JP4465693B2 - Tile carpet and recipe - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a tile carpet in which a thick backing layer is laminated on the back surface of a surface material.
[0002]
[Prior art]
It is publicly known that a backing layer of a tile carpet has a multilayer laminated structure of two or more layers, and that a reinforcing fabric is interposed between the respective layers (see, for example, Patent Document 1). It is publicly known that the back surface of a carpet lined with a thermoplastic resin emulsion and the surface of an interlining coated with a vinyl chloride resin foam coating are heated and melted by an infrared heater, and the carpet and interlining are bonded together. (For example, refer to Patent Document 2). A tile carpet in which carpet crushed waste is spread and laminated on a vinyl chloride resin paste layer applied to an endless belt, and further a vinyl chloride resin paste layer is applied thereon, and an intermediate layer of carpet crushed waste is formed in the backing layer. It is known (see, for example, Patent Document 3).
[0003]
[Patent Document 1]
JP-A-58-121922 (Claims, Fig. 1)
[Patent Document 2]
Japanese Patent No. 2534591 (Claims, FIG. 2)
[Patent Document 3]
Japanese Patent Publication No. 7-110530 (Claims, FIG. 2)
[0004]
[Problems to be solved by the invention]
In recent years, with the enforcement of the so-called PL law, the responsibility for disposal of products lies with the manufactured products, various methods for disposal of tile carpet after use and methods for recycling / recycling have been studied. Patent Document 3 relates to a method for recycling / recycling tile carpet (hereinafter referred to as tile carpet waste) discarded after use. In the method according to Patent Document 3, since the backing layer is easily peeled in the middle of the intermediate layer constituted by the crushed waste of tile carpet waste, the crushed waste of tile carpet waste that becomes the intermediate layer is thickened. Recycled tiles that can be obtained because the tile carpet waste that cannot be laminated can not be consumed, and the new resin composition must be thickly laminated on the front and back of the intermediate layer. Carpets are expensive. In addition, in the method according to Patent Document 3, a difference in stretch between the upper layer and the lower layer, which is laminated on the front and back of the intermediate layer, is easily caused by the new resin composition. There is also a problem in that the peripheral edge tends to warp.
[0005]
OBJECT OF THE INVENTION
Accordingly, a first object of the present invention is to recycle and apply the tile carpet waste to the backing layer of the tile carpet and consume it. The second object of the present invention is to reduce the amount of new resin composition used in the process of reclaiming tile carpet waste and applying it to the backing layer, so that the resulting recycled tile carpet does not become expensive. It is to be. The third object of the present invention is to obtain a recycled tile carpet in which the peeling of the backing layer applied by regenerating the tile carpet waste is eliminated, and the periphery does not warp. A fourth object of the present invention is to obtain a tile carpet that can be easily recycled in the backing layer of the tile carpet.
[0006]
[Means for Solving the Problems]
The tile carpet according to the present invention comprises: (a) a backing layer 25 having a thickness of 2 mm or more laminated on the back surface of the surface material 11; and (b) a tile carpet waste having a backing layer containing a vinyl chloride resin. Thickness of 10-mesh-pass tile carpet waste powder that was pulverized through a machine and passed through a sieve was mixed through a Banbury mixer, heated and melted through an extruder, and rolled into a sheet through a calendar. It is configured by laminating two or more fiber resin mixed backing materials 13 in which fibers having a length of 0.5 to 4 mm and a length of 0.5 to 10 mm are mixed. (C) Mixed in the fiber resin mixed backing material 13 (D) The backing layer is bonded to the back surface of the surface material 11 through the coating layer 27 of the first backing 15 of the vinyl chloride resin paste sol . This is the first feature.
[0007]
The second feature of the tile carpet according to the present invention is that, in addition to the first feature, two or more fiber resin mixed backing materials 13 and 13 constituting the backing layer 25 are heated and melted on their surfaces. It is in the point where it is made to overlap .
[0008]
The third feature of the tile carpet according to the present invention is that, in addition to any of the first and second features, two or more fiber resin mixed backing materials (13) constituting the backing layer 25 are provided. in that it is Awa together by a binder.
[0009]
A fourth feature of the tile carpet according to the present invention is that, in addition to any of the first, second and third features, two or more fiber resin mixed backing materials 13 constituting the backing layer 25 are provided. lies in being Awa together by a binder.
[0010]
A fifth feature of the tile carpet according to the present invention is a glass fiber mesh fabric having a coarse fiber resin mixed backing 13 in addition to any of the first, second, third and fourth features. It is in a point that it is reinforced by the reinforcing interlining 16 .
