JP2520818B2 - Carpet manufacturing method - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a method for manufacturing a carpet,
In particular, the present invention relates to a method for producing a carpet which can be easily brought into close contact with a rugged floor surface, is excellent in flexibility and dimensional stability, and has little warpage.

[0002]

2. Description of the Related Art There are asphalt-based and vinyl chloride-based materials for backing materials for carpets, but asphalt-based materials have an odor, soften at high temperature, and have a problem of polluting surroundings. . Further, the vinyl chloride type has a problem of environmental pollution because chlorine gas is generated during incineration when discarding the carpet.

In order to solve the above problems of conventional backing materials for carpets, an adhesive is used on a sheet obtained by previously molding a composition comprising cement and emulsion of a thermoplastic resin, and the back surface of the carpet. It has also been proposed to manufacture a backing carpet by pasting together (Japanese Patent Publication No. 60-58347). However, this method is inferior in productivity because it is necessary to mold the back substrate in advance, and there is a problem that the product carpet is too hard and lacks flexibility.

[0004]

SUMMARY OF THE INVENTION The present invention has excellent flexibility and dimensional stability, can be easily brought into close contact with an uneven floor surface, etc., and has little curling during use. It is intended to provide a method for easily manufacturing

[0005]

The method for producing a carpet according to the present invention comprises: a back surface of a front base material for a carpet and / or a back base material for a carpet; and an aqueous emulsion of a resin having a glass transition point of 5 ° C. Hydraulic inorganic cement powder 120-400 parts by weight, foam particles 2 per 100 parts by weight
0 to 200 parts by weight and a non-hydraulic inorganic powder of 0 to 300 parts by weight are applied to the backing material composition,
Before curing and drying the applied backing material composition, the back surface of the front base material for the carpet and the back base material for the carpet are overlapped with each other via the coating layer of the backing material composition and press-contacted to each other to form the applied layer. Is a method of curing and drying.

As the front and back substrates for carpets used in the present invention, various synthetic fibers such as polypropylene, polyethylene, polyethylene terephthalate,
Examples include spunbond such as nylon, non-woven fabric, miscellaneous felt, woven fabric, and woven fabric; woven fabric such as cotton, hemp, and wool; non-woven fabric of glass fiber and woven fabric. In particular, polypropylene fiber woven fabrics and non-woven fabrics are preferable because the shrinkage of the carpet is small. Further, paper such as Japanese paper can be used for the back substrate. Further, in order to improve the drying property during curing / drying, at least one of the front substrate and the back substrate, preferably the one that comes to the upper side when pressed and cured / dried Therefore, it is necessary to use a material having water permeability. Furthermore, it is necessary to use a combination of the front substrate and the back substrate, which have the same thermal shrinkage or the back substrate has a larger shrinkage than the front substrate, in order to prevent the warp of the product carpet. This is preferable because it can be prevented.

As an aqueous emulsion of a resin having a glass transition point of 5 ° C. or less for preparing the backing material composition of the present invention,
For example, 2-ethylhexyl acrylate [a glass transition point of its homopolymer is −85 ° C. (this is abbreviated as “Tg −85 ° C.” here)], n.butyl acrylate ( Tg −54 ° C.),
Ethyl acrylate (Tg-22 ° C), vinylidene chloride (Tg-18 ° C), isopropyl acrylate (Tg
-5 ° C), 2-ethylhexyl methacrylate (Tg-5
° C), n-propyl acrylate (Tg 8 ° C), n-butyl methacrylate (Tg 20 ° C), vinyl acetate (Tg
30 ° C.), acrylic acid (Tg 87 ° C.), n-propyl methacrylate (Tg 81 ° C.), styrene (Tg 10
0 ° C), acrylonitrile (Tg 100 ° C), methyl methacrylate (Tg 105 ° C), methacrylic acid (Tg
130 ° C), maleic anhydride, itaconic acid (Tg 1
30 ° C.), acrylic acid amide (Tg 153 ° C.), ethyl methacrylate (Tg 65 ° C.), vinyl chloride (Tg
79 ° C.), an emulsion of a homopolymer or a copolymer having a glass transition temperature of 5 ° C. or lower, which is obtained by emulsion-polymerizing one or more unsaturated monomers selected from ethylene, butadiene, etc., and Is a mixture of two or more of these polymer emulsions. Further, a resin emulsion (so-called powder emulsion) obtained by redispersing a water-redispersible resin powder produced from these emulsions in an aqueous medium can also be used.

