JP2012200323A - Recycled tile carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a recycled tile carpet having a low production cost, improving a recycling rate of a carpet waste material, inhibiting warpage and having a superior dimensional stability.SOLUTION: The recycled carpet includes: a pile cloth layer 2 having the upper surface of a base fabric 11 filled with piles 12; a filler resin layer 3 superposed on the lower side of the base fabric; and a backing layer 4 superposed on the lower side of the filler resin layer. The backing layer includes one or a plurality of backing resin layers 7, and a resin-impregnated fiber reinforced layer 6. At least a single backing resin layer is formed by dispersing recycled resin powder obtained by pulverizing vinyl chloride resin-containing carpet waste material and pressurizing it by heating, and has a content rate of the vinyl chloride resin of 5-30 mass%. The filler resin layer is formed by applying a vinyl chloride resin paste sol and the like to the lower surface of the pile cloth layer, and a content ratio of the recycled resin to the whole carpet 1 is 50 mass% or more.

Description

  The present invention relates to a recycled tile carpet using carpet waste material containing a vinyl chloride resin as a constituent material of a backing resin layer.

  When carpets are manufactured, a lot of cutting material is generated, and the amount of carpets to be disposed of from ordinary households and offices becomes enormous. Conventionally, such carpet waste has often been incinerated.

  However, when a carpet lined with a backing material made of a vinyl chloride resin is incinerated, there is a problem that harmful substances are easily generated. In recent years, there has been a strong demand for collecting and recycling carpet waste materials due to a demand for protecting the global environment. Against this background, a new carpet has been proposed that uses recycled carpet waste containing vinyl chloride resin.

  For example, the backing layer of a waste tile carpet lined with a vinyl chloride resin is scraped, the cutting powder is further pulverized and separated, and the pulverized product of the separated backing layer is added to a vinyl chloride resin paste sol by 0.5 wt% or more. A recycled tile carpet is known which is mixed at a ratio of 20% by weight or less, coated on a coating belt with a coater, and laminated with a base material with a tufted pile on a base fabric to form a resin backing layer on the back surface of the base material. (See Patent Document 1).

JP 2004-141434 A

  However, in the technique of Patent Document 1, when the vinyl chloride resin of the backing layer of the waste tile carpet is recycled, it is necessary to apply the vinyl chloride resin as a paste sol, and this paste sol tends to increase in viscosity. There was a problem that molding processability was not good, and it was difficult to obtain a product with sufficient quality as a product. For this reason, there was a restriction that the amount of vinyl chloride resin to be recycled as paste sol had to be reduced. That is, it is difficult to increase the recycling rate of waste tile carpet. The maximum proportion of carpet waste that can be contained in the backing layer of recycled tile carpet is 20% by mass, and the content ratio of carpet waste to the entire tile carpet, that is, the recycling ratio is less than 15% by mass. It was. As described above, in the prior art, the recycling ratio of the carpet waste material is small, and the recovered carpet waste material cannot be fully recycled.

  Furthermore, the paste sol coating method requires a large amount of power for mixing, kneading, and the like, and has a problem that the production energy cost of the carpet is high.

  The present invention has been made in view of such a technical background, and as a tile carpet that uses recycled vinyl chloride resin-containing carpet waste, the production energy cost can be reduced, and the content ratio of the carpet waste relative to the total mass of the tile carpet. An object of the present invention is to provide a recycled tile carpet that can increase the (recycle ratio), suppress warping, and has excellent dimensional stability.

  In order to achieve the above object, the present invention provides the following means.

[1] A pile fabric layer in which a pile is planted on the upper surface of a base fabric, a sealing resin layer laminated on the lower surface of the pile fabric layer, and a backing layer laminated on the lower surface side of the sealing resin layer A tile carpet with
The backing layer includes one or more backing resin layers and a reinforcing layer made of a nonwoven fabric or a woven fabric made of at least one kind of fiber selected from the group consisting of glass fibers and polyester fibers,
The reinforcing layer is impregnated with resin,
The at least one backing resin layer is a layer formed by spraying and heat-pressing a recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin, and the recycled resin powder. The vinyl chloride resin content in the backing resin layer formed by spraying is 5% by mass to 30% by mass,
The filler resin layer is made of a resin latex or a vinyl chloride resin paste sol containing 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of a vinyl chloride resin and having a viscosity of 500 mPa · s to 10000 mPa · s. Is formed by being applied to the lower surface of the pile fabric layer,
Formation of the eye sealing resin layer is ^{200g / m 2 ~800g / m 2} ,
The content ratio of the recycled resin to the entire tile carpet (not limited to the recycled resin powder, including recycled resin if there is a recycled resin of carpet waste material containing vinyl chloride resin) is 50 Recycled tile carpet characterized by being at least mass%.

[2] A pile fabric layer in which a pile is planted on the upper surface of the base fabric, a sealing resin layer laminated on the lower surface of the pile fabric layer, and a backing layer laminated on the lower surface side of the sealing resin layer A tile carpet with
The backing layer is a first backing resin layer laminated on the lower surface side of the sealing resin layer, and a reinforcing layer laminated on the lower surface side of the first backing resin layer, the group consisting of glass fibers and polyester fibers A reinforcing layer made of a nonwoven fabric or a woven fabric composed of at least one kind of fibers selected from the above, and a second backing resin layer laminated on the lower surface side of the reinforcing layer,
The reinforcing layer is impregnated with resin,
The first backing resin layer and the second backing resin layer are layers formed by spraying and heating and pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin, The vinyl chloride resin content in the first backing resin layer is 5% by mass to 30% by mass, the vinyl chloride resin content in the second backing resin layer is 5% by mass to 30% by mass,
The filler resin layer is made of a resin latex or a vinyl chloride resin paste sol containing 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of a vinyl chloride resin and having a viscosity of 500 mPa · s to 10000 mPa · s. Is formed by being applied to the lower surface of the pile fabric layer,
Formation of the eye sealing resin layer is ^{200g / m 2 ~800g / m 2} ,
The content ratio of the recycled resin to the entire tile carpet (not limited to the recycled resin powder, including recycled resin if there is a recycled resin of carpet waste material containing vinyl chloride resin) is 50 Recycled tile carpet characterized by being at least mass%.

[3] A pile fabric layer in which a pile is planted on the upper surface of the base fabric, a sealing resin layer laminated on the lower surface of the pile fabric layer, and a backing layer laminated on the lower surface side of the sealing resin layer A tile carpet with
The backing layer is a backing resin layer laminated on the lower surface side of the sealing resin layer, and a reinforcing layer laminated on the lower surface side of the backing resin layer, and is at least selected from the group consisting of glass fibers and polyester fibers A reinforcing layer made of a nonwoven fabric or a woven fabric composed of one kind of fiber,
The reinforcing layer is impregnated with resin,
The backing resin layer is a layer formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin, and the vinyl chloride resin in the backing resin layer The content is 5% by mass to 30% by mass,
The filler resin layer is made of a resin latex or a vinyl chloride resin paste sol containing 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of a vinyl chloride resin and having a viscosity of 500 mPa · s to 10000 mPa · s. Is formed by being applied to the lower surface of the pile fabric layer,
Formation of the eye sealing resin layer is ^{200g / m 2 ~800g / m 2} ,
The content ratio of the recycled resin to the entire tile carpet (not limited to the recycled resin powder, including recycled resin if there is a recycled resin of carpet waste material containing vinyl chloride resin) is 50 Recycled tile carpet characterized by being at least mass%.

