JPH0622490B2 - Tile carpet - Google Patents

Description

Detailed Description of the Invention a. TECHNICAL FIELD The present invention relates to a tile carpet laid on a floor material such as a building, and more specifically, by bending the backing layer of the tile carpet so as to form a gentle concave bottom surface, It is intended to obtain a tile carpet having a stable flat laying property on a base plane.

[Conventional technology]

Tile carpets for floor coverings are usually square unit boards that are provided with an elastic backing layer made of a thermoplastic resin such as vinyl chloride resin or bitumen on the back surface of a carpet such as pile fabric or needle punching nonwoven fabric. A large number of adjacent layers are abutted against each other to form a coated floor surface, and the backing layer is usually in a flat planar state.

[Problems to be Solved by the Invention]

The conventional tile carpet having a flat backing layer has different front and back physical properties due to the lamination of the carpet surface layer and the backing layer of the elastic resin, and tends to warp the peripheral edge due to internal strain during manufacturing. There was often a problem that the peripheral edge of the tile carpet was warped during and after the covering was applied, that is, when the tile tiles of rectangular shape were laid against each other, the edge pressure was increased when the contact pressure was increased. Warpage is liable to occur, and even if it is laid with an appropriate abutment pressure or with a predetermined joint gap, edge warpage is easily caused by the local pressing force of walking, moving objects, installation objects, etc. on the upper surface. There is a drawback that occurs, and therefore, generally, it is fixed to the floor surface by an adhesive coating on the entire surface or by a peripheral adhesive means with double-sided adhesive tape, and the edge warp is caused. Although the rise is prevented, the workability and economy are inevitably deteriorated by this bonding means, and it is also difficult to partially repair the tile carpet floor.

B. Structure of the Invention [Means for Solving the Problems] The present invention eliminates the above-mentioned peripheral warp in a conventional tile carpet having a backing layer in a flat planar state, and a good and stable laid floor without using adhesive means. This is a tile carpet whose surface can be easily obtained.

That is, the present invention has a glass fiber layer intervening in a position closer to the surface carpet side than the center of the layer thickness in the thermoplastic resin backing layer, and the backing layer is elastic by its own weight when laying the floor surface. The gist of the tile carpet is that it is curved so as to form a gentle concave bottom surface that can be deformed and come into close contact with the floor surface.

In the present invention, the surface carpet is a usual carpet such as a pile fabric, a needle punching nonwoven fabric, and a flocked fabric which have been conventionally used, and the backing layer is also the same natural or synthetic thermoplastic resin as the conventional one, for example, synthetic rubber having elasticity or natural rubber. , Vinyl chloride resin and other hot melt resins and mixtures thereof, and desired additives such as fillers and colorants are appropriately used.

As the glass fiber layer, a glass fiber woven cloth, woven cloth, non-woven cloth, chopped strand mat, or the like having dimensional stability and appropriate hardness is used. The glass fiber layer is a backing layer of the thermoplastic resin. An intervening layer is provided in the backing layer, deviating from the center of the layer thickness toward the surface carpet side.

Therefore, the tile carpet of the present invention comprises a four-layer laminate of a surface carpet, a thermoplastic resin first layer, a glass fiber layer, and a thermoplastic resin second layer, wherein the thermoplastic resin second layer is thicker than the first layer. The tile carpet of the present invention can be obtained by bending the backing layer by a suitable processing means so that the backing layer forms a gently curved lower surface.

The gently curved lower surface of the backing layer may have a degree of curvature such that it is elastically flattened by the weight of the tile carpet itself when the tile carpet is laid so as to be in close contact with the floor surface. Although it may be a concave curved plane having a substantially circular arc shape in the direction, it is preferably a concave spherical curved surface having a substantially circular arc curve in two orthogonal directions.

Therefore, as the bending forming means for the above-mentioned laminate, individual forming means by press work of a curved plane or a spherical curved surface pressing die can be used, but a particularly preferable processing means is to apply an appropriate pressure after the production of the laminate. By a continuous processing step of passing through a two-roll calender, a long laminate having internal contraction that increases in the direction from the surface of the carpet to the lower surface of the backing layer is formed, and this long laminate is cut into a square of a predetermined size. In this way, the tile carpet having a spherical concave curved concave bottom surface can be efficiently produced in a free state.

[Action]

The tile carpet of the present invention has a glass fiber layer having a small dimensional stability and a moderate hardness, which is located above the center of its thickness in the thermoplastic resin backing layer. ,
By adapting the elastic deformability of the gently curved lower surface of the backing layer to the weight of the tile carpet so that it is flat and in close contact with the laying floor surface, the peripheral lower surface of the tile carpet is strongly pressure-bonded to the floor surface to provide a stable laying state. At the same time, the downward internal stress of the peripheral edge has the effect of suppressing the upward warping external force.

The above effect is effectively produced by interposing the glass fiber layer above the center of the layer thickness of the backing layer. However, when the glass fiber layer is too close to the upper surface of the backing layer, the backing layer is protected. The dimensional stability and rigidity are deteriorated, and the layering strength with the surface carpet becomes insufficient, so that the above-mentioned adhesion stability and warp rise prevention properties tend to be difficult to obtain.

