JP2005312782A - Pollution-free recycled carpet and method of producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a recycled carpet whose quality and dimension stability are satisfactory and where the whole amount of a backing layer consisting of a pollution-free thermoplastic elastomer resin can be recycled for the same use by solving problems of the quality, dimension stability, recycling property, etc. at the same time in the case of recycling the carpet consisting of different kinds of material. <P>SOLUTION: In a pile fiber layer 3, a pile-removal prevention layer 7 is provided to a ground fabric 2 where pile threads 1 are tufted. A pair of upper and lower thermoplastic elastomer sheet layers 4b and 4c containing 30 to 75% calcium carbonate with respect to a mixture system are formed. Between the sheet layers 4b and 4c, a backing layer 6 is formed with a glass fiber nonwoven fabric layer 5 inserted therebetween. The pile fiber layer 3 and the backing layer 6 are adhered to each other with a hot melt adhesive layer 8, and the backing layer 6 is provided in a recyclable manner. The recycled carpet has the constitution of the layers. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a pollution-free recycled carpet and a method for manufacturing the same, and more particularly to a pollution-free recycled carpet in which a surface pile fiber layer and a backing layer are made of different types of thermoplastic resins and a method for manufacturing the same. .

  In recent years, global environmental problems have been closed, but for carpets, conventionally discarded carpets have been disposed of by landfill or incineration, causing problems such as a shortage of landfill sites and resource loss. . With the enforcement of the recycling law, it is urgently required to produce products that are easy to recycle and to establish a recycling system.

  On the other hand, many of the carpet base fabrics are made of polyvinyl chloride resin, but in recent years, PVC resins are concerned about the problem of dioxin generation during incineration. Construction of depolyvinyl chloride resin is also desired.

  As a conventional pollution-free type carpet, a backing material for tile carpet made of a mixture of a low molecular weight polypropylene, a polyolefin elastomer and an inorganic filler as shown in Patent Document 1 has been developed.

  In addition, the inventor has studied the recycling of carpets, and in Patent Document 2, a hot melt adhesive layer is provided between the backing layer and the pile fiber layer so that the temperature is equal to or higher than the melting point of the hot melt adhesive. Has proposed a recycling carpet that can easily separate the backing layer and the pile fiber layer, and a recycling method thereof.

Furthermore, in Patent Document 3, a nylon fiber pile fiber layer and a polyvinyl chloride resin backing layer, which are different materials, are crushed together without being separated, melt kneaded, and rolled into a backing material for a recycled sheet. A method of coating a paste sol of a polyvinyl chloride resin with a hard back layer and a glass mesh as an intermediate layer has been proposed.
Japanese Patent No. 3138935 JP 2002-191488 A Japanese Patent Laid-Open No. 7-32520

  A conventional general carpet has a structure as shown in FIG. 1, and a pile fiber layer 3 obtained by tufting a pile yarn 1 such as a filament or a spun yarn on a base fabric 2 made of a nonwoven fabric, a plain woven fabric, or the like. It consists of a backing layer 6 in which a glass fiber nonwoven fabric 5 or a mesh 5m is sandwiched between two layers of a polyvinyl chloride resin layer 4a containing calcium carbonate, a plasticizer and the like. Moreover, the general manufacturing method is made by joining and integrating the surface pile fiber layer 3 made of nylon fiber or polypropylene fiber and the backing layer 6 mainly composed of polyvinyl chloride resin, which is made by a tufting method. The backing layer is based on a polyvinyl chloride polymer for a special grade paste, using 50 to 150 parts of a phthalate plasticizer such as DOP (dioctyl phthalate), and 200 to 450 parts of granular carbonic acid. A paste-like resin mixed with calcium is sol-coated, heated by a heating furnace, and gelled. In general, the preparation of the backer agent and the bonding process of the surface pile fiber layer are continuously performed in one step. On the steel net belt flowing through the processing machine, coat the backing layer paste sol with the above composition, insert the glass fiber non-woven fabric or mesh, and then coat the backing layer paste sol to place the glass fiber non-woven fabric in the middle. The tufted pile fibers are inserted into the multilayer backing layer 6 sandwiched between the layers, and passed through a heating furnace to gel and simultaneously bond and solidify each layer such as the pile fiber layer to produce a sheet-like carpet. At this time, the two layers of the backing layer 6 mainly composed of polyvinyl chloride resin sandwiching the glass fiber may have the same composition, but are often changed according to the purpose.

