JP2002209710A - Rug and method for manufacturing that - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rug in which a porous backing layer is laminated directly on a surface material, having no thickness mottle, having appropriate load deformability and restoration, which is excellent in shock absorbing and feeling good to walk on, and a stable method for manufacturing the same. SOLUTION: In a rug in which a backing layer made of a thermoplastic resin composition in which a fabric is internally provided is laminated on the reverse of a textile surface material, and as the backing layer, a porous body formed of preferably a thermally expandable microcapsule, and having many independent bubbles 50 to 1,000 μm in bubble diameter, compressibility of 5% or higher, compression elasticity of 70% or higher, 3 to 10 mm thickness, and acceleration of impact of preferably 100 G or less is used.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rug used for carpets, mats and the like, which is excellent in shock absorption and walking feeling.

[0002]

2. Description of the Related Art In the function of a rug, in addition to an excellent walking sensation, it is extremely important to provide an excellent shock absorbing property capable of preventing obstacles caused by a collision with a floor surface due to a fall or the like. One of the performance. This shock absorption is JIS
It is expressed by the G value (acceleration of impact at the time of a fall collision) measured based on A6519, and it is considered that the smaller the G value, the better the shock absorption. For example, a floor of a gymnasium where excellent fall safety is required. As a material, this value is specified to be at least 100 G or less.

It is known that the G value is largely affected not only by the specifications of the rug itself such as the surface material and the back surface material of the rug, but also by the specifications of the laying foundation and the like. In the case of rugs, etc., when laid directly on a concrete substrate, they are approximately 110-130.
The value of G is known to decrease to around 90 G, for example, when a felt is used under a roll carpet.

[0004] On the other hand, there is a variety of factors associated with the sensibility of walking, and it is difficult to make a clear numerical value. However, it is important to impart appropriate load deformability and restoring property to a rug when walking. One of the representative indices is a compression ratio and a compression elastic modulus.

[0005] For this reason, conventionally, the above-mentioned rugs excellent in shock absorption and walking sensation have been provided under a normal carpet or mat having a non-porous backing layer made of SBR rubber, PVC resin or the like, under a felt or the like. This method not only requires new materials for laying, but also requires the skill and labor of craftsmanship. There were disadvantages.

[0006] In order to solve such a drawback, a method of simplifying the construction by directly providing porosity to the back surface of a carpet or mat has been studied, and a non-woven fabric, A method of laminating a porous material such as a urethane foam sheet or felt, a reactive isocyanate compound is directly applied as a backing layer on the back surface of the facing material, chemically reacted, foamed and cured, and thermoset porous with open cells Method of forming a conductive backing layer, the foaming sol of the PVC resin composition in which air was mechanically stirred and mixed in advance,
This is applied to the back surface of the facing material and heated and gelled to form a porous backing layer, a thermally decomposable chemical blowing agent such as an azo compound is mixed into a sol such as a PVC resin composition, and A method has been attempted in which a backing layer is applied to the back surface, thermally decomposed and foamed, and a porous backing layer is formed with a decomposed gas.

However, the method has an advantage that the thickness, type, combination and the like of the porous sheet can be selected according to the purpose. Therefore, it is generally easy to obtain a rug having a performance similar to the use of the above-described underlay, but a laminating apparatus is required. Extra equipment is required, workability is poor and expensive,
Compared with the method, the foaming method is a method of forming a porous body by foaming directly in the rug manufacturing process.However, it is very difficult to control the foam thickness in the manufacturing process. In addition, the mechanical strength of the urethane resin itself deteriorates with time due to oxidative deterioration, etc., and there is a problem in the production and use conditions.The method is based on the method of using the mechanical entrapment of air bubbles in the sol. Therefore, there is a great variation in the size and amount of air bubbles, and it is very difficult to control the unevenness of thickness, especially when using a high-viscosity sol with a large amount of inorganic filler. In addition, the sol itself in contact with the dressing material already contains air bubbles, so the fixing of the fiber of the dressing material is likely to be insufficient and fuzz is likely to occur. Low fuzz It is practically difficult to stably control porous materials with high porosity with excellent precision.The method uses thermal decomposition of chemical substances, so irregular thickness due to abnormal foaming, irregularities in the backing layer, fuzz, etc. are likely to occur Due to the difficulty of stable production, etc., it is not always satisfactory to provide a practical and rational provision of a rug with excellent shock absorption properties and walking feeling by directly providing the backing layer with porosity. is the current situation.

