JPH04339645A - Carpet and preparation thereof - Google Patents

Abstract

PURPOSE:To prepare a carpet capable of efficiently utilizing a carpet unnecessary material in a raw material, having sufficient general properties as a carpet using existing general carpet manufacturing equipment by lining the rear of a carpet base material with a backing material based on polyvinyl chloride. CONSTITUTION:The rear of a carpet base material is lined with a backing material 7 having at least two polyvinyl chloride resin layers 4, 5 and ground matter with a mean particle size of 3mm or less of a carpet unnecessary material is contained in the polyvinyl chloride resin layer 5 positioned on the rear side of the carpet so as to be unevenly distributed on the side of the deep layer part of said resin layer 5.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carpet in which the back surface of a carpet base material is lined with a backing material mainly composed of polyvinyl chloride resin, and a method for manufacturing the same.

0002

2. Description of the Related Art Generally, in the production of carpet tiles and the like, cut scraps are generated, and an enormous amount of carpet is discarded as unnecessary from households and offices. However, these unnecessary carpet materials are mainly incinerated as waste, but the processing cost is high, and especially those backed with thermoplastic resin backing materials such as polyvinyl chloride resin have a high calorific value. In addition to easily damaging the sintering furnace, it also causes the production of toxic chlorine compounds. Therefore, in recent years, there has been a strong demand for collecting and reusing unnecessary carpet materials for the purpose of resource conservation and pollution prevention. Conventionally, as a means of reusing waste materials from thermoplastic synthetic resin products, a mixture of crushed particles of this waste material and new thermofusible resin powder is melt-extruded in a T-die or the like to form a useful sheet-like product, and this sheet material is A method is known in which a mixture is bonded to a carpet under heat to form a backing material, and a method in which the mixture is spread on a sheet of cloth or paper and bonded in a heating furnace (Japanese Patent Publication No. 21859/1983). In addition, as a means of using carpet waste materials, latex or synthetic resin emulsion is applied to the back side of the carpet base material, and while this coated layer is undried or semi-dry, crushed material of carpet waste materials is sprinkled onto the layer. It has also been proposed to use it as a backing material (Utility Model Application No. 59-132581
No. 59-132582).

0003

[Problem to be Solved by the Invention] However, in the above-mentioned method of melt extrusion using a T-die, etc., when pulverized carpet unnecessary materials are used as waste, the viscosity of the melt becomes extremely high, making extrusion impossible. In order to achieve this, it is necessary to make the blending ratio of the pulverized material very small, which results in poor reuse efficiency of unnecessary materials, and it is difficult to obtain sufficient coagulation when lining the carpet base material with the obtained sheet material as a backing material. The problem was that it didn't have enough grip. In addition, in the above-mentioned method in which the powder mixture sprinkled on the sheet is bonded in a heating furnace, when the sheet is used as a carpet base material and the waste material is pulverized material not required for carpeting and the backing material is constructed in the scattered layer, it is also possible to use the sheet as a carpet base material. There was a problem in that the binding force between the material and the backing material was insufficient, and the strength for removing threads such as pile fibers of the base material was poor.

On the other hand, in the method proposed above, in which latex or synthetic resin emulsion is coated on the back side of the carpet base material and then crushed material not needed for the carpet is sprinkled, a backing material such as general polyvinyl chloride resin is used. Because the process is the opposite of the usual carpet manufacturing method used, which is to apply a paste resin onto a release belt and press the carpet base material onto it, existing manufacturing equipment cannot be used and new manufacturing methods are required. In addition to requiring a huge amount of equipment, the resulting carpet has the drawback that the pulverized material is unevenly distributed on the surface of the backing material, which particularly deteriorates the surface properties of the backing material.

[0005] In view of the above-mentioned circumstances, the present invention provides a carpet in which the back side of a carpet base material is lined with a backing material mainly made of polyvinyl chloride. The purpose of the present invention is to provide a carpet that has sufficient general performance and can be manufactured using existing general carpet manufacturing equipment as is.

[0006]

[Means for Solving the Problems] In order to achieve the above object, the carpet of the present invention has the carpet base material lined with a backing material having at least two polyvinyl chloride resin layers on the back surface, and the carpet has the above-mentioned features. This product adopts a structure in which crushed carpet-free material with an average particle size of 3 mm or less is unevenly distributed in the deep side of the resin layer in the polyvinyl chloride resin layer located on the back side of the carpet of the backing material. be.

