JP2944342B2 - Tile carpet with excellent combustion safety - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tile carpet excellent in combustion safety and suitable for floor coverings of stores, offices, houses, and the like.

[0002]

BACKGROUND OF THE INVENTION Generally, tile carpets are
The melt-spun synthetic resin filament is subjected to oiling, stretched, crimped, and wound into a pile yarn, which is then planted in a tufted base fabric by a tufting machine (flocking machine) to form a carpet base material. After applying a water-repellent agent such as a fluorine-based or silicone-based material to the base material, the base material is lined with a resin layer, heat-treated, and cut into a required size.

[0003] As the tufted base fabric, a polyester spunbond base fabric in which fibers are fixed with an acrylic, polyvinyl chloride or other binder is usually used, and a pile yarn made of nylon is used. ,
As the backing layer, a polyvinyl chloride resin is used.

[0004] This kind of carpet has a serious problem caused by toxic gas from the viewpoint of disaster prevention assuming a fire, and from the viewpoint of environmental pollution and the effect on incinerators in the incineration of waste carpet. .

That is, toxic gases that may be generated by burning carpets or the like include hydrogen cyanide (HC).
N), carbon monoxide (CO), nitrogen oxide (NOx), sulfur oxide (SOx), hydrogen chloride (HCl), hydrogen fluoride (HF) and the like. Among these toxic gases, hydrogen cyanide (HCN), nitrogen oxides (NOx),
Sulfur oxides (SOx) and hydrogen chloride (HCl) are particularly toxic, with acceptable concentrations of only a few ppm, reaching lethal doses at hundreds of ppm. Therefore, it can be said that it is indispensable to suppress the generation of these toxic gases during combustion as much as possible.

However, since the carpet described above uses nylon pile yarns, toxic gases such as hydrogen cyanide (HCN) and nitrogen oxides (NOx) are generated during combustion, and the backing layer and tuft staples are generated. A toxic gas such as hydrogen chloride (HCl) is generated by burning the polyvinyl chloride resin of the base cloth, and a toxic gas such as hydrogen cyanide (HCN) is generated by burning an acrylic binder.

As described above, the conventional carpet generates a highly toxic toxic gas, and thus has a problem in combustion safety. Therefore, it is possible to realize a tile carpet capable of minimizing the generation of toxic gas during combustion. It has become a challenge.

[0008]

In view of the above circumstances, the present inventors have studied to provide a carpet that generates less toxic gas, and as a result, in a conventional tile carpet, a binder of a tufted base cloth, The pile yarn implanted in the tuft base fabric and the polyvinyl chloride resin as the backing layer are factors causing the generation of toxic gas during combustion, and in addition, the oil agent used in the above-mentioned oiling and contained in the pile yarn Has also been found to be a factor in the generation of toxic gases, and by eliminating these factors as much as possible, the generation of toxic gases can be reduced as much as possible.

[0009] As a result of further detailed research based on this finding, the use of specific materials for each of the constituent elements has made it possible to minimize the generation of toxic gases during combustion, and to further reduce the oil content of the pile yarn. Is suppressed to a specific value or less, the generation of toxic gas can be further reduced, and the antifouling property, dimensional stability,
The present inventors have found that a tile carpet excellent in laying stability and the like can be obtained, and have accomplished the present invention.

That is, the combustion safety in the present invention is
A good tile carpet is a binderless polyester
Polyester filament on Luspunbond base cloth (2)
Carpet substrate on which pile yarn (3) made of
On the back side of (1), from the amorphous olefin polymer composition
No filling layer (4) and backing layer (5) are provided.
The pile yarn (3) has an oil content of 0.40% by weight or less.
Set at the bottom and intermediate in the backing layer (5)
As the base fabric, polyvinyl alcohol or ethylene-vinegar
Glass fiber cloth using vinyl acid binder (6)
The gist is that (7) is interposed .

[0011]

DETAILED DESCRIPTION OF THE INVENTION The tile carpet of the present invention is made of a polyester which is a material of a pile yarn (3) of a carpet substrate (1) and a polyester spunbond base fabric (2), and a sealing layer (4) and The amorphous olefin polymer of the backing layer (5) is a material having a low content of components that generate toxic gas when burned. Moreover, since the polyester spunbond base fabric (2) of the present invention does not have a binder as a component that generates toxic gas, the generation of toxic gas is reduced as much as possible, and the safety is excellent.

In addition, the filler layer (4) and the backing layer (5)
Is excellent in heat resistance and low-temperature properties, makes the dimensional stability and shape stability of the carpet good, and the adhesion force of the pile yarn (3) by the filling layer (4). Since the filling layer (4) and the backing layer (5) have the same components, there is an advantage that the affinity of both layers is high and delamination hardly occurs.