[0008]

DISCLOSURE OF THE INVENTION The present invention solves the above-mentioned conventional problems and has a porous backing layer directly laminated on a surface covering material, has less thickness unevenness, and has appropriate load deformability and resilience. An object of the present invention is to provide a rug excellent in shock absorption and walking sensation and a stable manufacturing method thereof.

[0009]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies to solve the above-mentioned problems, and as a result, have found that a specific closed cell obtained by making porous under specific conditions using a heat-expandable microcapsule can be used. The present invention has been found that a rug having a porous body as a backing layer has excellent characteristics. That is, the present invention relates to a rug in which a backing layer made of a thermoplastic resin composition in which a fiber cloth is embedded is laminated on a back surface of a fiber covering material, and is preferably formed as a backing layer, preferably by using heat-expandable microcapsules. Bubble diameter is 50-1000μ
m, a compression rate of 5% or more, a compression elastic modulus of 70% or more, and a porous body having a thickness of 3 to 10 mm. 1
A rug that is 00G or less, and 100 parts of a thermoplastic resin,
Inorganic fillers 100 to 5 having an average particle size of 30 μm or less
A sol composition obtained by uniformly mixing 00 parts, 5 to 200 parts of a plasticizer or water, and 3 to 30 parts of a heat-expandable microcapsule is applied on the surface of a running release belt, and fibers are placed thereon. After laminating a fabric and further applying the sol composition thereon, a fiber covering material is laminated, and subsequently, the ambient temperature on the belt front side is 140 ° C. or less, and the ambient temperature on the belt rear side is 140 to 250 ° C. This is a method for producing a rug, wherein the backing layer is expanded by 1.5 to 5 times by heat treatment in a heat treatment furnace set at a temperature of ° C, and then cooled.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The rug according to the present invention is a rug used for roll carpets, tile carpets, mats and the like, and has polyester fiber, polyester (core) / polyamide (sheath) composite on its surface. Fiber, or a nonwoven fabric or woven fabric made of a polyolefin fiber represented by polypropylene or the like as a primary base fabric, a polyamide fiber,
It has an outer material made of tufted yarn such as polyester fiber, polyacrylic fiber, polyolefin fiber, wool, etc., and yarn-dyed, first-dyed and post-dyed. A backing layer made of a porous body of a thermoplastic resin composition such as a resin, a butadiene resin, or an EVA resin is laminated.

[0011] There is no harm in incorporating a crosslinking agent partially into the thermoplastic resin composition as long as the flexibility is not impaired. A thermoplastic resin composition containing a polyisocyanate compound having a reactive isocyanate group as a curing agent based on an SBR rubber as disclosed in JP-A-2000-253986 is preferably used. Can be used.

The thermoplastic resin composition used in the present invention contains an inorganic filler, a plasticizer, water or the like as a main component in addition to the above-mentioned thermoplastic resin. In addition to these, a small amount of a stabilizer, a pigment, a hygroscopic agent, An adjusting agent, an emulsifier, a vulcanizing agent, a cross-linking agent and the like are appropriately contained and constituted according to the purpose.

