JP5654283B2 - Recycled tile carpet - Google Patents

Description

The present invention relates to a recycled tile carpet that can improve the dimensional stability of a tile carpet by using a tile carpet waste material containing a vinyl chloride resin as a constituent material of a backing layer.

When manufacturing a carpet, a large amount of cutting material is generated, and the amount of carpet to be disposed of from a general household or office becomes enormous. Conventionally, such carpet waste has often been landfilled or incinerated. However, when tile carpets lined with a backing agent made of a vinyl chloride resin are incinerated, there is a problem that harmful substances are easily generated. In recent years, from the viewpoint of protecting the global environment, there is a strong demand for collecting and recycling carpet waste. In order to meet such social demands, new carpets that are recycled from waste carpet materials containing vinyl chloride resin have been developed.

For example, chip-like or strip-like pieces (pellets) made of synthetic resin containing glass fiber and made mainly of vinyl chloride, produced from the backing material of used tile carpets, are collected and subjected to heat treatment. There is also known a technique for obtaining a backing material for a recycled tile carpet that is molded into a long sheet having a predetermined thickness and width while performing a pressure treatment. (See Patent Document 1).

In addition, the PVC backing layer of waste tile carpet discharged as industrial waste is pulverized, the powder is dispersed, heated, melted and pressurized, formed into a sheet, laminated with glass nonwoven fabric sandwiched, and tile A technique that enables recycling of various waste interior materials, which is used as a carpet backing layer, is also known (see Patent Document 2).

By using the technique as described above, it is possible to provide a recycled carpet using a carpet waste material containing a vinyl chloride resin as a part of the constituent material of the backing layer.

On the other hand, in order to improve dimensional stability, a technique of interposing a reinforcing layer made of a mesh-like glass woven fabric having a small linear expansion coefficient is also known. (See Patent Document 3).

In addition, even in the surface pile layer with excellent dimensional stability and warping performance, and the surface stitch layer with severe back-stitching, the reinforcing layer can be made as a mesh carpet that can be controlled to a predetermined thickness and is economical. A technique using a glass net of 25 to 400 mm ² is also known. (See Patent Document 4).
JP 2009-95521 A JP 2004-114663 A Japanese Patent Laid-Open No. 61-19886 JP 2009-131341 A

However, in the technique of Patent Document 1, the shrinkage of the backing layer made of a synthetic resin mainly composed of vinyl chloride produced from the used tile carpet backing material is large, and a plurality of short fiber glass fibers are random to each other. It is difficult to suppress the warping performance and dimensional stability of the tile carpet due to the difference in contraction between the upper and lower sheets with only the arrangement arranged in the direction, and the tile carpet that can withstand hard wear due to chair casters etc. It did not become.

Also in the technology of Patent Document 2, 40 parts of a powder of tile carpet backing material having a vinyl chloride resin polymer content of about 15 to 20% and a long vinyl chloride resin content of about 40 to 50% are used as components. By mixing 40 parts of the powder of the sheet, it can be formed as a new backing material. However, since the resin component is large and must be melted at a high temperature, the vinyl chloride resin that is the resin component is decomposed. This may occur and the tile carpet may lack dimensional stability. Moreover, a great deal of energy is required for processing. Furthermore, a glass nonwoven fabric is inserted to suppress dimensional changes. However, the glass nonwoven fabric is integrated with the backing layer only by inserting the glass nonwoven fabric, and the gelled vinyl chloride resin polymer is adhered to the surface of the glass nonwoven fabric. It was difficult to suppress the dimensional change of the tile carpet and the delamination of the backing layer. In order to integrate the glass nonwoven fabric with the backing layer and improve the dimensional stability, it is necessary to impregnate the glass nonwoven fabric with a resin in advance or impregnate it in a processing step.

Furthermore, in the techniques of Patent Documents 3 and 4, when recycled resin is used for the backing layer, irregularities are generated on the surface, and the woven fabric with a small void or the glass net with a large mesh reduces the adhesion area. There was no power to secure the dimensions of the carpet, and it was difficult to suppress the dimensional stability of the recycled tile carpet.

