JP5106207B2 - Tile carpet - Google Patents

Description

  The present invention relates to a tile carpet that can be laid on the floor surface of a floor blowing air-conditioning system of an office building, the floor of an apartment house, or a general house to provide air permeability, and can contribute to energy reduction by being used for under-floor air conditioning.

  Carpets are often used on floors such as offices, apartment buildings, and flooring of ordinary houses to protect the floor surface and improve heat insulation and create a comfortable living space. A tile carpet having a floor-type breathability is used.

  This tile carpet is composed of a carpet member having air permeability and a backing layer formed by laminating at least one of a mesh member, a breathable core material, and a breathable base on the back surface (see, for example, Patent Document 1) A composition comprising a hot melt porous adhesive cloth and a breathable carpet-like finishing material obtained by coating a coarse cloth fiber selected from a rubber chip layer, a net and a nonwoven fabric with a hot melt adhesive (see, for example, Patent Document 2) or a carpet A surface layer part, a backing part located on the back surface thereof, and a structure in which a thermoplastic resin adhesive is interposed between the two and joined together (for example, see Patent Document 2) are known. Conventional tile carpets are generally made of woven fabric made of glass fiber as the inner layer on the back of carpet that has been treated to prevent pile slippage, and are further shortened. Is configured by laminating a mat-like nonwoven fabric comprising a layer integrated with an adhesive, a powder of the adhesive or bonding by solvent bonding resin is mainly used.

However, although the above-mentioned adhesive has an excellent utility as such, in the case of bonding with a solvent, the treatment and processing costs of the solvent used are high, and there are problems in terms of the environment. Even if the adhesive resin powder is subjected to an adhesive treatment, a part of the molten mass of the resin spills out from the gap between the layers due to the cutting treatment, and there is a problem that delamination is likely to occur.
JP-A-8-42912 JP 2001-329469 A JP 2003-225153 A

  The present inventors have dealt with the above-mentioned problems, and reexamined the problems of tile carpets. As a result, since breathable tile carpets are used for air conditioning from the floor, the air permeability and the further improvement are considered. It was found that it is important not to cause delamination in the laminate to be used. Therefore, the present invention finds the necessary air permeability and peel strength as a tile carpet based on such knowledge, and by finding that the adhesive is specified in the laminate, it can be excellent in air permeability and contribute to energy reduction. In addition, it is an object to provide a tile carpet in which a molten lump does not come out of a gap during cutting and does not cause delamination.

That is, the tile carpet of the present invention suitable for the above purpose has a mass per unit area of 40 to 1800 g / m ² and an air permeability of 60 cc / cm ² / sec or more . Ri Na from the glass fiber woven fabric as the inner layer, basis weight mass by laminating 15 to 50 g / m ² der Ru substrates, further to the inner layer, the high-melting polyester short fibers and the thermally adhesive composite short fibers 35/65 A laminated body obtained by laminating a mat-like nonwoven fabric having a mass per unit area of 200 to 1000 g / m ^2, which is mixed at a ratio of 70/30, has a melting point of 70 to 160 ° C. and a mass per unit area of 80 to 250 g / m. ² is an adhesive made of a sheet of a web-like structure or a net-like structure , which is laminated and bonded either on the back side of the carpet or on the back side of the substrate of the glass fiber woven fabric. Thermal bonding Is constituted by conjugated delamination strength of air permeability 20~100cc / cm ² / sec, the carpets and mat nonwoven fabric characterized by having a 10 N / 25 mm or more properties.

Here, the heat-adhesive composite short fiber is a core-sheath type having a high melting point component as a core and a low melting point component as a sheath, and the high melting point component has a melting point higher by 50 ° C. than the melting point of the low melting point component. .

The mat-like nonwoven fabric is preferably composed of high-melting-point polyester short fibers and heat-adhesive composite short fibers having a fineness of 1.0 to 20.0 dtex .

