JPH02203816A - Manufacture of carpet - Google Patents

Abstract

PURPOSE:To improve the size stability and the strength by superposing a specific composition density of ethylene copolymer resin type thermal adhesive film, a glass unwoven fabric, and an ethylene copolymer resin composition of a molten and extruded sheet-form, mixed with an inorganic filler, in this order on the rear side of a carpet original cloth, and extruding and incorporating them in the heating time of a sheet. CONSTITUTION:To contact the rear side of carpet original cloth and a glass unwoven fabric solidly, an ethylene copolymer resin type thermal adhesive film of the composition density 10-200g/m<2> is used. The ethylene copolymer resin is composed mainly of ethylene, using alpha-olefin, a polar vinyl compound, and the like as a copolymer component adding to the ethylene, and it acts as an adhesive by melting with the heat of a molten and extruded sheet. To the rear side of the carpet original cloth, the ethylene copolymer resin type thermal adhesive film, the glass unwoven fabric, and a molten and extruded sheet-form ethylene copolymer resin type composition mixed with an inorganic filler are superposed in this order. And it is extruded in the heating time of the molten and extruded sheet, and the layers composing the carpet are incorporated by the molten-attaching function of the ethylene copolymer resin type thermal adhesive film by the sheet and the heat of the sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for manufacturing a carpet that exhibits good dimensional stability against changes in environmental temperature.

[Prior Art] Carpets basically consist of a carpet material and a backing material formed on the back surface thereof. Conventionally, as such a backing material, a material containing vinyl chloride resin or asphalt as a main component and blending an inorganic filler, a plasticizer, etc. therewith has been used. However, vinyl chloride resin-based backing materials have the disadvantage of producing a large amount of smoke in the event of a fire, and asphalt-based backing materials have problems with odor and low strength, so the development of new alternative backing materials is desired. Ta.

As a new alternative backing material, one using an ethylene copolymer resin composition containing an inorganic filler, which produces less smoke in the event of a fire, is non-toxic, odorless, and has greater strength than a vinyl chloride resin-based one, has attracted attention and is being studied. It's starting to happen.

[Problems to be Solved by the Invention] However, when a carpet with a simple structure is manufactured using such a backing material, the dimensional stability is not necessarily good, so it is not satisfactory especially for tile carpets. There wasn't.

By the way, tile carpets are small, flat carpets, and are generally rectangular with a side of about 30 to 50 cm. Tile carpets have the advantage that they are easier to handle and install than regular carpets, and can also be easily replaced due to dirt or the like. Furthermore, it has the advantage of being able to create various patterns by combining the colors, shapes, etc. of several types of tile carpets, and has recently come to be used rapidly. Most of these carpet tiles are installed by completely laying them from wall to wall. Therefore, unless dimensional changes due to temperature differences are minimized, for example, carpet tiles installed in the winter may expand and float in the summer. Otherwise, there was a risk that something constructed in the summer would shrink in the winter, causing problems such as gaps being formed.

In order to improve such drawbacks, for example, Japanese Patent Application Laid-Open No. 61
Japanese Patent No. 49886 discloses a method of using a mesh-like base fabric with a small coefficient of linear expansion against heat between the original carpet material and the backing material. However, according to the studies of the present inventors, this public polymer resin thermal adhesive film (b) glass nonwoven fabric (c) melt-extruded sheet-like inorganic filler-containing ethylene copolymer resin composition was added in this order. A method for manufacturing a carpet is provided, which comprises stacking the sheets together, pressing the sheets together while they are hot, and pressing the sheets together while they are hot.

In the present invention, the carpet material includes natural fibers,
Those manufactured from various materials such as synthetic fibers and recycled fibers can be used. More specifically, examples include tufted carpets and needle punch carpets made of natural fibers such as linen, cotton, and wool, and synthetic fibers such as polypropylene, polyamide, polyester, polyacrylonitrile, and polyvinylidene chloride. The back surface of these carpet raw materials may be subjected to a precoating treatment such as SBR latex treatment.

