient. On the other hand, when the content is more than 50 % by weight, the amount of smoke generated during combustion increases, and the surface tackiness of the composition is undesirably increased.

The crystalline polypropylene used as the component (c) in the present invention refers to an isotactic polypropylene insoluble in boiling n-heptane, including polypropylene which is generally commercially available for extrusion molding, injection molding, blow molding and the like. . In this case, a propylene homopolymer may be used,
Further, a copolymer of isotactic polypropylene having stereoregularity and another α-olefin may be used. The crystalline polypropylene may be a commercially available product, or may be manufactured. The production of the crystalline polypropylene is not particularly limited, and can be appropriately selected from conventional methods for producing a crystalline polypropylene and applied.

The α-olefin used for copolymerization with crystalline polypropylene includes α-olefins having 2 to 8 carbon atoms.
-Olefins, such as ethylene, butene-1, pentene-1, hexene-1, heptene-1, octene-1 and the like are preferred. Among these, ethylene or butene-1 is particularly preferable. In the present invention, the crystalline polypropylene as the component (c) is preferably a propylene homopolymer, a random copolymer or block of propylene / ethylene containing 1 to 30% by weight, preferably 2 to 25% by weight of an ethylene component. Copolymer, butene-1
A random copolymer or block copolymer of propylene / butene-1 containing 20% by weight is exemplified. the above
The crystalline polypropylene (c) can be used alone or in combination of two or more.

Further, the components (a) and / or
Alternatively, for (c), a denatured one can be used.
The above (a) or (c) may be used, for example, in the presence of unsaturated carboxylic acids such as acrylic acid, methacrylic acid, ethacrylic acid, maleic acid, fumaric acid, itaconic acid and / or their esters, acid anhydrides, metal salts Can be used after being modified with a derivative thereof. Among these modified products, those modified with maleic anhydride and itaconic anhydride are preferably used, and those modified with maleic anhydride are more preferably used.

The crystalline polypropylene of the component (c) comprises:
The amount is from 0 to 30 parts by weight based on 100 parts by weight of the resin component comprising the amorphous polyolefin as the component and the tackifier as the component (b). This crystalline polypropylene is effective in increasing the surface hardness and mechanical strength of the resin part comprising the components (a) and (b). The flexural rigidity of the entire carpet becomes too large, and the layability and cushioning properties are reduced. or,
The dimensional stability decreases due to the large amount of the crystal component. or,
The melt flow rate at 230 ° C. of the crystalline polypropylene is preferably in the range of 1 to 1000 g / 10 minutes. If the melt flow rate is lower than 1 g / 10 minutes, the melt viscosity of the composition becomes high, and the coatability becomes poor. If the melt flow rate is higher than 1000 g / 10 minutes, the mechanical strength of the composition will decrease.

The filler used in the component (d) of the present invention is an inorganic filler containing a carbonate of magnesium. Specific examples thereof include magnesium orthocarbonate (MgCO ₃ ), magnesium bicarbonate, and basic carbonate. Magnesium (4MgC
O ₃ .Mg (OH) ₂ .4H ₂ O), dolomite (magnesium calcium carbonate) (CaCO ₃ .MgC
O ₃ ), dolomite limestone, calcareous dolomite and the like. The original purpose of the filler is to function as a bulking agent,
The function is to provide rigidity to the whole resin part, to improve the hardness and heat resistance, and to improve the dimensional stability. However, magnesium carbonate has a decomposition temperature in the range of 300 to 540 ° C. In the tile carpet blended in the material, carbonates are decomposed at the time of combustion, carbon dioxide is generated, and digestion works, so that the amount of smoke generated in the entire tile carpet is reduced.