Therefore, in the present invention, in a normal tile carpet provided with a backing layer of a thermoplastic resin having a thickness of 2 to 7 mm, the glass fiber layer is less than 1/2 of the layer thickness of the backing layer from the surface carpet adhesive surface of the backing layer. , Experimentally confirmed that it is necessary to establish an intervention layer at a position of 1/4 or more.

The action of the gently curved lower surface of the backing layer is caused also by a unidirectional curved flat surface, but in the case of a concave spherical curved surface having curved in two orthogonal directions, more preferable warp rising prevention property can be obtained. In addition, due to the floor surface adsorption action, the action of stably maintaining the smooth laid state is increased.

〔Example〕

Hereinafter, embodiments shown in the drawings will be described together with a manufacturing method thereof.

FIG. 1 is an enlarged cross-sectional view of a main part of a tile carpet of the present invention, in which 1 is a surface carpet, 2 is a backing layer made of a thermoplastic resin, and 3 is a glass fiber layer provided as an intervening layer in the backing layer 2. As a result, the backing layer 2 is divided into a thin upper layer 21 and a thick lower layer 22 in thickness.

Reference numeral 31 denotes a gently curved lower surface formed by bending the backing layer 2, but in the laid state, it is flat along the floor surface F as illustrated.

An example of a specific method for manufacturing the above tile carpet will be described.

As a surface carpet, nylon fiber loops were erected on a base fabric made of polypropylene fiber, 1.0 kg /
Using a normal tufted carpet of m ² , the back surface is doctor-coated with plastisol of vinyl chloride resin to a thickness of about 1 mm, and then about 0.5 mm thickness, 40
After laminating glass fiber fabrics of g / m ² and doctor coating plastisol of vinyl chloride resin to a thickness of about 2.5 mm, the coating sol was gelled and cured by heating at 140 ° C.

This was subsequently passed under a relatively low pressure by means of a two-roll calender to obtain a tight laminate, which was then obtained on a suitable cutting machine to obtain a square tile carpet 50 cm on a side.

This product weighed 6.6 kg / m ^2, of which the 3.5 mm thick backing layer weighed about 5.6 kg / m ² and had a gently curved underside with a spherically curved surface.

As shown in FIG. 2 (a), the above product was placed on a floor F of a horizontal plane with the carpet surface facing down. As a result, the backing layer 2 having the gently concave curved lower surface 20 has the center of the peripheral edge thereof. The warp amount e to the surface was about 4 mm, but in a normal laying state in which the front and back surfaces are reversed and the carpet surface is facing up as shown in (b), the backing layer 2 has the gentle concave curved surface 20 (one-dot chain line). Is a virtual line) was in close contact with the floor surface F, resulting in a flat carpet surface.

This product was cut into 1 cm width along one side and the cut surface was placed on a horizontal plane, and in a free state, the bending of the lower surface of the backing layer was measured, and it was found to be approximately a circular arc with a radius of curvature of about 3.5 m. It was In addition, 1c
The same measurement was performed on a piece cut into m widths, and it was in a curved state of a substantially arc with a radius of curvature of about 4.5 m, and the backing layer as a whole was a gently curved shape with a substantially spherical curved surface.

In the above examples, when a filler such as calcium carbonate is added to the backing layer, the amount of warpage e decreases, but in this case, the bottom surface of the backing layer is calendered so that the bottom surface is slightly embossed. The amount of warpage e
Can be increased.

C. EFFECTS OF THE INVENTION In the tile carpet of the present invention, as described above, a glass fiber layer having dimensional stability and an appropriate hardness is provided as an intervention layer on the upper layer in the backing layer of the thermoplastic resin, and the backing layer is a floor. When laying a surface, it is curved so as to form a gentle concave bottom surface that can be elastically deformed by its own weight and adhere to the floor surface, so multiple tile carpets are closely laid adjacent to each other on the floor base without using adhesive means. However, it is easy to obtain a flat tile carpet laying surface without warping at the edge of the abutting edge, and the local load from the top surface also causes the individual tile carpets to resist warping and prevent movement against the floor surface. And the good laid condition can be maintained, and part of the tile carpet can be easily replaced, which has a significant effect on floor surface construction and maintenance management. To do.

[Brief description of drawings]

The drawings show an embodiment of the present invention. FIG. 1 is an enlarged cross-sectional view of a main part of a laid carpet, and FIG. 2 is a side view for explaining the condition of a tile carpet placed on a horizontal plane. . 1 …… Surface carpet, 2 …… Backing layer 3 …… Glass fiber layer, 20 …… Lower concave curved surface 21 …… Upper layer, 22 …… Lower layer e …… Warp amount

Claims (1)

[Claims] 1. A thermoplastic resin-based backing layer (2) having a surface thickness of the backing layer (2) 1 /
It has an intervening glass fiber layer (3) at a position within the layer of not more than 2 and not less than 1/4, and the backing layer (2) can be elastically deformed by its own weight when it is laid on the floor and adhere to the floor. A tile carpet that is curved so as to form a gently concave lower surface (20).