[4] A pile fabric layer in which a pile is planted on the upper surface of the base fabric, a sealing resin layer laminated on the lower surface of the pile fabric layer, and a backing layer laminated on the lower surface side of the sealing resin layer A tile carpet with
The backing layer is a reinforcing layer laminated on the lower surface side of the sealing resin layer, and is made of a nonwoven fabric or a woven fabric made of at least one fiber selected from the group consisting of glass fibers and polyester fibers. And a backing resin layer laminated on the lower surface side of the reinforcing layer,
The reinforcing layer is impregnated with resin,
The backing resin layer is a layer formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin, and the vinyl chloride resin in the backing resin layer The content is 5% by mass to 30% by mass,
The filler resin layer is made of a resin latex or a vinyl chloride resin paste sol containing 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of a vinyl chloride resin and having a viscosity of 500 mPa · s to 10000 mPa · s. Is formed by being applied to the lower surface of the pile fabric layer,
Formation of the eye sealing resin layer is ^{200g / m 2 ~800g / m 2} ,
The content ratio of the recycled resin to the entire tile carpet (not limited to the recycled resin powder, including recycled resin if there is a recycled resin of carpet waste material containing vinyl chloride resin) is 50 Recycled tile carpet characterized by being at least mass%.

  [5] The recycled tile carpet according to [2], wherein a thickness of the second backing resin layer is greater than or equal to a thickness of the first backing resin layer.

  [6] The recycled tile carpet according to item 2, wherein the thickness of the second backing resin layer is set to 2 to 3 times the thickness of the first backing resin layer.

  [7] 90% by mass or more of the recycled resin powder has a particle size of 1500 μm or less, a fiber content in the recycled resin powder of 10% by mass or less, and a specific gravity of the recycled resin powder of 1.9 or less. The recycled tile carpet according to any one of 1 to 6 above.

  [8] The resin impregnated in the reinforcing layer contains 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of resin latex or vinyl chloride resin, and has a viscosity of 500 mPa · s to 10000 mPa · s. 8. The recycled tile carpet according to any one of 1 to 7 above, wherein a vinyl chloride resin paste sol is used.

  [9] After the recycled resin powder having a vinyl chloride resin content of 5% by mass to 30% by mass obtained by pulverizing the carpet waste material is sprayed on the running belt, the powder sprayed on the belt is 140%. A method for producing a sheet for a backing resin layer of a recycled tile carpet, wherein the sheet for a backing resin layer is obtained by heating at a temperature of from ℃ to 180 ℃ and pressurizing in this heated state.

[10] The method for producing a sheet for the backing resin layer of recycled carpet tiles according to the recycled resin powder under 9 sparging at an application amount 300g / m ² ~4000g / m ² on the belt.

In the inventions of [1] to [4], a tile carpet using recycled vinyl chloride resin-containing carpet waste is provided. At least one backing resin layer is formed by spraying recycled resin powder obtained by pulverizing carpet waste material containing vinyl chloride resin and heating and pressurizing. In the conventional paste sol coating method, Since the backing resin layer is formed by the pulverized material dispersion method, the production energy cost can be reduced, and the recycled resin for the entire tile carpet (not limited to the recycled resin powder, but a carpet containing a vinyl chloride resin) If there is a resin (for example, a calendar-molded backing resin layer) using recycled waste materials, the content ratio of the recycled resin can be 50% by mass or more. Further, since the backing layer includes a reinforcing layer (impregnated with resin) made of a nonwoven fabric or a woven fabric made of at least one kind of fiber selected from the group consisting of glass fibers and polyester fibers, warping is suppressed. In addition, a recycled tile carpet having excellent dimensional stability is provided. Further, the filler resin layer is a vinyl chloride resin paste containing 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of the resin latex or vinyl chloride resin, and having a viscosity of 500 mPa · s to 10000 mPa · s. sol, are those formed by being applied on the lower surface of the pile fabric layer, and since the formation of the sealing resin layer is ^{200g / m 2 ~800g / m 2} , the resistance to fuzz resistance (fuzz resistance) Are better.

  In the invention of [2], the backing layer includes a first backing resin layer laminated on the lower surface side of the sealing resin layer, and a resin-impregnated reinforcing layer having the specific configuration laminated on the lower surface side of the first backing resin layer. And the second backing resin layer laminated on the lower surface side of the reinforcing layer, the warping of the tile carpet can be more sufficiently suppressed.

  In the invention of [5], since the thickness of the second backing resin layer in the invention of [2] is larger than or the same as the thickness of the first backing resin layer, warping is sufficient. It is suppressed.

  In the invention of [6], in the invention of [2], the thickness of the second backing resin layer is set to be 2 to 3 times the thickness of the first backing resin layer. The warp is sufficiently suppressed, and even when a pile fabric layer having a large shrinkage due to heat is used, the effect that the warp is sufficiently suppressed can be obtained.

  In the invention of [7], since 90% by mass or more of the recycled resin powder has a particle size of 1500 μm or less, the powder can be uniformly dispersed. Moreover, since the fiber content rate in recycled resin powder is 10 mass% or less, it is excellent in workability. Moreover, since the specific gravity of the recycled resin powder is 1.9 or less, it can be a light product with excellent strength.

  In the invention of [8], the adhesive strength between the resin-impregnated fiber reinforcing layer and other constituent layers in contact with the resin-impregnated fiber reinforcing layer can be improved.

  In the invention of [9], since the backing resin layer sheet is formed by a recycling method of the recycled resin powder, the backing resin layer sheet of the recycled tile carpet can be manufactured at a low energy cost. In addition, since the vinyl chloride resin content in the recycled resin powder is a low content of 5% by mass to 30% by mass, it has excellent strength and dimensional stability by heating and pressing at a low temperature of 180 ° C. or lower. A sheet for a backing resin layer can be produced.

In the invention [10], because spraying a recycled resin powder at application rates ^{300g / m 2 ~4000g / m 2} , can be manufactured more backing resin layer sheet with improved dimensional stability together with improved strength.

It is sectional drawing which shows an example (1st Embodiment) of the recycle tile carpet of this invention. It is sectional drawing which shows the other example (2nd Embodiment) of the recycled tile carpet of this invention. It is sectional drawing which shows other example (3rd Embodiment) of the recycle tile carpet of this invention. It is sectional drawing which shows other example (4th Embodiment) of the recycled tile carpet of this invention. It is sectional drawing which shows other example (5th Embodiment) of the recycled tile carpet of this invention. It is sectional drawing which shows other example (6th Embodiment) of the recycled tile carpet of this invention.

  One embodiment (first embodiment) of a recycled tile carpet according to the present invention is shown in FIG. The recycled tile carpet 1 of the present invention includes a pile fabric layer 2 in which a pile 12 is planted on the upper surface of a base fabric 11, a sealing resin layer 3 laminated on the lower surface of the pile fabric layer 2, and the sealing And a backing layer 4 laminated on the lower surface side of the resin layer 3.

  In the present invention, the backing layer 4 is composed of one or a plurality of backing resin layers 7, 8, 9 and a nonwoven fabric or woven fabric composed of at least one fiber selected from the group consisting of glass fibers and polyester fibers. And at least a reinforcing layer 6. The reinforcing layer 6 is impregnated with resin. That is, the fiber reinforcement layer 6 is a resin-impregnated fiber reinforcement layer.

  Among the backing resin layers, at least one backing resin layer is a recycled backing resin formed by spraying and heating and pressing recycled resin powder obtained by pulverizing carpet waste material containing vinyl chloride resin. Is a layer. The content of the vinyl chloride resin in the recycled resin powder is set to 5% by mass to 30% by mass on a mass average. Therefore, the vinyl chloride resin content in the recycled backing resin layer formed by powder dispersion is 5% by mass to 30% by mass.

