JPH06217860A - Tile carpet - Google Patents

Abstract

PURPOSE:To improve dimensional stability and to eliminate the wrinkles on the rear surface and the warpage at the time of mounting by using a specific fiber, welding the intersected points of these fibers and disposing a sheet having a specific shrinkage rate in a specific position. CONSTITUTION:The rear surface of a fiber layer 3 is back-lined with a back lining layer 4 consisting of a synthetic resin 5 disposed with a sheet 6. Thermally fusible composite fibers are used for this reinforcing sheet 6 which is formed by thermally fusing the intersected points of the thermally fusible composite fibers. The reinforcing sheet 6 having the thermal shrinkage rate higher than the thermal shrinkage rate of the fiber layer is used. The thermally fusible composite fibers are composite fibers which consist of at least two components varying in softening point or m.p. and in which the low melting component continuously forms a part of the fiber surfaces. The back lining layer 4 is back-lined with the synthetic resin 5 together with the reinforcing sheet 6. The reinforcing sheet 6 is disposed nearer the floor surface side than half the thickness of the back lining layer 4. The warpage of the carpet is hardly preventable if the position where the reinforcing sheet is disposed, is below half the above- mentioned thickness.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to tile carpets. More specifically, it relates to a tile carpet that can be easily manufactured and can be lined at high speed, has good dimensional stability, has no wrinkles on the back surface, and has no deformation such as concave warpage for a long time even when attached to the floor surface. .

[0002]

2. Description of the Related Art As a carpet for a building or a mobile home,
Roll-rolled long-length carpets and short-length rolled so-called tile carpets are used. The long carpet is usually about 1.8 m wide.
There is ~ 3m. When constructing a long carpet on the floor, a roll-shaped object is brought to the construction site and fixed to the floor by using an adhesive tape or tacking. .
Therefore, when constructing a narrow room or a room having a bend or a corner, it is necessary to cut a long one on site, which makes construction difficult. There is also a problem that a large amount of cutting waste is generated at the construction site. Further, long-length carpets such as needle punch carpets and tufted carpets have problems such as monotonous hue and pattern.

In place of such a carpet, tile tiles cut in a short shape have been rapidly used. The width of one side of the tile carpet is about 15 ~
It is as short as 150 cm and cut into various shapes such as a triangle, a quadrangle, and a hexagon. This carpet has a backing layer designed to have a high basis weight of about 1000 to 8000 g / m ² . Therefore, it is possible to select various sizes, patterns, cut shapes, hues, etc., which suit the construction site little by little, and combine them at the construction site. Therefore, a pattern having a design effect, such as a mosaic pattern or a painting pattern, can be freely produced. Moreover, one piece is short and easy to install. For this reason, instead of the above-mentioned long carpet, a short-cut tile carpet has been rapidly used.

However, in the tile carpet, a synthetic resin is applied to the fiber layer by heat such as a laminating method, a coating method, a heat fusion method, or the like, so that the fiber layer is thermally shrunk and warped in a concave shape.
There is a problem that so-called dimensional stability is poor. As an attempt to solve such a problem, Japanese Patent Laid-Open No. 59-13502.
Japanese Unexamined Patent Publication (Kokai) No. 3 discloses that a backing layer is provided with a composite material such as non-woven fabric or woven glass fiber, and Japanese Utility Model Publication No. 3-16536 discloses that a heat-shrinkable mesh reinforcing material is placed. . However, the tile carpets disclosed above are not sufficiently effective in terms of dimensional stability because they use glass fibers having a small heat shrinkage. In addition, the actual fair 3-16
The one disclosed in Japanese Patent No. 536 uses a mesh reinforcing material that is not heat-sealed, so that the mesh reinforcing material is likely to be misaligned or wrinkled during the lining, and thus the lining layer Since wrinkles are easily formed on the back surface and the heat shrinkage of the fiber layer and the reinforcing material is not well-balanced, warpage is not sufficiently prevented.

[0004]

DISCLOSURE OF THE INVENTION The present invention provides a tile carpet having the above-mentioned conventional tile carpet which has no concave warp, has good so-called dimensional stability, is easy to install, and can be installed in various arrangements. The purpose is to provide.

[0005]

Means for Solving the Problems The present invention has been achieved as a result of earnest research for solving the above problems, and has the following configurations. That is, No. 1 is a tile carpet comprising a backing layer (4) on which a sheet (6) is arranged and a fiber layer (3), in which the sheet (6) thermally fuses the intersections of the heat-fusible composite fibers. And that the heat shrinkage of the sheet is greater than the heat shrinkage of the fiber layer, and the sheet is arranged on the back surface side of less than 1/2 of the thickness of the backing layer. A tile carpet of the present invention, characterized in that the heat-fusible fiber used in the sheet (6) of the backing layer (4) is a heat-fusible composite monofilament. -It's a pet.

