JPH0578321B2 - - Google Patents

Description

[Detailed description of the invention]

(Industrial Application Field) The present invention relates to a tile carpet backing structure and a manufacturing method thereof, and more particularly to a tile carpet backing structure with excellent dimensional stability and low cost and a manufacturing method thereof. (Conventional technology) Traditionally, asphalt, polyolefin resin, PVC have been used as backing materials for carpet tiles.
Thermoplastic resins such as resins are commonly used. As for the structure of the backing layer, nonwoven fabrics or woven fabrics such as glass fibers are laminated in the backing layer to improve the dimensional stability of the product and reduce warping. JP-A No. 59-135023 discloses a tile in which the backing layer has a two-layer structure, an upper layer and a lower layer, and the upper layer contains 0 to 300 parts of filler per 100 parts of PVC, and the lower layer contains 300 to 800 parts of filler per 100 parts of PVC. Carpet is shown. In addition, Japanese Patent Application Laid-open No. 119780/1983 describes a tile carpet with a backing structure in which the amount of filler is 300% or less in the first layer (upper layer) and 250% or more in the second layer (lower layer) based on 100% resin. Disclosed. (Problems to be Solved by the Invention) However, as described above, in most cases, the upper layer of the backing layer of tile carpets has been in practical use, containing 300 parts or less of filler per 100 parts of resin. Mainly for economic reasons, this method uses a tufted fabric that is not coated with a resin for pile fixation as the upper surface layer, and the pile of the tufted fabric is applied to the first base fabric or backing layer by the resin on the upper layer of the backing layer. Fixed adhesive, filler per 100 parts of resin
If more than 300 parts were added, the viscosity of the resin would increase, making it difficult to penetrate into piles, resulting in insufficient fixation of the piles, so it was not put to practical use. Therefore, filler per 100 parts of PVC as the top layer.
If more than 300 parts are used, it is necessary to separately apply adhesive to secure the pile threads of the tufted carpet, which increases costs. On the other hand, carpet tiles are used as flooring materials in offices, public facilities, hotels, and libraries, but especially when laid in places where heavy objects are placed or moved, they tend to shrink or warp after being laid. This has become a problem in some cases. As a result of intensive research, the inventors of the present invention found that increasing the ratio of filler to PVC in the resin used in the upper layer is effective in reducing these shrinkage and warping, and by increasing the amount of filler, tiles Completed a tile carpet and its manufacturing method that improves the dimensional stability of the carpet, maintains the pile thread extraction strength, and reduces fuss without using special adhesives to fix the pile threads. did. (Means for Solving the Problems) The present invention has an upper surface layer made of a tufted pile fabric in which piles are planted on a base fabric, and an upper layer containing 300 to 400 parts by weight of a filler per 100 parts by weight of PVC.
It has a backing layer consisting of a lower layer containing 300 to 700 parts by weight of filler per 100 parts by weight of PVC, and one or more intermediate base fabrics are laminated in the backing layer, and the filler in the upper layer is Particle size is 200μ or more
Fillers less than 600μ account for 20-40% of the total fillers in the upper layer
This is a tile carpet characterized by: In the present invention, it has become possible to increase the dimensional stability of the backing layer of the tile carpet by mixing a large amount of filler not only in the lower layer but also in the upper layer. In that case, the preferred amount of filler in the upper layer is 300 to 400 parts of filler per 100 parts of PVC.
It is intended to mix in parts. And the particle size is 200μ
It is preferable that the above fillers are contained in an amount of 20 to 40% or more of the total fillers. If the filler with a particle size of 200 μ or more but less than 600 μ is less than 20%, the viscosity of the upper layer composition will increase, making it difficult to apply, resulting in poor penetration into the pile threads and base fabric, lowering the thread removal strength, and causing fuzz. Occur. In order to fix the pile by the upper layer of resin, the viscosity should be 5000
It is desirable to set it to around 20000CPS. In addition, fillers with a particle size of 200μ or more but less than 600μ
When it is 40% or more, bubbles and voids are formed in the backing layer, which tends to cause cracks and reduce the value of the product. Further, another invention provides an upper surface layer made of a tufted pile fabric in which piles are planted on a base fabric;
Upper layer containing 300 to 400 parts by weight of filler per 100 parts by weight of PVC and 300 parts by weight of filler per 100 parts by weight of PVC.
It has a backing layer consisting of a lower layer containing ~700 parts by weight, and one or more intermediate base fabrics are laminated in the backing layer, and the particle size distribution of the filler in the upper layer is similar to that of the upper layer. The tile carpet is made of fillers of 0 to less than 100μ...20 to 40%, 100 to less than 200μ...20 to 40%, 200 to less than 600μ...20 to 40% of the total filler. In order to obtain a filler having a specific particle size, for example, in the case of calcium carbonate, there is a method of appropriately crushing a lump of cold water or the like, and then sorting the crushed material using a sieve. That is, in order to obtain calcium carbonate with a particle size of 200μ or more and less than 600μ, block cold water is crushed with a crusher, and then passed through a sieve with a sieve size of 600μ.
Next, pass it through a sieve with a mesh size of 200μ and remove the remaining material. Similarly, to obtain particles with a particle size of 100 μm or more and less than 200 μm, pass the above-mentioned material through a 200 μm sieve through a 100 μm sieve, and take out the remaining particles. In addition, in order to obtain particles with a particle size of less than 100μ, it is sufficient to take out particles that have passed through the above-mentioned sieve with a mesh size of 100μ. Similar methods can be applied to fillers other than calcium carbonate. When the content of filler with a particle size of less than 100 μ is less than 20%, sedimentation and separation of the composition becomes more pronounced, resulting in decreased stability during storage. Moreover, when it was 40% or more, there was a drawback that the viscosity of the composition increased too much. The filler in the present invention includes calcium carbonate, aluminum hydroxide, magnesium carbonate, silica,
Conventionally used fillers such as talc, mica, and carbon black may be used. PVC in the present invention refers to polyvinyl chloride. In addition, the intermediate base fabric in the backing layer is made of glass fiber,
Fabrics, knits, non-woven fabrics such as polyester fibers, polyamide fibers, polypropylene fibers, rayon fibers, or composites thereof may be used, but those made of glass fibers or polyester are preferred because of their low elasticity. Another invention provides that after applying the PVC composition (B) on the surface of the release belt, placing one or more intermediate base fabrics, and further applying the PVC composition (A), A method for producing a tile carpet, in which a tufted pile fabric without resin applied thereon is placed and pressed, heated to gel, and then peeled off from a release belt, wherein the PVC composition (A) is 100 parts by weight of PVC. 300-400 parts by weight of filler, PVC composition (B)
contains 300 to 700 parts by weight of a filler per 100 parts by weight of PVC, and the PVC composition (A) is a liquid containing a filler and has a viscosity of 20,000 to 60,000 CPS (A-1).
and a filler-free liquid composition (A-2) are prepared respectively, and these two compositions are mixed to form a composition.
(A) is a method for manufacturing a tile carpet, characterized in that the method is applied to a releasable belt. In the present invention, increasing the ratio of filler in the PVC resin for the upper layer increases the viscosity and makes the pile threads insufficiently fixed, but in order to prevent this, the particle size of the filler has a special structure. did. However, in the case of this method, the viscosity is low even though the filler contains large particles with a size of 200μ or more, so if the composition is left for a long time, usually about 12 hours, inorganic materials with high specific gravity The problem with the use of fillers is that they precipitate, making them unusable as backing agents. Therefore, there was a problem when the coating work extended to the next day after resin preparation. In the present invention, in order to solve this problem, the PVC composition (A) for upper layer coating has a viscosity that contains a filler.
A composition of 20,000 to 60,000 CPS (A-1) and a liquid composition containing no filler (A-2) are prepared separately, and a two-step mixing process is performed in which the two compositions are mixed before coating. I went. After making this mixture, it is advisable to apply it within 12 hours. If (A-1) and (A-2) are mixed and left for a longer period of time, calcium carbonate will begin to precipitate.
A uniform backing layer cannot be obtained. Further, in order to prevent such sedimentation and separation, it is also possible to use a method of stirring the composition constantly or at regular intervals or circulating it through a pipeline. Next, the lower layer, that is, composition (B), is as shown in Attached Table 1.
Contains 100 parts of PVC, 100 parts of plasticizer, 400 parts of calcium carbonate, etc. For the bottom layer, the filler
If the amount is less than 300 parts, the carpet tiles will be too soft, resulting in poor dimensional stability and increased costs. Furthermore, if the amount of filler exceeds 700 parts, it will be difficult to mix uniformly with the resin, and the tile carpet will become too hard, resulting in poor cushioning properties during use. In the lower layer, although the ratio of filler to PVC is high, there is no need to penetrate the pile and there is no need to lower the viscosity, so problems with sedimentation and separation rarely occur as in the upper layer. (Examples) The present invention will be explained in more detail below using Examples. In the example, after applying 1.5 mm of the PVC composition (B) to the surface of the release belt to form the lower layer 5, a nonwoven fabric 7 made of glass fiber and a mesh 8 made of glass fiber were sequentially placed, and then the PVC composition (B) was applied to the surface of the release belt. 1.5 things (A)
mm was coated to form the upper layer 4, and a tufted fabric 3, which was simply tufted with nylon filaments on the PP base fabric 2, was placed and pressed onto it. It was heated in a hot air dryer at 190°C for 5 minutes to solidify it, and was peeled off from the release belt. As a result, the PVC composition (B) becomes the lower layer of the backing layer, and the PVC composition (A) becomes the upper layer. The compositions and physical properties of the upper and lower layer resins in this example are shown in the attached table. The composition for the upper layer, namely composition (A), contains 100 parts of PVC;
100 parts DOP, 350 parts calcium carbonate as filler
Contains parts, etc. Composition (A) is prepared by separately mixing (A-1) and (A-2) in the following amounts,
Thereafter, the two composition parts were mixed in equal amounts. As in (A-1) of this example, the composition containing calcium carbonate could be stored for about 100 hours without separation by increasing the viscosity to about 20,000 to 60,000 CPS.

[Table] Also, as shown in Figure 2, the mixing method at this time is that (A-1) and (A-2) are kneaded separately in blend tanks 11 and 13, and then mixed in storage tank 1.
Temporarily stored on 2nd and 14th. Immediately before processing, the mixture is continuously blended in a mixing device 15, temporarily stored in a service tank 16, and then supplied to a coater section. Next, a comparative example with respect to this example will be explained according to the attached table. Comparative Example 1 is conventionally known, and the upper layer contains 250 parts of calcium carbonate per 100 parts of PVC. Calcium carbonate is used as the filler in the upper layer, but particles with a particle size of 200 to 600μ are rarely used. The lower layer is the same as the lower layer in the example. In this case, the physical properties of the tile carpet are as follows:
The ratio of calcium carbonate to PVC is low, and the dimensional stability is lower than in the examples. In Comparative Example 2, the ratio of calcium carbonate to PVC in the upper and lower layers was 350 parts, which was exactly the same as in the example, and the dimensional stability was good. However, when the particle size distribution of calcium carbonate in the upper layer is 200 to 600 μ, it is 5% to 0.
Since 100μ is 50% and 100 to 200μ is 45%, the viscosity increases and the fuzz resistance and suture removal strength decrease. Next, in Comparative Example 3, the ratio of calcium carbonate to PVC in both the upper and lower layers is the same as in Examples and Comparative Example 2, so the dimensional stability is good, and at the same time, the particle size distribution of calcium carbonate in the upper layer is 200.
~600μ is 60%, so the viscosity is low, penetration into the pile is good, and there are no problems with fuzz resistance or suture removal strength. However, the storage stability of Examples and Comparative Example 1
It is worse than Comparative Example 2. In addition, those with a particle size distribution of 200 to 600μ in the upper layer are 60
%, voids were created within the layer and cracks occurred. From the above results, even when 350 parts of calcium carbonate is mixed with 100 parts of PVC, the particle size distribution is 20-40% for 0-100μ and 20-40% for 100-200μ.
%, 200 to 600μ is 20 to 40%, the storage stability is good and the fuzz resistance and suture removal strength can be satisfied.

【table】 [Brief explanation of the drawing]

FIG. 1 is a partial sectional view of a tile carpet showing an embodiment of the present invention, and FIG. 2 is a schematic diagram of an upper layer resin supply apparatus according to an embodiment of the present invention. 1... Pile, 2... Base fabric, 3... Upper surface layer, 4... Upper layer, 5... Lower layer, 6... Intermediate base fabric, 7... Nonwoven fabric, 8...
mesh, 11, 13... blend tank, 12,
14...Storage tank, 15...Intermediate blend tank,
16...Service tank.

Claims (1)

[Claims] 1. An upper surface layer made of a tufted pile fabric in which piles are planted on a base fabric, and 100 parts by weight of PVC,
PVC100 with upper layer containing 300-400 parts by weight of filler
A tile carpet comprising a backing layer consisting of a lower layer containing 300 to 700 parts by weight of filler based on the weight part, and one or more intermediate base fabrics are laminated in the backing layer, the upper layer A tile carpet characterized in that filler having a particle size of 200μ or more and less than 600μ accounts for 20 to 40% of the total filler in the upper layer. 2 For the upper surface layer made of tufted pile fabric with pile planted on the base fabric and 100 parts by weight of PVC,
PVC100 with upper layer containing 300-400 parts by weight of filler
A tile carpet comprising a backing layer consisting of a lower layer containing 300 to 700 parts by weight of filler based on the weight part, and one or more intermediate base fabrics are laminated in the backing layer, the upper layer A tile carpet consisting of fillers whose particle size distribution is as follows for all fillers in the upper layer. 0 to less than 100μ...20 to 40% 100 to less than 200μ...20 to 40% 200 to less than 600μ...20 to 40% 3 After applying the PVC composition (B) to the surface of the releasable belt, the intermediate One or more base fabrics are placed, the PVC composition (A) is further applied, a tufted pile fabric with no resin applied is placed on top of it, and the tufted pile fabric that is not coated with resin is pressed and heated to gel. A method for manufacturing a carpet tile that is peeled from a carpet, the method comprising:
PVC composition (A) is a filler based on 100 parts by weight of PVC.
Contains 300 to 400 parts by weight, and the filler of PVC composition (A) has a particle size of 200μ or more and less than 600μ
PVC (A) contains 20 to 40% of the total filler, and PVC composition (B) contains filler per 100 parts by weight of PVC.
The PVC composition (A) is a liquid composition containing a filler and has a viscosity of 20,000 to 60,000 CPS (A-1), and a liquid composition containing no filler (A-2). 1. A method for producing a tile carpet, which comprises preparing each of these two compositions in advance, mixing these two compositions to obtain a composition (A), and applying the mixture to a release belt.