As the inorganic filler, calcium carbonate, aluminum hydroxide, silica and the like are preferably used. These are generally effective not only for reducing the cost and improving the mechanical properties of the obtained rug, but also have a large effect on the handling viscosity of the sol-like resin composition in the rug manufacturing process. Are known. Particle size 100μ
The relatively large ones, around m, are not only inexpensive, but also have a low sol viscosity compared to those with a small particle size, even with the same amount used. In a sol resin composition containing an agent, such an inorganic filler having a relatively large particle diameter has been favorably used, including the cost advantage.

However, in the present invention, the selection of the average particle size of such an inorganic filler is extremely important in a different meaning from the conventional one. That is, according to the study results of the present inventors, when forming the porous backing layer obtained by the thermal expansion of the heat-expandable microcapsules, the average particle diameter of the inorganic filler used in combination is determined by the practical characteristics of the obtained porous body. In addition, it was found to have a very significant effect on controllability in the manufacturing process, so that selection on a scale different from the conventional one was necessary. That is, in the present invention, when selecting the average particle diameter of the inorganic filler to be employed, the thermal expansion property described below is used primarily to form a porous backing layer having a large number of closed cells. It is important to select the size based on the relative size relationship with the particle size of the microcapsules, and it is desirable to select the size within a range not exceeding at least the average particle size of the thermally expandable microcapsules. It is important to employ a thermally expandable microcapsule having an average particle diameter equal to or smaller than the average particle diameter, particularly for stably producing a porous body with a small thickness unevenness obtained by expanding a backing layer at a high magnification.

More specifically, since the average particle size of currently available thermally expandable microcapsules is generally about 10 to 40 μm, it is preferable to use an inorganic filler having an average particle diameter smaller than about 30 μm, more preferably. It is 20 μm or less, more preferably 10 μm or less.

The use of an inorganic filler having an average particle size slightly larger than the average particle size of the thermally expandable microcapsules is not necessarily excluded, but according to the results of studies by the present inventors, as described above, the use of an inorganic filler has a large size. Although the use of an inorganic filler having a particle size is inexpensive and useful for reducing the handling viscosity of a sol-like resin composition containing a large amount of an inorganic filler, as the average particle size of the thermally expandable microcapsules becomes larger, Despite the use of the same amount of heat-expandable microcapsules, the thermal expansion ratio of the backing layer obtained tends to decrease, the backing layer is considerably hard, the compressibility is small and the deformation is small, and the The tendency to give unfavorable results to the improvement of shock absorption and walking feeling becomes remarkable. Also, the controllability of the thickness tends to decrease, and the occurrence of uneven thickness tends to be remarkable. For this reason, even when using thermally expandable microcapsules having a relatively large particle size, it is desirable to stop using an inorganic filler having an average particle size of at least not more than approximately 30 μm.

Although the reason for this is not necessarily clear, when the thermally expandable microcapsules mixed in the sol resin composition having a relatively high viscosity are heated and thermally expanded, they are present in large amounts around the microcapsules. It is considered that the inorganic filler having a large specific particle diameter and a large specific gravity functions as a result of its low mobility, so that the thermal expansion of the microcapsules is largely suppressed. The increase in thickness unevenness is due to the fact that in the locally non-uniform blended portion where the amount of the inorganic filler in such a system is small, the suppression of the thermal expansion of the inorganic filler is relatively small as compared with other portions, and It is believed that the expansion is likely to proceed.

For these reasons, in the present invention, it is basically not preferable to use a commonly used inorganic filler having a large particle diameter of about 100 μm. However, for the purpose of slightly adjusting the viscosity of the sol-like resin composition, a small amount of the large particle diameter is added to the inorganic filler mainly containing the small particle diameter as long as the uniform thermal expansion by the microcapsules is not largely inhibited. There is no particular problem in using them together.

The amount of these inorganic fillers is not particularly limited, but is preferably 100 to 100 parts of the thermoplastic resin.
It is desirable to use in the range of 500 parts. When a large amount of the inorganic filler having a small particle diameter is used, the viscosity of the sol-like resin composition is adjusted as needed in the present invention in order to reduce the viscosity of the sol-like resin composition to a level that can be easily handled. In adjusting the viscosity, a method of partially using the above-mentioned inorganic filler having a large particle size is one method, but it is more effective to use a viscosity adjusting agent or to increase the sol adjustment temperature to about 50 ° C.