Of the above-mentioned magnesium carbonates, dolomite, dolomite-limestone, and calcareous dolomite are preferred from the viewpoint that a large amount of inexpensive and particle-sized fillers can be obtained. The average particle diameter of the inorganic filler containing magnesium carbonate used in the present invention is preferably 1 to 500 microns, and more preferably 10 to 300 microns. If the average particle size is 10 microns or less, the melt viscosity of the backing material composition becomes too high, and the coatability is deteriorated. If the thickness is 300 microns or more, the smoothness of the backing material surface is lost, and the mechanical strength of the backing material such as bending and tension is reduced. The compounding amount of the inorganic filler containing magnesium carbonate used in the present invention is 25 to 900 parts by weight based on 100 parts by weight of the total of the components (a) and (b). If the amount of the inorganic filler is less than 25 parts by weight, there is no effect of reducing the amount of smoke generated,
On the other hand, when the amount is more than 900 parts by weight, the melt viscosity of the composition becomes too high, so that the coating property is deteriorated, and the composition is hard,
It is not preferable because physical properties such as brittleness also occur.

In the present invention, in addition to the components (a), (b), (c) and (d), a very small amount of an antioxidant, a coloring agent, a softening agent such as oil and liquid polybutene, a wax and the like are required. It can be added accordingly. In addition to the resins (a), (b) and (c), in order to reduce rigidity or increase cold resistance, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, ethylene-acrylic A small amount of a soft resin such as an acid copolymer can also be added. In addition to the filler (d), fillers such as calcium carbonates, clays, silicas, talc, barium sulfate, calcium sulfate, calcium sulfite, and zinc white can be added for the purpose of increasing the amount.

These backing compositions in the present invention can be prepared by mixing at a temperature of 120 to 250 ° C., preferably 180 to 200 ° C., relatively easily. The backing of the carpet substrate can also be performed in the above temperature range, but if the temperature is too high, problems such as shrinkage and melting may occur when synthetic fibers such as polypropylene are used for part of the carpet substrate. There is also. A tile carpet can be manufactured by uniformly laminating and laminating the backing composition to a carpet substrate to a thickness of 0.5 to 20 mm in this temperature range, and then cutting or punching into a predetermined shape after cooling.

Further, a tile carpet with improved dimensional stability can be manufactured by inserting a glass fiber base cloth inside the backing layer. As a carpet substrate backed by using the backing material of the present invention, tufted carpet made from natural or synthetic fibers, loop carpet,
Woven carpets, knitted carpets, needle punched carpets, needle felt carpets, non-woven type carpets such as felt, and the like can be applied to all carpet base materials.

[0022]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to embodiments. However, the present invention is not limited to the following examples.

(Examples 1 to 5) Propylene / ethylene random copolymer RT2215 (manufactured by Lexen, USA, ethylene content: about 4% by weight, number average molecular weight: 3,800, melt viscosity: 190 ° C): 1500 cp
s), propylene / butene-1 random copolymer RT2
715 (manufactured by Lexen, USA, butene-1 content: about 35% by weight, number average molecular weight: 3,600, melt viscosity (190
° C): 1500 cps), an alicyclic petroleum resin ECR217 (manufactured by Tonex) as a tackifier, crystalline polypropylene J130G (manufactured by Ube Industries, Ltd.), dolomite D50 (manufactured by Hayashi Chemicals, 100 mesh) Using a pass product) and calcium carbonate (manufactured by CALCEED Co., Ltd., 100 mesh pass product), the mixture was mixed and stirred at 180 to 200 ° C. in a mixing tank to obtain a uniform composition. Next, while pouring the above-mentioned composition in a molten state on the back surface of the loop-shaped carpet base material, the composition is applied to a thickness of 1.5 mm with a doctor knife, and a glass fiber nonwoven fabric (0.5 mm thickness) is applied thereon. The above composition was re-applied to a thickness of 1.5 mm, solidified by cooling to form a backing layer, and cut into a size of 50 x 50 cm by a cutter to produce a tile carpet. For the above blended composition, the melt viscosity was measured, and for the obtained tile carpet, its thread removal strength, smoke emission amount, dimensional stability and low temperature flexibility were measured,
The results are shown in Table 1.

(Comparative Examples 1 to 4) Tile carpets were prepared in the same manner as in Examples 1 to 5, and the physical properties were measured. Table 1 shows the results.