Further, for the same purpose, the carpet manufacturing method of the present invention includes coating a polyvinyl chloride paste resin on a continuously running release belt to form a lower layer of the backing material, and then removing the uncured layer of the lower layer. After uniformly scattering pulverized carpet-free materials with an average particle size of 3 mm or less on the surface,
Furthermore, a structure is adopted in which a polyvinyl chloride paste resin is applied to form an upper layer of a backing material, and a carpet base material is pressure-bonded onto this upper layer.

[0008]

[Detailed structure and operation of the invention] The carpet of this invention has the following features:
Of the at least two layers of polyvinyl chloride resin constituting the backing material, the lower layer, that is, the resin layer located on the back side of the carpet, contains pulverized material that is not needed for the carpet, and the upper resin layer that is in contact with the carpet base material contains the pulverized material. Since it does not contain any unnecessary materials, the joint between the carpet base material and backing material is structurally similar to a normal carpet that does not use unnecessary materials. Therefore, in this carpet, the lining function of the backing material against the base material is not affected by the use of unnecessary materials, and in addition to ensuring the same performance as the above-mentioned ordinary carpet in terms of thread removal strength, etc., the dimensional stability etc. are as described below. In some cases, the effect of adding unnecessary materials may actually improve the performance.

[0009] Furthermore, since the unnecessary materials contained in the lower resin layer are unevenly distributed in the deep part of the layer, the surface properties of the backing material are not much different from those containing no unnecessary materials, and this makes it difficult to apply to the floor surface on which the carpet is laid. On the other hand, it can exhibit the same contact performance as the above-mentioned ordinary carpet.

[0010] The unnecessary carpet material used in this invention is:
This includes cut scraps produced during carpet manufacturing and used carpets that are discarded, but those backed with a backing material made of thermoplastic resin such as polyvinyl chloride are particularly suitable. Therefore, as mentioned above, such unnecessary materials are used as pulverized materials with an average particle size of 3 mm or less,
For this reason, a material having a large average particle size is not preferable because it causes the formation of fluff due to the fibrous material, which deteriorates the quality of the carpet.

[0011] Furthermore, as the above-mentioned pulverized material, it is desirable to use the resin-rich material obtained by pulverizing the unnecessary material and separating it into a resin-rich material and a fiber-rich material by wind classification or the like. In addition, in order to increase the recovery rate of the resin-rich component by the above-mentioned wind classification, etc., the amount passing through a mesh of 1 to 8 mm as the pulverized material of unnecessary material,
It is more preferable to classify using a portion that passes through a mesh of 5 to 7 mm. And the resin rich content obtained is
If necessary, perform secondary crushing to 3 mm as described above.
Those having an average particle size of the following, more preferably 0.5 to
A 3 mm mesh passage is used, optimally a 0.5-1 mm mesh passage.

[0012] The blending amount of the above-mentioned pulverized material in the lower polyvinyl chloride resin layer of the backing material is 5 to 2% in the resin layer.
It is preferable that the content is 0% by weight, particularly preferably 10 to 15% by weight; if it is too small, there will be poor economic effect due to the use of unnecessary materials, and if it is too large, interfacial peeling will easily occur. At the same time, it takes time for melting in the heating process performed at the final stage of production, resulting in a decrease in production efficiency. In addition, if unnecessary material backed by a backing material made of polyvinyl chloride is blended into the lower layer resin in an amount of 15% by weight or more, the polyvinyl chloride resin content in the total crushed material must be 10% or more. It is better to make it happen.

[0013] By the way, the pulverized material of the carpet unnecessary compounded in the lower layer is melted in the heating process at the final stage of production and integrated with the polyvinyl chloride of the lower layer, but the resin separated by air classification etc. as described above is Even the rich content contains a considerable amount of unmelted fibrous material, and as a result of this fibrous material suppressing the expansion and contraction of the underlying layer, the dimensional stability of the carpet may be improved compared to when unnecessary materials are not used.

[0014] The backing material in the carpet of the present invention may be composed of only a plurality of upper and lower polyvinyl chloride resin layers, but one layer may be inserted between the upper and lower resin layers for the purpose of improving dimensional stability and reinforcing Alternatively, it is more preferable to use two intermediate base fabrics.

FIG. 1 shows an example of the carpet of the present invention. 1 in the figure is a carpet base material in which pile 2 is flocked to a primary base fabric 3, and on the back side, it is composed of upper and lower layers 4 and 5 made of polyvinyl chloride resin, and an intermediate base fabric 6 interposed between both layers. It is lined with a backing material 7. Therefore, in the lower layer 5 of the backing material 7, there is crushed material 8 having an average particle size of 3 mm or less of unnecessary carpet material on the deep side, that is, in the intermediate base fabric 6.
It is unevenly contained on the interface side with

[0016] The carpet having the above-mentioned structure is manufactured by sequentially applying paste resin for the lower layer of the backing material, scattering the crushed material of unnecessary carpet material, and applying paste resin for the upper layer of the backing material on a continuously running releasable belt. By the manufacturing method of the present invention, which performs the steps of crimping the carpet base material, continuous production can be carried out efficiently and easily.