As the plasticizer, general plasticizers such as DOP and DNP can be used. When the thermoplastic resin is used in the form of an aqueous latex represented by SBR, water can be used for forming the sol resin composition instead of the plasticizer. The amount of the plasticizer or water is not particularly limited, but is preferably 5 to 200 parts with respect to 100 parts of the thermoplastic resin.

In the present invention, in order to effectively provide porosity to the backing layer made of such a resin composition and obtain a rug having excellent shock absorption and walking properties, heat-expandable microcapsules are used. It is blended into a sol of the composition, and is heated and expanded in the process of gelling the resin composition to form a porous body having closed cells.

As the porogen, the above-mentioned heat-expandable microcapsules are employed. This is because the heat-expandable microcapsules are a porogen that essentially forms closed cells, so the rugs used in the places where the intended repeated load is applied have a higher load-bearing capacity than open-cell porous bodies. , Easy to restore, stable shock absorption for a long time,
This is because walking can be expected.

As the heat-expandable microcapsules, those obtained by encapsulating a low-boiling hydrocarbon such as isobutane in a shell made of a commercially available thermoplastic resin are preferably used. These are usually 1
A hollow sphere having a specific gravity of about 1.0 with an average particle diameter of 0 to 40 μm and a maximum expansion ratio of about 70 times the volume, and the appropriate temperature at which the shell wall softens and expands depending on the type of thermoplastic resin. Are designed differently.

In the present invention, the sol composition is heat-expanded 1.5 to 5.0 times by using such heat-expandable microcapsules, the cell diameter is 50 to 1000 μm, the compression ratio is 5% or more, and the compression ratio is 5% or more. A porous body having a thickness of 3 to 10 mm with closed cells having an elastic modulus of 70% or more is formed. However, considerable efforts are required to effectively obtain the expansion ratio, cell diameter, and the like required by the present invention. I do.

The first is the selection of the particle size of the above-mentioned inorganic filler, the second is the selection of the softening temperature of the shell wall of the microcapsules, and the third is the sol-like resin composition containing the microcapsules. This is the selection of the heat treatment conditions.

Although the second and third conditions are related to each other, according to the results of studies by the present inventors, it has been found that a porous backing layer having an expansion ratio and a bubble diameter that meets the object of the present invention. In order to obtain the heat-expandable microcapsules, in a relatively large mobility stage where the remarkable increase in the viscosity of the resin composition layer due to heat gelation of the sol resin composition has not progressed much, It is important to have sufficient thermal expansion.

If the viscosity of the resin composition layer increases too much before the thermal expansion of the thermally expandable microcapsules starts, the thermal expansion is greatly suppressed, and the desired thermal expansion ratio and bubble diameter cannot be obtained. Variations in thickness tend to be large.

Therefore, when selecting the heat-expandable microcapsules, the softening temperature of the shell wall in the production process of the rug is basically lower than the temperature at which the gelation of the sol-like resin composition by heating rapidly proceeds. Selection of an object will give a favorable result. However, if the softening temperature of the shell wall is slightly higher than the temperature at which the hot gelation of the sol-like resin composition proceeds rapidly, the gelation actually takes a relatively long time compared to the rapid thermal expansion of the microcapsules. Requires
In the early stage of the heating gelation step, it is possible to utilize by heating and raising the temperature immediately above the softening temperature of the shell wall.

Specifically, the softening temperature of the shell wall, which can be suitably employed in the present invention, is slightly different depending on the heat gelation treatment conditions of the sol resin composition.
It is desirable to select from around 0 ° C or less, more preferably from 140 ° C or less.

