JPH01501691A - dimensionally stable carpet tiles - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] dimensionally stable carpet tiles Dimensional stability is one of the most important properties for carpet tiles. enough Without a stabilized backing material, the tile edges will curl, curl, and bulge. ling) or shrinkage problems may occur.

Carpet tiles typically have a secondary backing material bonded to the underside of the carpet. or otherwise manufactured by adhesion. This secondary backing material is made of woven It can be a crim, a composite material, or a combination of both. typical secondary The target backing material is made from jute, nylon, polypropylene or glass fiber. It can be made of woven reinforcement material. This woven reinforcement is then glued or or polyvinyl chloride, urethane foam, polyethylene, ethylene vinyl acetate, Alternatively, it can be covered with other backing materials such as asphalt material.

Attempts to increase dimensional stability have led to the use of many materials, the most common being is the use of polyvinyl chloride (PVC).

In such attempts, carpets, tiles are tufted. Alternatively, woven greige can be melted into a PvC case. Manufactured by hebless on release belt It will be done. At this point a stabilizing scrim may be added. This form of secondary backing material The related problems are homogeneity in PvC application, high energy costs and raw material cost. and the inability to use adhesive solvents for tile installation.

A further concern in the manufacture of carpet tiles is the prevention of combustion hazards. be. Naturally, large amounts of polymeric materials are incorporated into carpet tiles. This increases the potential for smoke hazards during combustion. Therefore, carpet tiles It would be desirable to find a better alternative way to impart dimensional stability to.

In one aspect, the present invention provides a gray adhesive bonded to an aqueous wet laid composite sheet. The aim is to create dimensionally stable carpet tiles with a high dimensional stability. This composite sheet is characterized by Generally, the Aachen test method (Aachen Te5t) shows that the carpe content is 0.10% or less. consisting of dimensionally stable reinforcing fibers in an amount sufficient to provide a dimensional change. This dimension is cheap Qualitative reinforcing fibers are present at 2 to 15% by weight based on the total composite sheet.

Generally, the composite sheet will have a weight of 1 to 3, based on the total weight of the composite sheet. 0% cellulose fibers, 2 to 30% organic polymeric binder material, and 60% 95% inorganic filler. This composite sheet has at least 5011/ It has an internal combined strength of (19,68) inches.

Generally, carpet tiles are bonded to composite sheets with a thickness of 0.1 to 2.5 mm. Composed of worn greige. Typically, the dimensionally stable reinforcing fiber is glass. The glass fibers account for 2 to 10% by weight of the entire composite sheet. 2 to 15% cellulose fibers by weight based on the total weight of the composite sheet. exist.

The present invention provides dimensionally stable carpet pieces that can be die-cut as tiles. It provides manufacturing. These tiles have a conventional PVC backing. - It is possible to use pets and has economical advantages. Moreover, the original Tiles made by Ming can have low polymer content and are fire resistant. It can have a high inert fill content which is desirable for disaster safety.

The present invention provides very good dimensional stability through an aqueous wet-laid sheet as a secondary backing material. Designed for carpets that can be die-cut as legally stable tiles. ing. This wet layup sheet is made of filler material and latex bond in the proper proportions and a fibrous material, in which case at least a portion of the fibrous material is dimensionally stable. consisting of a sufficient amount of dimensionally stable reinforcing fibers to provide a

Typically, secondary backing materials are disclosed in U.S. Pat. No. 4,225,383. It is made by an aqueous wet layup method. All weight percentages are not specified. To the extent possible, this is based on the total weight of the composite sheet. In wet layup method The sheets produced typically contain 1 to 30% by weight of total cellulose fibers. water-dispersible fibers, 2 to 30% by total weight as a film-forming, water-insoluble binder. of organic polymers and 60 to 95 total weight percent of finely divided, substantially water-insoluble It is described as having a non-fibrous inorganic filler. However, it does not contain inorganic fillers. The amount is not very critical for the subject application as carpet backing material and therefore , composite sheets having up to 60% inorganic filler by total weight are acceptable. Also, Cellulose fibers exceeding 20% by weight have a negative effect on the internal bond strength of the composite. Therefore, preferably the cellulose fiber content is below the level of 30%. more preferably at a level of 2 to 15% cellulose fiber by total weight. car More critical for the subject application as PET backing material is the composite sheet Dimensionally stable reinforcing material, such as glass fiber, in which at least a portion of the fibrous content of the This means that it must belong to. In general, the total weight of the thematic complex At least 2 to 15% by weight consists of dimensionally stable reinforcing fibers.