  However, when recycling these carpets, it is difficult to produce quality stable sheets by mixing recycled pulverized products with paste sol, and this method cannot be recycled due to production technology. It is in the situation. In recent years, as a countermeasure, a method has been studied in which a backing layer mainly composed of a polyvinyl chloride resin is formed into a sheet and a recycled material is mixed into the sheet. However, as described above, since the surface pile fiber layer 3 and the backing layer 6 are different materials, and the carpet is made of a nonwoven fabric of glass fiber or the like, the carpet is a part of the structure. There are problems such as being unable to return to the backing layer or the pile fiber layer due to the presence of different materials. Moreover, separating and reusing each of them is too costly for a normal commercial base, so that recycling has not been put to practical use, and waste carpets are being landfilled or incinerated.

  Moreover, in the backing material for tile carpets which consists of a mixture of a low molecular weight polypropylene, a polyolefin elastomer and an inorganic filler as shown in Patent Document 1, simply changing from a polyvinyl chloride resin to such a polyolefin resin, The manufacturing method is a conventionally known manufacturing method. Therefore, as with the carpet made of the above-mentioned polyvinyl chloride resin backing material, when recycling, it is difficult to produce a quality stable sheet by recycling recycled products such as pulverized products in the backing layer. There was a problem.

  On the other hand, the carpet made by the method of Patent Document 2 has large dimensional changes due to environmental temperature changes such as summer and winter, and even when properly laid during construction, gaps are formed over time, the carpet edge lifts, etc. It has been found that various problems occur.

  As a countermeasure against this, there is a method of providing fit to the back surface or floor surface of the backing layer during construction to alleviate problems after laying due to dimensional changes. However, these have problems in that the backing layer is contaminated and reused, and the floor surface is contaminated.

  Further, in Patent Document 3, a nylon fiber pile fiber layer and a polyvinyl chloride resin backing layer, which are different materials, are collectively pulverized without being separated, melt kneaded, and rolled into a backing material for a recycled sheet. A method of coating a paste sol of a polyvinyl chloride resin using a hard back layer and a glass mesh as an intermediate layer has been proposed.

  However, since this method recycles while mixing different kinds of resin, using it as a backing layer made of polyvinyl chloride resin has limitations on the mixing ratio of waste materials due to appearance, strength, flexibility, and other problems, There was a problem that the whole amount could not be recycled. Further, for the sake of dimensional stability, a glass mesh is sandwiched and adhered between a polyvinyl chloride sheet and a polyvinyl chloride sol, but it has been found that this glass mesh has insufficient dimensional stability.

  The present inventors have examined a recyclable recycled carpet that prevents dimensional changes due to this season, and further, a hair removal preventing layer 7 is applied to a base fabric to which pile yarn is tufted as shown in FIG. A backing layer 6 formed by sandwiching a glass fiber nonwoven fabric 5 between a pile fiber layer 3 and a pair of upper and lower polyvinyl chloride resin layers 4a is adhered by a hot melt adhesive layer 8, and the backing layer is provided so as to be recyclable. We propose a recycled carpet characterized by

  However, since the backing layer of this carpet is made of polyvinyl chloride resin, the construction of depolyvinyl chloride resin is desired because of concerns about the occurrence of dioxins during incineration. Various plastic materials have been studied intensively as alternative materials for resin.

  As a result, it was found that a thermoplastic elastomer resin is most effective as a raw material and is close to the characteristics of a polyvinyl chloride resin.

  However, it has been found that the carpet having the laminated structure of different materials has the following problems. That is, the first problem is that the sheet tends to stick to the calendar roll during molding. The second problem is that the adhesion between the thermoplastic elastomer sheet and the glass fiber nonwoven fabric is poor.

  In order to solve these problems, the object of the present invention is to make the material composition and composition of the carpet suitable, the quality and dimensional stability of the recycled carpet being good, and the same thermoplastic elastomer resin backing layer. It is an object of the present invention to provide a pollution-free recycled carpet that can be entirely recycled for use and a method for producing the same.

  In order to solve the above-mentioned problems, the present inventors have found that it is effective to set the composition and composition of the carpet according to the present invention and the manufacturing method thereof as follows.

  A first means is a recycled carpet composed of different materials, a pile fiber layer in which a pile-off layer is provided on a base fabric to which pile yarn is tufted, and heat containing calcium carbonate in a weight ratio of 30 to 75%. A pair of plastic elastomer resin layers are arranged on top and bottom, and a backing layer formed by sandwiching a glass fiber nonwoven fabric layer between the thermoplastic elastomer resin layers is bonded with a hot melt adhesive layer, and only the backing layer can be recycled. It is in that.