The sealing resin layer 3 is formed by applying any resin selected from the group consisting of the following (a), (b), and (c) to the lower surface of the pile fabric layer 2.
(A) Resin latex,
(B) a vinyl chloride resin paste sol having an inorganic filler content of more than 0 parts by mass and not more than 200 parts by mass and a viscosity of 500 mPa · s to 10000 mPa · s with respect to 100 parts by mass of the vinyl chloride resin;
(C) A vinyl chloride resin paste sol containing no inorganic filler and having a viscosity of 500 mPa · s to 10000 mPa · s.

Formation of the eye sealing resin layer 3 is set to ^{200g / m 2 ~800g / m 2} .

In the recycled tile carpet 1 of the present invention, the vinyl chloride resin-containing carpet waste material is recycled and can contribute to environmental protection. In addition, at least one backing resin layer is formed by spraying recycled resin powder obtained by pulverizing a carpet waste material containing vinyl chloride resin and applying heat and pressure. Since the backing resin layer is formed not by the method but by the pulverized product (powder) spraying method, the production energy cost can be reduced. Further, since the backing layer 4 includes a reinforcing layer 6 (impregnated with resin) made of a nonwoven fabric or a woven fabric made of at least one kind of fiber selected from the group consisting of glass fibers and polyester fibers, warping is caused. A recycled tile carpet which is suppressed and has excellent dimensional stability and shape stability is provided. Furthermore, the sealing resin layer 3 is formed by applying any resin selected from the group consisting of the above (a), (b) and (c) to the lower surface of the pile fabric layer 2, and because formation of the sealing resin layer 3 is ^{200g / m 2 ~800g / m 2} , has excellent resistance to fuzz resistance (fuzz resistance).

  In the present invention, a recycled resin for the entire tile carpet 1 (not limited to the recycled resin powder, but a resin obtained by recycling a carpet waste material containing vinyl chloride resin (for example, a calendar-molded backing resin obtained by calendering carpet waste material pellets). If there is a layer or the like), the content ratio of such recycled resin is also set to be 50% by mass or more (usually set to 50% to 85% by mass). As a result, the recycled tile carpet 1 having a large content ratio (that is, a recycling ratio) of the carpet waste material with respect to the total mass of the tile carpet 1 is provided. In the present invention, the at least one backing resin layer employs a configuration formed by spraying recycled resin powder obtained by pulverizing carpet waste material containing vinyl chloride resin and heating and pressing. Thus, it is possible to realize such a high recycling ratio of 50% by mass or more with low energy.

(First embodiment)
In the recycled tile carpet 1 shown in FIG. 1, the backing layer 4 includes a first backing resin layer 7 laminated on the lower surface of the sealing resin layer 3 and a reinforcing layer laminated on the lower surface of the first backing resin layer 7. A reinforcing layer 6 made of a nonwoven fabric or a woven fabric made of at least one fiber selected from the group consisting of glass fibers and polyester fibers, and a second backing resin layer 8 laminated on the lower surface of the reinforcing layer 6 And a calender-molded backing resin layer 31 laminated on the lower surface of the second backing resin layer 8. The reinforcing layer 6 is impregnated with resin. With this impregnating resin, the reinforcing layer 6 and the first backing resin layer 7 are bonded, and the reinforcing layer 6 and the second backing resin layer 8 are bonded.

  The first backing resin layer 7 and the second backing resin layer 8 are layers formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin. is there. The calender-molded backing resin layer 31 is a resin layer obtained by calender molding a carpet waste material containing a vinyl chloride resin.

(Second Embodiment)
2nd Embodiment of the recycled tile carpet 1 of this invention is shown in FIG. In the tile carpet 1 of FIG. 2, the backing layer 4 is a backing resin layer 9 laminated on the lower surface of the sealing resin layer 3 and a reinforcing layer laminated on the lower surface of the backing resin layer 9. It consists of a reinforcing layer 6 made of a nonwoven fabric or a woven fabric composed of at least one kind of fiber selected from the group consisting of fibers, and a calendered backing resin layer 31 laminated on the lower surface of the reinforcing layer 6. The reinforcing layer 6 is impregnated with resin. With this impregnating resin, the reinforcing layer 6 and the backing resin layer 9 are bonded, and the reinforcing layer 6 and the calendar-molded backing resin layer 31 are bonded.

  The backing resin layer 9 is a layer formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin. The calender-molded backing resin layer 31 is a resin layer obtained by calender molding a carpet waste material containing a vinyl chloride resin. In addition, since structures other than the backing layer 4 are the same as FIG. 1, the same code | symbol is attached | subjected about the same member and the description is abbreviate | omitted.

(Third embodiment)
3rd Embodiment of the recycled tile carpet 1 of this invention is shown in FIG. In the tile carpet 1 of FIG. 3, the backing layer 4 is a first backing resin layer 7 laminated on the lower surface of the sealing resin layer 3 and a reinforcing layer laminated on the lower surface of the first backing resin layer 7. It comprises a reinforcing layer 6 made of a nonwoven fabric or a woven fabric made of at least one fiber selected from the group consisting of glass fibers and polyester fibers, and a second backing resin layer 8 laminated on the lower surface of the reinforcing layer 6. . The reinforcing layer 6 is impregnated with resin. With this impregnating resin, the reinforcing layer 6 and the first backing resin layer 7 are bonded, and the reinforcing layer 6 and the second backing resin layer 8 are bonded.

  The first backing resin layer 7 and the second backing resin layer 8 are layers formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin. is there. In addition, since structures other than the backing layer 4 are the same as FIG. 1, the same code | symbol is attached | subjected about the same member and the description is abbreviate | omitted.

(Fourth embodiment)
A fourth embodiment of the recycled tile carpet 1 of the present invention is shown in FIG. In the tile carpet 1 of FIG. 4, the backing layer 4 is a reinforcing layer laminated on the lower surface of the sealing resin layer 3 and is a nonwoven fabric composed of at least one fiber selected from the group consisting of glass fibers and polyester fibers. Or it consists of a reinforcing layer 6 made of woven fabric, a backing resin layer 9 laminated on the lower surface of the reinforcing layer 6, and a calendered backing resin layer 31 laminated on the lower surface of the backing resin layer 9. The reinforcing layer 6 is impregnated with resin. With this impregnating resin, the reinforcing layer 6 and the sealing resin layer 3 are bonded, and the reinforcing layer 6 and the backing resin layer 9 are bonded.

  The backing resin layer 9 is a layer formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin. The calender-molded backing resin layer 31 is a resin layer obtained by calender molding a carpet waste material containing a vinyl chloride resin. In addition, since structures other than the backing layer 4 are the same as FIG. 1, the same code | symbol is attached | subjected about the same member and the description is abbreviate | omitted.

(Fifth embodiment)
5th Embodiment of the recycled tile carpet 1 of this invention is shown in FIG. In the tile carpet 1 of FIG. 5, the backing layer 4 is a reinforcing layer laminated on the lower surface of the sealing resin layer 3 and is a non-woven fabric composed of at least one fiber selected from the group consisting of glass fibers and polyester fibers. Or it consists of the reinforcement layer 6 which consists of woven fabric, and the backing resin layer 9 laminated | stacked on the lower surface of this reinforcement layer 6. FIG. The reinforcing layer 6 is impregnated with resin. With this impregnating resin, the reinforcing layer 6 and the sealing resin layer 3 are bonded, and the reinforcing layer 6 and the backing resin layer 9 are bonded.

  The backing resin layer 9 is a layer formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin. In addition, since structures other than the backing layer 4 are the same as FIG. 1, the same code | symbol is attached | subjected about the same member and the description is abbreviate | omitted.

