JP2018153641A - 汎用バッキングを有する床被覆材及び製造方法 - Google Patents
汎用バッキングを有する床被覆材及び製造方法 Download PDFInfo
- Publication number
- JP2018153641A JP2018153641A JP2018074748A JP2018074748A JP2018153641A JP 2018153641 A JP2018153641 A JP 2018153641A JP 2018074748 A JP2018074748 A JP 2018074748A JP 2018074748 A JP2018074748 A JP 2018074748A JP 2018153641 A JP2018153641 A JP 2018153641A
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- Japan
- Prior art keywords
- adhesive
- floor covering
- layer
- yarn
- primary backing
- Prior art date
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- Granted
Links
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Images
Classifications
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Abstract
Description
背景の項で説明した多数の床被覆材構造に対応するべく、製造業者及び設置業者は、床被覆材の耐久性及び快適性を高めるため、数々の設置技術を開発してきた。例えば、広幅カーペットは、住居用の設置においては、図18に示すように、典型的には引き伸ばされて、部屋の周囲に設置されたタックストリップに取り付けられる。図示するように、床2000の上にはクッション層2280が置かれ、タックストリップ2004が部屋の周囲に、壁2002にごく接近して配置されてもよい。(表面ヤーン2210として表される)タフテッド基布を有するカーペットは、パワーストレッチャを用いて引き伸ばされ、タックストリップ2004の裏側に折り込まれる。任意選択的には、引き伸ばしが不可能な大きな商業空間においては、カーペット2210を「両面接着」設置で適用する前に、接着剤層(図示しない)が床及びクッション層2280適用されてもよい。
床被覆材が汚れたり染みがついたりしたときには、床被覆材を埋め立て処分又は焼却処分するのではなく、リサイクルするのが望ましい。本願のリサイクルプロセスは、本願の床被覆材の製造により生じた廃棄物についても用いられ得る。そのようなリサイクルは、床被覆材を通常の使用中には遭遇することのない環境にさらすこと(すなわち、140 °F乃至212°Fの温度の温水又は蒸気への曝露)により達成され得る。
本発明の様々な実施形態を限定するのではなく説明するために、代表的な実施例を提示する。
例となる床被覆材は、織物表面と、少なくとも1つの高分子接着剤化合物と、強化繊維とを含んでいた。
すべての実施例において同一の織物表面が用いられた。織物表面は、従来のカーペット構造において用いられる構成要素を組み込んでいた。
本明細書に記載の実施例は、以下の市販のポリマ組成物のうち1つ又は複数を接着剤組成物及び/又はバッキング構成要素として組み込んでいた。正確な配合は不明であるが、これらの化合物の特性は下記の表1に記録されている。
全ての実施例において、ガラス繊維が強化繊維として用いられた。ガラス繊維は、直径が「寸法E」として分類され、約0.25インチの長さを有していた。これは、従来の予め形成された強化層において用いられていた寸法及び長さと一致する。本明細書において用いられるガラス繊維は、ペンシルバニア州フェアレスヒルズのNyconによって流通された。
タフテッド基材のコーティング後の強化繊維の分散率は、0.5オンス/平方ヤード未満になるように選択された。
実施例1及び2はアクリル系ペイントで塗装された。
実施例1乃至7,9,及び10は、手作業では剥離できなかった。実施例8は、手作業で剥離するには、1インチあたり約3ポンドの力を必要とした。
アーヘン安定性試験(Aachen Stability Test)(ITTS−004)は、モジュラ及び広幅カーペットの両方について床被覆材業界全体で用いられる標準的な安定性試験である。試験方法は以下のステップを含む。:(a)床被覆材サンプルが測定され;(b)床被覆材サンプルが60℃のオーブン内に2時間置かれ、取り出され、測定され;(c)床被覆材サンプルが20℃の溶液中に2時間置かれ、取り出され、測定され;(d)床被覆材サンプルが60℃のオーブン内に24時間置かれ、取り出され、測定され;(e)床被覆材サンプルが、21℃で相対湿度65%の標準的な環境に48時間置かれ、取り出され、測定された。
Claims (4)
- 広幅及びモジュラ床被覆材の両方に適用可能な汎用強化バッキング層を有する寸法安定性のある床被覆材の製造方法であって、
一次バッキング基材と、前記一次バッキングを基材第一の方向に貫通してタフトされた複数のヤーンとを備え、前記一次バッキング基材は表面及び前記表面と反対の裏面を有し、各ヤーンの一部は前記一次バッキング基材の前記裏面に位置するステッチを形成し、各ヤーンの間に隙間が存在する、タフテッド基布を提供することと、
前記タフテッド基布を塗布器に対して相対的に移動させ、前記ヤーンのステッチ部分と前記塗布器の間に隙間を形成すること、
接着剤と強化繊維の混合物を有する組成物を提供すること、
前記塗布器と前記タフテッド基布の間に制御された状態で圧力を加え、前記組成物を前記一次バッキング基材の前記裏面に向かう第二の方向に押すこと、
前記圧力が加えられ前記タフテッド基布が移動する間、前記強化繊維を前記第一の方向に支配的に倒れるように整列させ、前記強化繊維を前記第一の方向と略平行な繊維強化層中に配列させ、
前記組成物を濾過して前記強化繊維から接着剤を押出し、接着剤だけを前記ヤーンの間の前記隙間に押入れ、前記繊維が前記隙間を貫通するのを防止し、前記繊維強化層を積層すること、