In the present invention, in order to firmly adhere the back side of the carpet material and the glass nonwoven fabric (b), the basis weight is 10 to 2.
It was recognized that when using a mesh-like base fabric with a large degree of porosity, such as the one disclosed for the ethylene copolymer resin layer of 00 g/m2, the dimensional stability would not be sufficiently satisfied and the material would not hang. . Furthermore, Japanese Patent Application Laid-Open No. 19887/1987 proposes a method in which the backing material layer is divided into two layers and an intermediate base fabric having a small linear expansion coefficient against heat is provided between them.

However, this method requires the backing material to be laminated twice on the carpet base material, which is economically disadvantageous in terms of both equipment and operation.

The present inventors have improved the above-mentioned shortcomings in the prior art,
We investigated methods for economically producing carpets with excellent dimensional stability and strength, especially tile carpets. As a result, we have discovered a method for manufacturing a desired carpet in one step using an ethylene copolymer resin thermal adhesive film and a glass nonwoven fabric.

[Means for Solving the Problems] According to the present invention, an ethylene-based thermal adhesive film (a) having a basis weight of 10 to 200 g/m2 is used on the back side of the original carpet. This ethylene copolymer resin has ethylene as its main component and copolymerized components such as α-olefin and polar vinyl compounds.
) is melted by the heat possessed by the melt-extruded sheet of the component, and functions as an adhesive. More specifically,
Examples of the α-olefin include propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-decene, 4-methyl-1-pentene, etc., and the polar vinyl compound includes acetic acid. Vinyl, vinyl esters such as vinyl propionate, unsaturated carboxylic acids such as acrylic acid, methacrylic acid, fumaric acid, maleic anhydride, or their anhydrides, their sodium salts, potassium salts, lithium salts, magnesium salts, zinc Examples include unsaturated carboxylic acid salts such as salts and ammonium salts, unsaturated carboxylic acid esters such as methyl acrylate, ethyl acrylate, isobutyl acrylate, n-butyl acrylate, methyl methacrylate, and glycidyl methacrylate. Of course, two or more of these copolymerizable components may be copolymerized. These copolymerization components may be randomly copolymerized or graft copolymerized.

The ethylene-α-olefin copolymer resin preferably contains about 80 to 95 mol% of ethylene, and the ethylene-polar vinyl compound copolymer preferably contains 55 to 95 mol% of ethylene. % is preferred.

Two or more of these copolymer resins may also be used in combination.

From the viewpoint of adhesion to carpets and glass fibers or film productivity, preferred ethylene copolymer resins are ethylene-polar vinyl compound copolymers, especially ethylene-vinyl acetate copolymers, with an ethylene content of 70 to 70%. It is 95% by weight. Also, 190
The melt flow rate measured at ℃ and 2160g load is 0.
．． 1 to 200 g/10 minutes, particularly 1 to 100 g/10 minutes, is suitable.

The basis weight is 10 to 300g/rrr1, especially 30
It is preferable to use one having a weight of about 150 glrd.

If the basis weight is too low, it will not be possible to obtain a product with good dimensional stability, and on the other hand, if the basis weight is too high, the carpet will tend to become too rigid, so one should select and use a carpet within an appropriate range. .

In the method disclosed in Japanese Patent Application Laid-Open No. 19886/1986, a mesh-like base fabric having a degree of opening necessary for passing the backing material is used. If a nonwoven fabric treated with holes or a woven fabric is used, a carpet with excellent dimensional stability cannot be obtained.

In the present invention, (c) is melt-extruded into a sheet shape.
The layers constituting the carpet are integrated by utilizing the adhesive properties of the components and the adhesive properties of component (a) melted by the heat possessed by component (c), so there is no need for component (c) to pass through the glass nonwoven fabric. On the contrary, the glass nonwoven fabric used in the present invention has a small porosity, and when forming a carpet, these ethylene copolymer resins are mixed with aliphatic hydrocarbon resins and alicyclic resins for the purpose of improving thermal adhesion. For example, a tackifier such as a group hydrocarbon resin, an aromatic hydrocarbon resin, a polyterpene resin, a rosin, a styrene resin, etc.
They may be used in amounts up to % by weight. Furthermore, a slip agent and a lot number additive for improving the slip properties of the film can be blended.