If the glass transition temperature of the resin of the resin aqueous emulsion used is higher than 5 ° C., the resulting carpet becomes hard, which is not preferable.

The glass transition point (Tg) added to the unsaturated monomer for preparing the resin aqueous emulsion is the Tg of the homopolymer of the monomer as described above. However, since the Tg of the copolymer can be roughly estimated from the Tg of the homopolymer of the monomer and the ratio of the monomer, the resin aqueous emulsion having a Tg of 5 ° C. or lower used in the present invention is The polymer can be designed and manufactured based on the estimated value.

Aqueous emulsions having a Tg of 5 ° C. or less used in the present invention have various trade names, for example, ACRONAL S-400 and ACRONAL 8
Since it is commercially available as 0DN (the above are trade names of Mitsubishi Petrochemical Verdeche Co., Ltd.), the present invention can be carried out using such a commercially available resin aqueous emulsion.

As the hydraulic inorganic cement powder for preparing the backing material composition of the present invention, what is called Portland cement (for example, ordinary cement, white cement, early strength cement, super early strength cement, etc.), mixed Although there are so-called cements (for example, blast furnace cement, silica cement, fly-ash cement, etc.), alumina cement, hydraulic gypsum, etc., generally, Portland cement's ordinary cement and white cement are preferred.

The hydraulic inorganic cement powder is 120 to 120 parts by weight based on 100 parts by weight of the resin solid content of the resin aqueous emulsion.
It is 400 parts by weight, preferably 160 to 300 parts by weight. If the proportion of hydraulic inorganic cement powder is too low,
The carpet has good flexibility but poor elasticity, resulting in low strength and stickiness. When the carpet is too large, the carpet becomes hard and the water resistance deteriorates.

The foam particles for the backing material composition used in the present invention include inorganic foam particles such as shirasu balloons and foam glass spheres, and organic foam particles such as expanded polystyrene. Considering the flame retardancy and miscibility of the above, inorganic foam particles are preferable. Since the foam particles have the function of making the coating layer after curing of the backing material composition porous, by adding an appropriate amount of this to the backing material composition, the density of the cured backing material coating layer of the product carpet can be easily adjusted to 1 g / It can be reduced to ³ cm ³ or less, which contributes to making the product carpet porous and lightweight. In addition, by using the foam particles, it is possible to increase the fluidity of the baking material composition with a small amount of water, and to add extra water (water necessary for hardening the cement when hardening and drying the baking material coating layer by heating). Excess water other than the above) can be easily evaporated to quickly dry the coating layer.

The particle size of the foam particles is 10 to 800 μm,
It is preferably 20 to 500 μm. If the particle size is too large, it becomes difficult to uniformly mix the backing material composition when preparing the backing material composition, and it becomes impossible to form a backing material layer of sufficient quality in relation to the coating thickness of the backing material composition. If the particle size is too small, it becomes difficult to obtain a sufficient weight-reducing effect, and the surface area of the foam particles becomes too large, resulting in poor miscibility.

The blending amount of the foam particles is 20 to 200 with respect to 100 parts by weight of the resin solid content of the resin aqueous emulsion.
Parts by weight, preferably 30 to 150 parts by weight. If the blending amount is too small, not only the product carpet cannot be reduced in weight to a desired degree but also it becomes sticky, and the drying property of the coating layer of the backing material composition deteriorates,
It takes a long time to dry. Further, if the blending amount is too large, the backing material composition layer becomes hard and brittle, and the water resistance also decreases.

