JP5317128B2 - Tile carpet with air permeability and anti-slip performance and low VOC generation and method for manufacturing the same - Google Patents

Description

  The present invention relates to a tile carpet that is directly applied to a floor surface such as a flooring or a free access floor without using an adhesive and has a low VOC generation amount.

  A tile carpet is generally made by applying a seal to the underside of the carpet skin layer and laminating a vinyl chloride resin layer and a reinforcing layer made of glass fiber cloth, etc. in the vinyl chloride resin layer. It is fixed using an adhesive or adhesive. In addition, when a tile carpet is constructed on a floor surface such as a flooring in a general household, the carpet is relaid many times a year, and therefore, it is often constructed without using an adhesive (laying construction). However, in this case, mold is generated or corroded on the floor surface or the carpet back surface, which is a problem.

  In recent years, as exemplified by sick house syndrome, the problem of contamination of living environment due to harmful substances generated from housing building materials has been taken up, and persistent VOC (volatile) having aromatic rings such as formaldehyde, toluene, xylene and the like. Organic compounds) are also being regulated by indoor air environmental guidelines. Also in the carpet, it has become a problem to eliminate the VOC that is generated from the adhesive used at the time of construction and the carpet itself.

  Patent Document 1 discloses a carpet in which charcoal powder obtained by finely pulverizing charcoal is dispersed in a carpet coating material to suppress the occurrence of VOC such as formaldehyde and thereby reduce the influence thereof. It has not reached.

Patent Document 2 discloses a manufacturing method in which the back surface of a carpet is heated, the back stitch portion is melted, and then bonded and integrated with the non-woven fabric layer. Although presented, there are problems with the pulling strength of the pile yarn and the hardness of the carpet, which are not satisfactory.
JP 2000-287819 A JP 2009-268529 A

  The tile carpet that has been widely used in the past is made by using synthetic fibers as pile yarn, and by embedding pile in a spunbond base fabric with a tufting machine (flocking machine) to make the carpet skin layer, and sealing the lower side of this, The reinforcing layer and the vinyl chloride resin layer are lined and heat-treated, and then cut into a required size.

  Nylon yarn is often used as the pile yarn, and polyester spunbond fabric is often used as the spunbond fabric. Moreover, since many plasticizers are mixed in the vinyl chloride resin layer, the occurrence of VOC is inevitable. Moreover, when constructing on the floor surface, an adhesive or a pressure-sensitive adhesive is used, and naturally there are VOCs generated from these adhesives and pressure-sensitive adhesives. In addition, when laying and installing without using an adhesive or a pressure-sensitive adhesive, mold is generated or corroded on the floor or the back of the carpet, which is a problem.

  In view of the above-described circumstances, the present invention makes the entire tile carpet a breathable structure, is made of a material with less VOC generation, and further applies a breathable non-slip resin layer to the back of the tile carpet. The present inventors have found that a tile carpet that reduces the amount of VOC generated and that does not corrode the floor surface or the carpet back surface and does not generate mold even when installed and laid can be obtained. . In order to achieve the above object, the present invention provides the following means.

[1] In the tile carpet, the underside of the carpet skin layer is sealed with a breathable sealing layer, and the semi-molten thermoplastic powder is melted under the sealing layer. A small blob formed by wearing is partially fused, and has an adhesive layer having a gap communicating from the carpet surface side to the back surface side, a reinforcing layer included in the adhesive layer, and further, A nonwoven fabric layer having cushioning properties and air permeability is laminated on the lower side, and a non-slip resin layer is applied to the entire lower side of the nonwoven fabric layer so that the non-slip resin layer other than the convex shape does not form a film. Tile carpet, characterized by being secured.

[2] Foam EVA resin is used as the sealing layer, polyolefin resin is used as the thermoplastic resin powder of the adhesive layer, and the reinforcing layer is selected from glass fiber cloth and polyester fiber cloth. One or more reinforcing layers are included in the adhesive layer, a needle punched nonwoven fabric is used as the nonwoven fabric layer, and an acrylic foamed resin is used as the anti-slip resin layer. The tile carpet according to item 1 above.