  As a second means, a pair of a pile fiber layer in which a hair removal preventing layer is provided on a base fabric to which a pile yarn is tufted, and a thermoplastic elastomer resin layer containing calcium carbonate in a weight ratio of 30 to 75% are arranged up and down. In addition, in the method for producing a recycled carpet, a backing layer formed by sandwiching a glass fiber nonwoven fabric layer between the thermoplastic elastomer resin layers is bonded with a hot melt adhesive layer, and only the backing layer is provided so as to be recyclable. After melt-kneading the thermoplastic elastomer resin pellets to which calcium carbonate has been added using a Banbury mixer, a calender rolling method is used to obtain a thermoplastic elastomer sheet, and the surface temperature of the upper and lower thermoplastic elastomer sheet bonding surfaces is 105 ° C. to 160 ° C. Backing by heating and pressure bonding with glass fiber nonwoven fabric To form a layer, it is to simultaneously melt bonding the hot melt adhesive sheet through between the between the backing layer pile fiber layer.

  As a third means, a pair of a pile fiber layer in which a hair removal preventing layer is provided on a base fabric to which pile yarn is tufted, and a thermoplastic elastomer resin layer containing calcium carbonate in a weight ratio of 30 to 75% are arranged up and down. In addition, in the method for manufacturing a recycled carpet, a backing layer formed by sandwiching a glass fiber nonwoven fabric layer between the thermoplastic elastomer resin layers is bonded with a hot melt adhesive layer, and only the backing layer is provided so as to be recyclable. The thermoplastic elastomer resin layer is a pair of upper and lower recycled thermoplastic elastomer sheets that are made by melting and kneading the backing layer separated from the used pile fiber layer with a banbury mixer and then remanufacturing it by a calendar rolling method. Backing formed with a glass fiber nonwoven fabric layer between layers The surface temperature of the adhesive surface was thermocompression-bonded at a temperature of 105 ° C. to 160 ° C. to form a backing layer by adhering to the glass fiber nonwoven fabric, and interposed between the backing layer and the pile fiber layer. The hot melt adhesive sheet is melt-bonded at the same time.

  As described above, by using these material configurations, layer configurations, manufacturing conditions, and manufacturing methods according to the present invention, the sheet formability is good, the adhesion between each layer is good, and the tile carpet is necessary. Non-pollution type recycled tile carpet with good quality and practicality that retains dimensional stability, appearance, strength, flexibility, cushioning properties, etc., which are unique characteristics, and is 100% recyclable and environmentally hygienic. Could get.

  Further, since the olefin elastomer resin has no problem of generating dioxins at the time of incineration, it has become possible to obtain a pollution-free recycled carpet which is the object of the present invention and is good in terms of environmental hygiene.

  The best form of the recycled carpet of the present invention is provided with a pile fiber layer in which a hair loss preventing layer is provided on a base fabric to which pile yarn is tufted. A pair of thermoplastic elastomer resin layers containing calcium carbonate in a weight ratio of 30 to 75% are arranged up and down, and a backing layer formed by sandwiching a glass fiber nonwoven fabric layer between the thermoplastic elastomer resin layers is provided. The pile fiber layer and the backing layer are bonded with a hot melt adhesive layer, and only the backing layer is provided so as to be recyclable.

  The best mode of the production method of the present invention is a recycled thermoplastic elastomer sheet obtained by melting and kneading a backing layer separated from a used pile fiber layer with a Banbury mixer, and then remaking it by a calendar rolling method. Adhesion with the glass fiber nonwoven fabric is carried out by thermocompression bonding of the surface temperature of the backing layer formed by sandwiching the glass fiber nonwoven fabric layer between a pair of upper and lower recycled thermoplastic elastomer sheet layers at a temperature of 105 ° C. to 160 ° C. As a result, a backing layer is formed. A hot melt adhesive sheet interposed between the backing layer and the pile fiber layer is simultaneously melt bonded to achieve the original purpose.

  Examples of the present invention will be described in detail below.

  Since the waste material treatment after the carpet has been used is conventionally made of a different material, there is a problem that it cannot be returned to the backing layer or the surface pile fiber layer at present.

  With respect to this problem, a recycled carpet having a layer structure as shown in FIGS. 3 and 4 in which a hot melt adhesive layer 8 is provided between a backing layer 6 and a surface pile fiber layer 3 with a glass fiber nonwoven fabric sandwiched therebetween. This can be solved. That is, the pile fiber layer and the backing layer can be easily separated by heating the used waste carpet above the melting point of the hot melt adhesive.

  In addition, by changing the backing layer from conventional polyvinyl chloride resin to thermoplastic elastomer resin, it can be solved from the environmental problem of dioxin generation concern, but even if the waste carpet can be separated and reused by hot melt adhesive, Since the glass fiber nonwoven fabric is present in the thermoplastic elastomer resin, it has been considered that the backing layer of the thermoplastic elastomer resin cannot be recycled 100% for the same application.

  However, as a result of intensive studies by the present inventors, the glass fiber non-woven fabric is broken by heating and kneading the thermoplastic elastomer resin having the glass fiber non-woven fabric layer with a Banbury mixer, and almost becomes a glass powder. It was found that there was no adverse effect on quality and sheet formability even when reused.