Binder-free polyester spunbonded base fabric (2) to be used as a tufted base fabric for carpet substrate (1)
Can be obtained by pressing with the adhesive force of the molten filament itself, forming a sheet, and cooling, instead of fixing the fibers with a binder as in a normal base cloth. It is preferable that the binder-free polyester spunbond base fabric (2) has a thickness of about 0.1 to 1.5 mm and a basis weight of about 50 to 150 g / m ² .

As the amorphous olefin polymer of the polymer composition constituting the filling layer (4) and the backing layer (5),
Amorphous ethylene, propylene, butene, hexene, ethylene-propylene, ethylene-butene, ethylene-hexene, propylene-butene, propylene-hexene, ethylene-propylene-butene, ethylene-propylene-
Hexene, propylene-butene-hexene, etc., may be used, and two or more of these may be used in combination.

In the polymer composition, together with the above-mentioned amorphous olefin polymer as a main polymer, other resin components not containing a halogen element such as crystalline polypropylene as an auxiliary polymer, and an aliphatic petroleum resin Various additives such as a tackifier such as a wax, a melt viscosity reducing agent such as a wax, a filler such as calcium carbonate and magnesium hydroxide, and a flame retardant such as zinc borate and antimony oxide can be added as required. The amount of the tackifier in the filling layer (4) is about 10 to 50 parts by weight based on 100 parts by weight of the amorphous olefin polymer as the main polymer, and the amount of the filler is also 50 to 300 parts by weight. Parts. In addition, the backing layer is composed of 10 to 50 parts by weight of a tackifier,
It is preferable to use 500 parts by weight. In this case, the filling layer (4) preferably has a basis weight of about 300 to 1000 g / m ² , and the backing layer (5) has a thickness of about 2.0 to 3.5 mm.

In the tile carpet of the present invention, the pile yarn (3) of the carpet substrate (1) has an oil content of 0.4 to further suppress the generation of toxic gas.
It must be kept below 0% by weight, preferably 0.1 % by weight.
It is preferable to keep the content at 25% by weight or less. Here, the oil content refers to the percentage of the oil content on the fiber weight. By setting the oil content of the pile yarn (3), which is a component that generates toxic gas, low, the generation of toxic gas can be further suppressed. Furthermore, the oil repellent does not cause recontamination of the carpet product and does not hinder the formation of the water repellent coating when the water repellent is applied. Sufficiently exhibited, showing very good antifouling properties.

Furthermore, in the tile carpet of the present invention, it is necessary to interpose glass fiber cloths (6) and (7) as an intermediate base cloth in the backing layer (5) in order to improve dimensional stability. The glass fiber cloth (6) (7) The basis weight 30 to 50 g / m ² approximately nonwoven (7), and basis weight 25 to 45 g / m ² approximately woven and set the cloth (6)
Is preferable, and plural sheets may be interposed in the backing layer (5). Normally, about 20% by weight of the binder is used for the nonwoven fabric (7) and about 15% by weight of the woven cloth and the braided cloth (6). fiberglass cloth (6) (7) is polyvinyl alcohol or an ethylene - need Ru using <br/> the binder based on vinyl acetate. That is, since these binders do not contain a halogen element, the generation of toxic gas during combustion can be suppressed.

In order to manufacture the tile carpet excellent in combustion safety according to the present invention, a polyester filament melt-spun using a polyester chip is subjected to oiling to about 0.7 to 1.5% by weight according to a conventional method. , And stretched, crimped and wound up to give a pile yarn (3), which is planted in the binder-free polyester spunbond base fabric (2) by a tufting machine to form a carpet base material ( 1) and, if necessary, a treatment for applying a water-repellent such as a fluorine-based or silicone-based agent to the base material, and a filling layer and a backing layer are formed on the base material by melt-coating the amorphous olefin polymer composition. And then cut to the required size.

In this case, as described above, the pile yarn (3)
In order to reduce the oil content to 0.40% by weight or less, the oil agent is preferably removed by post-treatment after tufting. That is, when spinning polyester filaments, unless the oil content is set to about 1%, the spinnability deteriorates, and the processability such as stretching, crimping, winding and tufting also deteriorates after spinning. Therefore, these processes are performed in a state in which an oil agent of about 0.7 to 1.5% by weight is applied as described above, and the oil content is reduced to 0.40% by weight or less by post-treatment after tufting. It is better to remove the oil agent until.

As a means for removing the oil agent by post-treatment, a material which is easily sublimated or decomposed by heat, such as polyether, is used as an oil agent component, and a heat treatment is performed after tufting to volatilize the oil agent. And then immersing in hot water (40 to 60 ° C.), dehydrating (25% water content), and drying. Furthermore, a method combining these and the like can be mentioned.