Various non-hydraulic inorganic powders for the backing material composition used in the present invention can be used.
Examples thereof include calcium carbonate, talc, clay, silica sand, various ceramic particles, and various inorganic extender pigments. The non-hydraulic inorganic powder is 0 to 300 parts by weight with respect to 100 parts by weight of the resin solid content of the resin aqueous emulsion. By adding a non-hydraulic inorganic powder to the backing material composition, the hardness of the carpet can be increased.

Various other additives such as organic or inorganic pigments for coloring, dyes, various fiber powders and the like can be added to the backing material composition used in the present invention. Although the inorganic pigment is a kind of non-hydraulic inorganic powder, its content is usually relatively small.

The backing material composition of the present invention contains an appropriate amount of water. The water may be only water based on the resin aqueous emulsion, but usually, additional water is often added. If the amount of water is too small, the fluidity of the composition will be poor, and the coating workability will be poor, and if the amount of water is too large, separation of the resin aqueous emulsion and other components will occur, which is not preferable. Instead, the carpet after curing and drying may crack or shrink.
The amount of water present in the backing material composition is 100 to 200 parts by weight based on 100 parts by weight of the resin solid content.

The backing material composition of the present invention may further contain a defoaming agent, a plasticizer, a thickener, an antifungal agent, a wetting agent, a dispersant, an emulsifying agent, an antifreezing agent, etc., if necessary, that is, as an optional component. Can be blended. In particular, when a large amount of powder is used, it is effective to add a dispersant or a wetting agent for an extender pigment, a fluidizing agent for a cement or a water reducing agent.

In the present invention, the coating thickness when the backing material for the carpet and / or the backing material for the carpet is coated with the backing material composition is the coating thickness before curing and drying, that is, the total coating thickness. Wet coating thickness 0.5-5.0m
m, preferably 0.8 to 4.0 mm. If the coating thickness is 0.5 mm or less, the cushioning property of the product carpet deteriorates, and the carpet does not conform to the unevenness of the base, and the feel during walking deteriorates. If the coating thickness exceeds 5.0 mm, the product carpet becomes too heavy and it takes a long time to dry.

Next, the front substrate and the back substrate coated with the backing material composition as described above are coated with the back substrate and the back substrate of the front substrate before curing and drying of the coated backing material composition. The material and the backing material composition are overlapped with each other via a coating layer of the backing material composition and pressed against each other to cure and dry the coating layer. As a result, a carpet in which the front and back substrates of the carpet are integrally and firmly adhered to each other through the cured layer of the backing material, that is, a product carpet lined with the backing material layer is obtained. The heating temperature for curing and drying is usually 40 to 155 ° C, preferably 95 to 155 ° C.
Is.

According to the production method of the present invention, the applied backing material composition layer is cured with a part of the backing material composition permeating between the fibers of the front substrate and the back substrate, and dried. Therefore, the front base material and the back base material are integrally and firmly bonded to each other through the coated and cured product to form a carpet. Then, by using the above-mentioned relatively high heating temperature for the curing and drying, it is possible to accelerate the hydraulic reaction of cement, and the drying after the hydraulic reaction, and in combination with the inclusion of the foam particles, Within 2 hours, which is a suitable curing / drying time in a factory production line, preferably 1
Curing and drying can be completed within the time, and the product can be wound up as a carpet to improve workability (productivity).

Then, the coating / curing layer of the backing material composition of the obtained product carpet, that is, the product carpet becomes porous and lightweight (for example, the density is 1 g / cm ³ or less) by blending the foam particles, and It is excellent in flexibility (flexibility) and workability, and has little dimensional deformation (shrinkage etc.).

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. Parts and percentages given in these examples are by weight.