The amount of the heat-expandable microcapsules is not particularly limited, but is preferably selected from the range of 3 to 30 parts per 100 parts of the thermoplastic resin in consideration of the cost and the desired expansion ratio.

Preferred conditions for the heat gelation treatment include applying a sol-like resin composition containing a small particle size inorganic filler containing heat-expandable microcapsules on the surface of a rotating release belt, After laminating the surface-mounting materials, the material is guided into a heat treatment furnace in which the ambient temperature on the back side of the belt on which the laminate is placed is set at 140 ° C. to 250 ° C., heated and heated at a stretch, and then cooled. At this time, the ambient temperature on the belt surface side is desirably set to 140 ° C. or lower, preferably 120 ° C. or lower in order to prevent color burn of the surface material.

The temperature of the atmosphere on the back side of the belt should be as low as possible in order to promote the thermal expansion of the heat-expandable microcapsules as efficiently as possible prior to the progress of the gelation of the resin composition which competitively progresses. Is desirably set to a high value, preferably 180 to 220 ° C. for a PVC resin or an acrylic resin, and 160 to 220 ° C. for an SBR rubber.
The temperature is preferably set to 00 ° C. Further, the heat treatment furnace is divided into a plurality of regions along the running direction of the belt, and the temperature of the most upstream region is set equal to or higher than that of the downstream region, and the temperature is measured at once in the early stage of the heat treatment. More desirable effects can be obtained.

By taking these conditions, the desired thermal expansion ratio of the backing layer is 1.5 to 5.0 times, and the thickness is 3 to 5.0.
A porous body having a compression ratio of 5% or more and a compression elastic modulus of 70% or more and having a small thickness unevenness, which is composed of closed cells having a diameter of 10 mm and a cell diameter of 50 to 1000 μm, can be effectively obtained.

The main value of the bubble diameter of the porous body obtained in the present invention is the maximum expansion ratio of the volume expressed as a characteristic value of the used heat-expandable microcapsules, which is 70.
It is characterized by a relatively large value compared to the maximum bubble diameter of 40 to 140 μm calculated from about twice. Although the reason for this is not necessarily clear, it is thought that the viscosity of the atmosphere in which the heat-expandable microcapsules are thermally expanded is greatly involved, and under the conditions as in the present invention, the calculated bubble diameter is reduced. The shell wall of the microcapsule that thermally expands beyond it does not break due to the supporting pressure due to the moderate viscosity of the resin composition that is undergoing gelation, or even if it partially breaks, the bubbles themselves will not Such an unexpectedly large bubble diameter is formed by wrapping in a viscous body of the resin composition surrounding the resin and continuing expansion without causing significant bubble breakage, or by partial fusion of bubbles. Believe in things.

According to the present invention, the porous body having such unique properties is directly backed by a commonly used fiber covering material, thereby providing an excellent walking feeling and an impact without using an underlay such as a nonwoven fabric. It is possible to easily obtain a rug having excellent shock absorption with an acceleration of 100 G or less.

In the present invention, the main component of the bubble diameter is 1000
μm, the thermal expansion ratio exceeds 5 times, the porosity of the porous body becomes extremely high, and the thickness of the porous body is 10 μm.
However, when the applied load is removed, there is an advantage from the viewpoint of improving the shock absorption of the obtained rug, but the controllability is reduced due to the thickness unevenness of the porous body. It is easy for the recovery rate of the thickness to decrease,
Substantially undesirable.

When the main component of the bubble diameter is smaller than 50 μm or when the thermal expansion ratio is less than 1.5 times, the obtained porous body is slightly hard, and the obtained rug has a shock absorbing property and a walking feeling. Both are poor and not preferred.

More preferable specifications of the porous body include a resin composition layer having a thermal expansion ratio of 2 to 4 times, a thickness of 5 to 8 mm, a main body of a bubble diameter of 100 to 500 μm, a compressibility of 7 to 20%, and a compression elasticity. The rate of impact is 80% or more, and the more preferable impact acceleration of a rug having such a porous body as a backing layer is 90 G
It is as follows.

