JP2011163114A - Rental tile carpet and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a rental tile carpet to be repeatedly used which causes no shrinkage against repeated washing and drying. <P>SOLUTION: The rental tile carpet includes: a foundation cloth and a fabric with pile planted in the foundation cloth; a heat-crosslinking synthetic rubber layer (A) with a thickness of 0.5-2.0 mm; a reinforcing material layer; and a heat-crosslinking synthetic rubber layer (B) with a thickness of 2.0-3.5 mm, in this order. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a rental tile carpet and a method for manufacturing the same.

A tile carpet laid on the floor of a building in a high-rise office district or the like is contaminated when used for a certain period of time due to dust, dirt, soil on the soles, and the like. Usually, such stains are in the mobile washing machine that moves on the carpet while the tile carpet is installed on the floor inside the building because the tile carpet is inferior in washing durability in a general commercial washing machine. Removed. Also, particularly dirty tile carpets are replaced with new tile carpets. The removed tile carpet is usually disposed of.
On the other hand, a dust control mat is known as a mat excellent in washing durability. However, even in known dust control mats, shrinkage of 1% to 2% occurs due to repeated washing (see, for example, Patent Document 1).

Japanese Patent No. 3607264

  SUMMARY OF THE INVENTION An object of the present invention is to provide a rental tile carpet that can be repeatedly washed and that has minimal shrinkage due to washing.

As a result of intensive studies by the present inventors in order to solve the above problems, it has been found that the object of the present invention can be achieved by a tile carpet provided with a specific backing material.
That is, the first aspect of the present invention is a raw fabric having a base fabric and a pile planted on the base fabric, a thermally crosslinkable synthetic rubber layer (A) having a thickness of 0.5 to 2.0 mm, a reinforcing material layer, and a thickness. The present invention relates to a rental tile carpet provided with a heat-crosslinkable synthetic rubber layer (B) having a thickness of 2.0 to 3.5 mm in this order.
The rental tile carpet includes, for example, an original fabric having a base fabric and a pile planted on the base fabric, a heat-crosslinkable synthetic rubber layer (A) having a thickness of 0.5 to 2.0 mm, a reinforcing material layer, and a thickness. A heat-crosslinkable synthetic rubber layer (B) having a thickness of 2.0 to 3.5 mm can be laminated in this order, and can be produced by a method for producing a rental tile carpet including a step of integrating them. As the original fabric, it is preferable to use an original fabric that has been heat-treated under conditions of a temperature of 130 to 220 ° C. and a time of 10 to 180 seconds.
The second aspect of the present invention includes a base fabric and an original fabric having a pile planted on the base fabric, and a heat-crosslinkable synthetic rubber layer (C) having a thickness of 2.0 to 4.0 mm, and is thermally crosslinkable. The Mooney viscosity before vulcanization of the heat-crosslinkable synthetic rubber contained in the synthetic rubber layer (C) is 25 to 45, and the Rockwell hardness (A scale) of the heat-crosslinkable synthetic rubber layer (C) after vulcanization The present invention relates to a tile carpet for rental having a value of 50 to 70.
The rental tile carpet is a process of laminating and integrating a base fabric and an original fabric having piles planted on the base fabric and a heat-crosslinkable synthetic rubber layer (C) having a thickness of 2.0 to 4.0 mm. The heat-crosslinkable synthetic rubber contained in the heat-crosslinkable synthetic rubber layer (C) has a Mooney viscosity of 25 to 45 before vulcanization, and the rockwell of the heat-crosslinkable synthetic rubber layer (C) after vulcanization It can be produced by a method for producing a rental tile carpet having a hardness (A scale) of 50 to 70. As the original fabric, it is preferable to use an original fabric that has been heat-treated under conditions of a temperature of 130 to 220 ° C. and a time of 10 to 180 seconds.

  ADVANTAGE OF THE INVENTION According to this invention, it is possible to provide the tile carpet for rental which can be washed repeatedly and the shrinkage | contraction by washing is very slight.