The thermal adhesive film is used in an amount such that its basis weight is 5 to 200 g/rrl, preferably 15 to 100 g/rrl. If the basis weight is less than the above range, the adhesion between the carpet material and the glass nonwoven fabric will not be sufficient (and if the basis weight is too large, the heat retained by the melt-extruded sheet of component (c) will It does not melt sufficiently and has difficulty functioning as an adhesive.

In the present invention, a glass nonwoven fabric (b) is used to impart dimensional stability to the carpet. Glass nonwoven fabric is made by stacking glass fibers in any direction to a certain thickness.
It should be solidified with a coagulant so that component (c) will not substantially pass through to the component (a) side, and substantially no hole-opening treatment will be performed. By using such a glass nonwoven fabric with a small degree of porosity, the dimensional stability of the manufactured carpet is significantly improved. In the present invention, an ethylene copolymer resin composition containing an inorganic filler is used as the backing material. The ethylene copolymer resin used for this purpose can be the same as the ethylene copolymer resin explained for component (a).

(In order to maintain particularly excellent formability when extruding into a sheet using a T-die etc., the melt flow rate is 1 to 150 g/10 minutes, especially 1 to 50 g/10 minutes. It is preferable to use an ethylene-vinyl acetate copolymer as the ethylene copolymer resin from the viewpoints of economy, miscibility with inorganic fillers, flexibility, cold resistance, etc.

The copolymer preferably has a vinyl acetate content of about 10 to 40% by weight, considering the above properties and heat resistance. Of course, a part of such ethylene-vinyl acetate copolymer, for example, half or less, can be replaced with other ethylene copolymer resin, such as ethylene-α-olefin copolymer or ethylene-unsaturated carboxylic acid copolymer. Can be done.

Inorganic fillers to be kneaded into ethylene copolymer resin include:
Calcium carbonate, barium sulfate, silica, talc, clay, mica, magnesium hydroxide, aluminum hydroxide, etc. are used. These are cost reduction, weight addition,
It is used for the purpose of dimensional stability etc., and from the point of view of cost or miscibility with ethylene copolymer resin,
Particularly suitable is calcium carbonate. In order to achieve the above object, the amount of inorganic filler used in the ethylene copolymer resin composition is at least 20% by weight, preferably 30% by weight.
It is desirable that the amount be at least 80% by weight, but if the amount is increased too much, the sheet formability will deteriorate, so it is desirable that the amount be 80% by weight or less.

The ethylene copolymer resin is 20 to 80% by weight in the composition,
There is a method of using it by making a master batch of inorganic filler, which is preferably 30 to 80% by weight, and tri-blending this pellet and ethylene copolymer resin directly at an arbitrary ratio during T-die extrusion processing. .

Sheet forming is performed by a T-die extruder. At this time, the basis weight of the sheet is 1 kg/1 kg for tile carpets to give it weight and prevent it from moving when walking.
It is preferable to set it to r& or more, but if the area weight is too large, it will become too rigid and workability will deteriorate, so 5kg
It is preferable to set it to /nr or less.

In the present invention, the ethylene copolymer resin thermal adhesive film, the glass nonwoven fabric, and the melt-extruded sheet-like ethylene copolymer resin composition containing an inorganic filler are superimposed on the back side of the original carpet in this order, and then melted. The extruded sheet is pressed while hot, and the layers constituting the carpet are integrated by the melting adhesive action of the sheet and the ethylene copolymer resin thermal adhesive film caused by the heat possessed by the sheet. Suppressing integration is a process in which the crimping row is injected with tackifiers, waxes, and low molecular weight olefins, such as those exemplified above, in order to facilitate blending with inorganic fillers or to improve the sheet formability of the composition. A liquid plasticizer, oil, etc. can be used in place of a part of the ethylene copolymer resin. These additives for improving processability are
For example, it is used in an amount of up to 20% by weight of the total composition.

The ethylene copolymer resin composition may also contain additives such as various stabilizers, flame retardants, pigments, and the like.