The present invention has been made in view of such a technical background, and a composition obtained by pulverizing a carpet waste material containing a vinyl chloride resin is used as a backing layer of a tile carpet, and a predetermined reinforcing layer is provided. By using it, it aims at improving the adhesiveness of a backing layer and a reinforcement layer, and providing the recycled tile carpet excellent in dimensional stability.

As a result of intensive studies to solve such problems, the present inventors have obtained 0.5% of crushed glass fibers and pile yarns obtained by pulverizing carpet waste materials containing vinyl chloride resin. Using a resin composition containing 10% by weight as a backing layer, and using a nonwoven fabric of glass fiber having a fiber diameter of 8 μm or more and a length of 15 mm or more, a recycled resin is used, and the surface is uneven. Also in the backing layer, the present inventors have found that a recycled tile carpet having excellent adhesion between the backing layer and the reinforcing layer and having excellent dimensional stability can be obtained. In order to achieve the above object, the present invention provides the following means.

[1] A resin obtained by pulverizing a carpet waste material containing a surface pile layer made of a pile fabric in which pile yarn is planted on a base fabric, a reinforcing layer made of a nonwoven fabric of glass fiber, and a vinyl chloride resin In the recycled tile carpet composed of a backing layer made of the composition, the basis weight of the nonwoven fabric of glass fiber constituting the reinforcing layer is 15 to 38 g / m ² , and the fiber diameter of the nonwoven fabric of glass fiber is 8 μm or more, A recycled tile carpet having a fiber length of 15 mm or more and further containing 0.5 to 10% by weight of glass fiber and pile yarn crushed into the resin composition.

[2] The glass fiber non-woven fabric is composed of glass fibers that are heat resistant fibers having a heat resistant temperature of 400 ° C. or higher, and has a tensile strength of 120 N / 50 cm or higher and a heat shrinkage rate of 0.1% or lower after heat treatment at 180 ° C. for 10 minutes. 2. The recycled tile carpet according to item 1 above.

[3] The above-mentioned item 1 or 2, wherein the glass fiber non-woven fabric is joined to and integrated with the backing layer by the resin composition impregnated into the gaps of the glass fiber non-woven fabric. Recycled tile carpet.

[4] The recycled tile carpet according to any one of items 1 to 3, wherein the length of the pulverized glass fiber or pile yarn included in the resin composition is included in a range of 0.1 mm to 30 mm.

[5] The items 1 to 4 described above, wherein the thickness ratio between the backing layer located on the upper surface and the backing layer located on the lower surface of the reinforcing layer is 1: 1-1: 9. Recycled tile carpet as described.

In the invention of [1], the basis weight of the nonwoven fabric of glass fibers constituting the reinforcing layer is 15 to 38 g / m ² , the fiber diameter of the nonwoven fabric of glass fibers is 8 μm or more, and the fiber length is 15 mm or more. For this reason, the nonwoven fabric has a coarse mesh and the resin composition constituting the backing layer is likely to penetrate and can be integrated with the backing layer. Further, since the glass fiber and the pile yarn crushed into the resin composition contain 0.5 to 10 wt%, the glass fiber and the pile yarn are randomly arranged in the backing layer, The backing layer itself also exhibits strong dimensional stability. Furthermore, by using a resin composition obtained by pulverizing a carpet waste material containing a vinyl chloride resin, a recycled tile carpet having a high use ratio of recycled materials and sufficiently contributing to protection of the global environment can be obtained.

In the invention of [2], the glass fiber non-woven fabric is composed of glass fibers that are heat resistant fibers having a heat resistant temperature of 400 ° C. or higher, and has a tensile strength of 120 N / 50 cm or higher and a heat shrinkage ratio of 0.1% after heat treatment at 180 ° C. for 10 minutes. Accordingly, the performance and dimensions do not change even at high temperatures during processing of the tile carpet, and the dimensions do not change even in harsh environments when used after the tile carpet has been constructed.

In the invention of [3], since the glass fiber nonwoven fabric is joined and integrated with the backing layer by the resin composition impregnated into the gaps of the glass fiber nonwoven fabric, the in-layer peeling in the backing layer is performed. The dimensional stability of the non-woven fabric of glass fiber becomes the strong dimensional stability of the entire tile carpet.