The tile carpet of the present invention has a weight per unit area of 40 to 1800 g / m ² and an air permeability of 60 cc / cm ² / sec or more. A base material having a basis weight of 15 to 50 g / m ² is laminated, and further, a high melting point polyester staple fiber and a heat-adhesive composite staple fiber are mixed into the inner layer at a ratio of 35/65 to 70/30. A laminate formed by laminating a mat-like nonwoven fabric having a basis weight of 200 to 1000 g / m ² , a melting point of 70 to 160 ° C., a basis weight of 80 to 250 g / m ² , and or laminated, which said or laminated to the substrate back surface of the woven fabric of glass fibers are laminated and adhered in any was constructed integrally thermally bonded with an adhesive made of a sheet of focal or mesh structure of spider Therefore, unlike adhesion by film sheet or adhesion resin powder, air permeability is not hindered, and melted lumps do not come out from gaps at the time of cutting. In addition, the presence of the heat-adhesive conjugate fiber has an effect that the mat-like non-woven fabric has an inter-fiber adhesion and does not lose its shape.

The tile carpet of the present invention has a characteristic of air permeability of 20 to 100 cc / cm ² / sec and a peel strength of 10 N / 25 mm or more. It contributes to energy reduction and has various effects such as peeling at the time of cutting due to peel strength, and no peeling at the time of use.

  Hereinafter, specific embodiments of the present invention will be described in detail. First, the tile carpet of the present invention has air permeability as shown in FIG. 1, and a base made of a woven fabric of glass fibers as an inner layer on the back surface of the carpet 1 subjected to the pile omission prevention treatment 1a to stabilize the dimensions of the carpet. The carpet 1, the glass fiber base material 3, and the mat-like structure are formed by laminating the material 3 and further laminating a mat-like nonwoven fabric 2 made of a mixture of high melting point fibers and heat-adhesive composite short fibers. The nonwoven fabric 2 is formed by a configuration in which heat bonding is integrated with an adhesive 4 made of a web-like or mesh-structured sheet.

Here, as the carpet 1 having the above air permeability and preventing the pile from being removed, any one of a needle punch type, a tuft type, a woven carpet, etc. may be used, but the air permeability is moderately high. In general, air permeability of 60 cc / cm ² / sec or more is preferable, and nylon, polyester, polypropylene, acrylic and other chemical fibers such as nylon, polyester, polypropylene, and acrylic, wool, cotton, etc. to meet this requirement A tuft carpet or a woven carpet tufted with natural fibers is used, and if necessary, the back surface is impregnated with a small amount of rubber- or latex-based adhesive and subjected to pile removal prevention treatment 1a.

Carpet 1 the pile removal prevention processing has been performed is the basis weight mass 400~1800g / m ^2-position, preferably suitably 800 g / m ² front and back. And the glass fiber base material 3 is laminated | stacked in order to ensure dimensional stability on the said carpet back surface. Glass fiber substrate 3 having fabric made of the basis weight mass 15 to 50 g / m ^2, preferably 30 g / m ² net-like woven fabric before and after use. If it is less than 20 g / m ² , the contribution of dimensional stability between the respective layers is small, and if it exceeds 50 g / m ² , dimensional stability becomes excessive, which is not preferable.

  Next, a non-woven fabric made of a mixture of high melting point short fibers and heat-bondable composite short fibers is used for the mat-like non-woven fabric 2 laminated on the back surface of the glass fiber base 3. The mat-like non-woven fabric 2 can also be colored by adding high melting point fibers as original fibers such as black. The high melting point short fibers are preferably the same as or at least equivalent to the high melting point resin used for the heat-adhesive composite short fibers.

  On the other hand, the heat-adhesive conjugate fiber is preferably a core-sheath type having a high melting point component as a core and a low melting point component as a sheath. The high melting point component constituting the composite short fiber preferably has a melting point of 50 ° C. or higher than the melting point of the low melting point component, and the low melting point component preferably has a melting point in the range of 100 ° C. to 180 ° C. When the melting point of the high melting point component is less than 50 ° C. than the melting point of the low melting point component, the high melting point fiber side is also softened at the time of bonding between the single fibers, and a desired air permeability cannot be obtained. When the melting point of the low melting point component is less than 100 ° C., the treatment conditions for carrying out adhesion between fibers are difficult, which is not preferable from the viewpoint of heat resistance. Conversely, if the melting point of the low melting point component exceeds 180 ° C., the thermal characteristics of the high melting point fiber are affected, and the air permeability characteristics fluctuate due to the bonding, which is not preferable.