FIG. 1 shows an example of the configuration of a low smoke emitting tile carpet according to the present invention. In the figure, (1) is a carpet base material, and a pile yarn (3) made of polyester filament is planted in a loop shape on a binder-free polyester spunbond base fabric (2). )) Is set to 0.40% by weight or less. (4) a sealing layer made of an amorphous olefin polymer composition adhered to the back surface of the carpet substrate (1); (5)
Is a backing layer made of the same polymer composition provided outside the filling layer (4), and in this backing layer (5),
Two intermediate base fabrics are interposed between a glass braid (6) using an ethylene-vinyl acetate binder and a glass nonwoven fabric (7) using a polyvinyl alcohol binder.

[0022]

EXAMPLES Examples of the present invention will be specifically described below in comparison with Reference Examples and Comparative Examples. In the following description, “part” and “%” mean “part by weight” and “% by weight”, respectively.

REFERENCE EXAMPLE 1 As shown in the carpet base material (A) in Table 1 below, a polyester filament (a yarn count of 3000 denier / 1
p, pile density: 1/10, 55 st), and by a tufting machine, a polyester spunbond base fabric having a thickness of 3.0 mm, a basis weight of 100 g / m ² and no binder (shown as “No binder” in the table). , The following example
Same for 1 . ) And pile weight 680 g /
m ² of loop pile type tile carpet cloth to (A) was prepared.

[0024]

[Table 1] On the back side of the carpet base material (A), a melt at 170 to 200 ° C. of the following filling resin composition (P1) is weighted 40.
The mixture was coated at a rate of 0 g / m ² to provide a seal. On this seal layer, 170 to 2 of the following resin composition (Q1) for backing was used.
The melt at 00 ° C. was divided into three stages, and a glass cloth (basis weight 35 g / m ² ) was placed between the first and second stages, and a glass nonwoven fabric (basis weight 40 g) was placed between the second and third stages. / M ² ) are applied to each other to form a total thickness of 3.0 mm.
Was formed, and after cooling, it was cut into a predetermined size to produce a tile carpet.

[Filling Resin Composition (P1)] Amorphous ethylene / propylene random copolymer (RT2215 manufactured by Ube Lexen) 100 parts Crystalline polypropylene (J130G manufactured by Ube Industries) 5 parts Aliphatic Petroleum resin (T-300X, manufactured by Mitsui Petrochemical Industries, Ltd.) 25 parts Calcium carbonate (average particle diameter 30 μm) 100 parts Magnesium hydroxide (average particle diameter 10 μm) 30 parts [Resin composition for backing (Q1)] Amorphous ethylene / propylene random copolymer (RT2215 manufactured by Ube Lexen) 100 parts Crystalline polypropylene (J130G manufactured by Ube Industries) 8 parts Aliphatic petroleum resin (T-300X manufactured by Mitsui Petrochemical Industries) 20 Part: calcium carbonate (average particle diameter: 60 μm) 280 parts: magnesium hydroxide (average particle diameter: 10 μm): 2 0 part Comparative Example 1 Carpet base material (B) composed of the components shown in Table 1 above
Was produced in the same manner as in Reference Example 1. In this case, nylon BCF is used as the pile material, and a polyester spunbond base cloth (with a thickness of 0.1 mm) containing a polyvinyl chloride (PVC) binder is used as the tuft base cloth.
3 mmg / m ² , basis weight 100 g / m ² ).

On the back side of the carpet substrate (B) thus obtained, the filling resin composition (P1) and the backing resin composition (Q1) are formed in the same manner as in Reference Example 1 to form a tile carpet. Were prepared as Comparative Example 1, respectively.

Comparative Example 2 The following resin composition for backing (Q2) on an endless belt
Was coated at a thickness of 1.5 mm, and ester cloth (basis weight 20 g / m ² ) and a glass non-woven fabric (basis weight 40 g /
m ² ), and the following resin composition for backing (Q
3) was applied in a thickness of 1.5 mm, and the carpet substrate (A) was laminated thereon.
After heating for a minute, the mixture was cooled and cut into a predetermined size to produce a tile carpet.

[Resin composition for backing (Q2)] Polyvinyl chloride paste resin (P410 manufactured by Mitsubishi Kasei Vinyl Co., Ltd.) 100 parts Dioctyl phthalate (DOP) 100 parts Calcium carbonate (average particle diameter 30 μm) 300 parts [Backing Resin Composition (Q3)] Polyvinyl chloride paste resin (P410 manufactured by Mitsubishi Kasei Vinyl Co., Ltd.) 100 parts Dioctyl phthalate (DOP) 100 parts Calcium carbonate (average particle diameter 50 μm) 400 parts Comparative Example 3 Carpet base material ( Carpet substrate (B) instead of A)
A tile carpet was produced in the same manner as in Comparative Example 2 except that the above-mentioned was used.