There are no particular limitations on the method of blending the inorganic filler with the ethylene copolymer resin. By directly blending the powdered inorganic filler and ethylene copolymer resin using a calender roll, Banbury mixer, Henschel mixer, twin-screw kneader, etc., the pellet-shaped ethylene copolymer resin and inorganic filler are blended. A method of preparing a composition and performing T-die extrusion processing using the composition. It is also suitably carried out by mixing the powdered inorganic filler and the processability improving additive using a Banbury mixer, 12-screw kneader, etc., and passing the mixture through a pellet-shaped high-concentration tube. At this time, it is necessary to select conditions such that the thermal adhesive film is melted and the layers are bonded to each other and integrated by compression. For this purpose, the extruded sheet in the pressing part is maintained at a temperature at which it is in a softened state, for example, 100 to 200°C, and
The pressure roll may be maintained at a linear pressure of 2 to 10 kg/crrr.

In the present invention, by overlapping and pressing the layers constituting the carpet while the melt-extruded sheet is hot,
Utilizing the melt adhesive properties of the sheet, and using the heat possessed by the sheet to melt the ethylene-based thermal adhesive film and use it as an adhesive, these are integrated at the same time.
Carpets can be manufactured in stages. Instead of such a one-step process, applying a method in which the back side of the carpet material is coated with an ethylene-based thermal adhesive film not only complicates the process, but also puts tension on the carpet, making it more difficult to maintain its dimensional stability. Although this is not a preferable method because it will impair the properties, after pressing and integrating as described above, a tile carpet can be produced by cooling if necessary and cutting into a desired shape.

[Example] The present invention will be specifically explained below using Examples and Comparative Examples.

Example 1 10 parts of polyethylene wax (hereinafter abbreviated as PEWAX) (density 0.93 g/ctrl, molecular weight 4000),
Atactic polypropylene (hereinafter abbreviated as APP)
(density 0.87g/crtf, molecular weight 30000) 10
1 part, 0.2 parts of calcium stearate, and 80 parts of calcium carbonate at a temperature of 125 parts using a Banbury mixer.
After melt-mixing under conditions of 0.degree. C., the molten mixture was pelletized by passing through an extruder and discharging to obtain a pellet-shaped blend of high concentration calcium carbonate. (hereinafter CaC
It is abbreviated as 0,MB. ) Then Evaflex P3307
(Mitsui DuPont Polychemical ■) After cutting into a size of 500 mm, the following physical properties were evaluated.

(1) Dimensional stability Vertical direction (T
- Draw three standard lines in each direction (direction of flow of T-die sheet) and horizontal direction (direction perpendicular to the direction of flow of T-die sheet) at 23°C to the nearest 0.05 mm.
Measure the dimensions. Thereafter, it is left in a hot air circulation dryer at 60° C. for 2 hours, and then immersed in water at 20° C. containing 0.1% of a nonionic activator. After 2 hours, the specimen was taken out of the water, drained, dried in a dryer at 60° C. for 24 hours, left in standard conditions for 24 hours, and its dimensions were measured. Displays the change in dimensions between untreated dimensions and dimensions after treatment as a percentage.

(2) Stitch removal strength Using a normal tensile tester at 23°C and a tensile speed of 200 mm
The thread removal strength of the pile was measured under the condition of /min.

These evaluation results are shown in Table-1.

In addition, the first layer of thermal adhesive film layer is T-Guicy EVA,
A mixture obtained by tri-blending 40 parts by weight of vinyl acetate (33% by weight, 30 g/10 min) of M, F, R and 60 parts by weight of CaCOsMB was heated in a 65 mm extruder (L/ D=24), T-
A sheet of calcium carbonate-containing EVA with a width of 600 mm and a basis weight of 2.6 kg/r was formed under the processing conditions of a temperature of 150°C, and before the sheet was cooled and solidified, T-
From above, the carpet material (nylon pile, 1st
(base fabric) and Evaflex P created by the normal T-gui film molding method.

1905 (Mitsui DuPont Polychemical ■EVA
, vinyl acetate content 19% by weight, M, F, R2.5g
A three-layer structure in which a film with a basis weight of 30 g/rf (20 min.) and a glass nonwoven fabric (10 min.
The raw material for carpet tiles was created by feeding the carpet so that it was in contact with the sheet surface of the carpet.

Furthermore, a 500 mm thick layer of original tile carpet was used as a second layer.