In the present invention, the fiber layer (3) of the tile carpet means polyamide fiber, polyester fiber,
It is composed of various types of fiber layers (3) using various synthetic fibers such as polyolefin fibers and acrylic fibers, and natural fibers. The fiber layer (3) is tufted on the base fabric (2) with a loop pile or a cut pile, or
Various items such as a dollar punch, a spun lace, a heat-bonded non-woven fabric, etc. can be exemplified. Further, the fiber layer (3) is used by mixing various fibers at an arbitrary ratio, alternately laminating and aligning. Further, this fiber layer may not have a base cloth. The basis weight of the fiber layer (3) is about 300 to 1500 g / m ² . The base fabric (2) is a polyester spunbond non-woven fabric,
Woven and woven fabrics such as polyolefin insulation yarn and jute,
Etc. can be used.

The tile carpet of the present invention has a backing layer (4) of a synthetic resin (5) in which a sheet (6) (hereinafter sometimes referred to as a reinforcing sheet) is arranged on the back surface of a fiber layer (3). ) Is lined. The reinforcing sheet (6) is made of heat-fusible composite fibers, and is obtained by heat-sealing the intersections of the heat-fusible composite fibers. A knitted woven fabric or a non-woven fabric is used. ing. Moreover, the heat shrinkage rate of the reinforcing sheet (6) is larger than that of the fiber layer. The heat-fusible conjugate fiber is a conjugate fiber composed of at least two components having different softening points or melting points, and the low-melting component continuously forms a part of the fiber surface. The composite fibers include, for example, polypropylene / polyethylene terephthalate, polyethylene / polyethylene terephthalate, polyethylene / polypropylene /, low melting point copolyester / polyethylene terephthalate, low melting point polyamide / polyamide, and the like in parallel. Shaped, sheath-core and sea-island fibers can be used. The fiber has a fineness of about 50 to 8000.
d Preferably about 100-2000d is used. When the fiber is a spun yarn, the fineness is a fineness per spun yarn. As the fiber, spun yarn, multifilament, monofilament, or the like can be used. Above all, a composite monofilament is preferable because the sheet has high strength and the sheet has good shape stability. A sheet is formed by knitting or weaving the composite fiber into a sheet, and heating the composite fiber at a temperature equal to or higher than the softening point of the low melting point component of the composite fiber to heat-bond the intersections of the fibers. Since the intersection of the fibers is heat-sealed in the sheet, the sheet is stored in a roll winding form,
Alternatively, when the roll-wound sheet is used for backing with a synthetic resin, wrinkles do not occur in the sheet, so a tenter for stretching out slack or wrinkles of the sheet It does not require wrinkle rolls and can be lined at high speed.

In the present invention, the reinforcing sheet (6)
Uses a material having a larger heat shrinkage than the fiber layer after heat fusion. The control of heat shrinkage is performed by appropriately setting the manufacturing conditions for manufacturing the composite monofilament and the like, the manufacturing conditions of the sheet, and the like. For example, when the composite fiber is a monofilament, the spinning temperature and the drawing temperature are performed at a low temperature, the annealing after the drawing is performed at a low temperature, or the annealing of the sheet after heat fusion is performed at a low temperature. , And the like. In the case of the present invention, it is preferable that the heating temperature is 150 ° C. and the heat shrinkage is 2% to 15% larger than the heat shrinkage of the fiber layer under the condition of 1 minute. In particular, it is preferably 2.5 to 9%. If the difference in heat shrinkage is 2% or less, it is difficult to improve the dimensional stability of the carpet, and if it exceeds 15%, the carpet is deformed into a convex shape, which is not preferable.

The backing layer (4) is lined with a synthetic resin (5) together with the reinforcing sheet (6). The reinforcement sheet
The tongue (6) is arranged on the back surface side (floor surface side) with respect to half the thickness of the backing layer (4). If the position where the reinforcing sheet is arranged is less than 1/2, it is difficult to prevent the warp of the carpet. The sheet (6) may be exposed on the back surface side of the backing layer (4). The synthetic resin (5) is vinyl chloride resin, ethylene-vinyl acetate resin, low density polyethylene, high density polyethylene, non-crystalline polypropylene,
Asphalt, styrene-butadiene resin, or a mixture of these resins can be used. This resin (5)
Can also be used as a mixture with calcium carbonate, carbon black, titanium dioxide, silica, barium sulfate, various pigments, antioxidants and the like. The basis weight of the backing layer (4) is about 1000 to 800 without a reinforcing sheet.
It is 0 g / m ² .