In the present invention, when the porous body is formed, vulcanized rubber particles having excellent rubber elasticity are further compounded and used with the sol-like resin composition described above. It is useful in further improving the sex and walking feeling. Such materials include powdered vulcanized rubber and fine powder of waste tires. When these are used in combination, it is desirable to use the particles having a particle diameter of 1 mm or less, and the compounding amount is 10 to 100 parts with respect to 100 parts of the thermoplastic resin in the sol composition.
Use in the range of parts is desirable for stable production of the porous backing layer.

In the present invention, a high-strength, low-shrinkable fiber cloth is basically included in the sol-like resin composition layer in the production process of the rug. This is important for securing practical dimensional stability with low elongation when used in a place where a repeated load is applied, because the backing layer in the present invention is a porous body having a high porosity, This is particularly necessary when the rug is a tile carpet.

As such a high-strength, low-shrink fiber fabric, a woven or non-woven fabric made of glass fiber is usually used. And aromatic polyamide fiber woven fabrics and nonwoven fabrics are preferably used.

In the present invention, an expensive and highly shrinkable fiber cloth conventionally used for the purpose of preventing warpage may be used in combination, but it is not always necessary to use this together.

In the present invention, it is not always necessary to pre-coat the back surface of the fiber covering material with a non-porous sol-like resin composition in advance for the purpose of preventing fuzz as in the prior art. Without, the porous body-forming sol-like resin composition as a backing layer is directly laminated on the fiber facing material, heated to make it porous, and only by measuring the gelation is sufficient to grasp the fibers of the rug, and the fuzz There is no advantage that a good quality rug is easily obtained.

[0044]

EXAMPLES Hereinafter, the present invention will be described in more detail with reference to examples. The evaluation of the porous body and the rug in the examples is based on the following values.

<Bubble diameter and thickness of porous body>
The obtained rug was cut with a sharp knife in the thickness direction, and the cross section of the porous body was observed with a stereoscopic microscope. The thickness of the porous layer was measured by measuring the thickness of the porous layer below the primary base cloth of the cut surface.

<Expansion Ratio> The thickness of the porous layer was calculated by dividing the thickness of the sol resin composition by the value measured in advance before the heat treatment.

<Compression Rate and Compressive Modulus of Porous Material> JI
It was measured based on SL1022 reference 2.

<Acceleration at Impact> JIS A6519
Based on the above, on a rubber plate with a thickness of 8 mm, a Shore A hardness of 37, and a size of 300 x 150 mm placed on the upper surface of the rug,
It was measured as the maximum acceleration generated when a head model approximating a human head weighing 1.34 kg from a height of 20 cm was freely dropped.

<Caster chair test> JIS L1
Measured based on 904-9.

<Fuzz Test> Using a taper abrasion tester according to JIS L1023, the wheel was rotated 100 times on a worn wheel H-22, and the fuzziness was evaluated according to a fuzz determination standard.

<Thickness unevenness> The obtained rug was cut into 50 cm squares, and the thickness of the porous material layer was measured at the central part, both ends of the four sides, and nine points at the center of the cut rug, and visually determined. .

<Strength of thread removal> Measured according to JIS L1023.

<Upward warpage> Measured according to JIS L1904-7.