First, the rental tile carpet according to the first invention will be described.
The tile carpet for rental of the first invention includes a base fabric and a raw fabric having piles planted on the base fabric, a heat-crosslinkable synthetic rubber layer (A) having a thickness of 0.5 to 2.0 mm, a reinforcing material layer, And a thermally crosslinkable synthetic rubber layer (B) having a thickness of 2.0 to 3.5 mm in this order. The rental tile carpet may further include an optional layer. The tile carpet for rental of the first invention includes a base fabric and a raw fabric having piles planted on the base fabric, a heat-crosslinkable synthetic rubber layer (A) having a thickness of 0.5 to 2.0 mm, a reinforcing material layer, And the heat-crosslinkable synthetic rubber layer (B) of thickness 2.0-3.5mm can be laminated | stacked in this order, and it can manufacture with the manufacturing method including the process of integrating these layers. This manufacturing method may further include an optional step.

  In general, an original fabric obtained by planting pile yarn on a base fabric is affected by tension at the time of planting and variations in the outside air temperature during spring, summer, autumn and winter, and shrinkage occurs due to washing. However, the rental tile carpet of the first invention has a heat-crosslinkable synthetic rubber layer (A) having a thickness of 0.5 to 2.0 mm, a reinforcing material layer, and a heat-crosslinkable layer having a thickness of 2.0 to 3.5 mm. By using the backing material having the synthetic rubber layer (B) in this order, the shrinkage is negligible even after washing.

  For example, a woven fabric or a non-woven fabric made of synthetic fibers such as polyester fibers, polyamide fibers, acrylic fibers, and polyolefin fibers is used as the base fabric for planting the pile yarn. From the viewpoint of dimensional stability, the synthetic fiber is preferably a polyester fiber.

  When a woven fabric is used, the weaving method may be a normal weaving method such as plain weaving or twill weaving, and is not particularly limited. Conventionally known methods such as tufted and hooks are employed as a method for filing pile yarn on the base fabric. Further, examples of the shape include level cut, cut and loop, high cut low cut, all loop, and the like.

  Examples of the pile yarn include synthetic fibers such as polyester fiber, polyamide fiber, acrylic fiber, polyolefin fiber, and vinylon fiber, and are not particularly limited. Polyester fibers are preferable. The pile yarn is usually a single yarn of 2 to 100 denier, preferably 8 to 80 denier. The pile yarn is obtained by twisting a multifilament composed of a plurality of single yarns, and the thickness is usually 1,000 to 7,000 denier. One or a plurality of monofilaments having a thickness 10 to 100 times that of the single yarn can be twisted with a multifilament to form a pile yarn. Alternatively, a plurality of monofilaments having a single yarn of 200 to 500 denier can be twisted to form a pile yarn.

  The pile density of the pile yarn on the base fabric, that is, the number of gauges per inch and the number of stitches are preferably 5 to 13 and 4 to 15, respectively.

  Since the tile carpet for rental of the first invention uses a specific backing material, the shrinkage at the time of washing is very small. Further, from the viewpoint of shrinkage prevention and dimensional stability, the heat treated raw fabric is It is also possible to use it.

  The heat treatment conditions are preferably a temperature of 130 to 220 ° C. and a time of 10 to 180 seconds. For example, when heat treatment is performed at 120 ° C., 120 seconds, or 150 ° C. for 5 seconds, shrinkage may not be sufficiently prevented. In addition, when heat treatment is performed at a temperature of 230 ° C., 10 seconds, or 220 ° C. for 190 seconds, problems such as melting of the synthetic fiber may occur.

  As the heat treatment conditions, in particular, when the pile yarn is formed using polypropylene fiber, it is preferably 130 to 160 ° C. and 10 to 180 seconds. Moreover, when the pile yarn is formed using a polyamide fiber, it is preferable that it is 130-190 degreeC and 10 to 180 second. Furthermore, when the pile yarn is formed using polyester and / or recycled polyester fiber, it is preferably 130 to 220 ° C. and 10 to 180 seconds.