[3] The thermoplastic resin powder is transferred onto the surface of the sealing layer while being transported at a constant speed with the sealing layer side of the carpet skin layer having been sealed by a breathable sealing layer not formed into a film. After spraying, this powder is heated to a semi-molten state to form an adhesive layer, and a reinforcing layer and a non-slip resin layer are applied in an uneven shape on the upper side, and no non-slip resin layer other than the convex shape is formed. The small lumps formed by laminating the non-woven fabric layer, which is ensured of air permeability with a roll, pressurizing with a roll, and the thermoplastic resin powders are heated and fused to a semi-molten state are partially melted. A method for producing a tile carpet, characterized in that a carpet skin layer, a reinforcing layer, and a non-woven fabric layer are bonded and integrated through an adhesive layer having a gap that is attached and communicated from the carpet surface side to the back surface side.

  In the first invention, the underside of the carpet skin layer is sealed by a breathable sealing layer that does not form a film. Maintained. In addition, a gap formed by fusing the semi-molten thermoplastic resin powders to the lower side of the sealing layer is partly fused to form a void communicating from the carpet surface side to the back side. Since the adhesive layer has an air permeability, the adhesive layer can ensure air permeability. Furthermore, since the reinforcing layer is included in the adhesive layer, the dimensional stability of the tile carpet can be ensured. Furthermore, since a nonwoven fabric layer having cushioning properties and air permeability is laminated on the lower side of the adhesive layer, air permeability from the carpet skin layer to the nonwoven fabric layer is ensured. Since the non-slip resin layer is applied to the entire underside of the nonwoven fabric layer and the non-slip resin layer other than the convex shape does not form a film so that the air permeability is ensured, the air permeability of the entire tile carpet can be ensured. The anti-slip resin layer applied in a convex shape effectively acts to exhibit the anti-slip effect, and can be used without shifting when the tile carpet is used. Further, since the air permeability of the entire tile carpet is ensured, the tile carpet can be made such that the floor surface and the carpet back surface are not corroded and mold is not generated.

  In the second invention, a foamed EVA resin is used as the sealing layer, a polyolefin resin is used as the thermoplastic resin powder of the adhesive layer, and a glass fiber cloth or a polyester fiber cloth is used as the reinforcing layer. One or more reinforcing layers selected from are included in the adhesive layer, a needle punch nonwoven fabric is used as the nonwoven fabric layer, and an acrylic foamed resin is used as the anti-slip resin layer, A tile carpet with reduced VOC generation can be obtained.

  In the third invention, a thermoplastic resin is transported on the surface of the sealing layer while being transported at a constant speed with the sealing layer side of the carpet skin layer having been sealed by a breathable sealing layer not formed into a film. The powder is then sprayed, and then the powder is heated to a semi-molten state to form an adhesive layer. A reinforcing layer and a non-slip resin layer are applied in a concavo-convex shape on the upper side, and a non-slip resin layer other than the convex shape is formed. The non-woven fabric layer that is ensured to be air permeable without film formation is overlapped, pressed with a roll, and the thermoplastic resin powders are heated to a semi-molten state and fused to form a small part. Since the carpet skin layer, the reinforcing layer, and the nonwoven fabric layer are bonded and integrated through an adhesive layer having a gap that is fused and communicated from the carpet surface side to the back surface side, air permeability of the entire tile carpet is ensured, Corroding the floor and the back of the carpet It can be a manufacturing method for continuously producing a free tile carpet be mold occurs. Further, the anti-slip resin layer applied in a convex shape effectively acts to exhibit an anti-slip effect, and can be a tile carpet manufacturing method that can be used without shifting during use.