[0011]
In the tile carpet manufacturing method according to the present invention, a tile carpet waste having a vinyl chloride resin is pulverized through a pulverizer and mixed with a banbury mixer through a 10-mesh pass tile carpet waste fine powder. Then, it is heated and melted through an extruder, rolled into a sheet through a calendar, and a thickness of a vinyl chloride resin composition in which fibers having a length of 0.5 to 10 mm are mixed is 0.5 to 4 mm. The fiber resin mixed backing material 13 is formed, and the fiber resin mixed backing material 13 is placed on the endless belt 26 and conveyed, and the surface of the fiber resin mixed backing material 13 is preheated by the infrared radiation device 19 and the remaining heat is obtained. the paste sol 27 vinyl chloride resin of the same quality coating layered with the the fiber resin mixture backing 13 on the surface of the fiber resin mixture backing 13 tinged, the vinyl chloride The backing laminated surface material 11 of the first backing 15 to the coating layer 27 of resin paste sol is laminated, a vinyl resin paste sol 27 chloride through a heating zone 28 wherein the gelling.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a method for recycling and recycling tile carpet waste, and tile carpet waste is pulverized into a fine powder as a raw material for the fiber-resin mixed backing 13. The tile carpet waste used as the raw material is one in which a backing layer is laminated with a vinyl chloride resin or polyolefin resin having a temperature difference between a softening point or a melting point and a thermal decomposition point of 50 ° C. or more as a main resin. Is preferred.
[0013]
Tile carpet waste is first pulverized through a pulverizer, passed through a sieve to remove long fiber debris, passed through a pulverizer again to a fine powder of 10 mesh pass, and then mixed through a Banbury mixer. Then, the mixture is heated and melted through an extruder, rolled into a sheet through a calendar, and finished into a fiber resin mixed backing 13 having a thickness of 0.5 to 4 mm through a cooling roll. From the extruder, it is good to extrude the mixed melt of the fiber and the thermoplastic synthetic resin composition toward the base fabric, and the fiber-resin mixed backing 13 has the base fabric as a reinforcing interlining 16. Also good.
[0014]
Currently marketed tile carpets use needle punching felt, tufted pile fabric, pile woven fabric, pile knitted fabric, etc. as the surface material, and the weight of the fibers in the entire tile carpet is generally 30% by weight or less. In the pulverization process, the fibers may be removed by sieving, and the ratio of the fibers in the pulverized product may be adjusted to 10% by weight or less, generally about 5% by weight, and used as the raw material for the fiber resin mixed backing 13. In tile carpet waste in which a loop pile fabric is used as a surface material, the loop pile constituting the surface material is a long and continuous fiber yarn, so it is easy to remove by sieving, and the pulverized product The proportion of the fiber in the fiber can be 2 to 3% by weight.
[0015]
When forming a backing layer by laminating a plurality of fiber resin mixed backings, the surfaces of the fiber resin mixed backings to be laminated are heated and melted to overlap each other, or each fiber resin mixed backing by a binder. Paste the materials together.
[0016]
When the fiber resin mixed backing material is heated and melted and overlapped, a thermoplastic synthetic resin composition 15 is laminated on the back surface of the surface material 11, and the thermoplastic resin of the surface material 11 is simultaneously synthesized with the fiber resin mixed backing material 13. The resin composition 15 is also heated and melted. In addition, when the fiber resin mixed backing material is heated and melted and overlapped, a fiber resin mixed backing material having a reinforcing interlining 16 may be used. FIG. 2 illustrates the process of laminating the backing layer 25 by heating and melting the fiber resin mixed backing. In FIG. 2, 19 is an infrared radiation device, 20 is a heating cylinder, and 21 is a cooling zone. A reinforcing fabric 14 can be inserted between the fiber resin mixed backing 13a and the fiber resin mixed backing 13b to be overlapped. For the reinforcing fabric 14 and the reinforcing interlining 16, it is preferable to use a coarse glass fiber mesh fabric in which gaps that allow the melt of the fiber-resin mixed backing 13 to penetrate are distributed over the entire surface.
[0017]
When the fiber resin mixed backing is bonded with a binder, the reinforcing fabric 14 is inserted between the fiber resin mixed backing 13a and the fiber resin mixed backing 13b, and between the fiber resin mixed backing 13a and the surface material 11. And a binder is supported on the reinforcing fabric 14 and bonded together via the reinforcing fabric 14. FIG. 3 illustrates a process of laminating the fiber resin mixed backing material with a binder and laminating the backing layer 25, and the reinforcing fabric 14 is immersed in the binder storage tank 22, where the binder is applied to the front and back of the reinforcing fabric 14. The In the figure, reference numeral 23 denotes a cutter for cutting a laminate that becomes a surface material and a backing layer into a tile carpet 12 having a predetermined size.