  The heat-crosslinkable synthetic rubber layer (A) and the heat-crosslinkable synthetic rubber layer (B), which are backing materials in the first invention, may be the same or different, From the viewpoint of easy production, it is preferable that they are the same.

  For the heat-crosslinkable synthetic rubber layer (A) and the heat-crosslinkable synthetic rubber layer (B), known heat-crosslinkable synthetic rubbers used for ordinary dust control mats can be used. Examples of the heat-crosslinkable synthetic rubber include butadiene rubber (BR), styrene-butadiene rubber (SBR), chloroprene rubber (CR), nitrile-butadiene rubber (NBR), isoprene rubber (IR), ethylene-propylene-diene rubber ( FRP, EPDM), silicon rubber and the like. Nitrile-butadiene rubber (NBR) is particularly preferable from the viewpoint of durability.

  The Mooney viscosity of the heat-crosslinkable synthetic rubber before vulcanization is preferably 30-50. If the Mooney viscosity is less than 30, the rubber may ooze out to the pile surface, and if the Mooney viscosity exceeds 50, poor adhesion between the raw fabric and the rubber layer may occur. Moreover, it is preferable that the Rockwell hardness (A scale) of the heat-crosslinkable synthetic rubber layer ((A) layer and / or (B) layer) after vulcanization is 50-65. If the Rockwell hardness is less than 50, shrinkage may occur, and if the Rockwell hardness exceeds 65, cracking of the rubber layer may occur during washing.

  The heat-crosslinkable synthetic rubber layer (A) and the heat-crosslinkable synthetic rubber layer (B) are formed by, for example, forming a sheet of a heat-crosslinkable synthetic rubber or a composition containing the heat-crosslinkable synthetic rubber. Can be formed. If necessary, one or more known additives such as a vulcanizing agent, a vulcanization accelerator, a plasticizer, a colorant, an antiaging agent, a filler, and a dispersing agent are blended in the composition. The An example of the composition includes a composition containing at least a heat-crosslinkable synthetic rubber, a plasticizer, and a colorant. The blending ratio is preferably 10 to 10 parts by weight of the plasticizer with respect to 100 parts by weight of the heat-crosslinkable synthetic rubber. 20 parts by weight and 40-60 parts by weight of colorant.

  The heat-crosslinkable synthetic rubber layer (A) has a thickness of 0.5 to 2.0 mm, and the heat-crosslinkable synthetic rubber layer (B) has a thickness of 2.0 to 3.5 mm. When the thickness of the heat-crosslinkable synthetic rubber layer (A) is less than 0.5 mm, adhesion failure with the original fabric occurs. Moreover, when the thickness of the heat-crosslinkable synthetic rubber layer (A) exceeds 2.0 mm, a step with the existing tile carpet is generated due to the increase in thickness. When the thickness of the heat-crosslinkable synthetic rubber layer (B) is less than 2.0 mm, shrinkage occurs during washing. Further, when the thickness of the heat-crosslinkable synthetic rubber layer (B) exceeds 3.5 mm, a step difference problem occurs as in the case of the heat-crosslinkable synthetic rubber layer (A).

  Examples of the reinforcing material used in the reinforcing material layer include inorganic fibers, synthetic fibers, semi-synthetic fibers, and natural fibers. Inorganic fibers are preferable, and glass fibers are particularly preferable. The thickness of the reinforcing material layer is preferably 0.7 to 1.5 mm.

  When the raw fabric and the heat-crosslinkable synthetic rubber layer (A), the reinforcing material layer, and the heat-crosslinkable synthetic rubber layer (B), which are backing materials, are laminated and integrated, the heat constituting the backing material Even if the three layers of the crosslinkable synthetic rubber layer (A), the reinforcing material layer, and the heat crosslinkable synthetic rubber layer (B) are overlapped in advance before being overlapped with the raw fabric, One layer may be overlaid on the original fabric. A publicly known method can be adopted as a method of integrating. For example, the backing material and the raw fabric are superposed, pressurized and vulcanized. The temperature at the time of pressurization and vulcanization can be arbitrarily selected.