  Further, in this layer configuration, it was found that the adhesive force between the pile fiber layer 3 and the hot melt adhesive sheet layer 8 was weak, and problems such as the pile coming out during cutting, processing, construction, etc. occurred. For this reason, it is necessary to provide a hair removal prevention layer 7 coated with ethylene-vinyl acetate copolymer resin or the like on the base fabric 2 to which the pile yarn 1 is tufted to prevent the pile yarn 1 from coming off.

  One of the major problems in the case of using a thermoplastic elastomer resin backing layer is that it has a drawback that it easily adheres to a calender roll during sheet molding.

  Another problem with the thermoplastic elastomer resin backing layer is that the adhesiveness between the thermoplastic elastomer sheet and the glass fiber nonwoven fabric is poor and the practicality of the carpet is lacking. .

  As a result of diligent investigations by the inventors on the problem of using a thermoplastic elastomer resin backing layer, first, regarding the problem of adhesion to the calender roll at the time of the first molding, the thermoplastic elastomer resin is combined with calcium carbonate. It was found that the adhesion problem at the time of sheet molding can be solved by adding 30% to 75% calcium carbonate to the mixture system.

  Regarding the second problem of poor adhesion, manufacturing a backing sheet formed by sandwiching a glass fiber nonwoven fabric layer between a pair of upper and lower thermoplastic elastomer resin sheets containing 30 to 75% of calcium carbonate with respect to the mixture system In the method, it has been found that good adhesion can be obtained by bonding the glass fiber nonwoven fabric by thermocompression bonding with a laminator at a surface temperature of the thermoplastic elastomer sheet on both sides of 105 ° C. to 160 ° C. It was.

  As a specific method for producing this carpet made of thermoplastic elastomer resin, thermoplastic elastomer resin pellets containing calcium carbonate in an amount of 30 to 75% based on the mixture system are used in a Banbury mixer at 120 ° C. to 190 ° C., preferably 130 ° C. to A thermoplastic elastomer resin sheet 4b containing calcium carbonate and an antioxidant is formed by calendering the resin temperature of the thermoplastic elastomer at 130 ° C. to 180 ° C. after being heated and stirred at a resin temperature of 180 ° C. and melt kneading. Create Next, a glass fiber nonwoven fabric layer 5 is sandwiched between a pair of upper and lower thermoplastic elastomer sheets by a laminator, and the surface temperature of the adhesive surface of the thermoplastic elastomer sheet on both sides is thermocompression-bonded at a temperature of 105 ° C. to 160 ° C. The backing layer 6 is formed by bonding with a fiber nonwoven fabric. Each layer of the pile fiber layer having the multilayer backing layer 6, hot melt adhesive sheet layer 8, and hair removal preventing layer 7 is configured in the order shown in FIG. 3, and is heated at a temperature of 120 ° C. to 200 ° C. in a heating furnace. Recycled carpet is obtained by heating and simultaneously bonding each layer such as bonding with a backing layer made of thermoplastic elastomer, hot melt adhesive sheet layer, pile fiber layer having a hair removal prevention layer, and then cooling and solidifying. An initial method for manufacturing carpets was found.

  This layered carpet can solve the problem of sticking at the time of sheet molding, has good adhesion between each layer, including adhesion to the glass fiber nonwoven fabric, and should be a carpet of this layered structure As a result, quality characteristics such as dimensional stability, appearance, strength, flexibility, and cushioning required for carpets are good, and a recyclable, pollution-free carpet can be obtained.

  Moreover, the following method was discovered as a method of manufacturing an actual recycled carpet. A carpet that can be separated from the pile fiber layer 3 and a backing layer 6 made of a thermoplastic elastomer resin or the like containing 30 to 75% of calcium carbonate with respect to the mixture system as described above is higher than the melting point of the hot melt adhesive sheet 8. And the thermoplastic elastomer resin backing layer 6 having the glass fiber layer 5 is separated, and then heated and stirred by a Banbury mixer at a temperature of 120 ° C. to 190 ° C., preferably 130 ° C. to 180 ° C. A thermoplastic elastomer resin recycled sheet 4c containing calcium carbonate and glass powder is formed by calender molding at a resin temperature of the plastic elastomer of 130 ° C. to 180 ° C.

  Next, a glass fiber nonwoven fabric layer 5 is sandwiched between a pair of upper and lower thermoplastic elastomer resin recycled sheets 4c by a laminator, and the surface temperature of the adhesive surface of the thermoplastic elastomer sheets on both sides is 105 ° C. to 160 ° C. Then, the backing layer 6 is formed by bonding with the glass fiber nonwoven fabric. Each layer of the pile fiber layer having the multilayer backing layer 6, hot melt adhesive sheet layer 8, and hair removal preventing layer 7 is configured in the order shown in FIG. 4, and is heated at a temperature of 120 ° C. to 200 ° C. in a heating furnace. FIG. 4 shows a result of heating and performing simultaneous adhesion of each layer such as adhesion to a backing layer composed of a thermoplastic elastomer or the like, a hot melt adhesive sheet layer, and a pile fiber layer having a hair removal preventing layer, followed by cooling and solidification. The present inventors have found a method for producing a recycled carpet having such a layer structure.