In the invention of [4], since the length of the crushed glass fiber and pile yarn contained in the resin composition is included in the range of 0.1 mm to 30 mm, the glass fiber and pile yarn are randomly selected from each other. As a result, the inner layer of the backing layer is not peeled off, and the tile carpet can be provided with strong dimensional stability.

In the invention of [5], since the thickness ratio of the backing layer located on the upper surface and the backing layer located on the lower surface of the reinforcing layer is inserted so as to be 1: 1 to 1: 9, The reinforcing layer is inserted above the middle position in the thickness direction, and the recycled tile carpet is excellent in warpage performance and dimensional stability.

As shown in FIG. 1, the recycled tile carpet (1) of the present invention comprises a surface pile layer (2) made of a pile fabric in which a pile is planted on a base fabric, and a carpet waste material containing a vinyl chloride resin. A backing layer (3) made of a resin composition obtained by pulverization and a reinforcing layer (4) made of a glass fiber non-woven fabric are laminated and integrated.

The surface pile layer (2) in the present invention is not particularly limited, but, for example, a carpet base material with piles on the surface, tufted carpet, woven carpet, knitted carpet, electrodeposition carpet Etc. can be illustrated.

The carpet substrate is not particularly limited, and any carpet substrate can be used. For example, in addition to fabrics made by knitting and knitting yarns made of synthetic fibers such as polyester fibers, nylon fibers, polypropylene fibers, acrylic fibers, or natural fibers such as hemp, cotton, wool, etc., various fibers and yarns are needed. Nonwoven fabrics that are mechanically bonded by a ring or the like, or chemically bonded by an adhesive or the like can be used.

The pile material is not particularly limited, and materials made of fibers such as polyester fiber, nylon fiber, polypropylene fiber, acrylic fiber, rayon fiber, etc. can be suitably used. In addition, hemp, cotton, wool, etc. Those made of natural fibers can be used. Further, the pile layer forming means is not particularly limited, for example, a means for forming a pile layer by weaving such as warp pile weft, weft pile weave, etc., tufting machine etc. Examples thereof include a means for forming a pile layer, a means for forming a pile layer by a knitting machine, and a means for forming a pile layer by bonding pile yarns using an adhesive. The pile form is not particularly limited, and any form such as a cut pile or a loop pile may be used.

Further, a sealing layer (5) such as a low-viscosity polyvinyl chloride resin or a carboxy-modified styrene / butadiene copolymer may be provided on the lower surface of the surface pile layer (2). In particular, a low-viscosity polyvinyl chloride resin is preferable in terms of impregnation and adhesion.

In the present invention, a recycled tile carpet in which a large number of fiber components contained in a resin composition obtained by pulverizing a carpet waste material containing a vinyl chloride resin constituting a backing layer is randomly arranged in the backing layer. Although it contributes to the dimensional stability which is the basic performance of (1), the reinforcing layer (4) is required to further improve the dimensional stability.

The reinforcing layer (4) in the present invention improves the shape and dimensional stability of the recycled tile carpet (1), and it is necessary to use a glass fiber nonwoven fabric. The reinforcing layer (4) is laminated on or on the backing layer (3) to improve the shape stability of the carpet. That is, the non-woven fabric of glass fiber is composed of glass fibers which are heat resistant fibers having a heat resistant temperature of 400 ° C. or higher, and has a tensile strength of 120 N / 50 cm or higher and a heat shrinkage rate of 0.1% or lower after heat treatment at 180 ° C. for 10 minutes. Therefore, the carpet shape can be effectively stabilized. From this point, a nonwoven fabric of glass fiber is most suitable.

In the prior art, the basis weight of the nonwoven fabric made of glass fibers required 40 g / m ² or more in order to exhibit dimensional stability. In the present invention, the resin composition impregnates the nonwoven fabric. Dimensional stability can be ensured with low weight per unit area, and it is preferably in the range of 15 to 38 g / m ² . When the basis weight is lower than this range, the effect of dimensional stability is insufficient, and when the basis weight exceeds this range, any delamination between the resin layer and the nonwoven fabric is likely to occur.