Incorporation of dimensionally stable reinforcing fibers into the composite sheet in small proportions can Acceptable for use in PET backings, especially carpet tile backings. It was discovered that it provides a balance of physical properties that can be controlled. Therefore, 2 to 15%, preferably 2 to 10% aqueous moisture based on the total weight of the composite sheet. Formula layup composite sheets are suitable for subject dimensionally stable carpet tiles. Ru.

The subject composite sheet can be used with latex adhesive, hot melt adhesive or other adhesives Adhesive to glaze (carpet fabric or stockinette fabric) by means. Group Lage is the woven filament that forms all or part of the carpet surface. i.e. cut loops or non-cut loops of non-woven filaments or woven filaments. This is a cut loop (cut 1 loop or uncut 1 loop). Woven fabric The filaments may be woven and may be stitched; Alternatively, it can be applied to the backing material. The composite of the present invention is pasted It is the underside of this secondary backing material, if present.

Latex or other adhesive materials can be applied by conventional means, i.e., knife applicators, spray The composite sheet is applied to the glaze by a fog machine or hot melt extrusion. contact with the latex adhesive. The entire assembly is then pressed, dried and Allows close contact of the glaze to the coalescing sheet. collection of dried carpets The mature body can then be die cut into tiles of appropriate dimensions. The above steps is a drum laminator or the composite sheet and glaze are separated from each other during curing. Can be carried out on other application systems, which are not.

Reinforcing fibers that are dimensionally stable are those that undergo changes in conditions such as temperature and humidity. is also defined as a fibrous material that resists dimensional change. Sometimes this property is called “memory ” is called. For example, glass fiber is a fibrous material with very good dimensional stability. It is quality. On the other hand, nylon tends to shrink when subjected to heat treatment, and therefore makes nylon an undesirable fibrous material for targets.

Preferred dimensionally stable fibrous materials for use in the subject composite sheets are generally Generally, the length is 0.01 to 1.5 inches (0.25 to 38 inches) and the diameter is 0.0 0.045 to 0.0133 m glass fiber. Glass fiber is preferred; Other suitable dimensionally stable fibrous materials can be used. For example, graphite, carbon, and mineral fibers such as silica, or polyester and aramid Synthetic fibers such as fibers can be used.

Typically 0.04 to 4 inches (1 to 10 inches), preferably 0.125 inches. Polyester fibers having a length of 1.5 inches and a diameter of 6 denier are preferred. So Above, a combination of various dimensionally stable fibers such as polyester fibers and glass fibers can be used.

List all fibers with dimensional stability equal to or better than glass fibers However, Chinese cabbage experts can determine whether certain reinforcing fibers meet this requirement. It is generally accepted that it is easy to determine whether

Dimensional stable reinforcing fibers in sufficient quantity to provide dimensional stability and internal strength to the backing material. used. Dimensional stability is determined by the Aachen test with a change of less than 0.10%. The internal bond strength shall be at least 50 I/inch (1968 &/cf L). The Aachen test will be held at the Aachen Institute in Europe. This is a standardized carpet backing stability test that is more specified for dimensional stability.

The Aachen test involves measuring the dimensions of a piece of carpet that has been at room temperature for 24 hours. It consists of Next, heat the carpet at 140'F (60C) for 2 hours and submerge it in water. Soak at room temperature for 2 hours, remove from water, and heat at 140°C (60°C) for 24 hours. , and then left at room temperature for 48 hours. After completing this series of conditions, the carpet Measure the cut pieces again and calculate the changes.

Other additives can of course be used in the composite sheet. these Additives include processing aids for wet deposition processes such as stabilizers, flocculants, and defoamers. can be included. It also contains antioxidants, colorants, antistatic agents, plasticizers, and waxes. Other additives can be added, such as axes.