(Sixth embodiment)
FIG. 6 shows a sixth embodiment of the recycled tile carpet 1 of the present invention. In the tile carpet 1 of FIG. 6, the backing layer 4 is a calendered backing resin layer 31 laminated on the lower surface of the sealing resin layer 3 and a reinforcing layer laminated on the lower surface of the calendered backing resin layer 31. It comprises a reinforcing layer 6 made of a nonwoven fabric or a woven fabric made of at least one fiber selected from the group consisting of glass fibers and polyester fibers, and a backing resin layer 9 laminated on the lower surface of the reinforcing layer 6. The reinforcing layer 6 is impregnated with resin. With this impregnating resin, the reinforcing layer 6 and the calendar-molded backing resin layer 31 are bonded, and the reinforcing layer 6 and the backing resin layer 9 are bonded.

  The backing resin layer 9 is a layer formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin. The calender-molded backing resin layer 31 is a resin layer obtained by calender molding a carpet waste material containing a vinyl chloride resin. In addition, since structures other than the backing layer 4 are the same as FIG. 1, the same code | symbol is attached | subjected about the same member and the description is abbreviate | omitted.

  As shown in the first to sixth embodiments, in the backing layer 4 of the present invention, the mutual arrangement relationship (upper and lower arrangement positions) of the backing resin layers 7, 8, 9 and the reinforcing layer 6 is not particularly limited. . Further, a configuration in which another layer (for example, a calendar-molded backing resin layer 31) is laminated and integrated between the backing resin layers 7, 8, and 9 and the reinforcing layer 6 may be employed.

  In the present invention, the pile fabric layer 2 is obtained by planting the pile 12 on the upper surface of the base fabric 11, and is not particularly limited. For example, tufted carpet, woven carpet, knitted carpet, Examples include electrodeposition carpets.

  Any material can be used as the base fabric 11 and is not particularly limited. For example, synthetic fibers such as polyester fiber, nylon fiber, polypropylene fiber, acrylic fiber, hemp, cotton, In addition to a fabric knitted and woven from yarns such as natural fibers such as wool, the various fibers and yarns are mechanically connected by needling or the like, or chemically bonded by an adhesive or the like. Nonwoven fabric etc. are mentioned.

  The pile 12 is not particularly limited. For example, the pile 12 can be preferably made of polyester fiber, nylon fiber, polypropylene fiber, acrylic fiber, rayon fiber or the like, and in addition, hemp, cotton, Those made of natural fibers such as wool can be used. The means for forming the pile layer is not particularly limited. For example, means for forming a pile layer by weaving such as warp pile weft, weft pile weave, etc. Examples thereof include a means for forming a pile layer, a means for forming a pile layer by a knitting machine, and a means for forming a pile layer by bonding pile yarns using an adhesive. The pile form is not particularly limited, and may be any form such as a cut pile or a loop pile.

  The sealing resin layer 3 is formed by applying 1) resin latex to the lower surface of the pile fabric layer 2, or 2) 0 part by mass of an inorganic filler with respect to 100 parts by mass of the vinyl chloride resin. And a vinyl chloride resin paste sol having a viscosity of 500 mPa · s to 10000 mPa · s is applied to the lower surface of the pile fabric layer 2 or 3) an inorganic filler. And a vinyl chloride resin paste sol having a viscosity of 500 mPa · s to 10000 mPa · s is applied to the lower surface of the pile fabric layer 2. Although it does not specifically limit as said resin latex, It is preferable to use SBR resin (styrene-butadiene copolymer) latex and / or EVA resin (ethylene-vinyl acetate copolymer resin) latex.

Formation of the eye sealing resin layer 3 (fixed amount) is set to a range of ^{200g / m 2 ~800g / m 2} . If it is less than 200 g / m ² , the fuzz resistance is lowered, and if it exceeds 800 g / m ² , there is a problem that the curing or drying energy is increased to increase the cost and the recycling ratio is lowered. Among them, formation of the eye sealing resin layer 3 is preferably a ^{250g / m 2 ~650g / m 2} .

  In the case of using the vinyl chloride resin paste sol, if the content of the inorganic filler with respect to 100 parts by mass of the vinyl chloride resin exceeds 200 parts by mass, the fuzz resistance is lowered. In addition, when the viscosity of the vinyl chloride resin paste sol is less than 500 mPa · s, the resin is soaked into the base fabric and the workability is lowered, and when the viscosity exceeds 10,000 mPa · s, the fuzz resistance is lowered. Among them, it is preferable to use a vinyl chloride resin paste sol having a viscosity of 1000 mPa · s to 6000 mPa · s.

  The inorganic filler is not particularly limited, and examples thereof include calcium carbonate, magnesium hydroxide, aluminum hydroxide, talc, silica, and clay.

  The backing resin layers 7, 8 and 9 are layers formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin. The carpet waste material containing the vinyl chloride resin is not particularly limited, and examples thereof include cut end materials at the time of carpet production, carpets discarded from general households and offices, etc. A carpet (such as a tile carpet) lined with a vinyl chloride resin is preferably used.

  A method for obtaining a recycled resin powder by collecting and crushing a backing layer (vinyl chloride resin) from the carpet backed with the vinyl chloride resin is not particularly limited. For example, a backing layer made of a vinyl chloride resin is used. Is removed from the carpet waste material, and this release waste material is pulverized using a pulverizer (for example, the pulverization method described in JP-A-2003-47878 can be employed). And a fiber component, and the separated resin component is further pulverized (for example, a pulverization method described in JP-A-2006-326152 can be employed).

  The recycled resin powder obtained by pulverization may contain fiber components such as pile fibers and nonwoven fabric fibers constituting the waste carpet material.

  The content of the vinyl chloride resin in the recycled resin powder needs to be 5% by mass to 30% by mass on a mass average. If it is less than 5% by mass, it becomes difficult to form the backing layer 4 having sufficient strength even when heated and melted due to insufficient resin components. If it exceeds 30% by mass, the vinyl chloride resin may be decomposed because it must be melted at a high temperature due to an increase in the resin content, and if this occurs, the dimensional stability of the tile carpet is reduced. descend. On the other hand, if it exceeds 30% by mass, melting at a high temperature is required, so a great amount of energy is required during processing. Especially, it is preferable that the content rate of the vinyl chloride resin in the said recycled resin powder is 10 mass%-20 mass% in a mass average. In addition, since a large number of recycled resin powders obtained by pulverization have different vinyl chloride resin content ratios depending on each powder, the mass average of many recycled resin powders used for these uses (not number average) It defines the range of the vinyl chloride resin content. Accordingly, the vinyl chloride resin content in each of the backing resin layers 7, 8, 9 formed by spraying the recycled resin powder and heating and pressing is 5% by mass to 30% by mass. Especially, it is preferable that the vinyl chloride resin content rate in each backing resin layer 7,8,9 formed by spraying the said recycling resin powder and heating and pressurizing is 10 mass%-20 mass%.

  The average particle diameter of the recycled resin powder is preferably 500 μm to 1200 μm. When it is 500 μm or more, it is possible to prevent the powder from rising during production and maintain a good working environment, and when it is 1200 μm or less, it is possible to uniformly disperse, reduce voids, and improve workability. it can.

  90% by mass or more (including 100% by mass) of the recycled resin powder preferably has a particle size of 1500 μm or less. In this case, uniform dispersion can be achieved to reduce voids and improve workability. Can be made. Further, the fiber content in the recycled resin powder is preferably 10% by mass or less (including a fiber content of 0% by mass not containing fibers). In this case, there is an advantage that processability can be improved with less fiber clumps. There is. The recycled resin powder preferably has a specific gravity of 1.6 to 1.9.