Next, the rental tile carpet according to the second invention will be described.
The tile carpet for rental of the second invention includes a base fabric and a raw fabric having piles planted on the base fabric, and a heat-crosslinkable synthetic rubber layer (C) having a thickness of 2.0 to 4.0 mm. . The rental tile carpet may further include an optional layer. The Mooney viscosity before vulcanization of the heat crosslinkable synthetic rubber contained in the heat crosslinkable synthetic rubber layer (C) is 25 to 45, and the Rockwell hardness of the heat crosslinkable synthetic rubber layer (C) after vulcanization ( (A scale) is 50-70. The tile carpet for rental of the second invention is obtained by laminating a base fabric and an original fabric having piles planted on the base fabric, and a heat-crosslinkable synthetic rubber layer (C) having a thickness of 2.0 to 4.0 mm, It can be manufactured by a manufacturing method including a step of integrating the original fabric and the backing material. This manufacturing method may further include other optional steps.

  The tile carpet for rental of the second invention uses a backing material having a thickness of 2.0 to 4.0 mm formed from a heat-crosslinkable synthetic rubber having a specific Mooney viscosity and a specific Rockwell hardness. By doing so, the shrinkage is negligible even after washing. The tile carpet for rental of the second invention can prevent shrinkage during washing with a simple structure without using a reinforcing material such as glass fiber.

  As a raw material, the above-mentioned thing can be used. It is also possible to heat-treat the raw material under the same conditions as described above.

  The backing material in the second invention includes a heat-crosslinkable synthetic rubber layer (C) having a thickness of 2.0 to 4.0 mm. As the heat-crosslinkable synthetic rubber used for the heat-crosslinkable synthetic rubber layer (C), those described above can be used. If the Mooney viscosity of the heat-crosslinkable synthetic rubber before vulcanization is less than 25, the rubber oozes out to the pile surface. If the Mooney viscosity exceeds 45, poor adhesion occurs during washing. Further, if the Rockwell hardness of the heat-crosslinkable synthetic rubber layer after vulcanization is less than 50, problems such as undulation will occur during washing, and if the Rockwell hardness exceeds 70, problems such as cracking during washing will occur. Will occur.

  The heat-crosslinkable synthetic rubber layer (C) can be formed by sheeting a heat-crosslinkable synthetic rubber or a composition containing the heat-crosslinkable synthetic rubber, as described above. In the composition for forming the heat-crosslinkable synthetic rubber layer (C), as described above, a vulcanizing agent, a vulcanization accelerator, a plasticizer, a colorant, an anti-aging agent, a filler, One or more known additives such as a dispersant are blended. An example of the composition is a composition containing at least a heat-crosslinkable synthetic rubber, a plasticizer, and a colorant. The blending ratio is preferably 5 to 100 parts by weight of the heat-crosslinkable synthetic rubber. 15 parts by weight and 40 to 60 parts by weight of colorant.

  The heat-crosslinkable synthetic rubber layer (C) has a thickness of 2.0 to 4.0 mm. When the thickness of the heat-crosslinkable synthetic rubber layer (A) is less than 2.0 mm, adhesion failure with the original fabric occurs. Further, when the thickness of the heat-crosslinkable synthetic rubber layer (A) exceeds 4.0 mm, a step with the existing tile carpet is generated due to the increase in thickness.

  When the raw fabric and the heat-crosslinkable synthetic rubber layer (C), which is a backing material, are laminated and integrated, a known method can be adopted as described above. For example, the backing material and the raw fabric are There are methods of overlapping, pressing and vulcanizing.