The fiber diameter of the non-woven fabric made of the glass fibers is required to be 8 μm or more and the fiber length is 15 mm or more. If it is this fiber diameter and fiber length, it will become a nonwoven fabric with which the eyes of a nonwoven fabric become coarse and resin permeates easily. When the fiber diameter and fiber length deviate from this range, the nonwoven fabric is fine and the resin is difficult to penetrate.

The reinforcing layer (4) needs to be inserted between the backing layer (3). That is, it is necessary to insert so that the ratio of the thickness of the backing layer located on the upper surface and the backing layer located on the lower surface is 1: 1 to 1: 9. If it is this position, the reinforcing layer (4) will be inserted above the intermediate position in the thickness direction of the backing layer, suppressing the movement of the surface pile layer (2) that tends to expand and contract, warping performance, In addition, the recycled tile carpet has excellent dimensional stability. For example, when constructing in a hard-use place where the walking frequency is intense, it is preferable to laminate the upper layer of, for example, 1: 9, which is excellent in high warpage performance and dimensional stability, and is comfortable walking in a general office etc. To, for example, a 1: 1 intermediate layer is preferred.

A backing layer (3) made of a resin composition obtained by pulverizing a carpet waste material containing a vinyl chloride resin in the present invention forms a tile carpet shape, and a carpet containing a vinyl chloride resin. It is obtained by crushing waste materials. The carpet waste material containing the vinyl chloride resin is not particularly limited as long as it contains glass fiber or pile yarn. For example, a carpet to be disposed of is preferably a tile carpet in which vinyl chloride resin is lined, nonwoven fabric or woven fabric made of glass fiber is inserted, and pile yarn is planted.

The scraping method and pulverization method for obtaining a finely pulverized product that has been scraped and pulverized from a vinyl chloride resin-backed carpet waste material are not particularly limited. The separated waste material is pulverized using a pulverizer, and the resulting pulverized material is separated into resin and fiber components by wind vibration classification or the like (for example, a pulverization method described in JP-A-2003-47878) And a method of further pulverizing the separated resin component (see Japanese Patent Application No. 2004-310179).

The resin composition obtained by pulverizing the carpet waste material containing the vinyl chloride resin in the present invention needs to contain 0.5 to 10% by weight of pulverized glass fiber and pile yarn. If the content of the glass fiber and the pile yarn is present, the glass fiber and the pile yarn are randomly arranged in the backing layer (3), so that the backing layer (3) itself has a strong dimensional stability. Will be demonstrated.

Furthermore, the length of the crushed glass fiber or pile yarn contained in the resin composition needs to be included in the range of 0.1 mm to 20 mm. If the length of the glass fiber or the pile yarn, the glass fiber or the pile yarn is arranged in a random direction without penetrating in the thickness direction, and the delamination in the backing layer (3) is caused. It does not occur, and strong dimensional stability can be imparted to the recycled tile carpet (1).

As a method of forming a resin composition obtained by pulverizing a carpet waste material containing a vinyl chloride resin in a backing layer (3) and inserting a reinforcing layer (4), powder spraying, coating, calendaring Although known processing techniques such as processing can be used, powder spray processing is preferable in order to use as much recycled resin as possible.

For example, as a method of powder dispersion processing, first, a resin composition obtained by pulverizing a waste carpet material containing the vinyl chloride resin containing 0.5 to 10% by weight of crushed glass fibers and pile yarns is scattered. In Prior to the addition, it is possible to blend a plasticizer, a lubricant, a filler, a pigment, and the like, if necessary. Next, the pulverized material is sprayed from a scatter disposed above on an endless releasable belt that continuously runs. In this scatter, a roller having a surface on which a large number of dimples (dents) such as golf balls are formed is arranged at the lower spraying port, and the pulverized material that has entered the dimples by rotating the roller is removed. This is a device that sequentially sprays downward, and can store the stored pulverized material in a desired amount. Next, the pulverized product dispersed on the endless releasable belt is heated and melted by using a heating device, and is pressed with a pressure roll to form the backing layer (3). Furthermore, a plurality of backing layers (3) can be formed by arranging a plurality of the scatterers vertically above a releasable belt that continuously runs in a tile carpet processing machine, and the plurality of backing layers ( It becomes possible to insert the reinforcing layer (4) between 3).