前記第一の方向に略平行な湿式の連続的に重複する強化繊維層を形成して、床被覆材の全体の寸法安定性を提供すること、
前記繊維強化層と分離された接着剤を切断すること、
を含む、方法。 - 広幅及びモジュラ床被覆材の両方に適用可能な汎用強化バッキング層を有する寸法安定性のある床被覆材の製造方法であって、
第一の方向に延びる一次バッキング基材と、前記一次バッキング基材を貫通してタフトされた複数のヤーンとを備え、前記一次バッキング基材は表面及び前記表面と反対の裏面を有し、各ヤーンの一部は前記一次バッキング基材の前記裏面に位置する端部を有するステッチを形成し、各ヤーンの間に隙間が存在するする、タフテッド基布を提供することと、
前記タフテッド基布を塗布器に対して相対的に移動させ、前記ヤーンのステッチ部分と前記塗布器の間に空間を形成すること、
接着剤と強化繊維の混合物を有する組成物を提供すること、
前記塗布器と前記タフテッド基布の間に制御された状態で圧力を加え、前記接着材と強化繊維を前記一次バッキング基材の前記裏面に向かう第二の方向に押すこと、
前記強化繊維を前記第一の方向に支配的に倒れるように整列させ、前記強化繊維を前記第一の方向と略平行な繊維強化層中に配列させ、
前記組成物を濾過して前記強化繊維から接着剤を分離させ、溶解性の接着剤を前記ヤーンの間の前記隙間に押入れ、前記強化繊維層と前記第一次バッキング基材の間に繊維を含まない溶解性の接着剤層を形成し、前記第一の方向に略平行な強化繊維層を形成するために前記接着剤と前記強化繊維層を一緒に積層すること、
前記繊維強化層と分離された接着剤を切断すること、
を含み、
前記強化繊維層と前記第一次バッキング基材の間の前記接着剤は溶解して前記
床被覆材のリサイクリングが可能となり、前記ヤーン、基布、強化繊維および接着剤が分離されリサクルされることが可能となる、方法。 - リサイクル可能な寸法安定性のある床被覆材であって、
縦方向に延び、複数のヤーンがタフトされた一次バッキング基板であって、前記一次バッキング基材は、表面と前記表面と反対の裏面と、前記裏面に位置する端部を有するステッチ部分を形成する各ヤーンの部分と、前記各ヤーンの端部の間に存在する隙間とを有する前記一次バッキング基板と、
そのままで形成され、ケースに入れられ接着剤と一緒に積層され配列された強化繊維の連続的に重複した、湿式の不織布の強化層であって、前記強化繊維は連続的に重複した前記強化層における縦方向に支配的には配列され、重複した前記強化層は前記一次バッキング基板と略平行であり、前記ステッチ部分の端部は前記強化層と直接接触しており、前記強化繊維の重複した強化層に付着しており、前記直接接触および前記強化層の前記ステッチ部分の付着は前記床被覆材の寸法安定性をもたらし、前記強化層と前記一次バッキング基板は空間によって分離されている、強化層と、
前記重複した強化層と前記一次バッキング基材との間の前記空間中の前記接着剤の層と、
を含み
前記ヤーン、一次バッキング基材、強化繊維および接着剤は分離されており、リサイクル可能な床被覆材。 - 前記接着剤が溶解性であり、前記接着剤が溶解するとき、前記ヤーン、一次バッキング基材および強化繊維が選択的に分離される、請求項3に記載のリサイクル可能な床被覆材。
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Application Number | Priority Date | Filing Date | Title |
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US201261797496P | 2012-12-10 | 2012-12-10 | |
US61/797,496 | 2012-12-10 | ||
US14/090,190 | 2013-11-26 | ||
US14/090,190 US9339136B2 (en) | 2012-12-10 | 2013-11-26 | Floor coverings with universal backing and methods of making, installing, and recycling |
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JP2015546515A Division JP2016509136A (ja) | 2012-12-10 | 2013-11-27 | 汎用バッキングを有する床被覆材及び製造、設置、及びリサイクルの方法 |
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EP (1) | EP2929081B1 (ja) |
JP (2) | JP2016509136A (ja) |
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EP2929081A4 (en) | 2016-08-10 |
EP2929081B1 (en) | 2019-03-13 |
WO2014093022A1 (en) | 2014-06-19 |
US20140158276A1 (en) | 2014-06-12 |
AU2013360109B2 (en) | 2018-03-15 |
JP2016509136A (ja) | 2016-03-24 |
EP2929081A1 (en) | 2015-10-14 |
US20170037554A1 (en) | 2017-02-09 |
US9506175B2 (en) | 2016-11-29 |
CN105051285A (zh) | 2015-11-11 |
CN105051285B (zh) | 2017-03-15 |
US20160230324A1 (en) | 2016-08-11 |
AU2013360109A1 (en) | 2015-07-02 |
US9926657B2 (en) | 2018-03-27 |
JP6629906B2 (ja) | 2020-01-15 |
US9339136B2 (en) | 2016-05-17 |
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