  The rental tile carpet according to the first and second inventions can be used by being laid on the floor in a building. By using these rental tile carpets, it is possible to provide a method of using a tile carpet that is used after being placed on the floor and washed off the floor and then placed on the floor after washing. It becomes possible. The place where the tile carpet after washing is placed on the floor again may be the original place where the tile carpet was removed or another place, and any tile carpet may be used as long as the size is the same. Can be used in any place. Since the rental tile carpet of the present invention does not shrink even if it is washed using a general commercial washing machine, it is not necessary to use a mobile washing machine as in the prior art. Further, in the tile carpet of the present invention, dirt that could not be removed by the mobile washing machine can be removed by using a commercial washing machine, so that the tile carpet can be used repeatedly over a long period of time. it can.

  EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, a following example does not limit the scope of the present invention.

(Experimental example 1)
[Creation of original fabric (1)]
A pile made of polyester fiber is planted on a nonwoven fabric made of polyester fiber under the conditions of gauge: 5/32 inch, stitch: 8.0 / inch, pile length: cut pile 7.0 mm / loop pile 3.0 mm. Then, heat treatment was performed under the conditions of a temperature of 180 ° C. for 60 seconds to prepare an original fabric (1).

[Creation of backing material (1) (upper layer (1) -1 and lower layer (1) -2)]
Carbon black (colorant) 50 parts by weight, bis (2-ethylhexyl) phthalate (DOP) (plasticizer) 15 parts by weight, zinc oxide (vulcanization accelerator), stearic acid, per 100 parts by weight of NBR with Mooney viscosity 40 (Lubricant), octylated diphenylamine (anti-aging agent), 2-mercaptobenzothiazolecyclohexylamine (vulcanization accelerator), sulfur (vulcanizing agent), and a dispersant are blended and kneaded to obtain an NBR composition. It was. Then, the NBR composition was made into a sheet, and an upper layer backing material (1) -1 (thickness: 1.0 mm) and a lower layer backing material (1) -2 (thickness: 2.0 mm) were prepared. In the examples, the upper layer of the backing material means a thermally crosslinkable synthetic rubber layer bonded to the original fabric, and the lower layer of the backing material means a thermally crosslinkable synthetic rubber layer facing the ground.
In the examples, the Mooney viscosity was measured according to JIS K 6300-1 (manufactured by Shimadzu Corporation, Mooney Viscometer).

[Create tile carpet (1)]
An upper layer backing material (1) -1 (thickness: 1.0 mm), glass fiber, and lower layer backing material (1) -2 (thickness: 2.0 mm) are placed in this order on the original fabric (1), and the temperature is 145. The integrated tile carpet (1) was produced by performing adhesion and vulcanization by pressing for 10 minutes at 490 to 150 ° C. and a pressure of 5 kg / cm ² (490 kPa). The size of the produced tile carpet was 50 cm × 50 cm. The Rockwell hardness (A scale) of the backing materials ((1) -1 and (1) -2) was 58.
In the examples, the Rockwell hardness (A scale) was measured according to JIS K 6253 (MD-1 manufactured by ASKER).

(Experimental Examples 2-9)
An integrated tile carpet was prepared in the same manner as in Experimental Example 1, except that the conditions for heat-treating the original fabric, the thickness of the backing material, and the presence or absence of glass fibers were changed according to Table 1.
In Experimental Examples 6 and 8, the tile carpet could not be produced because the pile melted when the raw fabric was heat-treated.

(Experimental example 10)
[Creation of original fabric (2)]
A pile made of polyester fiber is planted on a nonwoven fabric made of polyester fiber under the conditions of gauge: 5/32 inch, stitch: 8.0 / inch, pile length: cut pile 7.0 mm / loop pile 3.0 mm. Then, heat treatment was performed under conditions of a temperature of 180 ° C. for 60 seconds to prepare an original fabric (2).

[Creating backing material (2)]
Carbon black (colorant) 50 parts by weight, diisononyl phthalate (DINP) (plasticizer) 10 parts by weight, zinc oxide (vulcanization accelerator), stearic acid (lubricant), 100 parts by weight of NBR with Mooney viscosity 45 Octylated diphenylamine (anti-aging agent), 2-mercaptobenzothiazolecyclohexylamine (vulcanization accelerator), sulfur (vulcanizing agent), and parts by weight of a dispersant were blended and kneaded to obtain an NBR composition (2). It was. Thereafter, the NBR composition (2) was made into a sheet to prepare a backing material (2) (thickness: 2.0 mm).