The processing temperature for heating and melting the pulverized material is 180 ° C. or lower because the resin composition contains a vinyl chloride resin, and has excellent strength and stable dimensional stability in the tile carpet (1). It can be set as the backing layer (3) to provide.

In the present invention, the application amount of the resin composition of the backing layer (3) made of the resin composition obtained by pulverizing the carpet waste material containing the vinyl chloride resin is preferably 300 to 4000 g / m ^2. . If the application amount is 300 to 4000 g / m ² , the energy of the recycled tile carpet (1) is strong if it is melted by the heat of the heating device from above and cooled and pressurized without requiring large energy, It becomes a dimensional stable backing layer. Below this range, formation as a strong layer is difficult, and above this range, melting becomes difficult and formation as a layer becomes difficult, which is economically disadvantageous.

Furthermore, the reinforcing layer (4) can be inserted between the backing layer (3). After the insertion, the resin constituting the backing layer is impregnated to the inside by heating and pressurization for forming the backing layer, and is laminated with the reinforcing layer (4) made of the nonwoven fabric of glass fiber with a strong adhesive force.

Even when a large amount of recycled resin is used, a recycled tile carpet excellent in dimensional stability can be obtained by forming the backing layer (3) and inserting the reinforcing layer (4).

The recycled tile carpet (1) of the present invention comprises the surface pile layer (2), each backing layer (3), and a reinforcing layer (4) laminated, heated, pressurized, cooled, and finally a predetermined shape, For example, if it cuts into a square of 500 mm square, the recycled tile carpet (1) as a final product will be obtained.

In addition, the recycled tile carpet (1) of this invention is not specifically limited to what is manufactured with the said manufacturing method.

Examples of the present invention will be described below.

<Example 1> A polyester fiber nonwoven fabric (carpet base material) having a basis weight of 90 g / m ² as a surface pile layer and a pile yarn made of nylon fibers tufted into a loop pile (pile basis weight 610 g / m ² ) Carpet prepared with a low-viscosity polyvinyl chloride resin sealing layer (applying amount 300 g / m ² ) on the back surface to prevent pile slippage and containing vinyl chloride resin in a powder spraying machine The resin composition obtained by pulverizing the waste material (containing 5% by weight of crushed glass fiber and pile yarn) is put into a scatter located above the endless releasable belt and placed on the endless releasable belt. After spraying at an application rate of 2000 g / m ² , the finely pulverized product was heated and melted at 170 ° C. with a heating device, and then pressurized with a water-cooled cooling and pressurizing roll. Next, a carpet having a fiber diameter of 10 μm, a fiber length of 20 mm, and a reinforcing layer made of a non-woven fabric of glass having a basis weight of 25 g / m ² , and further containing a vinyl chloride resin thereon. The resin composition obtained by pulverizing the waste material (containing 5% by weight of crushed glass fiber and pile yarn) is put into a scatter located above the endless releasable belt and placed on the endless releasable belt. The sprayed amount was sprayed at 2000 g / m ² , and then the finely pulverized product was heated and melted at 170 ° C. with a heating device and pressurized with a water-cooled cooling and pressing roll. Furthermore, the surface pile layer was laminated | stacked, and it heat-pressed then, and finally cut | judged into the square of 500 mm square, and manufactured the tile carpet.

<Example 2> Recycled tile in the same manner as in Example 1 except that the content of the crushed glass fiber and pile yarn contained in the resin composition obtained by pulverizing the carpet waste is 2% by weight. Got the carpet.

<Example 3> Recycled tile in exactly the same way as in Example 1 except that the content of the crushed glass fiber and pile yarn contained in the resin composition obtained by pulverizing the carpet waste is 8% by weight. Got the carpet.

Example 4 A recycled tile carpet was obtained in exactly the same manner as in Example 1 except that the basis weight of the reinforcing layer made of a glass nonwoven fabric was 20 g / m ² .

To obtain a recycled carpet tiles except that the basis weight of the reinforcing layer made of <Example 5> glass nonwoven fabric is 35 g / m ² in the same manner as in Example 1.