Implementation type λ In Example 1, the basis weight of the thermal adhesive film was 100g.
A carpet was manufactured and evaluated in exactly the same manner as in Example 1, except that the ratio was changed to /rrr. The results are shown in Table-1.

In Implementation Example 1, the type of thermal adhesive film was Evaflex V-340 (EV manufactured by Mitsui DuPont Polychemicals).
A, vinyl acetate content 10wt% M, F, R1,9g/1
A carpet was manufactured and evaluated in the same manner as in Example 1, except that the heating time was changed to 0 minutes). The results are shown in Table 1.

Embodiment A In Example 1, the type of thermal adhesive film was changed to ethylene-
A carpet was produced in the same manner as in Example 1, except that the methacrylic acid copolymer resin was changed to Nucrel 925 (Mitsui DuPont Polychemical ■, M, F, R 25 g/10 min, methacrylic acid content 15 wt%). and conducted an evaluation.

The results are shown in Table-1.

In Example 1, the type of thermal adhesive film was ethylene-ethyl acrylate copolymer resin, Evaflex E
EA A702 (manufactured by Mitsui DuPont Polychemical ■, M, F, R 5g/10 minutes Ethyl acrylate content 19
A carpet was manufactured and evaluated in exactly the same manner as in Example 1, except that the ratio was changed to (wt%). Table 1 shows the results.
Shown below.

Example In negative example-1, the type of thermal adhesive film was Evaflex V-34085wt%, and the hydrocarbon adhesive F
TR-6100 (manufactured by Mitsui Petrochemical Industries, Ltd., softening point 97°C
) A carpet was produced and evaluated in exactly the same manner as in Example 1, except that the blended composition was changed to 15 wt%. The results are shown in Table-1.

Example 1 In Example 1, the type of glass nonwoven fabric was changed to a basis weight of 20.
A carpet was manufactured and evaluated in exactly the same manner as in the example except that the carpet was changed to 0 g/d. The results are shown in Table-1.

Example 1 In Example 1, the ratio of EVA and CaCO3MB in the second layer was changed to EVA, 60 wt% CaCO3MB4
A carpet was manufactured and evaluated in the same manner as in Example 1, except that the content was changed to 0 wt%.The results are shown in Table 1.
Shown below.

Example In Example 1, the second layer was Keldax 6826, which is a mixture of EVA, process oil, and calcium carbonate.
(USA 1) Manufactured by Upont, calcium carbonate content 72w
A carpet was manufactured and evaluated in the same manner as in Example 1, except that t%, M, F, R, 3 g/10 min) was used. The results are shown in Table 1.

Comparative Example Example 1 except that the first layer is not used.
Carpets were manufactured and evaluated in exactly the same manner. The results are shown in Table-2.

Comparative Example λ In Example 1, the first layer was made of high-pressure low-density polyethylene (Mirason M-68 (M, F, R2 manufactured by Mitsui Oil Industries, Ltd.)).
3g/10 minutes, density 0.916g/arrr...less than L
It is abbreviated as DPE. ) A carpet was manufactured and evaluated in exactly the same manner as in Example 1, except for changing to . The results are shown in Table-2.

Comparative Example λ In Example 1, a carpet was manufactured and evaluated in exactly the same manner as in Example 1, except that the glass nonwoven fabric was not used. The results are shown in Table-2.

[Effects of the Invention] According to the present invention, a carpet raw material, an ethylene-based thermal adhesive film, and a glass nonwoven fabric are superimposed on a sheet of a melt-extruded inorganic filler-containing ethylene copolymer resin composition, and the above-mentioned sheet is A tile carpet with good dimensional stability, strength, interlayer adhesion, etc. can be manufactured by a simple operation of pressing the carpet while it is hot.

Claims (1)

[Claims] 1. On the back side of the original carpet (a) an ethylene copolymer resin thermal adhesive film with a basis weight of 10 to 200 g/m^2, (b) a glass nonwoven fabric, and (c) a melt-extruded sheet. A method for manufacturing a carpet, which comprises stacking the inorganic filler-containing ethylene copolymer resin compositions in this order and pressing the sheets together while they are hot.