The formation of the backing resin layer 7, 8, 9 is preferably also set to 300g / m ² ~4000g / m ² in both. Backing resin layers 7, 8, and 9 having sufficient strength and sufficient dimensional stability can be formed by being 300 g / m ² or more, and cost reduction and weight reduction can be achieved by being 4000 g / m ² or less. Can be planned. Among them, the formation of the backing resin layer 7, 8, 9, and more preferably also set to 400g / m ² ~3500g / m ² in both.

  The reinforcing layer 6 mainly serves to improve the shape stability and dimensional stability of the recycled tile carpet 1 of the present invention. As the reinforcing layer 6, a nonwoven fabric or a woven fabric composed of at least one fiber selected from the group consisting of glass fibers and polyester fibers is used. The nonwoven fabric or woven fabric having such a structure has high strength and heat resistance, has little change with time, and has a large contact area with the resin layer, so that the shape and dimensions of the tile carpet 1 can be stabilized. Can do. Especially, the nonwoven fabric which consists of glass fiber is suitable at the point which can fully stabilize the shape and dimension of the tile carpet 1. FIG.

The basis weight of the reinforcing layer 6 (not including the amount of impregnating resin) is preferably a ^{15g / m 2 ~60g / m 2} . The shape stability and dimensional stability of the tile carpet 1 can be sufficiently secured by being 15 g / m ² or more, and delamination between the reinforcing layer 6 and the backing resin layer can be prevented by being 60 g / m ² or less. it can.

  The reinforcing layer 6 is impregnated with resin. It is desirable that the resin is impregnated throughout the thickness of the reinforcing layer 6. Thus, by impregnating the resin up to the inside of the reinforcing layer 6, the structure of the reinforcing layer (nonwoven fabric or woven fabric composed of at least one fiber selected from the group consisting of glass fiber and polyester fiber) 6 is further increased. The reinforcement layer and the backing resin layer are strongly integrated with each other, and the shape and dimensions of the tile carpet 1 can be further stabilized, and the warp can be sufficiently prevented, and the chair caster. Sufficient dimensional stability is exhibited even if hard wear due to, for example, is repeated many times (durable dimensional stability is obtained).

As the resin impregnated in the reinforcing layer 6, it is preferable to use any resin selected from the group consisting of the following (d), (e), and (f).
(D) resin latex,
(E) a vinyl chloride resin paste sol having an inorganic filler content of more than 0 parts by mass and not more than 200 parts by mass and a viscosity of 500 mPa · s to 10000 mPa · s with respect to 100 parts by mass of the vinyl chloride resin;
(F) A vinyl chloride resin paste sol containing no inorganic filler and having a viscosity of 500 mPa · s to 10000 mPa · s.
In this case, adhesiveness and workability can be improved. Impregnation fixed amount of the resin (solid content) is preferably set to ^{100g / m 2 ~300g / m 2} . The resin latex is not particularly limited, but SBR resin latex and / or EVA resin latex is preferably used.

Among them, it is more preferable to impregnate the reinforcing layer 6 with the vinyl chloride resin paste sol having the above-mentioned specific configuration. In this case, a drying step requiring large heat energy is not required, which is economically advantageous. If the viscosity is using the vinyl chloride resin paste sol 500mPa · s~10000mPa · s, by doctor coating method or the like, it is possible to lower the amount coated of ^{100g / m 2 ~1000g / m 2} .

  In the recycled tile carpet 1 shown in FIGS. 1 and 3, the thickness of the second backing resin layer 8 is preferably larger than or equal to the thickness of the first backing resin layer 7, and in this case, the warp is sufficiently large. It is suppressed. In particular, the thickness of the second backing resin layer 8 is particularly preferably set to be 2 to 3 times the thickness of the first backing resin layer 7.

  Next, an example is given and demonstrated about the manufacturing method of the said recycled tile carpet 1. FIG. First, recycled resin powder having a vinyl chloride resin content of 5% by mass to 30% by mass obtained by pulverizing carpet waste is put into a scatter of a powder spraying machine. At this time, if necessary, a plasticizer, a lubricant, a filler, a pigment, and the like can be mixed. Next, after the recycled resin powder is sprayed from the scatter onto the traveling releasable belt, the powder sprayed on the belt is heated to 140 ° C. to 180 ° C. and melted. A sheet for backing resin layer is obtained by forming a sheet by pressurizing with the use of. Since the vinyl chloride resin content in the recycled resin powder is as low as 5% by mass to 30% by mass, it has sufficient strength and is stable to the tile carpet 1 by heating and pressing at a low temperature of 180 ° C. or lower. A backing resin layer 9 capable of imparting dimensional stability can be formed.

Application rate of the recycled resin powder is preferably set to ^{300g / m 2 ~4000g / m 2} . When it is 300 g / m ² or more, a backing resin layer having sufficient strength and sufficient dimensional stability can be formed, and when it is 4000 g / m ² or less, recycled resin powder does not require large heat energy. Can be melted to form a backing resin layer. Among them, application rate of the recycled resin powder may be more preferably in ^{400g / m 2 ~3500g / m 2} .

  In the scatter, a roller having a surface on which a large number of dimples (dents) such as golf balls are formed is arranged at the lower spout, and the resin powder that has entered the dimple is sprinkled by rotating the roller. This is a device that sprays downward from the mouth, and the resin powder stored in the scatter can be sprayed in a desired amount.

  Next, the resin-impregnated reinforcing layer 6 is overlaid on the backing resin layer 9 and then pressed by a pressure roll or the like to obtain a laminate.

On the other hand, a vinyl chloride resin paste sol having a viscosity of 500 mPa · s to 10000 mPa · s (an inorganic filler such as calcium carbonate with respect to 100 parts by mass of the vinyl chloride resin) on the back surface of the pile fabric layer 2 (the surface on which no pile is implanted) which contained 200 parts by mass or less than 0 parts by mass, or after the free inorganic filler) was applied ^{200g / m 2 ~800g / m 2} , to cure the paste sol by heating the pile fabric 2 Then, the sealing resin layer 3 is formed. Next, the pile fabric 2 is overlapped on the resin-impregnated reinforcing layer 6 of the laminate with the sealing resin layer 3 on the lower side and sandwiched between a pair of rolls at a temperature of 120 ° C. to 160 ° C. After thermocompression bonding, the recycled tile carpet 1 (see FIG. 5) is obtained by cutting into a predetermined shape such as a square shape.

  In addition, the said manufacturing method is only what showed the example, and the recycled tile carpet 1 of this invention is not specifically limited to what is manufactured with the said manufacturing method.

  Next, specific examples of the present invention will be described, but the present invention is not particularly limited to these examples.

<Materials used>
(Pile fabric layer)
A polyester fiber non-woven fabric (base fabric) having a basis weight of 90 g / m ² is tufted with a pile yarn made of nylon fibers as a loop pile (pile basis weight 610 g / m ² ).
(Reinforcing layer)
Resin impregnation obtained by applying 300 g / m ^{2 of} vinyl chloride resin paste sol with a viscosity of 1500 mPa · s to a nonwoven fabric composed of glass fibers with a basis weight of 35 g / m ² by a doctor coating application method and heating and curing at 150 ° C. for 3 minutes. Reinforcing layer (resin impregnated throughout the thickness direction of the nonwoven fabric).
(Recycled resin powder A)
The backing layer (vinyl chloride resin) is peeled from the carpet waste lined with vinyl chloride resin, and this peeled waste is pulverized using a pulverizer, and the resulting pulverized product is divided into resin and fiber by wind vibration classification. Recycled resin powder A having an average particle size of 850 μm obtained by separating and further pulverizing the separated resin. 92% by mass of the recycled resin powder A has a particle diameter of 1500 μm or less, the fiber content in the recycled resin powder A is 2% by mass, and the specific gravity of the recycled resin powder A is 1.78. The distribution of the vinyl chloride resin content in the recycled resin powder A is 8 to 24% by mass, and the mass average is 18% by mass.
(Recycled resin powder B)
The backing layer (vinyl chloride resin) is peeled from the carpet waste lined with vinyl chloride resin, and this peeled waste is pulverized using a pulverizer, and the resulting pulverized product is divided into resin and fiber by wind vibration classification. Recycled resin powder B having an average particle size of 700 μm obtained by separating and further finely pulverizing the separated resin. 96% by mass of the recycled resin powder B has a particle diameter of 1500 μm or less, the fiber content in the recycled resin powder B is 2% by mass, and the specific gravity of the recycled resin powder B is 1.75. The distribution of the vinyl chloride resin content in the recycled resin powder B is 18 to 24% by mass, and the mass average is 20% by mass.