Typically, the composite sheets of the present invention have a thickness of 0.1 to 2.5 m.

Preferably it is 0.5 to 1.27 dragons. Its gauge or thickness is dimensional stability It is important for the amount of material required per unit area to provide. Therefore, 0.2 A minimum thickness of 5 m is preferred. Thicknesses above this minimum value provide additional stability and lower back protection. Add to the page.

However, the dimensional stability can be achieved by changing the composition percentage of reinforcing fibers along with the thickness. Of course, it is possible to obtain better results, but within the scope specified here. The enclosure provides the stability, texture, and It seems to be the most applicable for giving appearance. Also, these preferred thicknesses is most compatible with current engineering requirements for carpet tile installation and maintenance. It's something you get.

Carpet tiles according to the invention are further illustrated by the following examples. par All centages are based on the total weight of the composite sheet unless otherwise specified. Ru.

Example 1 15% latex (60,5 styrene/37,4 butadiene), legally stable glass A composite sheet with fibers having a thickness of 0.76 ml was obtained.

Various composite sheets were used to demonstrate the superiority of the subject composite sheets used as backing materials. The composition of the composite sheet to be tested is shown in Table ■ below.

Table I A' 15.0 7.5 Polyester 3.0 0.76 B' 13.0 12 ．． 0 Polyethylene 5.0 0.76 CI5.0 7.0 Glass 3.0 0. 761, is not an embodiment of the present invention.

2. Manufactured by Amoco Company.

Layer each backing material onto standard glaze with latex adhesive to create a 9x9 and 8X8 inches (22,8x22.8 and 20x20CI!L) carpet tiles A sample was formed. The lamination technique used was that the glaze was applied manually with a knife applicator. Apply by moving, apply backing material and heat on drum for 7 minutes at 280'F (137,78°C) The layers were dried under sufficient pressure to maintain contact between the layers. Thailand made The samples were then tested for % dimensional change, ie, the Achen test. Each backing material to see if this changes the dimensional stability. Tested. The first latex adhesive rXJ is 7. OOO centipoise (7Pa -s) and the viscosity of 26 styrene/36 butadiene/2 itaconic acid/36 vinyl chloride The second latex adhesive rYJ has a polymer ratio of 20,000 cm. Poise (20Pa-s) and 33StiV7/65Butadiene/2Itaconic acid polyester It had a mer ratio.

The results are listed in Table ■.

Table ■ A' -0,28/-0,18-0,14/-0,19B'-0,19/-0 ,14-0,13/-0,12C-0,09/-0,04-0,03/-0,0 1D Not tested -0,01/zero The data shows that backing materials rCJ and rDJ are superior to all others. There is. rCJ and rDJ are each dimensional values with a change of less than 0.1 in the Aachen test. Meets qualitative standards.

All other samples fail this dimensional stability test.

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Claims (8)

[Claims] 1. Provides a carpet tile dimensional change of less than 0.10% in the Aachen test. bonded to an aqueous wet-laid composite sheet containing sufficient dimensionally stable reinforcing fibers to Dimensionally stable carpet tile with stained glaze. 2. The above dimensionally stable reinforcing fibers weigh 2 to 15 times based on the entire composite sheet. A carpet tile according to claim 1, wherein the carpet tile is present in an amount of %. 3. The composite sheet contains 1 to 30% cellulose based on the total weight of the composite. fiber, 2 to 30% organic polymer as binder material, and 60 to 95% free The carpet tile of claim 1, comprising a structural filler. 4. The composite sheet has an internal weight of at least 50 g/inch (19.689/cm) The carpet tile of claim 1 having bond strength. 5. The composite sheet has an internal weight of at least 50 g/inch (19.68 g/cm) 4. The carpet tile of claim 3 having bond strength. 6. A car according to claim 1, wherein the composite sheet has a thickness of 0.1 to 2.5 mm. -Pet tiles. 7. The above dimensional stability reinforcing fibers are glass fibers, polyester fibers or The carpet tile according to claim 1, which is a mixture of. 8. The composite sheet comprises 2 to 15% by weight of cellulose fibers and 2 to 10% by weight of cellulose fibers. 4. A carpet tile according to claim 3, comprising glass fibers.