<Comparative Example 1> Recycled tile in the same manner as in Example 1 except that the content of crushed glass fiber and pile yarn contained in the resin composition obtained by pulverizing carpet waste is 0% by weight. Got the carpet.

To obtain a recycled carpet tiles except that the basis weight of the reinforcing layer made of <Comparative Example 2> glass nonwoven is 40 g / m ² is in the same manner as in Example 1.

<Comparative Example 3> A recycled tile carpet was obtained in exactly the same manner as in Example 1 except that the fiber diameter constituting the reinforcing layer made of a glass nonwoven fabric was 5 µm.

Comparative Example 4 A recycled tile carpet was obtained in exactly the same manner as in Example 1 except that the fiber length constituting the reinforcing layer made of a glass nonwoven fabric was 10 mm.

A dimensional stability test was examined on each recycled tile carpet (1) obtained as described above based on the following evaluation method. The results are shown in Table 1.

(Dimensional stability test) (A) According to JISL4406, each vinyl chloride recycled tile carpet (1) was allowed to stand at 60 ° C. for 2 hours, then immersed in tap water for 2 hours, and then allowed to stand at 60 ° C. for 24 hours. Measured at 20 ° C. and 65 RH% for each of the vertical direction of the recycled tile carpet (1) and the horizontal direction of the recycled tile carpet (1). Three samples were measured and the average value was obtained. (B) 500 mm square recycled tile carpet (1) Rotate a chair caster with a load of 90 kg on the surface of a sheet, measure the vertical and horizontal dimensions, and compare the vertical and horizontal values with the dimensions before rolling. The average value is shown. If both (A) and (B) have a value of less than ± 0.15%, the tile carpet can withstand actual use. In addition, if the delamination occurred in the backing layer while the chair caster was rotating, the tile carpet was not able to withstand actual use.

As apparent from Table 1, the recycled tile carpets of Examples 1 to 5 all obtained tile carpets excellent in dimensional stability and capable of withstanding use.

In contrast, the recycled tile carpets of Comparative Examples 1 to 4 did not provide good performance with respect to dimensional stability. Further, in Comparative Examples 2 and 4, delamination occurred in the backing layer.

It is a schematic sectional drawing of the recycling tile carpet which concerns on one Embodiment in this invention.

DESCRIPTION OF SYMBOLS 1 ... Recycled tile carpet 2 ... Surface pile layer 3 ... Backing layer 4 ... Reinforcement layer 5 ... Sealing layer

Claims (2)

On the lower surface of a surface pile layer made of a pile fabric in which pile yarn is planted on a base fabric, a first backing layer on the lower surface of the surface pile layer, a reinforcing layer on the lower surface of the first backing layer, and a first layer on the lower surface of the reinforcing layer. Laminate two backing layers,
The reinforcing layer is made of glass fiber, which is a heat-resistant fiber having a heat-resistant temperature of 400 ° C. or higher, and has a tensile strength of 120 N / 50 cm or higher and a heat shrinkage of 0.1% or less after heat treatment at 180 ° C. for 10 minutes. Consists of
The first and second backing layers are made of a resin composition obtained by pulverizing a carpet waste material containing a vinyl chloride resin ,
The basis weight of the nonwoven fabric of glass fiber constituting the reinforcing layer is 15 to 38 g / m ² , the fiber diameter of the nonwoven fabric of glass fiber is 8 μm or more, the fiber length is 15 mm or more, and the resin composition In addition to containing 0.5 to 10% by weight of glass fiber and pile yarn crushed into a product ,
The first and second backing layers have a coating ratio of 300 to 4000 g / m ² when the resin composition is applied by powder spraying, and a thickness ratio between the first backing layer and the second backing layer is 1: 1 to 1. 1: 9 formed,
By the resin composition impregnated to the inside of the gap of the glass fiber nonwoven fabric constituting the reinforcing layer by heating and pressurization for forming the backing layer in a state where the reinforcing layer is inserted between the backing layers, The glass fiber nonwoven fabric is joined and integrated with the backing layer,
Recycled tile carpet characterized by that. The recycled tile carpet according to claim 1 , wherein the length of the pulverized glass fiber or pile yarn contained in the resin composition is in the range of 0.1 mm to 30 mm.