Example 1 100 parts by mass of vinyl chloride resin, 150 parts by mass of calcium carbonate having an average particle diameter of 5 μm, 88 parts by mass of DOP, 1 part by mass of stabilizer, 0.6 parts by mass of pigment, 1 part by mass of hygroscopic agent, heat Expandable microcapsules (Matsumoto Microsphere F- manufactured by Matsumoto Yushi Seiyaku Co., Ltd.)
82D: a resin composition for a backing layer, which is maintained at 35 ° C., comprising 10 parts by mass of an average particle diameter of 20 to 25 μm and a shell wall softening temperature of 125 to 130 ° C., is supplied onto a rotating release belt, and then After sequentially supplying a glass fiber woven fabric and a glass paper having an aperture of 5 mm as an intermediate base fabric, and further supplying the resin composition, a 3,000 dtex BCF nylon soaked yarn was used as a primary base fabric of a polyester fiber nonwoven fabric. The surface material obtained by tufting was supplied and laminated, and then heated at once in a heat treatment furnace heated to 210 ° C., 205 ° C., and 200 ° C. from the upstream area, with the belt surface side divided into 110 ° C. and the back side divided into three chambers. The thermally expandable microcapsules are thermally expanded to promote gelation of the sol-like resin composition, and then cooled to obtain a thickness of 7 mm, a thermal expansion ratio of 2.5 times, There was obtained 150 to 250 [mu] m, the compression ratio of 9%, 92% compressive elasticity modulus pile weight per unit area 800 g / ^{m 2} with a porous backing layer, a rug pile length 5.0 mm. This rug has little thickness unevenness and the impact acceleration is 86
It was G and had excellent shock absorption and excellent walking sensation.

The tile carpet obtained by cutting this rug into a square of 50 cm has no warpage and exhibits excellent morphological stability with very little elongation even in a caster test.
The thread pulling strength was sufficient and the quality was excellent without fuzz.

Comparative Example 1 A rug was prepared in the same manner as in Example 1 except that calcium carbonate having an average particle diameter of 5 μm was replaced with calcium carbonate of 100 μm. The results obtained are shown in Table 1,
Compared with Example 1, the G value of the rug is slightly larger, the backing layer also has a slightly smaller expansion ratio, and the bubble size is mainly smaller. It was found to be inferior in quality, with a low compression ratio and slightly hard overall, with large unevenness in thickness and conspicuous unevenness.

(Comparative Example 2) In Example 1, the microcapsules having a shell wall softening temperature of 188 to 198 ° C (Expancel 091DU-12 manufactured by Nippon Philite Co., Ltd.)
0: Average particle size 28 to 38 μm, partition wall softening temperature 188
Except for the use of a rug, a rug was prepared in the same manner as in Example 1. The obtained results are shown in Table 1. As compared with Example 1, the expansion ratio was lower and the bubble diameter was smaller, the G value was larger, and the effect of adding the porogen was small.

(Comparative Example 3) In Example 1, all except that no glass fiber cloth was used as the intermediate base cloth.
A rug was created in the same manner as described above. The results obtained are shown in Table 1. The elongation was large in the caster chair test, and the tile carpet was not practical.

[0059]

[Table 1] *: Average particle diameter 20 to 25 μm **: average particle diameter 28 to 38 μm ***: stabilizer 1.0, pigment 0.6, 1.0 part by weight of hygroscopic agent. ：: good ×: bad △: slightly poor

Comparative Example 4 A rug was prepared in the same manner as in Example 1 except that microcapsules were not used. The non-porous backing layer of the obtained rug has a thickness of 2.8 mm, a compressibility of 2.5%, and a compression modulus of 95.
%, The impact acceleration of the rug was 128 G, and both the shock absorption and walking sensation were poor.

[0061]

The rug of the present invention is a rug in which a porous backing layer is directly laminated on a surface covering material, which has little unevenness in thickness, and has excellent load absorbing properties and resilience, and is excellent in shock absorption and walking feeling. In addition, the heat-expandable microcapsules forming closed cells having a partition wall resin having a relatively low softening temperature capable of being sufficiently thermally expanded before the heat-gelation of the sol-like resin composition sufficiently proceeds, the micro-encapsulated It is blended with a sol-like resin composition containing an inorganic filler smaller than the average particle diameter of the capsule, and is directly laminated on the back surface of the fiber covering material with the fiber fabric inside, and quickly heated 1.5 to 5 times. Only by forming a rug having a porous body having a thickness of 3 to 10 mm in the backing layer by thermal expansion and gelling, the rug can be continuously and stably and easily obtained. .