The lining can be performed by various known methods. As an example, a vinyl chloride paste etc.
It can be performed by a method of pasting using a tape, a method of laminating a synthetic resin through a T-die, a method of laminating, or a method of heating and adhering each synthetic resin sheet extruded in advance. The reinforcing sheet can be arranged at the same time when the synthetic resin is lined, or can be formed by a method such as lining the synthetic resin and then fusing to the back surface thereof. Further, the synthetic resin (5) of the backing layer (4) is not only a single layer but also a first synthetic resin (8) and a second synthetic resin (9) having a two-layer structure or a multilayer structure having more layers. It may be any one (FIG. 2). The reinforcing sheet (6) of the backing layer (4) is arranged in two or more layers if it is on the back side (lower side) of the backing layer (4) with a thickness of 1/2 or less. May be. If the reinforcing sheet (6) is a single layer, it may be laminated with another sheet having a different heat shrinkage rate. In the carpet of the present invention, the back surface of the fiber layer (3) may be adhered with an SBR binder or a vinyl acetate binder, and the back surface thereof may be lined with a synthetic resin.

Hereinafter, the present invention will be described in more detail with reference to Examples. In each example, the evaluation method of the physical properties and performances of the reinforcing sheet, tile carpet, etc. was as follows. Heat shrinkage rate: Using a hot air dryer, a 25 cm × 25 cm reinforcing sheet was heated at a predetermined temperature for 1 minute, and its area shrinkage rate (%) was measured. Dimensional stability: 25cm x 25cm using hot air dryer
After heating the tile carpets at 80 ° C for 48 hours, place them on a horizontal stainless steel plate and visually check for gaps between the backing layer of the carpet and the stainless steel plate, and there is no gap on all four sides of the carpet. Was determined to have good dimensional stability. Those having a gap on any one or more of the four sides of the carpet were judged to have poor dimensional stability.

Examples 1 to 3 and Comparative Examples 1 to 2 As a fiber layer, a polyester spunbonded base fabric is tufted with a nylon bulky yarn having a total spunbond method of 2400d and a filament number of 136f. It was used. This fabric has a pile yarn gauge of 1/1
The loop pile was 0 and the pile length was 6.2 mm. Further, the heat shrinkage of this material is 5.1% under the heating condition of the temperature of 150 ° C. for 1 minute, and is 8.
It was 6%.

Apart from the original fabric of this carpet, a reinforcing sheet
As a sheath, the sheath component is polypropylene / the core component is polyethylene terephthalate, and the composite ratio is 1/1 (volume ratio),
A heat-fusible composite monofilament having a fineness of 400 d was woven, and a heating roll was used to obtain a reinforcing sheet (a) in which the intersections of the fibers were heat-sealed. The reinforcing sheet (a) is heated at a predetermined temperature for 1 minute using a hot air heater and annealed.
Reinforcement sheets (b, c, d, e) were obtained. In this reinforcing sheet, the number of monofilaments driven is 9 warps / 2.
It was 5 mm and 9 wefts / 25 mm. Table 1 shows the strength, heat shrinkage, and other physical properties of this reinforcing sheet.

A tile carpet having a thickness of 5 mm backed with a vinyl chloride resin having the reinforcing sheet arranged on the back surface of the original carpet was obtained. For the lining, use a coating device equipped with a coater, a roller for adjusting the thickness, a dryer, etc., and arrange the reinforcing sheet at a predetermined position. A vinyl chloride paste mixed with DOP, calcium carbonate, etc. was coated. After coating, the vinyl chloride resin was solidified by heating at a temperature of 180 ° C. for 50 seconds and then cut with a cutter to obtain a tile carpet of 25 cm × 25 cm. For the sheet position in Table 1, the length from the back surface of the fiber layer was obtained. Table 1 shows the performance and the like of the carpet. From Table 1, it was found that the carpet of the present invention had good dimensional stability and good adhesion to the floor surface. The back side of the tile carpet was attached to the finished concrete floor with double-sided adhesive tape and used for a long period of 3 years. After observing the appearance, there was no deformation such as concave warpage. (Examples 1, 2, and 3) On the other hand, when the reinforcing sheet is excessively annealed and the reinforcing sheet having a heat shrinkage ratio lower than that of the original sheet of the carpet is arranged, a concave warp is recognized. The dimensional stability was poor (Comparative Examples 1 and 2).