(Comparative Example 5) 100 parts by weight of polyvinyl chloride paste resin MHE-100 (manufactured by Denki Kagaku) and 120 parts by weight of dioctyl phthalate were placed in a mixing tank and stirred to homogenize, and then 350 parts by weight of dolomite was obtained. The mixture was uniformly mixed and stirred to obtain a composition. Then, the composition is applied on a release paper to a thickness of 1.5 mm, a 0.5 mm glass fiber non-woven fabric is stuck thereon, and the composition is further applied thereon to a thickness of 1.5 mm, The carpet base material used in Example 1 was adhered thereon, heated to 160 ° C., cooled, and cut by a cutter into a size of 50 × 50 cm to produce a tile carpet. Table 1 shows the physical properties of the composition and the tile carpet.

Comparative Example 6 Straight Asphalt 80
-100 (manufactured by Cosmo Oil) 22% by weight, propylene / ethylene random copolymer Lextaq RT2535, 4
4% by weight of alicyclic petroleum resin Heylets T-300X (manufactured by Mitsui Petrochemical) and 70% by weight of calcium carbonate 100 mesh pass (manufactured by Calceed) are mixed and stirred at 180 to 200 ° C. in a heating and mixing tank, A homogeneous composition was obtained. Next, 150 to 1 on the back surface of the loop-shaped carpet substrate.
The composition preheated to 60 ° C. was applied to a thickness of 3 mm with a doctor knife while pouring. Next, a second base cloth was bonded to the surface of the backing material layer, and after cooling, cut into a size of 50 × 50 cm by a cutting machine. Table 1 shows the physical properties of the composition and the tile carpet.

The measuring method was as follows. (1) Melt viscosity: ASTM D3236 (2) Smoke emission: ASTM E662 (Smoke emission (Ds value)
(3) Thread pull strength: JIS L1021 (4) Low temperature flexibility: A sample was formed into a sheet of 100 × 10 × 2 mm and bent around a rod having a diameter of 25 mm as a central axis to observe cracks (0 ° C.). (5) Dimensional stability: cooling at -20 ° C (2 hours), 60 ° C (2 hours)
Time) Measurement after 25 cycles of heating cooling / heating cycle

[0028]

[Table 1]

As is evident from Table 1, the tile carpet lined with the resin composition blended within the scope of the present invention is excellent in various physical properties.

[0030]

As described above, the resin composition for tile carpet backing according to the present invention comprises an inorganic filler containing crystalline polypropylene and magnesium carbonate in a resin component comprising an amorphous polyolefin and a tackifier. When this is used as a backing material for tile carpets, a tile carpet with low smoke emission during combustion and excellent heat resistance, dimensional stability, pile fixing properties, layability, etc. is obtained. be able to.

Continued on the front page (51) Int.Cl. ⁷ Identification code FI C08L 23/02 C08L 23/10 23/10 D06M 11/04 Z (72) Inventor Takaya Sakaguchi 3-1 Chikko Shinmachi, Sakai City, Osaka Ube Industries, Ltd. (56) References JP-A-3-124488 (JP, A) JP-A-60-185870 (JP, A) JP-A-61-4744 (JP, A) JP-A 1-272878 (JP) JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) D06M 15/00-15/715 C08L 23/00-23/36

Claims (4)

(57) [Claims] (1) 100 parts by weight of a resin portion comprising (a) 50 to 90% by weight of an amorphous polyolefin and (b) 10 to 50% by weight of a tackifier for petroleum resin , and (c) crystalline polypropylene 0 And (d) an inorganic filler containing magnesium carbonate (25 to 90 parts by weight).
0 parts by Ri is Na is incorporated, amount of smoke during combustion (Ds value, most
The resin composition for lining a tile carpet, wherein (large value) is 95 to 124 . 2. The method according to claim 1, wherein the amorphous polyolefin is propylene.
2. The composition according to claim 1, which is a butene-1 copolymer.
A resin composition for lining a tile carpet described above. 3. The petroleum resin tackifier is alicyclic petroleum.
Claim 1 or Claim 2 which is a resin tackifier.
3. The resin composition for backing a tile carpet according to 2. 4. A tile carpet comprising a backing layer made of the resin composition according to claim 1.