[0018]
A back material 24 such as a non-woven fabric, paper, or film may be bonded to the outer surface of the fiber resin mixed backing material 13b which is the back surface of the tile carpet 12. As the surface material, needle punching felt, tufted pile fabric, pile fabric, and pile knitted fabric are used as in the case of conventional tile carpet. For the binder to which the thermoplastic synthetic resin composition 15 applied to the back surface of the surface material 11 and the fiber resin mixed backing material are bonded, a vinyl chloride resin and polyolefin having the same components as the main resin of the fiber resin mixed backing material 13 are used. A resin or an acrylic resin is used.
[0019]
In order to make it easy to recycle and recycle the tile resin 12 into a fiber resin mixed backing material 13 when the tile carpet 12 is discarded, a paste sol 27 of the same quality as the synthetic resin of the fiber resin mixed backing material 13 is used as the fiber resin. The mixed backing material 13 is applied and laminated, and the paste material sol coating layer 27 is laminated with the backing material 11 of the first backing 15 made of the thermoplastic synthetic resin composition, and the ratio of the synthetic resin in the backing layer 25 is increased. It is good to keep. In that case, the fiber-resin mixed backing 13 is preheated by the infrared radiation device 19 while being mounted on the endless belt 26 and conveyed, and a paste sol 27 is applied and laminated on the surface of the fiber-resin mixed backing 13 that is charged with the residual heat. To do. Then, the paste sol 27 is easily heated in the heating zone 28, and the temperature in the heating zone 28 can be suppressed to suppress the thermal deterioration of the surface material 11. The reinforcing fabric 14 is inserted on the fiber-resin mixed backing 13 when the paste sol 27 is applied. In order to facilitate recycling and recycling when the tile carpet 12 is discarded, it is recommended to use a vinyl chloride resin as the main synthetic resin of the paste sol 27 and the fiber resin mixed backing material 13.
[0020]
【The invention's effect】
According to the present invention (Claim 1), the fiber / resin mixed backing contains fibers longer than the thickness, and the fiber / resin mixed backing has a thickness of 4 mm or less. The front and back sides of the backing material are connected, and the fiber-mixed backing material is prevented from being peeled off by the mixed fibers. For this purpose, the mixing amount of fibers mixed in the fiber resin mixed backing 13 is set to 1% by weight or more. Even if the fiber resin mixed backing material is a pulverized tile carpet waste, even if weak spots that tend to cause cracks in the fiber resin mixed backing material are generated due to the mixed fibers contained in the raw material, multiple When the sheets are stacked, the mixed spots of the fibers are not averaged to form a weak point in the backing layer. And since the external force which acts on a backing layer is disperse | distributed to the multi-layer fiber resin mixed backing material which comprises, the backing layer becomes the strength stable. In the present invention, the mixing amount of the fibers mixed in the fiber resin mixed backing 13 is set to 30% by weight or less, even if fiber mixing spots occur, the fibers are bonded to the main resin of the fiber resin mixed backing. In order to prevent the mixed spots of fibers from forming weak points on the fiber-resin mixed backing.
[0021]
In the present invention (Claim 1), since the backing layer is formed by superimposing a plurality of thinly formed fiber resin mixed backings, even if heating may be performed during the lamination process, the heating is performed. It can be performed separately for each thin fiber-resin mixed backing. After the lamination, as shown in FIG. 2 and FIG. 3, even when a plurality of fiber resin mixed backing materials are heated simultaneously through the heating cylinder 20, the heating becomes preliminary or auxiliary, and at one time. Heat is not easily transferred to the inside of the backing layer, as in the case of heating a thick laminate of laminated thermoplastic synthetic resin compositions for backing, and the temperature difference generated between the front and back of the backing layer shrinks after cooling. Inconveniences that manifest themselves as a difference and thereby tend to warp the tile carpet are avoided.
[0022]
According to the present invention, since the backing layer is reinforced by the reinforcing fabric, even if fiber mixing spots occur in the fiber-resin mixed backing, it becomes a weak point and the backing layer is easily cracked. In the tile carpet manufacturing process, the reinforcing interlining can be used as a binder carrier as shown in FIG. 3, and the binder is directly applied to the backing or the surface material. Therefore, there is no need for a roll coater or a doctor coater for directly applying the binder to the backing or the surface material, and the tile carpet can be easily manufactured.