Example 1 Front substrate: A loop pile tufted carpet (basis weight 1000) in which polypropylene yarn was planted on a primary base fabric obtained by weaving polypropylene flat yarn in a plain weave pattern.
g / m ² , width 1.6 m (This is abbreviated as “polypropylene tufted” for convenience.) Back substrate: Spunbond nonwoven fabric made of polypropylene (Mitsui Petrochemical Industrial Co., Ltd., trade name Syntex PS-106)
(Basis weight 30g / m ² , width 1.6m)

Backing material composition: Acronal S-400 * 1 (in resin solid content) 100 parts Normal Portland cement 200 parts Calcium carbonate * 2 100 parts Shirasu balloon * 3 100 parts Water 40 parts Note) * 1 Mitsubishi Yuka Birdiche Co., Ltd. product name,
Acrylic ester-styrene copolymer resin aqueous emulsion, resin solid content concentration 57%, Tg of resin is 0 ° C or less * 2 ... Dowa Mining Co., Ltd. product name KD-80 * 3 ... Idiji Chemical Co., Ltd. Product name Shirasu Balloon
Winylite SB-9011

The above-mentioned backing material composition was kneaded with an agitator until no agglomerates were observed (about 15 minutes). The obtained backing material composition slurry was applied on the back surface of the above-mentioned front substrate with a knife coater to a wet thickness of 2.5 mm, and the back substrate was immediately overlaid on the coated surface,
It was lightly pressed with a Niprol so that the backing material composition of the coating layer impregnated between the fibers of the back substrate.

The obtained laminate is heated by applying hot air at 120 ° C. for 30 minutes from the back substrate side to cure and dry it,
After cooling with air cooling for 10 minutes, it was punched into a 50 × 50 cm size to obtain a tile carpet. The density of the backing material composition layer was 0.68 g / ml.

The composition of the backing material composition of this example,
The carpet manufacturing conditions and the like are listed in Table 1.

Example 2 Table Base Material: Polyester / nylon tufted carpet (basic weight 1000
g / m ² ) (This is abbreviated as “polyester / nylon / tuffed” for convenience.) Back substrate: Spunbond nonwoven fabric made of polyester (Mitsui Petrochemical Co., Ltd., trade name Syntex R-24, basis weight 6)
9 g / m ² ) (for convenience, this is abbreviated as “polyester spunbond”)

Backing material composition: Acronal 80DN * 1 (in resin solid content) 100 parts White cement 200 parts Shirasu balloon * 2 100 parts Silica sand (No. 8) 100 parts Iron oxide (black) * 3 1 part Water 50 parts Note ) * 1 Mitsubishi Yuka Verdeche Co., Ltd. product name,
Acrylonitrile-acrylic acid ester copolymer resin aqueous emulsion, resin solid content concentration 50%, Tg of resin
Is below 0 ℃ * 2 ・ ・ ・ Idiji Kasei Co., Ltd. Product name Shirasu Balloon
Winylite SB-9011 * 3 ・ ・ ・ Nippon Bengal Industry Co., Ltd. product name 2DB

Using the above-mentioned front substrate, back substrate and backing material composition, a tile carpet was manufactured according to the method of Example 1. Table 1 shows the composition of the backing material composition and the carpet manufacturing conditions. The density of the backing material composition layer of the obtained carpet was 0.68 g / ml.

Examples 3 to 12 Comparative Examples 1 to 4 The backing material composition and the carpet manufacturing conditions were changed as shown in Tables 1 to 5, except that the tile carpet was manufactured according to the method of Example 1. did.

[0034]

[Table 1]

[0035]

[Table 2]

[0036]

[Table 3]

[0037]

[Table 4]

[0038]

[Table 5]

Notes for Tables 1 to 5: * 1 ... Trade name of Mitsubishi Yuka Verdeche Co., Ltd., aqueous emulsion of acrylic ester-styrene copolymer resin, solid concentration of resin 57%, Tg of resin 0 ° C or less * 2 ・ ・ ・ Loop pile tufted carpets (basic weight 1000g) in which polypropylene yarns are planted on a primary base cloth obtained by weaving polypropylene flat yarns in a lattice pattern.
/ M ² , width 1.6 m) * 3 ・ ・ ・ Mitsui Petrochemical Industry Co., Ltd. trade name, polypropylene spunbond nonwoven fabric, basis weight 30 g / m ² , width 1.6 m * 4 Mitsubishi Yuka Verdeche Product name: Acrylonitrile-acrylic acid ester copolymer aqueous emulsion, solid content concentration 50%, Tg of resin below 0 ° C * 5 ... Polyester / nylon tufted car with polyester non-woven fabric as primary base fabric Pett (basis weight 1000g
/ M ² ) * 6 ... Polyester spun bond (Mitsui Petrochemical Industry Co., Ltd. trade name Syntex R-24, basis weight 69 g /
m ² ) * 7 ... Trade name of Mitsubishi Yuka Verdeche Co., Ltd., aqueous emulsion of acrylic ester-styrene copolymer resin, solid content concentration 50%, Tg of resin is 3 ° C.