  In addition, the particle size distribution data (for example, “92% by mass of the powder has a particle size of 1500 μm or less”) of the recycled resin powder is measured by a wet measurement method using a MICROTRAC particle size analyzer manufactured by Nikkiso Co., Ltd. It is the value calculated | required based on the obtained particle size distribution. The wet measurement method is a method of dispersing powder in water, irradiating a flowing powder group with laser light, and performing particle size analysis using the forward scattered light.

  The average particle diameter of the recycled resin powder is an area-based average particle diameter determined using a MICROTRAC particle size analyzer manufactured by Nikkiso Co., Ltd.

  The distribution of the vinyl chloride resin content in the recycled resin powder is determined as follows. That is, after each recycled resin powder is dissolved in THF (tetrahydrofuran) and centrifuged, the soluble content is reprecipitated with methanol, the insoluble content is dried, and the mass is measured by measuring the mass of each powder. This operation for obtaining the rate was carried out on 10 samples arbitrarily selected (about 100 g of powder was taken as 1 sample), and the distribution of the vinyl chloride resin content in the recycled resin powder was calculated from the minimum and maximum values. The mass average value of the vinyl chloride resin content in the recycled resin powder is an average value for the 10 samples.

<Example 1>
The above-mentioned recycled resin powder A is put into a powder spraying machine, and the recycled resin powder A is sprayed on the moving endless releasable belt at a spraying amount of 3500 g / m ² from the scatter of the spraying machine, The recycled resin powder A was heated and melted by heating to 170 ° C. with a heating device, and then formed into a sheet by pressing with a water-cooled cooling and pressing roll from the upper surface side to form the backing resin layer 9. The vinyl chloride resin content in the backing resin layer 9 was 18% by mass. Next, after superposing the resin impregnated reinforcing layer 6 on the backing resin layer 9, the surface was heated to 150 ° C. and pressurized with a water-cooled cooling and pressure roll to obtain a laminate. .

On the other hand, 500 g of a vinyl chloride resin paste sol having a viscosity of 2500 mPa · s (containing 100 parts by mass of calcium carbonate with respect to 100 parts by mass of the vinyl chloride resin) on the back surface (the surface on which the pile is not implanted) of the pile fabric layer 2. After applying / m ² , the pile fabric 2 is cured by heating at 150 ° C. for 3 minutes to form the sealing resin layer 3, and then the upper surface of the resin-impregnated reinforcing layer 6 of the laminate is heated to 150 ° C. The pile fabric 2 is overlapped on the resin-impregnated reinforcing layer 6 with the resin layer 3 on the lower side (the lower surface is also heated to 150 ° C.) and sandwiched between a pair of rolls. After thermocompression bonding, the recycled tile carpet 1 shown in FIG. 5 was obtained by cutting into a 500 mm × 500 mm square shape.

<Example 2>
The recycled resin powder B was charged into a Banbury kneader and kneaded, and then formed into a long sheet (calendar molding backing resin layer 31) having a thickness of 1.2 mm using a calendar molding machine.

Next, the recycled resin powder A is put into a powder spreading machine, and the recycled resin powder A is placed on the upper surface of the endless release belt together with the release belt from the scatter of the spreading machine. On the long sheet 31 being transported in the horizontal direction, it is sprayed at a spraying amount of 1500 g / m ² , and then heated to 170 ° C. by a heating device to heat and melt the recycled resin powder A, and then the upper surface side thereof The backing resin layer 9 was formed by pressurizing with a water-cooled cooling and pressurizing roll. The vinyl chloride resin content in the backing resin layer 9 was 18% by mass. Next, after superposing the resin impregnated reinforcing layer 6 on the backing resin layer 9, the surface was heated to 150 ° C. and pressurized with a water-cooled cooling and pressure roll to obtain a laminate. .

On the other hand, 500 g of a vinyl chloride resin paste sol having a viscosity of 2500 mPa · s (containing 100 parts by mass of calcium carbonate with respect to 100 parts by mass of the vinyl chloride resin) on the back surface (the surface on which the pile is not implanted) of the pile fabric layer 2. After applying / m ² , the pile fabric 2 is cured by heating at 150 ° C. for 3 minutes to form the sealing resin layer 3, and then the upper surface of the resin-impregnated reinforcing layer 6 of the laminate is heated to 150 ° C. The pile fabric 2 is overlapped on the resin-impregnated reinforcing layer 6 with the resin layer 3 on the lower side (the lower surface is also heated to 150 ° C.) and sandwiched between a pair of rolls. After thermocompression bonding, the recycled tile carpet 1 shown in FIG. 4 was obtained by cutting into a 500 mm × 500 mm square shape.

<Example 3>
The recycled resin powder B was charged into a Banbury kneader and kneaded, and then formed into a long sheet (calendar molding backing resin layer 31) having a thickness of 1.2 mm using a calendar molding machine.

Next, the recycled resin powder A is put into a scatter of a powder spraying machine, and the recycled resin powder A from the scatter is placed on the upper surface of the endless releasable belt together with the releasable belt in the horizontal direction. After spraying at 500 g / m ² on the long sheet 31 being conveyed to the top, and then heating and melting the recycled resin powder A by heating to 170 ° C. with a heating device, water cooling is performed from the upper surface side. The second backing resin layer 8 was formed by pressurization with a cooling and pressure roll of the formula. Next, after the resin-impregnated reinforcing layer 6 is overlaid on the second backing resin layer 8, the recycled resin powder A is further applied onto the resin-impregnated reinforcing layer 6 from a scatterer at an application amount of 500 g / m ² . Then, after heating and melting the recycled resin powder A with a heating device to 170 ° C., pressure is applied with a water-cooled cooling and pressing roll from the upper surface side, and backing resin layer 31 / second backing is performed. A laminate in which the resin layer 8 / the resin impregnated reinforcing layer 6 / the first backing resin layer 7 were laminated and integrated in this order was obtained. The vinyl chloride resin content in the first backing resin layer 7 was 18% by mass, and the vinyl chloride resin content in the second backing resin layer 8 was 18% by mass.

On the other hand, 500 g of a vinyl chloride resin paste sol having a viscosity of 2500 mPa · s (containing 100 parts by mass of calcium carbonate with respect to 100 parts by mass of the vinyl chloride resin) on the back surface (the surface on which the pile is not implanted) of the pile fabric layer 2. After applying / m ² , the pile fabric 2 is cured by heating at 150 ° C. for 3 minutes to form the sealing resin layer 3, and then the upper surface of the resin-impregnated reinforcing layer 6 of the laminate is heated to 150 ° C. The pile fabric 2 is overlapped on the resin-impregnated reinforcing layer 6 with the resin layer 3 on the lower side (the lower surface is also heated to 150 ° C.) and sandwiched between a pair of rolls. After thermocompression bonding, the recycled tile carpet 1 shown in FIG. 1 was obtained by cutting into a 500 mm × 500 mm square shape.