  The tile carpet of the present invention will be described in detail with reference to the drawings. FIG. 1 is a sectional view showing an embodiment of the tile carpet of the present invention. In the figure, a tile carpet 1 includes a carpet skin layer 2, a sealing layer 3, an adhesive layer 4, a reinforcing layer 5 included in the adhesive layer 4, a cushioning and breathable nonwoven layer 6, and the nonwoven fabric. The anti-slip resin layer 7 is laminated on the entire lower side of the layer. In the carpet skin layer 2, pile yarn 2-1 is planted on a base fabric 2-2. The anti-slip resin layer 7 is a concave portion 7-2 which is applied in a concavo-convex shape and has air permeability without being formed by a non-slip resin layer other than the convex portion 7-1 and the convex portion.

  The carpet skin layer 2 is configured by planting pile yarn 2-1 on a base fabric 2-2. Although it does not specifically limit as a base fabric, A polyester spunbond base fabric is preferable and common. Further, the pile yarn is not particularly limited, but an olefin type yarn that generates little harmful gas during combustion is preferable. The carpet skin layer in which the pile is planted on the base fabric is fixed by a breathable sealing layer 3 that does not form a film.

  The sealing layer 3 is preferably coated with a foamed resin composition so as not to form a film and dried. As the resin, an EVA-based resin is preferable for fixing the pile yarn to the base fabric while generating a small amount of VOC and ensuring the air permeability of the carpet skin layer.

The adhesive layer 4 is formed by spraying thermoplastic resin powder and then heating the powder to a semi-molten state. As the thermoplastic resin powder, a polyolefin resin is preferably used. Specific examples include polyethylene, polypropylene, APAO (amorphous polyolefin), and the like. The coating amount of the thermoplastic resin powder, that is, the basis weight of the adhesive layer 4 is preferably set to ²⁰⁰ to 700 g / m ² . If it is less than 200 g / m ^2, it is not preferable because sufficient adhesive force cannot be obtained, and if it exceeds 700 g / m ² , it is not preferable because sufficient air permeability cannot be obtained.

  The thermoplastic resin powder preferably has an average particle size of 90 to 1000 μm. If it is less than 90 μm, the powder is likely to rise and the working environment is deteriorated, which is not preferable. If it exceeds 1000 μm, it is not preferable because the thermoplastic resin powder is difficult to melt when heated and a sufficient adhesive strength cannot be obtained.

Further, in the tile carpet of the present invention, it is recommended that one or more glass fiber cloths or polyester fiber cloths are interposed as the reinforcing layer 5 in order to stabilize the dimensions. As the glass fiber cloth, having a basis weight 30 to 50 g / ^{m 2} approximately nonwoven, and basis weight 25 to 45 g / ^{m 2} approximately woven and set fabrics are preferred. The reinforcing layer 5 is disposed on the adhesive layer 4 to be impregnated with the resin and integrated.

  In the present invention, a non-slip resin layer 7 fixed to a nonwoven fabric layer 6 having cushioning properties and air permeability is laminated on the lowermost layer portion of the tile carpet. The anti-slip resin layer forms the anti-slip resin layer 7 by applying an acrylic foamed resin obtained by foaming an emulsion having an acrylic polymer in an uneven shape and drying. The convex portion of the anti-slip resin layer is formed with a number of micro-dents on the surface of the anti-slip resin layer, and a micro-cavity is formed in the micro-pits, and a non-slip resin layer having a vacuum adsorption force is formed. ing. Further, the concave portion of the anti-slip resin layer is an anti-slip resin layer in which air permeability is ensured without forming the anti-slip resin layer. Therefore, the tile carpet of the present invention ensures air permeability from the uppermost carpet skin layer 2 to the non-woven fabric layer 6 to which the anti-slip resin layer 7 of the lowermost layer is fixed.

