JP2714947B2 - Manufacturing method of tile carpet - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a technique for producing a tile carpet by backing a hot-melt resin composition. 2. Description of the Related Art Tufted carpets include asphalt, attack polypropylene, polypropylene, polyethylene,
It is known that a heat-fusible resin composition such as ethylene / vinyl acetate / copolymer is melted by heating and back-coated to impart formability (JP-B-62-19546, JP-B-62-19547, JP-B-62-19547). 19
548, JP-B 62-9022, JP-B 61-42034, JP-B 61-39
0, JP-B-58-47510, JP-B-57-389, JP-B-56-3780
6, No. 60-992, No. 59-23591). According to the prior art, these heat-fusible resin compositions are heated and melted, and are directly applied to the back of the carpet by a T-die extruder or a doctor device. [Problems to be Solved by the Invention] Conventionally, a hot-melt resin composition conventionally used for backing, even if it is an asphalt having a relatively low softening point, is heated and melted at 150 to 180 ° C., Most of the base fabric of tufted carpets and needle punching carpets, which account for the majority of carpets, has a softening point of 140-160 ° C and a melting point of 165-1.
The result is a 75 ° C polypropylene tape yarn. Since the softening and melting points of the commonly used carpet base fabric and the heat-fusible resin composition are close to each other, the carpet base fabric may be melted at the time of coating, and the heat-fusing property may be reduced. It is not possible to apply the resin composition thickly at a time, so it is necessary to adopt a method of applying the resin composition several times thinly, cooling it each time it is applied, and gradually increasing the thickness of the backing layer in this way. Nagata (JP-B 62-19546, JP-B 62-1954)
7). However, in the method according to the present invention, the carpet which has been coated with the heat-fusible resin composition and once cooled becomes hard and plate-like, so it cannot be wound up each time, and therefore, it is divided into several times while cooling. In order to perform coating, it is necessary to arrange several coating devices and transport the carpet so that they pass straight through them, which requires a large space for installing the coating devices and makes the process management complicated. There are disadvantages. Incidentally, in order to impart cushioning properties to a conventional carpet, a vinyl chloride paste resin (sol) is mechanically foamed and applied to the back of the carpet at a time by applying a thick coating.
There is also a method of laminating a carpet on a layer of vinyl chloride paste resin that is thickly coated on an endless belt as described in the issue, but tile carpet does not necessarily require cushioning, Since the value is determined by the quality of the pile surface, it is far too inappropriate to use a much more expensive vinyl chloride paste resin for tile carpet than hot melt resin compositions such as asphalt and polyethylene. It is economic. In addition, if only the backing layer of the heat-fusible resin composition is laminated on the back of the carpet, as described in JP-B-37-17680, the heat-fusible resin composition previously formed into a sheet is used. It is only necessary to temporarily heat and melt only the surface of the backing material consisting of, and superimpose the carpet on the surface of the backing material in the heated and molten state, but on the surface of the backing material in the heated and molten state, When the carpets are overlapped, the heat of the surface of the backing material is instantaneously taken away by the carpet and the surface of the backing material is solidified, so that the melt of the hot-melt resin composition constituting the backing material penetrates into the back of the carpet. Since the anchoring effect is not exhibited, the backing material and the carpet are easily separated, and a tile carpet having high peel strength and durability cannot be obtained. Accordingly, an object of the present invention is to provide a conventional heat-fusible resin composition which is inexpensive as compared with a vinyl chloride paste resin on the back of a carpet using a polyolefin tape yarn having a low softening and melting point as a base fabric. The present invention aims to effectively and economically manufacture a durable tile carpet that is hardly backed at once and the backing layer is hardly peeled off. The present invention has been completed with such an object, and is a heat-meltable resin composition which is laminated on an endless belt 11 provided with mold release properties, and the entire front and back sides are in a heat-melted state. In the method of manufacturing a tile carpet, a base carpet 14 is superimposed on and adhered to the backing layer 13, the endless belt 11 is peeled off, the backing layer 13 is transferred to the base carpet 14, and cut into a required shape. Its endless belt
The base carpet 14 of the backing layer 13 of the heat-fusible resin composition, which is laminated on
The temperature difference is applied to the front and back of the backing layer 13 on the endless belt 11 so that the front side on which the lining is over is in a high-temperature melting state and the back side of the backing layer 13 in contact with the endless belt 11 is in a low-temperature melting state. It is characterized by the following. BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, with reference to the drawings, FIG. 1, FIG. 2, and FIG. 3 illustrate a manufacturing process of a tile carpet according to the present invention, 11 is an endless belt, and 12 is A tank for supplying the hot-melt resin composition to the endless belt, 13 is a backing layer of the hot-melt resin composition laminated on the endless belt,