  The polymer constituting the heat-fusible composite short fiber is, for example, a high melting point component and a low melting point component of a thermoplastic resin of any one of a polyester resin, a polyethylene resin, a polypropylene resin, and a polyamide resin. Specific examples include high-melting polyester fiber (melting point: about 250 ° C. to 270 ° C.) and low melting point polyester fiber (melting point: about 100 ° C. to 200 ° C.), ester / nylon composite fiber, polyester / polyethylene composite fiber, polypropylene / Examples thereof include polyethylene composite fibers. Particularly, a composite of a high melting point polyester and a low melting point polyester is most practical.

  The high melting point short fiber and the heat-adhesive composite short fiber constituting the nonwoven fabric have a fiber mixing ratio of 25/75 to 70/30, preferably 35/65 to 70/30, and the high melting point short fiber is a high melting point resin. It is preferable that the heat-adhesive composite short fiber is a core-sheath composite of polyester low-melting resin and high-melting resin, and the fineness of the short fiber is in the range of 1.0 to 20.0 dtex. If the blend ratio is 25/75 to 70/30 and the heat-adhesive composite short fiber exceeds 75, it is difficult to control the air permeability, and if it is less than 30, the adhesion between the fibers is weak, so the form as a mat is maintained. It is not preferable because of inferiority.

The fineness of the short fibers is preferably in the range of 1.0 to 20.0 dtex, and if it is less than 1.0 dtex, the mat itself is dense and the air permeability is difficult to control. On the other hand, if it exceeds 20.0 decitex (dtex), the air permeability can be controlled. Then, it is preferred that the mat-like nonwoven fabric having a basis weight mass of 200 to 1000 g / m ^2. If it is less than 200 g / m ² , the cushioning property as a mat is poor, and if it exceeds 1000 g / m ² , the cushioning performance is sufficient, but it is not preferable because it is difficult to control air permeability.

  Then, an adhesive is used for laminating and integrating the air-permeable pile-treated carpet 1, the base material 3 made of glass fiber, and the mat-like nonwoven fabric 2 as a cushioning material. The film sheet is not air permeable and has poor adhesive strength when bonding and integrating. In addition, when the adhesive resin powder is used, a considerable amount of adhesion is required, and there is a problem that a molten lump comes out from the gap when cutting after being integrated. Is used.

Adhesive 4 made of sheet focal or network of spider is good normal even basis weight mass 20 to 40 g / m ^2, in the present invention having a basis weight mass 80~250g / m ^2, preferably 100 to 200 g / m ² A thin web-like or network-structured non-woven fabric is used, and the melting point is effective in the range of 70 to 160 ° C., preferably 90 to 150 ° C. In general, it is melt-spun into a spunbond shape, and is accumulated in a web shape or a net shape to form a sheet. This adhesive has excellent air permeability as well as good adhesiveness.

If the mass per unit area is less than 80 g / m ² , the adhesion between the layers may be insufficient. On the other hand, if it exceeds 250 g / m ² , the adhesion is sufficient, but it is not preferable because the air permeability is difficult to control. . Further, the melting point of the heat bonding material is preferably in the range of 70 to 160 ° C. If it is less than 70 ° C., it is preferable in terms of adhesion, but there is a problem in terms of heat resistance, whereas if it exceeds 160 ° C., the thermal characteristics of the high melting point fiber. This is not preferable because the air permeability characteristics fluctuate.

Thus, the present invention is based on the premise that each layer of the air-permeable carpet 1, the base material 3 made of glass fiber, and the mat-like non-woven fabric 2 is laminated with the adhesive material 4 made of a web-like or network-structured sheet as described above. Furthermore, in view of the importance of air permeability and no delamination of the laminate as a tile carpet, the present inventors have found a suitable air permeability and a peel strength between the carpet and the mat-like nonwoven fabric. Air permeability is preferably 20~100cc / cm ² / sec, when the air conditioner when it is less than 20cc / cm ² / sec laying carpet on the floor, a high flow resistance, because it may carpet floating undesirable. Further, if it exceeds 100 cc / cm ² / sec, the air permeability is good, but it is not preferable because the air permeability control becomes difficult and the cushioning property may be reduced.

  On the other hand, the delamination strength is preferably 10 N / 25 mm or more, particularly preferably 15 N / 25 mm or more, and if it is less than 10 N / 25 mm, peeling occurs during cutting or peeling during use, which is not preferable. In addition, if the upper limit is in the range of 10 N / 25 mm or more, it is not necessary to provide extra peel strength more than necessary.