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI theme coat ゛ (Reference) D06M 101: 32 D06M 101: 32 101: 36 101: 36 (72) Inventor Shigemi Ozaki Yoro-cho, Yoro-gun, Gifu Prefecture 10 Murohara Inside the Gifu Plant of Mitsubishi Burlington Co., Ltd. (72) Inventor Toshihiro Kasai 4-160 Sunadabashi, Higashi-ku, Nagoya-shi, Aichi F-term in the Mitsubishi Rayon Co., Ltd. Product Development Laboratory 3B120 AA15 AA19 AA30 AB22 BA17 BA38 DB01 EB11 4L031 AA18 AA21 AA26 AB32 AB33 DA00 DA11 4L033 AA07 AA08 AA09 AB05 AB06 CA15 CA68

Claims (12)

[Claims] 1. A rug in which a backing layer made of a thermoplastic resin composition containing a fiber cloth is laminated on the back surface of a fiber covering material, and the backing layer has a cell diameter of 50 to 100.
A rug comprising a porous body having a large number of closed cells of 0 μm, a compressibility of 5% or more, a compressive elasticity of 70% or more, and a thickness of 3 to 10 mm. 2. The rug according to claim 1, wherein the air bubbles are formed by heat expansion of the heat-expandable microcapsules. 3. The rug according to claim 1, wherein the acceleration of the impact of the rug is 100 G or less. 4. The porous body has a bubble diameter of 100 to 500 μm,
The compression rate is 7 to 20%, the compression modulus is 80% or more, the thickness is 5 to 8 mm, and the acceleration of impact is 90 G or less.
The rug according to any one of claims 1 to 3. 5. The thermoplastic resin according to claim 1, wherein the butadiene-based resin contains a small amount of a polyisocyanate compound having a reactive isocyanate group.
The rug described in the section. 6. The rug according to any one of claims 1 to 5, wherein at least one of glass fiber, aromatic polyamide fiber, and high-strength low-shrinkage polyester fiber is used as the fiber cloth. . 7. 100 parts of a thermoplastic resin having an average particle size of 3
100 to 500 parts of an inorganic filler having a particle size of 0 μm or less, 5 to 200 parts of a plasticizer or water, and heat-expandable microcapsules 3
A sol-like composition obtained by uniformly mixing 〜30 parts of the sol-like composition is applied on the surface of a running release belt, a fiber cloth is laminated thereon, and the sol-like composition is further applied thereon. The fiber surface covering material is laminated, and subsequently, the ambient temperature on the belt front side is 140 ° C. or less, and the ambient temperature on the belt rear side is 140 ° C.
A method for producing a rug, wherein the backing layer is expanded 1.5 to 5 times by heat treatment in a heat treatment furnace set at ~ 250 ° C, and then cooled. 8. The method for producing a rug according to claim 7, wherein an inorganic filler having an average particle size equal to or less than the average particle size of the thermally expandable microcapsules is used. 9. The method for producing a rug as set forth in claim 7, wherein heat-expandable microcapsules having a maximum thermal expansion temperature of 160 ° C. or less are used. 10. The sol composition according to claim 7, further comprising 10 to 100 parts of vulcanized rubber particles.
A method for producing a rug according to the above item. 11. The atmosphere temperature on the belt surface side is 120.
℃ or less, the ambient temperature on the back side of the belt is 180 to 220 ℃
The method for producing a rug according to any one of claims 7 to 10, which is set to: 12. The heat treatment region is divided into a plurality of regions along the running direction of the belt, and the atmosphere temperature in the most upstream region is set to be equal to or higher than that in the downstream region. The method for producing a rug according to any one of claims 7 to 11, wherein the rug is performed.