  Here, if the content of calcium carbonate exceeds 75%, the dispersion into the thermoplastic elastomer becomes poor, the appearance of the backing sheet is remarkably deteriorated, and the sheet becomes brittle.

  Moreover, when the content of calcium carbonate is less than 30%, it becomes easy to stick to the calender roll at the time of molding the thermoplastic elastomer sheet, the mold release from the calender roll becomes worse at the time of molding, and the production stability becomes worse. Which is undesirable.

  In addition, as other release agents for calcium carbonate, stearic acid, barium stearate, calcium stearate, magnesium stearate, zinc stearate, other fatty acids, fatty acid metal salts and the like may be further added.

  Furthermore, an antioxidant may be added for the purpose of preventing deterioration in physical properties due to heat and oxidative degradation when heat treatment is performed during molding or recycling.

  Antioxidants include octadecyl-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate, pentaerythrityl tetrakis [3- (3,5-di-t-butyl-4-hydroxy Phenyl) propionate], 1,3,5-trimethyl-2,4,6-tris (3,5-di-t-butyl-4-hydroxybenzyl) benzene, 2,4-bis- (n-octylthio)- 6- (4-hydroxy-3,5-di-t-butylanilino) -1,3,5-triazine, 2,2-thio-diethylenebis [3- (3,5-di-t-butyl-4- Hydroxyphenyl) propionate], bis (3,5-di-t-butyl-4-hydroxybenzylphosphonate ethyl) calcium, polyethylene wax, tris- (3,5-di-t-butyl-4-hydroxybenzyl)- Hindered phenolic oxidation of isocyanurate, 2, 4, -bis [(octylthio) methyl] -O-cresol, isooctyl-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate Inhibitor, 1,1,3-tris (2-methyl-4-hydroxy-5-tert-butylphenyl) butane, bis [3,3-bis (4'hydroxy-3-tert-butylphenyl) butanoic acid] Phenol compounds such as glycol esters, distearyl disulfide, dilauryl thiopropionate, dimyristyl thiodipropionate, dithioether thioether compounds such as distearyl thiodipropionate, tris (2,4- Phosphorous antioxidants such as (di-t-butylphenyl) phosphite and other conventional antioxidants commonly used in polyolefin compositions can be applied.

  The addition amount of the antioxidant is preferably about 0.02 to 0.3%.

  As this specific manufacturing method, after heating the melting point of the hot melt adhesive sheet 8 or higher and separating the backing layer 6 of the thermoplastic elastomer resin having the glass fiber layer 5, in the same manner as described above, using a Banbury mixer, A thermoplastic elastomer recycled sheet 4c containing 30 to 75% of calcium carbonate with respect to the mixture system and a glass powder in which the glass fiber nonwoven fabric is broken is prepared by melt kneading and calender rolling.

  The recycled thermoplastic elastomer sheet 4c is made into two layers, the glass fiber nonwoven fabric 5 is sandwiched between the sheets, and is thermocompression-bonded at a temperature of 105 ° C. to 160 ° C. by a laminator, and is cooled and solidified. The backing layer 6 of the laminated sheet of the thermoplastic elastomer resin 4c / glass fiber nonwoven fabric 5 / thermoplastic elastomer resin 4c, which is well bonded to the glass fiber nonwoven fabric, can be obtained. When this pressure bonding temperature is lower than 105 ° C., the adhesive strength between the thermoplastic elastomer resin and the glass fiber nonwoven fabric is weak, and when it exceeds 160 ° C., the thermoplastic elastomer sheet is stretched, wrinkles are generated and the workability of the laminate is extremely poor. Therefore, there arises a problem that the manufacture becomes difficult.

  A layer of a pile fiber having a hot melt adhesive sheet 8 and a hair loss prevention layer 7 is laminated on the backing layer 6 made of this recycled laminated sheet, and heated at a temperature of 120 to 200 ° C. in a heating furnace. Then, by simultaneously fusing the thermoplastic elastomer sheet and simultaneously bonding the hot melt adhesive sheet, and then cooling and solidifying, a multi-layered recycled carpet as shown in FIG. 4 is manufactured.

  The carpet with this layer structure can also solve the problem of sticking at the time of sheet molding, and has good adhesion between each layer including adhesion to the glass fiber nonwoven fabric. By doing so, quality characteristics such as dimensional stability, appearance, strength, flexibility, cushioning properties, etc. necessary for the carpet were good, and a recyclable pollution-free carpet could be obtained.