Examples of the non-woven fabric layer 6 include polyester fibers, nylon fibers, synthetic fibers such as polyolefin fibers, etc., or natural fibers such as wool and cotton, or a mixture of a plurality of natural fibers. It is also preferable from the aspect of warpage prevention. Thickness 1.0 to 5.0 mm, preferably a 2.0 to 5.0 mm, more preferably an apparent density of 0.05~0.15g / cm ³ at 0.08~0.12g / cm ³ is there. If the thickness is less than 1.0 mm, it cannot play the role of protecting the thermoplastic resin powder, that is, the adhesive layer 4 or cushioning, and if the thickness exceeds 5.0 mm, it will peel off in the nonwoven fabric layer during construction. It is easy and does not satisfy the adhesive strength.

  Examples of the nonwoven fabric layer include spunbond nonwoven fabric, chemical bond nonwoven fabric, and needle punched nonwoven fabric. In the present invention, since the foamed resin layer is applied and dried in a separate process, Needle punched nonwoven fabrics that do not easily enter, cause thermal shrinkage during heating, and prevent reverse warping are suitable.

  Next, FIG. 2 is a schematic view showing one embodiment of a process for producing a tile carpet of the present invention. Heat is applied to the surface of the sealing layer 3 while being transported at a constant speed with the sealing layer side of the carpet skin layer 2 having been sealed in advance by a breathable sealing layer 3 not formed in a separate process. A plastic resin powder is sprayed, and then the powder is heated to a semi-molten state to form an adhesive layer 4, and a glass woven fabric is laminated as a reinforcing layer 5 on the upper side. The non-slip resin layer 7 is applied to the non-woven fabric, and the dried non-woven fabric layer 7 is overlapped, pressed with a roll, and the thermoplastic resin powders are heated to a semi-molten state and fused together to form a small lump. The carpet skin layer, the reinforcing layer, and the nonwoven fabric layer are bonded and integrated through an adhesive layer having a gap that is partially fused and communicated from the carpet surface side to the back surface side, and then cooled and cut to a specified dimension. Tile carpet.

Next, the present invention will be described specifically by way of examples. In addition, the measurement of the characteristic value in an Example was performed as follows.
(1) Slip resistance test A slip resistance test was performed as a measure of slip prevention and adsorption strength. A vertical load of 8 kg was uniformly applied to a 20 × 20 cm test sample, the test sample was pulled in the horizontal direction, the maximum static frictional force was measured with a tensile tester, and 150 N or more was passed.
(2) Dimensional stability
Measurement in the normal state of JIS L4406 was performed, and compared with the cut size, 0.1% or less in both the vertical and horizontal directions was regarded as acceptable.
(3) TVOC
Measured according to JIS A 1901 (20L small chamber method). Less than 400 μg / m ³ was considered acceptable.

<Example 1>
A polyester yarn of 3060 dtex 288f was planted on a polyester spunbond base fabric to prepare a carpet pile skin of a pile weight of 680 g / m ² . Next, an EVA-based resin composition in the form of foam was applied to the back side of the skin layer at 180 g / m ² (after drying) to prepare a carpet skin layer with a seal. Next, the carpet skin layer 2 is conveyed at a constant speed with the sealing layer side facing up, and 400 g / kg of thermoplastic resin powder (polyethylene resin powder having an average particle size of 200 μm) is formed on the surface of the sealing layer 3. m ² sprayed and overheated. In some mutually substantially fusing plurality of particles, in a state where the particles and the fusion of the adjacent began elsewhere, out of the heating furnace, a glass woven fabric (basis weight 40 g / m ²⁾ on the previously separate A non-woven fabric layer 7 (polyester needle punch, weight per unit area: 500 g / m) coated with an acrylic anti-slip resin in a bowl shape (coating amount 300 g / m ² , convex width 4 mm, height 1 mm, concave width 11 mm) ² ) were overlapped and pressed with a roll, and the carpet skin layer, the reinforcing layer, and the nonwoven fabric layer were bonded and integrated via the fused adhesive layer.

When the characteristic values of the tile carpet thus obtained were measured, the slip resistance test was 200 N, and the dimensional stability was 0.04% in both the vertical and horizontal directions. The TVOC measurement was 30 μg / m ³ and passed.