<Example 4>
Example 1 except that 500 g / m ^{2 of a} vinyl chloride resin paste sol having a viscosity of 1800 mPa · s (containing 100 parts by mass of calcium carbonate with respect to 100 parts by mass of vinyl chloride resin) was applied to the back surface of the pile fabric layer 2. Thus, a recycled tile carpet 1 shown in FIG. 5 was obtained.

<Example 5>
Example 1 except that 500 g / m ^{2 of} vinyl chloride resin paste sol having a viscosity of 1000 mPa · s (containing 100 parts by mass of calcium carbonate with respect to 100 parts by mass of vinyl chloride resin) was applied to the back surface of the pile fabric layer 2. Thus, a recycled tile carpet 1 shown in FIG. 5 was obtained.

<Example 6>
Example 1 except that 500 g / m ^{2 of} vinyl chloride resin paste sol (containing 180 parts by mass of calcium carbonate with respect to 100 parts by mass of vinyl chloride resin) having a viscosity of 3500 mPa · s was applied to the back surface of the pile fabric layer 2. Thus, a recycled tile carpet 1 shown in FIG. 5 was obtained.

<Example 7>
Example 1 except that 500 g / m ^{2 of} vinyl chloride resin paste sol having a viscosity of 1000 mPa · s (containing 80 parts by mass of calcium carbonate with respect to 100 parts by mass of vinyl chloride resin) was applied to the back surface of the pile fabric layer 2. Thus, a recycled tile carpet 1 shown in FIG. 5 was obtained.

<Comparative Example 1>
Vinyl chloride resin paste sol (90 parts by mass of plasticizer, 100 parts by mass of vinyl chloride resin, 400 parts of calcium carbonate) containing 10% by mass of a vinyl chloride resin backing layer (recycled waste material) peeled from the carpet waste material lined with vinyl chloride resin Is coated on the endless releasable belt with a thickness of 1.3 mm, and then a glass fiber nonwoven fabric having a basis weight of 35 g / m ² is superposed on the upper surface, and further on this , A vinyl chloride resin paste sol (90 parts by mass of plasticizer, 100 parts by mass of vinyl chloride resin, calcium carbonate) containing 10% by mass of a vinyl chloride resin backing layer (recycled waste material) peeled from the carpet waste material lined with vinyl chloride resin 400 parts by mass) was coated with a thickness of 1.3 mm. Further, the pile fabric layer 2 is overlaid thereon, pressed between a pair of rolls, heated and cured at 160 ° C., and then cut into a 500 mm × 500 mm square shape to obtain a recycled tile carpet. It was.

<Comparative example 2>
Example 1 except that 500 g / m ^{2 of} vinyl chloride resin paste sol having a viscosity of 25000 mPa · s (containing 120 parts by mass of calcium carbonate with respect to 100 parts by mass of vinyl chloride resin) was applied to the back surface of the pile fabric layer 2. A recycled tile carpet was obtained.

<Comparative Example 3>
Example 1 except that a vinyl chloride resin paste sol having a viscosity of 4500 mPa · s (containing 300 parts by mass of calcium carbonate with respect to 100 parts by mass of vinyl chloride resin) was applied to the back surface of the pile fabric layer 2 at 500 g / m ^2. A recycled tile carpet was obtained.

<Comparative example 4>
Example 1 except that 70 g / m ^{2 of a} vinyl chloride resin paste sol having a viscosity of 2500 mPa · s (containing 100 parts by mass of calcium carbonate with respect to 100 parts by mass of vinyl chloride resin) was applied to the back surface of the pile fabric layer 2. A recycled tile carpet was obtained.

<Comparative Example 5>
Example 1 except that a vinyl chloride resin paste sol having a viscosity of 2500 mPa · s (containing 100 parts by mass of calcium carbonate with respect to 100 parts by mass of vinyl chloride resin) was applied to the back surface of the pile fabric layer 2 at 900 g / m ^2. A recycled tile carpet was obtained.

  In Tables 1 and 2, “Recycling ratio relative to the entire carpet” indicates the content ratio (% by mass) of the recycled resin (resin recycled from carpet waste containing vinyl chloride resin) relative to the entire tile carpet. It is. That is, the “recycle ratio with respect to the entire carpet” is, for example, the content (% by mass) of the recycled resin powder A with respect to the entire tile carpet in the recycled tile carpet of the first embodiment (FIG. 5). For carpets (Fig. 4), the total content (% by mass) of recycled resin powder A (powder sprayed) and recycled resin powder B (calendered rather than sprayed) with respect to the entire tile carpet In the recycled tile carpet of Example 3 (FIG. 1), the total content (% by mass) of recycled resin powder A (powder sprayed) and recycled resin powder B (calendered rather than sprayed) with respect to the entire tile carpet. It is.

  Each recycled tile carpet obtained as described above was evaluated for performance by the following evaluation method. These results are shown in Tables 1 and 2.

<Dimensional stability evaluation method>
(Method A)
The dimensional stability of the tile carpet was evaluated according to JIS L4406-2000. That is, after measuring the vertical length and horizontal length of the recycled tile carpet in advance at 20 ° C. and 65 RH% to obtain values before the test, the recycled tile carpet is left at a temperature of 60 ° C. for 2 hours. Then, it is immersed in tap water for 2 hours, then left at 60 ° C. for 24 hours, then left at 20 ° C. and 65 RH% for 24 hours, and under this condition the vertical length and width of the tile carpet The length change rate (%) with respect to the value before the test and the change rate (%) with respect to the value before the test were obtained. Three samples were evaluated, and the average value of these six change rates (%) was taken as the dimensional change rate (%). In the evaluation by this A method, a dimensional change rate of 0.10% or less was regarded as acceptable.
(Method B)
After measuring the length and width of the recycled tile carpet in advance at 20 ° C and 65RH% to determine the values before the test, a chair caster with a load of 90kg was placed on the recycled tile carpet. In this state, after the chair caster was rotated 2000 times at the same position, the chair caster was allowed to stand for 24 hours at 20 ° C. and 65 RH%, and the vertical and horizontal lengths of the tile carpet were measured under this condition. The change rate (%) of the vertical length with respect to the value before the test and the change rate (%) of the horizontal length with respect to the value before the test were determined. Three samples were evaluated, and the average value of these six change rates (%) was taken as the dimensional change rate (%). Even in this evaluation by the B method, a dimensional change rate of 0.15% or less was accepted.

<Warpage evaluation method>
The amount of warp (mm) of the tile carpet was measured in accordance with JIS L4406-2000. That is, each recycled tile carpet is left in a standard environment of (20 ± 2) ° C. and (65 ± 2) RH% for 24 hours, and then the tile carpet is placed on a horizontal test bench. The distance between the four corners of the test plate and the upper surface of the test table was measured, and the average value was defined as the amount of warpage (mm). A warp amount of 0.5 mm or less was regarded as acceptable.

<Fuzz resistance (fuzz resistance) evaluation method>
After the wear ring is placed on the pile fabric layer of the recycled tile carpet and a load of 300 g is applied, the wear ring is rotated and moved 20 times so as to circulate on the same circumference. Visually, based on the following criteria, it was judged in five stages from grade 5 to grade 1, and grade 4 or higher was accepted.
(Criteria)
“Grade 5”: Pile form is almost unchanged from the pre-test “Grade 4”… Slight fluff is recognized “Grade 3”… Fuzz is recognized on the same circumference of the sample “Grade 2” "... Fluff is generated in a bundle of fibers and a remarkable change is recognized in the pile form." First grade ": The pile does not retain its original shape.

<Production rationality evaluation method>
The number of processes and the amount of energy used were comprehensively judged, and those with a small production load were marked with “◯” and those with a large production load were marked with “x”.