Example 1 A polyester filament (3000) melt-spun from a polyester chip (polyethylene terephthalate)
(15.6 denier x 192 deniers) was used to prepare a polyether-based oil emulsion (average molecular weight: 1.500, ethylene oxide: 40 mol%, propylene oxide: 60 mol%) using kissrole at a solid content of 1.0%.
And subjected to oiling, stretching, crimping, and winding according to a conventional method, and using a 1/10 inch gauge tufting machine to obtain a binder-free polyester spunbond base fabric (thickness: 0.3 mm). , Basis weight 100g /
m ² ) to prepare a loop pile type tile carpet substrate having a pile length of 3.0 mm. Then, the carpet base material is heat-treated at 200 ° C. for 10 minutes by a hot air dryer to volatilize the oil agent, and the oil content of the pile yarn is reduced to 0.34%.
After cooling to room temperature, a 10% solution of a fluororesin-based water repellent (AG730 manufactured by Asahi Glass Co., Ltd.) was spray-coated at a weight ratio of pile fiber of 30% and dried.

Next, on the back surface of the carpet base material, a melt at 170 to 200 ° C. of the filling resin composition (P1) was applied at a rate of a basis weight of 400 g / m ² to perform filling. The backing resin composition (Q1) 1
The melt at 70 to 200 ° C. is divided into three stages, and a glass fabric (basis weight 35 g / m ² ) using an ethylene-vinyl acetate-based binder is provided between the first and second stages. A glass non-woven fabric (basis weight 40 g / m ² ) using a polyvinyl alcohol-based binder was interposed between the third stage and a backing layer having a total thickness of 3.0 mm was formed by coating, and then cooled. Thereafter, the tile carpet was cut into a predetermined size to produce a tile carpet.

Example 2 A carpet base material was prepared by using oleyl oleate, which is a hydrophilic oil agent, as an oil agent, passed through a 50 ° C. hot water tank circulating after tufting as an oil agent removing method, and then dehydrated.
Dry with hot air at ℃, the oil content of the pile yarn is 0.20%
The tile carpet was produced in the same manner as in Example 1 except that the setting was made as follows.

For each of the tile carpets of the above Examples , Reference Examples and Comparative Examples, smoke-generating and toxic gases (HCN, C
O, NOx, SOx, HCl, and HF) analysis values and antifouling properties were measured by the following measurement methods, respectively. The results are shown in Table 2 below together with the oil content of the pile yarn.

[Smoke emission] D measured by the NBS smoke density chamber method
Shown by S maximum value. [Combustion gas analysis values] Gas detection tube method ASTM E66 of NBS chamber method
2 was measured. [Antifouling property] Immediately after product processing, Taber abrasion test (load 500g, 50
Times), the water repellency was measured.

[0034]

[Table 2] From the above table 2, the tile carpet of Comparative Example 1-3, was not sufficiently suppress the generation of toxic gases. Further according to the invention
The tile carpet of Reference Example 1 with a high oil content
Then, although the generation of toxic gas is not sufficient,
It was able to win suppressed to such an extent that not disabled, poor in antifouling
Was. This contrast, carpet tiles according to the present invention (Example 1, 2), the generation of toxic gases can be sufficiently suppressed, the occurrence of chromatic poison gas is significantly reduced, yet shows excellent performance in antifouling properties It turns out that there is.

[0035]

According to the present invention, it can sufficiently suppress the generation of toxic gases, and yet shows excellent dimensional stability and shape stability, moreover carpet tile with good antifouling property is provided .

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view showing a configuration example of a low-smoke emitting tile carpet according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Carpet base material 2 ... Polyester spun bond base fabric 3 ... Pile thread 4 ... Filler layer 5 ... Backing layer 6 ... Glass fiber cloth (glass braided cloth) 7 ... Glass fiber cloth (glass nonwoven cloth)

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) D05C 17/02 D04H 1/42 A47G 27/02

Claims (1)

(57) [Claims] An amorphous olefin polymer composition is provided on the back side of a carpet substrate (1) in which a pile yarn (3) made of polyester filaments is planted on a binder-free polyester spunbond base fabric (2). consisting the sealing layer (4) and the backing layer (5) Ri name provided with the pile yarn (3), the oil content is 0.40 wt% or less
And a polyvinyl alcohol as an intermediate base fabric in the backing layer (5).
Use of alcohol-based or ethylene-vinyl acetate-based binder
A tile carpet having excellent combustion safety, wherein the used glass fiber cloths (6) and (7) are interposed .