[0023]
According to the present invention, as shown in FIG. 2, without using a binder, the fiber-resin mixed backing is heated, and at the same time, the first backing made of the thermoplastic synthetic resin composition coated and laminated on the surface material is heated and melted. A backing layer can be laminated.
[0024]
According to the present invention, when the fiber resin mixed backing is laminated by heating and melting, the fiber resin mixed backing is supported by the reinforcing interlining, so it does not melt and break.
[0025]
According to the present invention, since the tile carpet surface is constituted by a long and continuous loop pile, it is easy to scrape the loop pile at the time of disposal to separate it from the backing layer, and to easily recycle the waste into the backing layer of the tile carpet. Become.
[0026]
According to the present invention, the ratio of the synthetic resin in the backing layer 25 is high, and the tile carpet 12 that can be easily recycled and recycled to the fiber resin mixed backing 13 by being pulverized into fine powder at the time of disposal can be efficiently obtained.
[0027]
Thus, according to the present invention, the tile carpet waste can be consumed as the main raw material of the backing layer, and the present invention is very advantageous in treating the tile carpet waste.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a tile carpet according to the present invention.
FIG. 2 is a sectional side view of a tile carpet manufacturing apparatus according to the present invention.
FIG. 3 is a sectional side view of a tile carpet manufacturing apparatus according to the present invention.
FIG. 4 is a sectional side view of a tile carpet manufacturing apparatus according to the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 11 Surface material 12 Tile carpet 13 Fiber resin mixed backing 14 Reinforcement fabric 15 First backing 16 Reinforcement interlining 17 Loop pile 18 Base fabric 19 Infrared radiation device 20 Heating cylinder 21 Cooling zone 22 Binder storage tank 23 Cutter 24 Back material 25 Backing layer 26 Endless Belt 27 Base Tosol 28 Heating Zone

Claims (6)

(A) In a tile carpet (12) formed by laminating a backing layer (25) having a thickness of 2 mm or more on the back surface of the surface material (11), (b) a tile in which the backing layer (25) comprises a vinyl chloride resin. The carpet waste is pulverized through a pulverizer and then passed through a sieve. The 10-mesh-pass tile carpet waste fine powder is mixed through a Banbury mixer, heated and melted through an extruder, and passed through a calendar to form a sheet. It is formed by laminating two or more fiber resin mixed backings (13) in which fibers having a thickness of 0.5 to 4 mm and a length of 0.5 to 10 mm are mixed, and (c) fiber resin The mixed amount of fibers mixed in the mixed backing (13) is 1 to 30% by weight, and (d) the backing layer (25) is a coating layer (27) of the first backing (15) of the vinyl chloride resin paste sol. The Carpet tiles, characterized by being bonded to the back surface of the surface member (11) and.   2. The tile carpet according to claim 1, wherein two or more fiber resin mixed backing materials (13, 13) constituting the backing layer (25) are superposed by heating and melting their surfaces.   The tile carpet according to claim 1, wherein two or more fiber resin mixed backing materials (13) constituting the backing layer (25) are bonded together with a binder.   The tile carpet according to claim 3, wherein the binder is supported on a reinforcing fabric (14) made of a coarse glass fiber mesh fabric. One fiber resin mixture backing (13), supra claim 1 and claim 2 and claim 3, characterized in that it is reinforced by the reinforcement by eyes crude fiberglass mesh fabric interlining (16) 1 The tile carpet as described in the item .   Tile carpet waste containing vinyl chloride resin is pulverized through a pulverizer and passed through a sieve, and 10 mesh pass tile carpet waste fine powder is mixed through a banbury mixer and then heated and melted through an extruder. , Rolled into a sheet through a calendar, and formed into a vinyl resin resin composition (13) having a thickness of 0.5 to 4 mm, comprising a vinyl chloride resin composition in which fibers having a length of 0.5 to 10 mm are mixed. Then, while the fiber resin mixed backing (13) is placed on the endless belt (26) and transported, the surface of the fiber resin mixed backing (13) is preheated by the infrared radiation device (19), and the residual heat. A paste sol (27) having the same quality as the vinyl chloride resin of the fiber resin mixed backing material (13) is applied and laminated on the surface of the fiber resin mixed backing material (13) bearing the same, and the vinyl chloride resin The surface layer (11) with the first backing (15) is laminated on the coating layer (27) of the first sol, and the vinyl chloride resin paste sol (27) is gelled through the heating zone (28). The manufacturing method of the characteristic tile carpet.

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