  Also, the pile fiber layer has few impurities because it is separated, and at least it can be reused for plastic molded products such as nylon and polypropylene.

  The total thickness of the thermoplastic elastomer resin layer in the backing layer 6 is preferably in the range of 1 mm to 4 mm, and the upper and lower thickness configurations of the glass fiber nonwoven fabric may be appropriately changed according to the quality of the carpet. If it is thinner than 1 mm as a whole, the cushioning property of the carpet is poor, and if it exceeds 4 mm, the weight becomes heavy and the workability is poor, which is disadvantageous in terms of cost.

  Examples of the thermoplastic elastomer resin used herein include ethylene / propylene copolymer elastomers such as EP rubber, EPT and EPDM which are terpolymer elastomers obtained by copolymerization of dienes, polyisobutylene which is a polymer of isobutylene, and butyl rubber. Polyolefins such as by-product atactic polypropylene produced as a by-product during isotactic polypropylene production and produced as a by-product APP produced as a by-product APP as a by-product during ethylene / propylene copolymer production Elastomers and mixtures of these polyolefin elastomers with low or high molecular weight polypropylene, styrene elastomers such as styrene-butadiene-rubber, styrene-butadiene-styrene, ethylene / styrene copolymers, etc. Polyurethane elastomers, polyester elastomers, etc. is good.

  Examples of the hot melt adhesive used here include ethylene-vinyl acetate copolymer resin, polyurethane resin, ethylene-propylene copolymer resin, propylene-butene-1 copolymer resin, etc. The one having the melting point of 60 ° C. to 100 ° C., preferably 65 ° C. to 90 ° C. is effective. In these materials, the upper pile layer and the backing layer can be easily separated by melting the hot melt adhesive in an atmosphere having a melting point or higher or in warm water. When this hot melt adhesive is used as a sheet, the film or sheet has a thickness of 20 to 300 μm, preferably 50 to 250 μm, from the viewpoints of adhesiveness and cost.

  As the hair loss prevention layer 7 used here, ethylene-vinyl acetate copolymer resin, polyurethane resin, polyvinyl alcohol resin, acrylic resin, SBR (styrene butadiene rubber), MBR (methyl methacrylate butadiene rubber), NBR (Nitrile / butadiene rubber) adhesives are good.

In addition, as the glass fiber nonwoven fabric 5 used here, a glass fiber diameter of 6 to 20 μm, preferably 9 to 13 μm, and a basis weight of 15 to 60 g / m ² is suitable. If the basis weight is less than 15 g / m ² , there are problems such as breakage due to tension during lamination with the thermoplastic elastomer sheet and difficulty in workability. If the basis weight exceeds 60 g / m ² , it is disadvantageous in terms of cost. Further, in order to facilitate the adhesion between the thermoplastic elastomer sheet and the glass fiber nonwoven fabric 5, the glass fiber nonwoven fabric 5 was subjected to a surface treatment such as coating with a thermoplastic elastomer, an ethylene-vinyl acetate copolymer resin or the like. Glass fiber nonwoven fabric 5 may be used, and the adhesiveness is further improved, which is preferable.

  Moreover, when a glass mesh is used as an alternative to a glass fiber nonwoven fabric, the dimensional stability is poor, which is not preferable.

Next, a first embodiment of the present invention will be described.
(1) Creation of a pile fiber layer First, 100% nylon multifilament yarn is tufted into a base fabric 2 of a polyester nonwoven fabric having a basis weight of 120 g to produce a pile fiber layer 3 having a pile length of 3 mm and a width of 2050 mm, a so-called living machine. did. This raw machine was supplied to the backing process, and the back surface of the raw machine was coated with an ethylene-vinyl acetate copolymer resin adhesive for preventing the pile yarn 1 from coming off as a hair removal prevention layer 7, thereby creating a pile fiber layer 3. .

(2) Preparation of olefin-based elastomer sheet 60% calcium carbonate and 40% olefin-based elastomer (LE-3140N manufactured by Riken Technos Co., Ltd.) were melt-kneaded with a Banbury mixer at a resin temperature of 170 ° C, and then a temperature of 160 ° C. The sheet 4b having a thickness of 1 mm and a width of 2050 mm was formed by calendering with a calender roll.

(3) Preparation of backing layer This olefinic elastomer sheet layer 4b is made into two layers, a glass fiber nonwoven fabric 5 having a basis weight of 35 g / m ² and a width of 2050 mm is sandwiched between the sheets, and thermocompression bonded at a temperature of 130 ° C. with a laminator. Thus, a backing layer 6 made of a laminated sheet of the recycled olefin elastomer sheet layer 4b / glass fiber nonwoven fabric 5 / recycled olefin elastomer sheet layer 4b to which the recycled olefin elastomer sheet layer 4b and the glass fiber nonwoven fabric 5 were bonded was obtained. .