<Example 2>
A tile carpet was produced in the same manner as in Example 1 except that the glass woven fabric (weight per unit area: 50 g / m ² ) was used instead of the glass woven fabric (a basis weight: 40 g / m ² ). The slip resistance test at this time was 200 N, and the dimensional stability was 0.06% in both the vertical and horizontal directions, and passed. The TVOC measurement was also passed at 30 μg / m ³ .

<Comparative Example 1>
In Example 1, a tile carpet was prepared in the same manner as in Example 1 except that instead of the thermoplastic resin powder, a polyethylene resin film extruded from a T-die extruder (coating amount 400 g / m ² ) was used. The slip resistance test, dimensional stability, and TVOC measurement were acceptable, but after one month of use, mold was generated on the back of the carpet, which was unacceptable.

<Comparative example 2>
In Example 1, a tile carpet was prepared in the same manner as in Example 1 except that the glass woven fabric of the reinforcing layer was not inserted. The slip resistance test and TVOC measurement were acceptable, but the dimensional stability was unacceptable at 0.11% in both the vertical and horizontal directions.

<Comparative Example 3>
In Example 1, when the tile carpet was prepared without applying the acrylic anti-slip resin, it was 20 N in the slip resistance test and could not be laid.

  Tile carpets are often used for flooring in offices and the like for heavy walking. However, the tile carpet of the present invention has a low VOC generation amount and has a luxurious atmosphere that the carpet brings out. As a matter of course, there is a high possibility that it will be widely adopted not only for general households but also for hotels and offices.

Tile carpet schematic sectional view of the present invention Manufacturing process schematic diagram of the present invention

DESCRIPTION OF SYMBOLS 1 Tile carpet 2 Carpet skin layer 3 Sealing layer 4 Adhesive layer 5 Reinforcing layer 6 Non-woven fabric layer 7 Non-slip resin layer 8 Thermoplastic resin powder 9 Heating furnace 2-1 Pile yarn 2-2 Base fabric 7-1 Convex 7 -2 recess

Claims (3)

  In the tile carpet, the underside of the carpet skin layer is sealed by a breathable sealing layer, and the semi-molten thermoplastic resin powder is fused to the bottom of the sealing layer. The resulting small lumps are partially fused to each other, and have an adhesive layer having a gap communicating from the carpet surface side to the back surface side. The reinforcing layer included in the adhesive layer, and further below the adhesive layer A nonwoven fabric layer with cushioning and breathability is laminated, and a non-slip resin layer is applied to the entire underside of the non-woven fabric layer so that the non-slip resin layer other than the convex shape does not form a film, ensuring air permeability. Tile carpet characterized by being.   A foamed EVA resin is used as the sealing layer, a polyolefin resin is used as the thermoplastic resin powder of the adhesive layer, and a layer selected from glass fiber cloth and polyester fiber cloth as the reinforcing layer or A plurality of reinforcing layers are included in the adhesive layer, a needle punched nonwoven fabric is used as the nonwoven fabric layer, and an acrylic foamed resin is used as the anti-slip resin layer. The tile carpet described.   While transporting at a constant speed with the sealing layer side of the carpet skin layer subjected to sealing by a breathable sealing layer not forming a film, spraying thermoplastic resin powder on the sealing layer surface, Next, this powder is heated to a semi-molten state to form an adhesive layer, and a reinforcing layer and an anti-slip resin layer are applied to the upper side of the adhesive layer so that a non-slip resin layer other than the convex shape does not form a film. Are overlapped with a nonwoven fabric layer that has been secured, pressed with a roll, and the thermoplastic resin powders are heated to a semi-molten state and fused, and the small lumps are partially fused together. A method for producing a tile carpet, characterized in that a carpet skin layer, a reinforcing layer, and a nonwoven fabric layer are bonded and integrated through an adhesive layer having a gap communicating from the carpet surface side to the back surface side.

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