  Specific examples of the present invention will be described below together with comparative examples.

50% by mass of polyester short fiber having a fineness of 16.7 dtex and a fiber length of 64 mm, 10% by mass of black short-wearing polyester short fiber having a fineness of 11.1 dtex and a fiber length of 64 mm, and a fineness of 4.4 dtex ( dtex) non-woven fabric (air permeability) having a weight per unit area of 592 g / m ² (after needle processing and heat-bonded) comprising 40% by weight of polyester / low-melting polyester composite fiber having a fiber length of 51 mm (melting point of low-melting polyester: 110 ° C.) : 100 cc / cm ² / sec) Spider web-like adhesive sheet (manufactured by Kureha Tech Co., Ltd .: Dynac (registered trademark)) polyester resin with a basis weight of 120 g / m ² , and a glass fiber net basis weight on it. 30 g / m ² is placed thereon, and further a spunbond substrate (polyester fiber, basis weight 100 g / m) m ² ), a nylon long fiber having a fineness of 2800 dtex is tufted and laminated with the back surface of a tuft carpet having an air permeability of 102 cc / cm ² / sec backed on the back surface and a basis weight of 813 g / m ² , 150 Through a hot air heat treatment machine (length: 24 m, treatment speed: 4.0 m / min) at a temperature of 1559 g / cm with a basis of a pair of iron rollers at room temperature and a clearance of 4 mm and a pressure of 4.0 kg / cm ^2. A tile carpet having m ² and a thickness of 7.3 mm was obtained.

50% by mass of polyester short fiber having a fineness of 16.7 dtex and a fiber length of 64 mm, 10% by mass of black short-wearing polyester short fiber having a fineness of 11.1 dtex and a fiber length of 64 mm, and a fineness of 4.4 dtex ( dtex), a nonwoven fabric (air permeability: 100 cc) having a mass per unit area of 592 g / m ² (heat treated after needle processing) consisting of 40% by weight of polyester / low-melting polyester composite fiber having a fiber length of 51 mm (melting point of low-melting polyester: 110 ° C.) / Cm ² / sec) Spider web-like adhesive sheet (manufactured by Kureha Tech Co., Ltd .: Dynac (registered trademark)) nylon resin with a basis weight of 105 g / m ² is stacked, and a glass fiber net basis weight is 30 g / m ² is placed on the spunbond substrate (polyester fiber, basis weight 100 g / m ² ). A hot air heat treatment machine at 150 ° C. is laminated with the back side of a tuft carpet having a basis weight of 813 g / m ² with a permeability of 102 cc / cm ² / sec tufted with a nylon long fiber having a fineness of 2800 dtex and backed on the back side. (24 m in length, processing speed 4.0 m / min) and laminated at the outlet part with a pair of normal iron rollers at a clearance of 4 mm and a pressure of 4.0 Kg / cm ² , with a total basis weight of 1526 g / m ² and a thickness of 6 A 9 mm tile carpet was obtained.

50% by mass of polyester short fiber having a fineness of 16.7 dtex and a fiber length of 64 mm, 10% by mass of black short-wearing polyester short fiber having a fineness of 11.1 dtex and a fiber length of 64 mm, and a fineness of 4.4 dtex ( dtex) non-woven fabric (air permeability) having a weight per unit area of 592 g / m ² (after needle processing and heat-bonded) comprising 40% by weight of polyester / low-melting polyester composite fiber having a fiber length of 51 mm (melting point of low-melting polyester: 110 ° C.) : 100 cc / cm ² / sec) with an adhesive net having a structure of a random coil with a wire diameter of 0.1 mmφ, an adhesive material having a basis weight of 200 g / m ² of polyethylene resin is layered thereon, and a glass fiber net basis weight is 30 g. / M ² and a spunbond substrate (polyester fiber, basis weight 100 g / m) ² ) Nylon long fibers with a fineness of 2800 dtex were tufted and backed, and the bottom of the tufted carpet having a basis weight of 813 g / m ² with an air permeability of 102 cc / cm ² / sec was laminated at 150 ° C. It is passed through a hot-air heat treatment machine (length 24 m, treatment speed 4.0 m / min), and the outlet is laminated and bonded with a pair of iron rollers at room temperature at a clearance of 4 mm and a pressure of 4.0 Kg / cm ² , giving a total weight of 1638 g / m ^2. A tile carpet having a thickness of 7.8 mm was obtained.