Example 4, Comparative Example 3 In Example 1, the same reinforcing sheet and resin for the backing layer as in Example 1 were used, but the arrangement position of the reinforcing sheet was changed, and the back surface of the fiber layer was changed. To 1.1 mm (1.1 / 5 of the thickness of the backing layer) (comparative example 3), and 2.8 mm (2.8 / 5 of the thickness of the backing layer).
Was obtained (Example 4). A composite monofilament reinforcing sheet arranged on the fiber layer side less than 1/2 of the thickness of the synthetic resin layer has poor dimensional stability. The performance was good (Table 1).

Examples 5 and 6 As the reinforcing sheet, the sheath component was made of high-density polyethylene / the core component was polyethylene terephthalate, and the composite ratio was 3 /.
2 (volume ratio), a heat-fusible composite monofilament having a fineness of 480d was woven, and a heating roll was used to obtain a reinforcing sheet (f) in which the intersections of the fibers were heat-sealed. The reinforcing sheet (f)
Was heated at a predetermined temperature for 2 minutes using a hot air heater and annealed to obtain a reinforcing sheet (g). In this reinforcing sheet, the number of monofilaments driven is 7 warps / 2.
It was 5 mm and 7 wefts / 25 mm. As a backing layer, 70% by weight of low-density polyethylene and 30% by weight of ethylene-vinyl acetate copolymer were mixed and melt-cast to a thickness of 2.
1 mm sheet (A) and 1 mm thick sheet (B)
Got The sheet was heated with a heater at a temperature of 140 ° C. for 3 minutes. The heated sheet (A), the reinforcing sheet, and the heated sheet (B) were laminated in this order on the back surface of the same original sheet of carpet as used in Example 1. Temperature 1
The fiber layer was lined with a synthetic resin by heating for 45 seconds with a heater heated to 80 ° C. After cooling, cut with a cutter, and
A tile carpet of cm × 25 cm was obtained. The thickness of the backing layer of this carpet was slightly reduced by heating to 3 mm. Also, the reinforcing sheet should be placed from the back side of the fiber layer 2
mm (2/3 of the thickness of the backing layer). Comparative Examples 4 and 5 In the above-mentioned Example 1, only the reinforcing sheet had a basis weight of 30 g /
It was changed to a glass fiber non-woven fabric obtained by the paper making method of m ² .
(Comparative Example 4) A reinforcing sheet was used to obtain a polyethylene phthalate monofilament having a fineness of 400d.
The sheet without annealing was obtained. (Comparative Example 5) Table 1 shows physical properties such as strength and heat shrinkage of these reinforcing sheets. In Comparative Examples 4 and 5, the dimensional stability was poor. In Comparative Example 5, wrinkles were generated on the back surface of the tile carpet.

[0017]

EFFECTS OF THE INVENTION Since the tile carpet of the present invention uses a sheet in which specific fibers are used and the intersections of the fibers are heat-sealed, wrinkles of the sheet do not occur and slack of the sheet and A tenter for wrinkling and wrinkle rolling was not required, and the lining could be done at high speed. Further, the tile carpet of the present invention uses specific fibers, heat-bonds the intersections of the fibers, and arranges the sheet having a specific shrinkage ratio at a specific position, so that the dimensional stability is good and the back surface is covered. If it is mounted on the floor, it can be prevented from warping in a concave shape, and the carpet does not warp in a concave shape even if heat or pressure from a human foot is applied. Further, this carpet can be used in a state where there is no adhesive, tack, etc. on the floor, or it can be spread with an adhesive or the like and has good dimensional stability for a long period of time.

[0018]

[Brief description of drawings]

Figure 1 is a tile car with a single backing layer of synthetic resin.
Pett,

[Fig. 2] is a tile car with two layers of synthetic resin for the backing layer.
Shows a pet.

[Explanation of symbols]

 1: Pile 2: Base fabric 3: Fiber layer 4: Backing layer 5: Synthetic resin 6: Sheet 7: Back side 8: First synthetic resin 9: Second synthetic resin

[Table 1]

Claims (2)

[Claims] 1. A tile carpet comprising a backing layer and a fiber layer on which a sheet is arranged, wherein the sheet is obtained by heat-sealing the intersections of the heat-fusible composite fibers, and heat shrinkage of the sheet. A tile carpet characterized in that the rate is higher than the heat shrinkage rate of the fiber layer and the sheet is arranged on the back side of the backing layer with a thickness of less than 1/2 of the thickness of the backing layer. 2. The tile carpet as claimed in claim 1, wherein the heat-fusible composite fiber used for the sheet of the backing layer is a heat-fusible composite monofilament.