(4) Production of tile carpet having hot melt adhesive sheet layer Next, in the tile carpet manufacturing apparatus, the backing layer 6 made of the above laminated sheet was placed on a steel net belt with a thickness of 200 μm, a width of 2050 mm, and a melting point of 80 ° C. -Insert the vinyl acetate hot melt adhesive sheet 8, insert the tufted pile fiber layer 3 having the above-described configuration, and pass it through a dry heat oven at 180 ° C to obtain the olefin elastomer resin layer of the hot melt adhesive sheet 8. Each layer such as 4b and the pile fiber layer 3 was bonded at the same time, and then cooled and solidified to produce a multilayer tile carpet for recycling as shown in FIG.

(5) Evaluation of recycled tile carpet having the above configuration <Dimensional stability evaluation test method>
Assuming temperature changes in summer and winter, the dimensional change in this temperature change is measured. Specifically, a 500 mm × 500 mm tile carpet test piece is left as an initial dimension in an atmosphere at 23 ° C. for 4 hours, and then measured vertically and horizontally with a caliper. The test piece is placed in a constant temperature bath at −20 ° C. and 50 ° C. for 4 hours, taken out, and immediately measured vertically and horizontally with a caliper.

本測定により、寸法変化率が０．０３％以下を良好と判定する。
判定結果を次の表１に示す。

From this measurement, a dimensional change rate of 0.03% or less is determined to be good.
The determination results are shown in Table 1 below.

  By using these material configurations, layer configurations, manufacturing conditions, and manufacturing methods, the sheet formability is also good, the adhesion between each layer is also good, and the dimensional stability, appearance, It was possible to obtain a non-polluting tile carpet for recycling that has good quality and practicality while retaining strength, flexibility, cushioning properties, etc., and can be recycled 100%, and at the same time has good environmental hygiene.

The second embodiment of the present invention is as follows.
(1) Creation of pile fiber layer The pile fiber layer 3 similar to Example 1 was created.

(2) Preparation of Recycled Olefin Elastomer Sheet The pile fiber layer 3 and the backing layer 6 were separated by melting the hot melt adhesive in the 85 ° C. atmosphere of the tile carpet shown in Example 1. The olefin-based elastomer resin containing calcium carbonate and glass fiber nonwoven fabric 5 is melted by heating and stirring at 170 ° C. with a Banbury mixer, passing through a calendar roll at 160 ° C., and calendered to obtain a thickness of 1 mm and a width. A 2050 mm recycled olefin elastomer sheet 4c was molded.

(3) Preparation of backing layer This olefinic elastomer sheet layer 4c is made into two layers, a glass fiber nonwoven fabric 5 having a basis weight of 35 g / m ² and a width of 2050 mm is sandwiched between the sheets, and heat-pressed at a temperature of 130 ° C. with a laminator. Thus, a backing layer 6 composed of a laminated sheet of the recycled olefin elastomer sheet layer 4c and the recycled olefin elastomer sheet layer 4c / glass fiber nonwoven fabric 5 / recycled olefin elastomer sheet layer 4c bonded to the recycled olefin elastomer sheet layer 4c was obtained. .

(4) Production of Tile Carpet Having Hot Melt Adhesive Sheet Layer Next, a recycled tile carpet having a multilayer structure as shown in FIG.

(5) Evaluation of recycled tile carpet having the above configuration <Dimensional stability evaluation test method>
Test method similar to Example 1. The measurement results are shown in Table 1.
By using these material configurations, layer configurations, manufacturing conditions, and manufacturing methods, sheet formability is also good, adhesion between each layer is good, and dimensional stability, which is a necessary characteristic as a tile carpet, It was possible to obtain a pollution-free recycled tile carpet that has good quality and practicality that retains its appearance, strength, flexibility, cushioning properties, etc., and can be recycled 100% and at the same time has good environmental hygiene.

<Comparative Example 1>
(1) Preparation of olefin-based elastomer sheet 20% calcium carbonate and 80% olefin-based elastomer (LE-3140N manufactured by Riken Technos Co., Ltd.) were melt-kneaded at a temperature of 170 ° C by a Banbury mixer, and then a calendar at a temperature of 160 ° C. The sheet 4b having a thickness of 1 mm and a width of 2050 mm was calendered by a roll, but adhered to the calender roll,
Good sheet molding could not be performed.

<Comparative example 2>
(1) Creation of Olefin Elastomer Sheet An olefin elastomer sheet 4b having a thickness of 1 mm and a width of 2050 mm similar to that of Example 1 was molded.