  As is clear from the table, the recycled tile carpets of Examples 1 to 7 of the present invention have a low production energy cost and a large content ratio (recycle ratio) of the carpet waste material to the entire tile carpet, and are also resistant to fuzz. It has excellent properties, warpage is suppressed, and dimensional stability is excellent.

  On the other hand, the recycled tile carpet of Comparative Example 1 forms a backing resin layer by applying a recycled vinyl chloride resin paste sol, which increases the production energy cost of the carpet and makes the production rational. It was inferior and the recycle ratio was low (it was difficult to produce with a high recycle ratio from the viewpoint of molding processability). Moreover, the recycled tile carpets of Comparative Examples 2 to 4 were inferior in fuzz resistance. Further, the recycled tile carpet of Comparative Example 5 was inferior in production rationality because of the increased number of processes and the amount of energy used.

  The recycled tile carpet according to the present invention is used, for example, by laying it on a floor surface of a general home or office.

DESCRIPTION OF SYMBOLS 1 ... Recycled tile carpet 2 ... Pile fabric layer 3 ... Sealing resin layer 4 ... Backing layer 6 ... Reinforcement layer 7 ... 1st backing resin layer (powder dispersion)
8 ... Second backing resin layer (powder spray)
9 ... Backing resin layer (powder spray)
11 ... Base fabric 12 ... Pile 31 ... Backing resin layer (calendar molding)

Claims (10)

A pile fabric layer in which a pile is planted on the upper surface of the base fabric, a sealing resin layer laminated on the lower surface of the pile fabric layer, and a backing layer laminated on the lower surface side of the sealing resin layer Tile carpet,
The backing layer includes one or more backing resin layers and a reinforcing layer made of a nonwoven fabric or a woven fabric made of at least one kind of fiber selected from the group consisting of glass fibers and polyester fibers,
The reinforcing layer is impregnated with resin,
The at least one backing resin layer is a layer formed by spraying and heat-pressing a recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin, and the recycled resin powder. The vinyl chloride resin content in the backing resin layer formed by spraying is 5% by mass to 30% by mass,
The filler resin layer is made of a resin latex or a vinyl chloride resin paste sol containing 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of a vinyl chloride resin and having a viscosity of 500 mPa · s to 10000 mPa · s. Is formed by being applied to the lower surface of the pile fabric layer,
Formation of the eye sealing resin layer is ^{200g / m 2 ~800g / m 2} ,
A recycled tile carpet, wherein the content of the recycled resin in the entire tile carpet is 50% by mass or more. A pile fabric layer in which a pile is planted on the upper surface of the base fabric, a sealing resin layer laminated on the lower surface of the pile fabric layer, and a backing layer laminated on the lower surface side of the sealing resin layer Tile carpet,
The backing layer is a first backing resin layer laminated on the lower surface side of the sealing resin layer, and a reinforcing layer laminated on the lower surface side of the first backing resin layer, the group consisting of glass fibers and polyester fibers A reinforcing layer made of a nonwoven fabric or a woven fabric composed of at least one kind of fibers selected from the above, and a second backing resin layer laminated on the lower surface side of the reinforcing layer,
The reinforcing layer is impregnated with resin,
The first backing resin layer and the second backing resin layer are layers formed by spraying and heating and pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin, The vinyl chloride resin content in the first backing resin layer is 5% by mass to 30% by mass, the vinyl chloride resin content in the second backing resin layer is 5% by mass to 30% by mass,
The filler resin layer is made of a resin latex or a vinyl chloride resin paste sol containing 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of a vinyl chloride resin and having a viscosity of 500 mPa · s to 10000 mPa · s. Is formed by being applied to the lower surface of the pile fabric layer,
Formation of the eye sealing resin layer is ^{200g / m 2 ~800g / m 2} ,
A recycled tile carpet, wherein the content of the recycled resin in the entire tile carpet is 50% by mass or more. A pile fabric layer in which a pile is planted on the upper surface of the base fabric, a sealing resin layer laminated on the lower surface of the pile fabric layer, and a backing layer laminated on the lower surface side of the sealing resin layer Tile carpet,
The backing layer is a backing resin layer laminated on the lower surface side of the sealing resin layer, and a reinforcing layer laminated on the lower surface side of the backing resin layer, and is at least selected from the group consisting of glass fibers and polyester fibers A reinforcing layer made of a nonwoven fabric or a woven fabric composed of one kind of fiber,
The reinforcing layer is impregnated with resin,
The backing resin layer is a layer formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin, and the vinyl chloride resin in the backing resin layer The content is 5% by mass to 30% by mass,
The filler resin layer is made of a resin latex or a vinyl chloride resin paste sol containing 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of a vinyl chloride resin and having a viscosity of 500 mPa · s to 10000 mPa · s. Is formed by being applied to the lower surface of the pile fabric layer,
Formation of the eye sealing resin layer is ^{200g / m 2 ~800g / m 2} ,
A recycled tile carpet, wherein the content of the recycled resin in the entire tile carpet is 50% by mass or more. A pile fabric layer in which a pile is planted on the upper surface of the base fabric, a sealing resin layer laminated on the lower surface of the pile fabric layer, and a backing layer laminated on the lower surface side of the sealing resin layer Tile carpet,
The backing layer is a reinforcing layer laminated on the lower surface side of the sealing resin layer, and is made of a nonwoven fabric or a woven fabric made of at least one fiber selected from the group consisting of glass fibers and polyester fibers. And a backing resin layer laminated on the lower surface side of the reinforcing layer,
The reinforcing layer is impregnated with resin,
The backing resin layer is a layer formed by spraying and heat-pressing recycled resin powder obtained by pulverizing a carpet waste material containing a vinyl chloride resin, and the vinyl chloride resin in the backing resin layer The content is 5% by mass to 30% by mass,
The filler resin layer is made of a resin latex or a vinyl chloride resin paste sol containing 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of a vinyl chloride resin and having a viscosity of 500 mPa · s to 10000 mPa · s. Is formed by being applied to the lower surface of the pile fabric layer,
Formation of the eye sealing resin layer is ^{200g / m 2 ~800g / m 2} ,
A recycled tile carpet, wherein the content of the recycled resin in the entire tile carpet is 50% by mass or more.   The recycled tile carpet according to claim 2, wherein a thickness of the second backing resin layer is greater than or equal to a thickness of the first backing resin layer.   The recycled tile carpet according to claim 2, wherein a thickness of the second backing resin layer is set to be 2 to 3 times a thickness of the first backing resin layer.   90% by mass or more of the recycled resin powder has a particle size of 1500 μm or less, a fiber content in the recycled resin powder of 10% by mass or less, and a specific gravity of the recycled resin powder of 1.9 or less. The recycled tile carpet according to any one of 1 to 6.   The resin impregnated in the reinforcing layer is a resin latex or a vinyl chloride resin containing 0 to 200 parts by mass of an inorganic filler with respect to 100 parts by mass of a vinyl chloride resin and having a viscosity of 500 mPa · s to 10,000 mPa · s. The recycled tile carpet according to any one of claims 1 to 7, wherein a paste sol is used.   After the recycled resin powder having a vinyl chloride resin content of 5% by mass to 30% by mass obtained by pulverizing the carpet waste material is sprayed on the running belt, the powder sprayed on the belt is 140 ° C. to 180 ° C. A method for producing a backing resin layer sheet for a recycled tile carpet, characterized in that the backing resin layer sheet is obtained by heating to ° C and pressurizing in this heated state. Method for producing a sheet for recycling carpet tiles backing resin layer of claim 9, applied at application rates 300g / m ² ~4000g / m ² of the recycled resin powder on the belt.

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