Reference numeral 14 denotes a base carpet, 15 denotes a tenter that conveys the base carpet, 16 denotes a guide roller, and 17 denotes a spreading roller that spreads and overlaps the base carpet on the backing layer. Conventionally used hot-melt resin compositions are used,
It is heated and melted and laminated on an endless belt, or laminated on an endless belt and then heated and melted. In the latter case, a pet-like heat-fusible resin composition is used in the form of a powder without powder, which is dispersed and laminated on an endless belt, and heated from the front side of the lamination and / or the back side of the endless belt. The whole of the lamination on both sides is heated and melted. In order to provide a temperature difference between the front and back of the backing layer 13 of the heat-fusible resin composition thus laminated, the endless belt 11 is cooled in advance through a cooling zone 18 as shown in FIG. The heat-fusible resin composition is melted into a film through a T-die or a doctor and coated and laminated, or
When heating and melting the front and back surfaces of the heat-fusible resin composition laminated on the endless belt 11 as shown in FIG. 2, the heating zone 19 on the front side, which is the bonding surface with the base carpet 14, is extended. And shorten the heating zone 20 on the back side, or
As shown in FIG. 3, a heating zone 21 is provided only on the front side to heat only the front side, or the entire layer of the heat-fusible resin composition covering the front and back is heated and melted and then the back side is heated. The endless belt side may be cooled, and the backing layer 13
Is not particularly limited. The base carpet 14 may be pre-heated through a heating zone 22 before being superimposed on the backing layer 13 as shown in FIGS. As shown in FIG. 2, several types of heat-fusible resin compositions 12A and 12B can be laminated on the endless belt 11, and in this case, the first laminate 13A on the back surface side is formed.
Thick lamination of ultra-low-price, low-adhesion, heat-fusible resin composition with a filler of 100 P.HR or more, and a filler of 10 P.HR or less for the last laminate 13B on the front side It is preferable to laminate a relatively expensive heat-fusible resin composition having high adhesiveness. When it is desired to put a secondary base cloth on the tile carpet, the secondary base cloth may be placed on the endless belt instead of the release material. According to the present invention, the heat-fusible resin composition is not directly coated on the base carpet 14 but backed by an endless belt.
Laminate on 11 and adjust the amount of heat of the high-temperature backing laminate 13 to be melted, make the front side into a molten state that shows adhesiveness, and make the back side unrelated to the adhesion cooler than the front side Therefore, even if it is thickly laminated, the base carpet 14 will not be thermally contracted, melted or damaged or deformed by the amount of heat it has. In particular, according to the present invention, several types of hot-melt resin composition 12A
・ 12B ……… Laminated on the endless belt 11, which can be transferred at a time, and at the same time, a low-price heat-fusible resin containing a large amount of filler that gives the tile carpet a thickness and weight. By laminating the composition 12A thickly on an endless belt and finally laminating the highly adhesive heat-fusible resin composition 12B, the melt of the heat-fusible resin composition penetrates into the back of the carpet and anchors. This makes it possible to economically obtain a tile carpet having excellent pile removal strength, stable shape, and a stable thickness. Furthermore, these several types of heat-fusible resin compositions 13A and 13B can be simultaneously laminated on the endless belt 11 from the tanks 12A and 12B provided close to each other, and the backing layer 13 and the base carpet 14 It is only necessary to superimpose them, and there is no need to heat them after superposition.Therefore, there is no need for long backing equipment and the space in the factory can be effectively used. It is very convenient.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1, FIG. 2, and FIG. 3 are side views of a tile carpet backing device according to the present invention. 11 ... Endless belt, 12 ... Tank, 13 ... Backing layer, 14 ... Carpet, 15 ... Tenter, 16/17 ... Roller, 18 ... Cooling zone, 19/20/21/22 ... Heating zone.

Claims (1)

(57) [Claims] A base material carpet 14 is superimposed and adhered onto a backing layer 13 of a heat-fusible resin composition in which the whole of the front and back surfaces which are laminated on an endless belt 11 having release properties are in a heat-melted state and adhered. In a method of manufacturing a tile carpet in which the belt 11 is peeled and the backing layer 13 is transferred to the base carpet 14 and cut into a desired shape, the endless belt
The base carpet 14 of the backing layer 13 of the heat-fusible resin composition, which is laminated on
The temperature difference between the front and back of the backing layer 13 on the endless belt 11 is such that the front side on which the superposed layer 13 is in a high-temperature melting state and the back side of the backing layer 13 in contact with the endless belt 11 is in a low-temperature melting state. A method for manufacturing a tile carpet, comprising: