JPH06169837A - Manufacture of carpet - Google Patents

Abstract

PURPOSE:To provide a manufacturing method of a carpet which is excellent in elasticity, flexibility, shrinkage resistance and dimensional stability. CONSTITUTION:A coating agent application surface of a carpet base material formed by applying a resin acqueous emulsion coating agent to a backing material composite layer composed of hydraulic inorganic cement powder and non- hydraulic inorganic powder is superposed on resin aqueous emulsion, brought into press-contacting with each other before the backing material composition is hardened and the coating agent is dried, and then heated at a temperature of 85-170 deg.C to be hardened and dried. A resin aqueous emulsion having a glass transition point of -50 to +50 deg.C is as a backing material composition, and 120-400 pts.wt. cement powder and 160-600 resin aqueous emulsion having a glass transition point of -10 pts.wt. inorganic powder are mixed with 100 pts.wt. resin. A resin aqueous emulsion having a glass transition point of -10 to +30 deg.C is used as a resin aqueous emulsion coating agent, and only the resin aqueous emulsion may be used, but preferably inorganic filling material is mixed therewith.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a carpet manufacturing method,
In particular, the present invention relates to a method for manufacturing a carpet that can be easily adhered to a rugged floor surface, is excellent in flexibility and dimensional stability, and has little warpage.

[0002]

2. Description of the Related Art Carpet backing materials include asphalt-based materials and vinyl chloride-based materials, but asphalt-based materials not only have an odor,
In particular, it hardens to become crispy in the winter and softens at high temperatures to stain the surroundings and cause thermal deterioration.
Further, the vinyl chloride type has a problem in terms of environmental pollution that harmful chlorine gas is generated when the carpet is incinerated at the time of disposal.

In order to solve the above-mentioned problems of conventional backing materials for carpets, an adhesive agent is used on a sheet preformed from a composition composed of an emulsion of cement and a thermoplastic resin to form a carpet surface. It has been proposed to manufacture a backed carpet by laminating the back surface of a base material (Japanese Patent Publication No. 60-58347). However, in this method, when the cement is rapidly exposed to high temperature during its production, it becomes brittle, and it is necessary to slowly heat the sheet to cure and dry it, resulting in poor productivity, and the product carpet is too hard. There was a problem such as lack of flexibility.

[0004]

DISCLOSURE OF THE INVENTION The present invention is excellent in flexibility, flexibility, shrinkage resistance and dimensional stability, is relatively light,
An object of the present invention is to provide a method for easily manufacturing a carpet that can be easily adhered to an uneven floor surface or the like and that is less likely to warp during use.

[0005]

According to the method for producing a carpet of the present invention, an aqueous emulsion of a resin having a glass transition point of -50 to 5 ° C is used to prepare a hydraulic inorganic cement powder 120 to 400 with respect to 100 parts by weight of the resin solid content. Parts of a backing material composition containing 160 parts by weight to 160 parts to 600 parts by weight of a non-hydraulic inorganic powder, and a carpet base material coated with an aqueous emulsion coating agent of a resin having a glass transition point of −10 to 30 ° C. To form a laminate having a structure in which the backing material composition is laminated via the coating surface of the coating agent before curing and drying of the backing material composition and before drying of the coating agent. The method is characterized by heating to a temperature of 170 ° C to cure and dry the backing material composition and dry the coating agent.

Examples of the carpet base material used in the present invention include various synthetic fibers such as polypropylene, polyethylene, polyethylene terephthalate and nylon, natural fibers such as tufted carpet such as cotton, hemp and wool, and needle punched carpet. , Spunbond, non-woven fabric, miscellaneous felt, woven fabric, woven fabric and the like, and further, glass fiber non-woven fabric and woven fabric.

A backing substrate may be used in the carpet produced by the present invention. As the back substrate, in addition to the same ones that can be used as the front substrate, paper such as Japanese paper can be used.

The front base material and the back base material are at least one of the base materials in order to improve the drying property at the time of curing / drying, and preferably as the base material which comes to the upper side when they are pressed against each other and cured / dried. It is desirable to use a material having water permeability. Further, when the back substrate is used, a combination of the front substrate and the back substrate having the same heat shrinkage or the back substrate having a higher shrinkage than the front substrate should be used. However, it is preferable since the product carpet can be prevented from warping.

An aqueous emulsion of a resin having a glass transition point of -50 to 5 ° C. used in the backing material composition of the present invention, or a glass transition point of -10 to 30 ° C. used in a coating agent applied to a carpet front substrate. Aqueous emulsions of resins contain various unsaturated monomers, such as 2-ethylhexyl acrylate, which give homopolymers having different glass transitions (the homopolymers have a glass transition of -85).
C. (herein, this is abbreviated as “Tg-85 ° C.”)}, n.butyl acrylate (Tg-54
C), ethyl acrylate (Tg-22C), vinylidene chloride (Tg-18C), isopropyl acrylate (T
g-5 ° C.), 2-ethylhexyl methacrylate (Tg
-5 ° C), n-propyl acrylate (Tg 8 ° C), n-butyl methacrylate (Tg 20 ° C), vinyl acetate (Tg 30 ° C), acrylic acid (Tg 87 ° C), n-propyl methacrylate (Tg) 81 ° C), styrene (T
g100 ° C), acrylonitrile (Tg 100 ° C),
Methyl methacrylate (Tg 105 ° C), methacrylic acid (Tg 130 ° C), maleic anhydride, itaconic acid (T
g 130 ° C.), acrylic acid amide (Tg 153
C.), ethyl methacrylate (Tg 65.degree. C.), vinyl chloride (Tg 79.degree. C.), and one or two or more kinds of unsaturated monomers appropriately selected from ethylene and butadiene. .

The glass transition point (Tg) added to the unsaturated monomer for preparing the resin aqueous emulsion is the value of Tg of the homopolymer of the monomer as described above. Generally, the Tg of the copolymer can be easily estimated from the copolymerization ratio of the monomer homopolymer Tg and the monomer. Therefore, an aqueous emulsion of a resin having a glass transition point of −50 to 5 ° C. for a backing material composition used in the present invention or an aqueous emulsion of a resin having a glass transition point of −10 to 30 ° C. for a coating material for a surface material for a carpet is used. Designed the polymer based on such estimated approximate values,
By repeating the experiment, a resin aqueous emulsion having a desired Tg value can be easily produced.

The glass transition point of the resin for the resin emulsion for the backing material composition is -50 to 5 ° C, and the resin may be a homopolymer or a copolymer. Further, the resin emulsion may be a mixture of two or more kinds of resin emulsions, and further,
A resin emulsion (commonly known as a powder emulsion) obtained by redispersing a water-redispersible resin powder produced from a resin emulsion in an aqueous medium may be used.

A resin emulsion for a backing material composition is not preferable when the glass transition temperature of the resin is higher than 5 ° C., because the resulting carpet becomes hard. If the glass transition point of the resin is lower than -50 ° C, the dimensional stability and resistance to water deformation of the carpet deteriorate, which is not preferable.

In addition, the resin aqueous emulsion for the coating material for the surface material for carpet has a resin glass transition point of -10 to 10.
It is 30 ° C, preferably 5 to 25 ° C. When the glass transition point of the resin exceeds 30 ° C., the applied resin becomes hard even if a plasticizer is used in combination, and the filler and the like may fall off from the surface base material when the carpet is bent, which is not preferable. If the glass transition point of the resin is too low, the resulting carpet will have reduced water resistance, poor shrinkage resistance, reduced yarn removal strength, or blocking, which may cause contamination. Prone. The glass transition point of the resin is preferably 10 ° C. or more higher than the glass transition point of the resin of the resin aqueous emulsion for the backing material composition.

The resin aqueous emulsion having a glass transition point of −50 to 5 ° C. or the resin aqueous emulsion having a glass transition point of −10 to 30 ° C. is widely marketed under various trade names. Can be carried out using the resin emulsion of.

Next, as the hydraulic inorganic cement powder for preparing the backing material composition of the present invention, what is called Portland cement (for example, ordinary cement, white cement, early strength cement, super early strength cement, etc.), There are those called mixed cement (for example, blast furnace cement, silica cement, fly ash cement, etc.), alumina cement, hydraulic gypsum powder, etc., but generally Portland cement, particularly ordinary cement, and white cement are preferred.

The hydraulic inorganic cement powder is used in an amount of 120 to 120 parts by weight based on 100 parts by weight of the resin solid content of the resin aqueous emulsion.
It is 400 parts by weight, preferably 160 to 300 parts by weight. If the proportion of cement powder is too low, the flexibility of the carpet will be good, but the elasticity will be poor and the strength and dimensional stability will be poor. Further, if the proportion of cement powder is too large, the carpet becomes hard and the water deformation resistance becomes poor.

Various non-hydraulic inorganic powders can be used for the backing material composition of the present invention. Examples thereof include calcium carbonate, silica sand, talc, clay, aluminum hydroxide, and various other inorganic extender pigments.

The non-hydraulic inorganic powder is 160 to 600 with respect to 100 parts by weight of the resin solid content of the resin aqueous emulsion.
Parts by weight. If the proportion is too small, the carpet becomes soft and sticky, and the dimensional stability becomes poor. On the other hand, if the proportion is too large, the carpet becomes hard and the water deformation resistance deteriorates. The non-hydraulic inorganic powder also contains an inorganic pigment for the purpose of coloring, but the addition amount thereof is usually relatively small.

The backing material composition of the present invention may contain foam particles such as shirasu balloon, if necessary. However, since such foam particles have a high volume concentration, the content thereof is: 15 for non-hydraulic inorganic powder
It is desirable that the amount is less than wt%.

The backing material composition of the present invention contains an appropriate amount of water. The water may be only water based on the resin emulsion, but usually additional water is often added. Generally, if the amount of water is too small, the composition becomes poor in fluidity and the workability at the time of application is deteriorated, and if the amount of water is too large, separation of the resin aqueous emulsion and other components occurs, which is preferable. Not only does it cure
After drying, the carpet may crack or shrink. The amount of water in the backing material composition is 10% resin solids.
100 to 200 parts by weight is preferable with respect to 0 parts by weight.

The backing material composition of the present invention may further contain pigments or dyes for coloring, various fiber powders, antifoaming agents, plasticizers, thickeners, antifungal agents, if necessary, that is, as optional components. , Water reducing agents, flow agents, hardening modifiers, wetting agents, dispersants, emulsifiers, antifreezing agents, flame retardants, and the like, and glass nets or resin nets can be used as a reinforcing material, but these are known. Since this is a technology, its detailed description is omitted. As described above, the inorganic pigment for coloring is contained in the non-hydraulic inorganic powder and the compounding amount thereof is usually small.

Further, it is possible to optionally add an aqueous resin emulsion other than the above-mentioned resin emulsion to the backing material composition of the present invention.
Even when other resin emulsions are added, the addition amount of the above resin aqueous emulsion is 60% by weight or more in terms of resin solid content based on the total resin solid content.

When the backing material is not used for the carpet produced by the present invention, the backing material composition is directly applied to the surface of a plate-like body or sheet or film having releasability to form a sheet. It is desirable to form a molded body. The composition of the backing material composition used in this case is 160 to 360 parts by weight of hydraulic inorganic cement powder and 160 to 460 parts by weight of non-hydraulic inorganic powder with respect to 100 parts by weight of the resin solid content of the resin aqueous emulsion. Preferably.

Next, in the present invention, the resin aqueous emulsion coating agent having a glass transition point of -10 to 30 ° C applied to the carpet front substrate may consist of the same resin aqueous emulsion, but in general, It is desirable to add an extender pigment as a filler to 600 parts by weight or less, preferably 160 to 400 parts by weight, based on 100 parts by weight of the resin solid content. When the extender pigment is added, the resulting carpet has little shrinkage, is imparted with hardness, and has good punching workability. The coating amount of the resin aqueous emulsion coating agent is 80 to 450 g / m ² in terms of solid content. By adhering the uncured and undried cement-containing backing material composition layer in the undried state coated with the resin aqueous emulsion coating agent, it is possible to improve the adhesiveness and the pile removing strength of the carpet.

Next, the method for producing a carpet of the present invention will be described in detail. A method for forming a laminate of the above-mentioned backing material composition layer and the above-mentioned coating agent-applied carpet front substrate is described. , Various methods are possible, as a typical method, a backing material composition sheet formed by previously molding the backing material composition into a sheet, and a carpet front substrate to which a coating agent has been applied in advance. Can be superposed on each other via the surface coated with the coating agent to form a laminate. However, other methods, for example, on the coated surface of the coating material of the carpet base material coated with the coating material,
There is also a method in which the backing material composition is directly applied or spread to form a laminate. However, since the method is the most typical method and is a simple method, the method will be mainly described in detail below.

First, a backing material composition containing the above resin aqueous emulsion, hydraulic inorganic powder, non-hydraulic inorganic powder, and other additives to be blended as necessary is first formed into a sheet. To do. There is no particular restriction on the molding method, but usually, a method of applying a backing material composition on the surface of a plate-like body, a film or a sheet, etc., to which a suitable releasing agent has been applied to impart releasability. It is convenient to do in.

Examples of the plate-shaped body to which the backing material composition is applied include metal plates such as iron plates, glass plates, ceramic plates, synthetic resin plates and plywood. Also,
Examples of the film or sheet include a synthetic resin film or sheet, a sheet made of paper or a woven fabric, a glass cloth, a carbon fiber cloth, or the like. Further, in order to impart releasability, as the release agent applied on the surface of the plate-like body, film, sheet, etc., for example, a release oil or a release agent such as used at the time of mortar or concrete construction is used. Type grease, etc., in the case of synthetic resin films and sheets, the surface of them is treated with silicone resin or fluororesin, and in the case of paper or fabric sheets, silicone resin or fluororesin treatment, or Releasability can also be imparted by laminating a film having releasability.

When a backing material composition is applied to the surface of a plate-like body, a film or a sheet having release properties, or a backing substrate to form a backing material sheet, the coating amount of the composition is The coating thickness before curing and drying, that is, the wet thickness is 0.5 to 3.0 mm, preferably 0.8 to 2.5 mm. If the coating thickness is too thin, the cushioning properties of the product carpet will deteriorate, and the carpet will not conform to the irregularities of the groundwork, resulting in a poor feel during walking. Further, if the coating thickness becomes too thick, it takes a long time to cure and dry, and the productivity decreases.

Next, a sheet-like molded article of the backing material composition molded in this way is coated with the above-mentioned resin-based aqueous emulsion coating agent on the coating surface of the coating material of the carpet front substrate. Before curing / drying the molded article and before drying the above-mentioned coating agent, press-contact with each other to 85
To 170 ° C., preferably 130 to 155 ° C., to cure and dry the sheet-shaped molded product, and to dry the coating agent. Then, a carpet in which the front substrate for carpet is firmly and integrally adhered to the sheet-like molded product of the cured and dried backing material composition, that is, a product carpet lined with a backing material layer is obtained.

If the heating temperature during the curing / drying and drying treatment is too low, the treatment takes a long time, and if it is too high, blisters are likely to occur between the backing material layer and the surface base material of the resulting carpet.

According to the production method of the present invention, the resin water-based emulsion has a high strength of being firmly and integrally bonded to the cured product of the backing material molded body in a state of permeating between the fibers of the surface base material,
It is possible to efficiently and easily produce a carpet having a good balance of flexibility (flexibility), dimensional stability (shrinkage resistance), conformability to a floor surface, workability, and the like.

That is, in the present invention, curing and drying after pressure contact between the sheet-like molded body of the backing material composition and the surface base material coated with the resin emulsion coating agent is 85 to 170.
Since it is carried out at a high temperature of ℃, the curing and drying time is shortened and productivity is improved, but the strength of the backing material layer to be molded does not decrease. Generally, in order to cure and dry an ordinary cement molded product by heating at a high temperature, it is necessary to humidify or use an autoclave. This is to prevent the water-containing cement from drying out during heating at high temperature and interfering with hydraulic hardness. However, in the method of the present invention, since the cement in the water-containing state is heated while being wrapped in the resin emulsion, even if the heating temperature for curing / drying is relatively high,
The water required for hydraulic hardening does not evaporate immediately, and the resin emulsion layer formed into an appropriate film also acts to suppress the evaporation of water and hold the water for a certain period of time. further,
Since it is a relatively high temperature curing / drying, the time required for hydraulic hardening is also shortened.Thus, even if it is heated at a relatively high temperature, it is possible to dry out cement in a water-containing state. While preventing, the hydraulic reaction and drying can be completed promptly, and the backing material layer of the resin-containing hardened cement having excellent strength can be formed in a short time.

Further, the cured layer of the backing material composition comprises
Since the numerous bubbles are formed by the steam generated by the high temperature heating, the density is 0.8 to 1.2 g / c.
It is light as m ³ , has excellent cushioning properties, and feels good when walking.

If the curing / drying temperature is lower than 85 ° C., it takes time to cure / dry, resulting in a decrease in productivity. In addition, the cured product of the backing material layer of the carpet has few bubbles, is light in weight and feels. It is inferior in sex and walking. Further, when the curing / drying temperature is higher than 170 ° C, the water content of the cement in the water state is rapidly volatilized so that the hydraulic reaction cannot sufficiently proceed, and the backing material layer and the surface are not able to proceed. It is not preferable because blisters easily form between the base material layer and the base material layer.

Further, the carpet obtained by the production method of the present invention does not necessarily have a backing material such as an asphalt-based, vinyl chloride-based or amorphous polypropylene-based backing material which is widely used at present. Since it does not require a backing cloth) and no backing material is used, it is excellent in punching workability, has a small number of production processes and is excellent in productivity, and is incinerated for disposal. Occasionally no toxic gas is generated and the calorific value is low, so disposal is easy.

[0036]

EXAMPLES The present invention will be described in more detail below with reference to Examples and Comparative Examples. All parts and percentages given in these examples are by weight.

Example 1 Polyester / nylon tufted carpet having a polyester non-woven fabric as a primary base fabric (basis weight: 1000 g / m ² ).
(Hereinafter, referred to as "PET / PET tufted") is used as a base fabric for a front base material, and a coating material for the front base material having the following composition is added to the base fabric so that the solid content is 350 g / m ^2. The resulting coating agent is undried PET /
Nylon tufted is continuously supplied.

Coating material for surface base material: Acronal YJ-2716D * 1 (in solid content) 100 parts Calcium carbonate * 2 100 parts Defoamer * 3 0.4 parts 10% Sodium tripolyphosphate aqueous solution 10 parts Water 100 parts increase Adhesive * 4 (The number of parts where the viscosity of the agent becomes 4000 cps) Note) * 1 ... Product name of Mitsubishi Petrochemical Badishe Co., Ltd.,
Acrylic ester-styrene copolymer resin aqueous emulsion, solid content concentration 48%, Tg of resin 24 ° C * 2 ... Dowa Mining Co., Ltd. product name KD-1200 * 3 ... San Nopco company product name San Nopco 8034 * 4: Mitsubishi Yuka Birdishe Co., Ltd. product name, Lattecor D

On the other hand, a backing agent composition having the following composition was mixed on a polyester film having a release agent treatment of 500 μm with a stirrer until no agglomerates were observed (about 15 minutes), and a wet thickness of 2. 0 mm continuously coated with a knife coater to form a backing agent composition sheet, and the above-mentioned continuously supplied undried PET / nylon tufted coating agent is immediately applied onto the sheet. After overlapping with the sides overlapping, and pressing with a roll,
The polyester film side was brought into contact with an iron plate heated to a surface temperature of 140 ° C. and heated for 15 minutes to cure / dry the backing agent composition sheet and dry the coating agent.

Backing Agent Composition: Butyl Acrylate / Styrene Copolymer Resin Aqueous Emulsion * 1 (in Resin Solid Content) 100 Parts Normal Portland Cement 200 Parts Calcium Carbonate * 2 250 Parts Water 80 Parts * 1 ... The solid content is 50%, the Tg of the resin is −30 ° C., and this resin emulsion is hereinafter referred to as “resin emulsion”. * 2 ... Dowa Mining Co., Ltd. product name KD-80

Table 1 shows the composition of the backing material composition and other production conditions.

Example 2 Instead of the polyester film used in Example 1, polyester spunbond (basis weight 60 g /
m ² ) is used to apply the backing material composition onto the backing material, and a butyl acrylate / styrene copolymer resin water-based emulsion (solid content 50%) is used as the resin water-based emulsion for the backing material composition. %, Tg of resin was −45 ° C. (hereinafter, this resin emulsion is referred to as “resin emulsion”), and otherwise the carpet was manufactured according to the method of Example 1. Table 1 shows the composition of the backing material composition and other manufacturing conditions.

Example 3 In the case of Example 1, a polyester film having a thickness of 500 μm and treated with a release agent between a base plate and a roll rotatably provided adjacent to the upper surface of the base plate. While the PET / nylon tufted obtained by continuously applying the same coating agent in the same manner as in 1. above is fed and taken up, the polyester film in front of the roll and the undried PET agent / Nylon tufted with the same backing material composition used in Example 1 and adjusting the gap between the roll and the base plate to wet the backing material composition. Of the backing material composition formed into a sheet-like formed body having a size of 2 mm, and the formed sheet-like formed body of the backing material is pressed and integrated with the above-mentioned PET / nylon tufted undried coating agent by the roll. Was continuously taking over, further 140 ° C. The molded body in the same manner as with Example 1 from the polyester film side
Then, the backing material composition sheet was cured and dried for 15 minutes to dry the coating material, and a backing material composition-backed carpet was obtained.

Table 2 outlines the composition of the backing material composition used in Example 3 and other essential points of the production conditions.

Examples 4 to 12 Comparative Examples 1 to 12 Tables 1 to 6 show backing material compositions and other production conditions.
Carpet was manufactured according to the method of Example 1 except for the changes as described above.

[0046]

[Table 1]

[0047]

[Table 2]

[0048]

[Table 3]

[0049]

[Table 4]

[0050]

[Table 5]

[0051]

[Table 6]

Note to Tables 1 to 6: * 1 ... Dowa Mining Co., Ltd., trade name KD-80 * 2 ... When the filler is mixed, the same filler as in Example 1 is used. The amount is compounded. * 3 ... Butyl acrylate / styrene copolymer resin aqueous emulsion, solid content 56%, Tg of resin is -30 ° C * 4 ... Nylon tufted carpet with polyester non-woven fabric as primary base cloth, basis weight 1000g / M ² * 5 ・ ・ ・ Mitsubishi Yuka Birdish Co., Ltd. trade name, acrylic ester / styrene copolymer resin aqueous emulsion, solid content 48%, Tg of resin is 24 ° C. * 6 butyl acrylate / styrene Copolymer resin aqueous emulsion, solid content 57%, resin Tg of -45 ° C * 7 ... Mitsubishi Yuka Birdiche Co., Ltd. trade name, ACRONAL YJ-3042D acrylic ester / styrene copolymer resin aqueous emulsion, solid 50% min, Tg of resin is 3 ° C * 8 ... Mitsubishi Yuka Birdiche Co., Ltd. product name, Acronal YJ -1650D Acrylic ester / styrene copolymer resin aqueous emulsion, solid content 49%, resin Tg is 8 ° C * 9 ... Butyl acrylate polymer resin aqueous emulsion, solid content 50%, resin Tg is -54. ℃

Tables 7 and 8 show the results of the physical property tests performed on the carpets obtained in the above Examples and Comparative Examples.
It was as shown in.

[0054]

[Table 7]

[0055]

[Table 8]

Note to Tables 7 and 8: * 1 Flexibility A tube having a diameter of 20 mm is placed on the table base material of the tile carpet, and the state when the carpet is bent 180 ° along the tube is visually inspected. It was evaluated according to the standard. ◎ ・ ・ ・ No abnormality at all ○ ・ ・ ・ No abnormality in each layer, but it takes some time for the bent part to return to its original position △ ・ ・ ・ Bend remains in the bent part × ・ ・ ・ Bends

* 2 Floor compatibility Tile carpet (50 × 50 cm) was rolled up and left for 2 hours, then opened naturally and placed on plywood with a thickness of 10 mm and left at 20 ° C. for 2 hours. It was examined and evaluated according to the following criteria. ◎ ・ ・ ・ Completely adapts to the base (plywood) ○ ・ ・ ・ Almost completely adapts to the base △ ・ ・ ・ Slightly lifts from the base × ・ ・ ・ Raises from the base and makes a sound when pressed from above

* 3 Shrinkability A tile carpet (50 × 50 cm) was placed at 50 ° C. for 10
After leaving in 0% RH air for 7 days or 14 days, and at 20 ° C
Each state after immersion in water for 1 day or 3 days was examined and evaluated according to the following criteria. ◎ ・ ・ ・ No change ○ ・ ・ ・ Slight change (swelling, etc.) △ ・ ・ ・ Swelling or warping, but returns to the original after drying × ・ ・ ・ Swelling or warping is remarkable

* 4 Touch to the touch With the back side of the tile carpet facing up, plywood (10 m thick)
m) and placed at 2 Kg / cm ² and then released, the compression deformation was examined and evaluated according to the following criteria. H: No compression deformation (hard) S: Compression deformation (soft)

* 5 Blocking resistance to the floor surface After applying a carpet to the concrete surface, press at a temperature of 50 ° C. for 5 days with a load of 15 kg / (50 cm × 50 cm), then return to room temperature and remove the load. The condition when the carpet was peeled from the floor was examined and evaluated according to the following criteria. ◎: There is no residue on the floor ○: Almost no residue on the floor △: There is not much residue on the floor, but it is sticky ×: There is residue on the floor

* 6 Thread pull-out strength The pile thread pull-out strength (Kg / thread) of JIS L-1021-1979 (mat test method) was measured.

As is clear from the comparison of Tables 7 and 8,
The carpets obtained in the respective examples are excellent in balance of physical properties such as flexibility, shrinkage resistance, touch feeling, workability and blocking resistance to the floor surface, in comparison with the carpets obtained in the comparative examples. ing. The carpets obtained in Comparative Example 2, Comparative Example 4, and Comparative Example 11 are relatively well balanced in physical properties, but the carpets obtained in Comparative Example 2 and Comparative Example 11 are all drawn. The strength is extremely low,
Comparative Example 4 requires a long time for curing and drying, and thus is inferior in productivity.

[0063]

According to the production method of the present invention, the carpet front substrate and the backing material composition layer (a hydraulic cement hardened material layer having porosity, lightness, flexibility and cushioning properties) are integrally formed. Combined carpet can be manufactured efficiently, and the resulting carpet has flexibility (flexibility), dimensional stability (shrink resistance), conformability to the floor surface (constructibility), pile yarn pull-out strength, etc. Good balance.

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Claims (1)

[Claims] 1. A water-based emulsion of a resin having a glass transition point of -50 to 5 ° C., 120 to 400 parts by weight of hydraulic inorganic cement powder and 160 to 600 parts by weight of non-hydraulic inorganic powder based on 100 parts by weight of the resin solid content. And a layer of a backing material composition containing a glass transition point of -10 to 30
C., a carpet surface base material coated with a resin aqueous emulsion coating agent, and curing the backing material composition described above.
Before the drying and before the drying of the above-mentioned coating agent, a laminate having a structure that is laminated via the coating surface of the coating agent is formed, and then the above-mentioned laminate is heated to a temperature of 85 to 170 ° C and the above-mentioned backing. A method for producing a carpet, which comprises curing and drying a material composition and drying a coating agent.