(2) Creation of backing layer This olefinic elastomer sheet layer 4b is made into two layers, a glass fiber nonwoven fabric 5 having a basis weight of 35 g / m ² and a width of 2050 mm is sandwiched between the sheets, and thermocompression bonded at a temperature of 100 ° C. with a laminator. Thus, a backing layer 6 made of a laminated sheet of the olefin elastomer sheet layer 4b / glass fiber nonwoven fabric 5 / recycled olefin elastomer sheet layer 4b was obtained.
However, it was confirmed that the backing material composed of this laminated sheet has very poor adhesive force between the olefin elastomer sheet and the glass fiber nonwoven fabric and is not practical as a carpet backing material.

<Comparative Example 3>
(1) Creation of Olefin Elastomer Sheet An olefin elastomer sheet 4b having a thickness of 1 mm and a width of 2050 mm similar to that of Example 1 was molded.

(2) Creation of backing layer This olefinic elastomer sheet layer 4b is made into two layers, a glass fiber nonwoven fabric 5 having a basis weight of 35 g / m ² and a width of 2050 mm is sandwiched between the sheets, and thermocompression bonded at a temperature of 170 ° C. with a laminator. . As a result, it was confirmed that the olefin-based elastomer sheet was stretched by tension, wrinkles were generated and the workability of the laminate was remarkably deteriorated, and production was difficult.

Sectional drawing which shows the layer structure of the conventional common carpet. Sectional drawing which shows the layer structure of the recycled carpet which consists of the backing layer structure made from the conventional polyvinyl chloride resin. Sectional drawing which shows the layer structure of the carpet for recycling which shows the Example of this invention. Sectional drawing which shows the layer structure of the recycled carpet which shows the other Example of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Pile thread 2 Base fabric 3 Pile fiber layer 4a Polyvinyl chloride resin layer 4b Thermoplastic elastomer sheet layer 4c Recycled thermoplastic elastomer sheet layer 5 Glass fiber nonwoven fabric 5m Glass mesh 6 Backing layer 7 Hair loss prevention layer 8 Hot melt adhesive Sheet

Claims (3)

  In a recycled carpet composed of different materials, a pile fiber layer in which a pile-off layer is provided on a pile fabric tufted with pile yarn, and a thermoplastic elastomer resin layer containing calcium carbonate in a weight ratio of 30 to 75% are placed up and down. And a backing layer formed by sandwiching a glass fiber nonwoven fabric layer between the thermoplastic elastomer resin layers with a hot-melt adhesive layer, and only the backing layer is provided so as to be recyclable. Pollution-free recycled carpet.   A pile fiber layer provided with a hair loss preventing layer on a base fabric to which pile yarn is tufted, and a thermoplastic elastomer resin layer containing calcium carbonate in a weight ratio of 30 to 75% are arranged in a pair, and the thermoplastic elastomer. In a manufacturing method of a recycled carpet in which a backing layer formed by sandwiching a glass fiber nonwoven fabric layer between resin layers is bonded with a hot melt adhesive layer, and only the backing layer is provided so as to be recyclable, calcium carbonate is added. After melt-kneading the thermoplastic elastomer resin pellets with a Banbury mixer, it is made into a thermoplastic elastomer sheet by a calender rolling method, and the surface temperature of the upper and lower thermoplastic elastomer sheet bonding surfaces is thermocompression bonded at a temperature of 105 ° C. to 160 ° C. Forming a backing layer by bonding with non-woven fabric Both manufacturing method of non-polluting type of recycled carpet, which comprises simultaneously melt bonding the hot melt adhesive sheet through between the between the backing layer pile fiber layer. A pile fiber layer provided with a hair loss preventing layer on a base fabric to which pile yarn is tufted, and a thermoplastic elastomer resin layer containing calcium carbonate in a weight ratio of 30 to 75% are arranged in a pair, and the thermoplastic elastomer. In a method for manufacturing a recycled carpet in which a backing layer formed by sandwiching a glass fiber nonwoven fabric layer between resin layers is bonded with a hot melt adhesive layer and only the backing layer is provided so as to be recyclable, the thermoplastic elastomer resin layer is A recycled thermoplastic elastomer sheet is obtained by melting and kneading the backing layer separated from the used pile fiber layer with a Banbury mixer and then re-fabricating by a calendar rolling method, and glass fiber between a pair of upper and lower recycled thermoplastic elastomer sheet layers. Table of the adhesive surface of the backing layer formed across the nonwoven fabric layer A hot melt adhesive sheet formed between the backing layer and the pile fiber layer by forming a backing layer by thermocompression bonding at a temperature of 105 ° C. to 160 ° C. and bonding to the glass fiber nonwoven fabric. A method for producing a pollution-free recycled carpet, characterized by melting and adhering at the same time.

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