Comparative Example 1
Taft spunbond substrate (polyester fiber, weight per unit area weight 100 g / m ²⁾ basis weight mass of the fineness 2800 dtex nylon filament is tufted backing aeration of 102cc on the back / cm ² / sec is 813 g / m ² Polyethylene resin in which 300 μm polyethylene powder was sprayed at an application rate of 160 g / m ² with the back side of the carpet facing up, and then a plurality of particles were almost fused, and the other particles began to be fused in the other parts. A glass fiber net weight per unit area of 30 g / m ² is placed on the three-dimensional net, and a polyester fine fiber of 50 mass% with a fineness of 16.7 decitex and a fiber length of 64 mm and a fineness of 11.1. Decitex, 10% by mass of black original polyester short fiber with a fiber length of 64 mm, fineness of 4.4 decitex, fiber length of 51 mm Riesuteru / low melting polyester bicomponent fibers (of the low-melting-point polyester melting: 110 ° C.) (after needling, already thermal bonding process) basis weight Weight 592 g / m ² consisting of 40 wt% of the nonwoven fabric (air permeability: 100 cc / cm ² / sec ) And passed through a hot air processing machine (length: 24 m, processing speed: 5 m / min) at 150 ° C., and laminated and bonded to the outlet with a pair of normal iron rollers at a clearance of 4 mm and a pressure of 4.0 kg / cm ^2. A tile carpet having a basis weight of 1568 g / m ² and a thickness of 6.9 mm was obtained.

Comparative Example 2
Fineness 16.7 decitex (dtex), polyester short fiber 50% by mass 64 mm, fineness 11.1 decitex, black original polyester short fiber 10% by mass 64 mm, fineness 4.4 decitex (dtex), Nonwoven fabric (air permeability: 100 cc / weight per unit weight) of 592 g / m ² (weight processed after needle processing) comprising 40% by weight of polyester / low melting point polyester composite fiber having a fiber length of 51 mm (melting point of low melting point polyester: 110 ° C.) cm ² / sec) the weight per unit area mass 80 g / m ² of modified polyethylene adhesive film overlaid on its upper placing the glass fiber net basis weight mass 30 g / m ^2, a further spunbonded substrate (polyester fiber thereon, eyes Nylon long fiber with a fineness of 2800 dtex is tufted to a mass of 100 g / m ² ) and backed The bottom surface of the tufted carpet having an air permeability of 102 cc / cm ² / sec and a basis weight of 813 g / m ² is laminated on the bottom, and heated at 150 ° C. with a hot air heat treatment machine (length 24 m, treatment speed 4.0 m / min) ) And laminated and bonded with a pair of room temperature iron rollers at a clearance of 4 mm and a pressure of 4.0 kg / cm ² to obtain a tile carpet having a total weight of 1476 g / m ² and a thickness of 6.9 mm.

Comparative Example 3
20% by mass of polyester short fiber having a fineness of 16.7 dtex and a fiber length of 64 mm, 10% by mass of black original polyester short fiber having a fineness of 11.1 dtex and a fiber length of 64 mm, and a fineness of 4.4 dtex ( dtex), a nonwoven fabric (air permeability) having a basis weight of 601 g / m ² (after needle processing and heat-bonding treatment) consisting of 70% by weight of a polyester / low-melting polyester composite fiber having a fiber length of 51 mm (melting point of low-melting polyester: 110 ° C.) : 100cc / cm ² / sec) spider focal adhesive sheet onto (Kureha Corporation: Dynac Corporation) superimposed basis weight mass 120 g / m ² of polyester resin, a glass fiber net basis weight mass 30 g / m ² thereon Placed on it, and further on it a spunbond substrate (polyester fiber, basis weight 100 g / m ² ) fineness 2 Nylon filaments of 800 decitex are tufted and laminated with the back side of a tuft carpet having an air permeability of 102 cc / cm ² / sec and a basis weight of 813 g / m ² backed on the back side. 24 m in length and a processing speed of 4.0 m / min), with a pair of iron rollers at room temperature at the outlet and laminated and bonded at a clearance of 5 mm and a pressure of 4.0 Kg / cm ² with a total basis weight of 1566 g / m ² and a thickness of 5 A 9 mm tile carpet was obtained.