[Create tile carpet (2)]
The backing material (2) (thickness: 2.0 mm) is placed on the original fabric ( ² ) and pressed at a temperature of 145 ° C. to 150 ° C. and a pressure of 5 kg / cm ² (490 kPa) for 10 minutes. The integrated tile carpet (2) was made. The size of the produced tile carpet was 50 cm × 50 cm. The backing material had a Rockwell hardness (A scale) of 65.

(Experimental Examples 11 to 16)
An integrated tile carpet was prepared in the same manner as in Experimental Example 10, except that the conditions for heat-treating the original fabric, the thickness of the backing material, and the presence or absence of glass fibers were changed according to Table 2.
In Experimental Example 13, glass fibers were sandwiched between the original fabric and the backing material.

[Tile carpet shrinkage test]
The size before and after washing and drying was measured for each tile carpet produced. For washing, an aqueous solution in which the product name “Sand Clean LS” manufactured by Clariant Japan Co., Ltd. is dissolved as a detergent (3% by weight), the pH is adjusted to 12 using sodium metasilicate, and the temperature is maintained at 50 ° C. It was used. Each tile carpet was washed in a washing machine for 10 minutes, then rinsed twice in a batch washing machine, and then dried in a batch drying machine at 100 ° C. for 30 minutes, 50 times. . The results are shown in Tables 1 and 2.

  The rental tile carpet of the first and second inventions can maintain a good rental tile carpet state even after repeated washing and drying.

Claims (7)

  An original fabric having a base fabric and a pile planted on the base fabric, a heat-crosslinkable synthetic rubber layer (A) having a thickness of 0.5 to 2.0 mm, a reinforcing material layer, and a thickness of 2.0 to 3.5 mm Rental tile carpet provided with a heat-crosslinkable synthetic rubber layer (B) in this order.   An original fabric having a base fabric and a pile planted on the base fabric, a heat-crosslinkable synthetic rubber layer (A) having a thickness of 0.5 to 2.0 mm, a reinforcing material layer, and a thickness of 2.0 to 3.5 mm A method for producing a rental tile carpet, comprising a step of laminating and integrating the heat-crosslinkable synthetic rubber layer (B) in this order.   The manufacturing method of the tile carpet for rental of Claim 2 using the raw fabric heat-processed on the conditions of temperature 130-220 degreeC and time 10-180 second.   A base fabric and an original fabric having piles planted on the base fabric, and a heat-crosslinkable synthetic rubber layer (C) having a thickness of 2.0 to 4.0 mm, are included in the heat-crosslinkable synthetic rubber layer (C) Rental tile in which the Mooney viscosity before vulcanization of the heat-crosslinkable synthetic rubber is 25 to 45, and the Rockwell hardness (A scale) of the heat-crosslinkable synthetic rubber layer (C) after vulcanization is 50 to 70 carpet.   It includes a step of laminating and integrating a base fabric and an original fabric having a pile planted on the base fabric, and a heat-crosslinkable synthetic rubber layer (C) having a thickness of 2.0 to 4.0 mm, and heat-crosslinkable synthesis The Mooney viscosity before vulcanization of the heat-crosslinkable synthetic rubber contained in the rubber layer (C) is 25 to 45, and the Rockwell hardness (A scale) of the heat-crosslinkable synthetic rubber layer (C) after vulcanization is The manufacturing method of the tile carpet for rental which is 50-70.   The method for manufacturing a tile carpet for rental according to claim 5, wherein the raw fabric heat-treated under conditions of a temperature of 130 to 220 ° C and a time of 10 to 180 seconds is used.   A method for using a rental tile carpet according to claim 1 or 4, or a rental tile carpet manufactured by the method for manufacturing a rental tile carpet according to claim 2, 3, 5, or 6. The rental tile carpet that has been used is removed from the floor, washed, and then placed on the floor again after washing.