Here, the paste resin used to form the upper and lower layers of the backing material is a combination of an emulsion polymer of polyvinyl chloride and DO
It is a paste-like product in which required additives such as fillers, stabilizers, and pigments are blended into a sol mixture with a plasticizer such as P (dioctyl phthalate), and it gels when heated to form a homogeneous resin layer.

[0018] However, the crushed material of unnecessary carpet material is
Rather than being pre-mixed into the paste resin for the lower layer, it is sprinkled onto the uncured surface of the lower layer of backing material that has been previously coated as described above. This is because if the pulverized material is added to the paste resin in advance and mixed, the viscosity of the mixture becomes extremely high (for example, when 10% by weight of the pulverized material is blended into the paste resin composition in the example below, the viscosity is several hundred thousand cps, Also 5% by weight
Even if the composition of The reason for this increase in viscosity is thought to be that the crushed carpet material is porous and absorbs a large amount of the plasticizer in the paste resin.

The amount of the pulverized material to be sprayed corresponds to the amount of the pulverized material in the lower layer, but is usually 1 kg per square meter.
Hereinafter, it is particularly preferable to set it to 250 g or less.

After forming the upper and lower layers of the backing material and crimping the carpet base material as described above, heat curing is performed in accordance with a conventional method to harden the upper and lower layers, and then, if necessary, the carpet product is Cut according to size or shipping method. Here, the above-mentioned heat curing does not require any special means or conditions, and can be carried out at 150 to 190
Heating may be performed at ℃ for about 5 to 15 minutes. However,
By this heat curing, the resin component of the crushed material of the carpet unnecessary material is melted and integrated with the lower layer resin, and in particular, when the resin component is polyvinyl chloride, it forms a single layer with the lower layer resin.

FIG. 2 shows an example of the configuration of an apparatus applied to the manufacturing method of the present invention. In the figure, reference numeral 9 denotes a release belt that runs endlessly in one direction at a constant speed. Cloth sticking roller 13a
, a press roller 13b, an upper layer resin supply pipe 10b, a coater 11b, and a press roller 14 are installed.

[0022] In the above device configuration, first, a polyvinyl chloride paste resin 5a for the lower layer is continuously delivered from the supply pipe 10a onto the belt 9 at a constant rate, and the coater 11a coats the lower layer with a thickness of usually about 1 to 3 mm. It is molded into 5. Next, on the surface of this lower layer 5, a pulverized material 8 having an average particle size of 3 mm or less of carpet unnecessary material is continuously and uniformly sprayed in a fixed amount by a scattering device 12, and an intermediate base fabric 6 is spread on the sprayed surface by a roller 13.
It is pasted at point a, and then pressed by a presser roller 13b whose clearance or pressure is adjusted.

The pressing roller 13b presses the intermediate base fabric 6 against the lower layer 5 to wet the intermediate base fabric 6 with the paste resin 5a of the lower layer 5 using capillary action, thereby making the intermediate base fabric 6 and the lower layer It functions to eliminate the air between the two and bring them into close contact in a wet state, thereby preventing interfacial separation between the two in the manufactured carpet. However, if the intermediate base fabric 6 is pre-wetted with a plasticizer or surfactant,
This pressing roller 13b can be omitted.

On the intermediate base fabric 6 thus pasted, a polyvinyl chloride paste resin 4 for the layer above the supply pipe 10b is applied.
a is continuously drawn out at a constant rate and formed into an upper layer 4 having a thickness of usually about 1 to 3 mm in a coater 11b.Furthermore, the carpet base material 1 is laminated on the surface of this upper layer 4 and is pressed by a press roller 14. , a laminated carpet material is obtained. The obtained carpet material is then led to a heat treatment furnace (not shown), where it is heated and cured as described above, and after cooling, if necessary, it is cut into a desired size to become a product.

[0025]

[Examples] Examples and comparative examples of the present invention will be explained in detail below.

Examples 1 to 3 A polyvinyl chloride resin composition having the following composition was used as a paste resin for forming the upper and lower layers of the backing material, and the lower layer of the backing material was formed by a manufacturing method using the manufacturing apparatus shown in FIG. The structure shown in FIG. 1 contains the following pulverized carpet-free material in such a manner that the weight ratio in the lower layer is 10% in Example 1, 5% in Example 2, and 15% in Example 3. manufactured carpets. In addition, Examples 1 to 3
The thicknesses of the upper and lower layers of the backing material were both set to 1.7 mm, and the supply amount of the paste resin for the lower layer was increased or decreased in response to the difference in the blending amount of the crushed carpet-free material.