  Next, in order to evaluate the tile carpets obtained in the above examples and comparative examples, the performances were compared in consideration of the characteristics of air permeability and peel strength. The results are shown in Table 1.

The measurement method and evaluation for each item in the table were as follows.
Mass per unit area: g / m ²
A 500 mm × 500 mm sample piece is cut out from the sample, and the mass is measured to a unit of 0.1 g. The mass is quadrupled and expressed in g / m ² . The measurement is performed three times (n = 3), and the average value is rounded off and indicated by an integer.
Thickness: mm
A 50 mm × 50 mm sample piece was cut out from the sample, measured at 3 points with a dial gauge having a contact area of 5 cm ² and a pressing pressure of 20 g, and expressed in mm. Measured 3 times (n = 3), rounded off the average value, and shown to 2 digits after the decimal point.
Air permeability: cc / cm ² / sec
It was measured with a fragile type tester described in 6.27.1 of JIS L 1096.
Peel strength: N / 25mm
The sample is a 25 × 200 mm sample piece, and the carpet back / nonwoven fabric interface is peeled from the short piece by about 50 mm parallel to the long side. The peeled carpet back and the nonwoven fabric are each peeled off at a mounting speed of 200 mm / min on a chuck of a Tensilon tensile tester. The peel strength at this time is determined. Measured 5 times (n = 5) and shown as the average value.
Cutting state evaluation Although the product was cut into 50 cm × 50 cm, the state of the cut surface by the cutting process was evaluated as follows.
The cut surface is clean and no delamination is observed. ○
The cut surface is clean, but some delamination is observed. △
Although the cut surface is clean, delamination is observed and leakage of resin or the like is observed. ×

上記表より本発明の実施に係るタイルカーペットは比較タイルカーペットに比し裁断性評価ならびにタイルカーペットとしての総合評価において優れたものであることが理解され、既知タイルカーペット等に対し問題点に充分、改善がなされていることが認められた。

From the above table, it is understood that the tile carpet according to the implementation of the present invention is superior in cutting property evaluation and comprehensive evaluation as a tile carpet as compared with the comparative tile carpet, and is sufficient for problems with known tile carpets, It has been observed that improvements have been made.

It is a perspective developed view which shows the structure of the tile carpet which concerns on this invention.

Explanation of symbols

1: Carpet having air permeability and treated to prevent pile omission 2: Mat-like non-woven fabric 3: Glass fiber base material 4: Spider web-like or network structure adhesive

Claims (3)

On the reverse side of the carpet that has been subjected to a pile omission prevention treatment with a basis weight of 40 to 1800 g / m ² and an air permeability of 60 cc / cm ² / sec or more ,
Ri Na from the glass fiber woven fabric as the inner layer, basis weight mass by laminating 15 to 50 g / m ² der Ru substrate,
Furthermore , a mat-like non-woven fabric in which high-melting polyester short fibers and heat-adhesive composite short fibers are mixed at a ratio of 35/65 to 70/30 and the basis weight is 200 to 1000 g / m ² is laminated on the inner layer. a laminated body was formed by,
The melting point is 70 to 160 ° C., the weight per unit area is 80 to 250 g / m ² , and the lamination is performed by either laminating on the back surface of the carpet or laminating on the back surface of the glass fiber woven fabric. Constructed by heat bonding and integration with an adhesive made of a web of web-like or mesh-like structure ,
A tile carpet characterized by having an air permeability of 20 to 100 cc / cm ² / sec and a delamination strength between the carpet and mat-like nonwoven fabric of 10 N / 25 mm or more. The heat-adhesive composite short fiber is a core-sheath type having a high melting point component as a core and a low melting point component as a sheath, and the melting point of the high melting point component is 50 ° C. higher than the melting point of the low melting point component. The tile carpet described. The tile carpet according to claim 1 or 2 , wherein the mat-like non-woven fabric is composed of a high-melting polyester short fiber and a heat-adhesive composite short fiber having a fineness of 1.0 to 20.0 dtex .

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