The above Examples 1 to 12 and Comparative Examples 1 to 4
The physical properties of the product carpet obtained in the above were tested and the results are shown in Tables 6 and 7.

[0041]

[Table 6]

[0042]

[Table 7]

Note to Tables 6 and 7: * 1 Flexibility A tube with a diameter of 50 mm is placed on the table base material of the tile carpet, and cracks and peeling are visually observed when the carpet is bent 180 ° along the tube. And evaluated according to the following criteria. The test is conducted at 20 ° C. ◎ ・ ・ ・ No abnormality ○ ・ ・ ・ No abnormality, but it takes some time for the bent part to return to its original shape. △: A habit remains in the bent portion. × ・ ・ ・ breaks. * 2 Floor compatibility Tile carpet (50 x 50 cm) is rolled and left for 2 hours, then allowed to open naturally, placed on plywood with a thickness of 10 mm, and allowed to stand at 20 ° C for 2 hours, then the tile carpet surface Lightly touching with a fingertip, the floating state of the tile carpet was examined and evaluated according to the following criteria. ◎ ・ ・ ・ Fully compatible with the base material (plywood) ○ ・ ・ ・ Almost completely compatible with the base material △ ・ ・ ・ Slightly lifted from the base material, with some edge sleds, etc. × ・ ・ ・ From the base material Float and make a sound when pressed from above * 3 Shrinkable Tile Carpet (50 x 50 cm) at 60 ℃, 90
After leaving it in the air of% RH for 7 days, leaving it in the air of 50 ° C and 90% RH for 7 days, and immersing it in the water of 40 ° C for 7 days,
Each state after immersion in water at 20 ° C. for 7 days was examined and evaluated according to the following criteria. ◎: No change at all ○: Slightly harder △: Harder ×: Deformation or brittleness * 4 Feeling of finger touch Plywood (thickness 10 m with the back side of the tile carpet facing up)
m) was placed on m) and pressed at 5 Kg / cm ² and then released for compression, the compression deformation was examined and evaluated according to the following criteria. H: No compression deformation (hard) S: Compression deformation (soft)

As is clear from the comparison between Tables 6 and 7,
The carpets obtained in the examples have excellent balance in flexibility, floor conformability, shrinkage resistance, touch to the touch, and workability, as compared with the carpets obtained in the comparative examples.

[0045]

According to the method of the present invention, it is possible to easily produce a carpet in which the front and back substrates for carpet are integrally bonded via a porous and soft hydraulically hardened cement layer, The obtained carpet has excellent balance in flexibility (flexibility), dimensional stability (shrinkage resistance), conformability to the floor surface, workability, and the like.

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Claims (1)

(57) [Claims] 1. A water-based inorganic cement powder 120 per 100 parts by weight of the resin solid content in an aqueous emulsion of a resin having a glass transition point of 5 ° C. or less on the back surface of the front substrate for carpet and / or the back substrate for carpet. To 400 parts by weight, foam particles 20 to 200 parts by weight and non-hydraulic inorganic powders 0 to 3
The backing material composition containing 100 parts by weight of the coating material is applied, and the back surface of the front material for the carpet and the backing material for the carpet are coated with the backing material before curing and drying of the applied backing material composition. A method for producing a carpet, which comprises press-coating the composition layer on top of each other, and curing and drying the coating layer.