<Paste resin composition> Polyvinyl chloride resin
1
00 parts by weight dioctyl phthalate

100 parts by weight calcium carbonate

400 parts by weight
Fixing agent

2 parts by weight pigment

2 parts by weight anti-foaming agent

5 parts by weight <Crushed material from unnecessary carpet material> Using cut carpet scraps made of pile-flocked base fabric lined with a backing material made of polyvinyl chloride resin, 5 parts by weight of the pulverized material.
The fraction passing through the mesh of ~7 mm was collected and separated into a resin-rich fraction and a fiber-rich fraction by wind classification, and this resin-rich fraction (resin fraction recovery rate 70 to 90% by weight) was further crushed for secondary pulverization. The amount that passed through the mesh of .5 to 1 mm was used for blending into the lower layer of the backing material.

Comparative Example A carpet was manufactured in the same manner as in Examples 1 to 3, except that the pulverized material not needed for the carpet was not blended into the lower layer of the backing material. The thickness was set to 1.7 mm, the same as in Examples 1 to 3, by increasing the supply amount by an amount commensurate with the lack of pulverized material.

Each of the carpets manufactured in the above examples and comparative examples was tested for fuzz resistance, thread removal strength, and dimensional stability as carpet performance. The results are shown in Table 1 along with the blending amount of the pulverized carpet-free material in the lower layer of the backing material. In addition, each test item was investigated by the following method.

<Fuzz Resistance> Pile filament retention was examined by rubbing the carpet surface with a needle-equipped abrasion wheel at a load of 300 g and 20 rotations to determine whether fluff could be removed. The evaluation was ○...good, ×...poor.

<Thread removal strength> The removal strength (kgf/piece) of the pile threads was measured according to the provisions of JIS L 1021.

<Dimensional stability> (A)...Carpet 60
℃→40℃→0℃→-20℃→20℃ sequentially 2
After being placed under variable temperature conditions for a period of time, the longitudinal and lateral dimensions were measured, and the values compared with the dimensions before undergoing the temperature alteration were expressed as the average values of the longitudinal and lateral dimensions.

(B)...Load of 90 kg on the carpet surface
After rolling the chair caster with 2000 rotations, the vertical and horizontal dimensions were measured, and the values compared with the dimensions before rolling were expressed as the average vertical and horizontal values.

[0034]

[Table 1]

[0035] From the results in Table 1, it is clear that although the carpet according to the present invention partially uses carpet unnecessary materials as raw materials, it has the same performance as a carpet of the same structure that does not use carpet unnecessary materials. Equipped with the above general performance,
In particular, it is clear that the dimensional stability is excellent, and the dimensional stability (B) test also revealed that no delamination occurs.

[0036]

Effects of the Invention According to the present invention, a carpet is produced in which the back side of a carpet base material is lined with a backing material mainly made of polyvinyl chloride. In addition to being able to efficiently reuse unnecessary carpet materials, the thread removal strength and
In general performance such as fizz resistance, dimensional stability, and delamination resistance, we have created a carpet that is comparable to those that do not use the unnecessary materials mentioned above, and that can be manufactured using existing general carpet manufacturing equipment as is. This can greatly contribute to resource conservation, pollution prevention, and reduction in waste treatment costs.

[Brief explanation of drawings]

FIG. 1 is a sectional view showing an example of a carpet of the present invention.

FIG. 2 is a schematic side view showing an example of the configuration of an apparatus used for manufacturing the same carpet.

[Explanation of symbols]

1...Carpet base material 4...Backing material lower layer 4a...Paste resin for lower layer 5... Backing material upper layer 5a...Paste resin for upper layer 7...Backing material 8...Crushed material not needed for carpeting 9...Release belt 12...Quantitative spraying device

Claims (2)

[Claims] Claim 1: At least two
In a carpet lined with a backing material having a polyvinyl chloride resin layer, the polyvinyl chloride resin layer located on the back side of the carpet of the backing material contains pulverized material having an average particle size of 3 mm or less. A carpet made of resin that is unevenly distributed in the deep side of the resin layer. 2. A lower layer of backing material is formed by coating a polyvinyl chloride paste resin on a continuously running release belt, and then a pulverized material with an average particle size of 3 mm or less of carpet-free material is applied to the uncured surface of the lower layer. 1. A method for producing a carpet, which comprises uniformly dispersing a polyvinyl chloride paste resin, forming an upper layer of a backing material, and pressing a carpet base material onto this upper layer.