JPH07110530B2 - Carpet manufacturing method - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION This invention relates to carpets method for producing the backing material is lined mainly composed of polyvinyl chloride resin on the back surface of the carpet cloth.

[0002]

2. Description of the Related Art Generally, in the production of tile carpets, cut scraps are generated, and the amount of carpets that are no longer needed and discarded from general households, offices, etc. has reached a huge amount. However, although these carpet-unnecessary materials are mainly sent to incineration as waste, the processing cost is high, and especially the one backed by a thermoplastic resin backing material such as polyvinyl chloride resin has a high heat capacity. It easily damages the sintering furnace and causes toxic chlorine compounds. Therefore, in recent years, for the purpose of resource saving and pollution prevention, it has been strongly demanded to collect and reuse unnecessary carpet materials. Conventionally, as a means for reusing wastes of thermoplastic synthetic resin products, a mixture of crushed particles of the wastes and new heat-meltable resin powder is melt-extruded with a T-die to form a useful sheet-like product, There is known a method of thermocompression-bonding a sheet-like material to a carpet to form a backing material, and a method of spraying the mixture on a sheet such as cloth or paper and bonding the sheet in a heating furnace (Japanese Patent Publication No. 60-21859). Further, as a means of utilizing the carpet-unnecessary material, latex or synthetic resin emulsion is applied to the back surface of the carpet base material, and a pulverized product of the carpet-unnecessary material is sprayed on the layer in a state where the coating layer is undried or semi-dried. It has also been proposed to use it as a backing material (Shokai 59-132581).
No. 59-132582).

[0003]

However, in the above-mentioned method of melt extrusion with a T-die or the like, when a crushed material of carpet unnecessary material is used as a waste material, the viscosity of the melt becomes extremely high, and therefore extrusion is possible. In addition, it is necessary to reduce the blending ratio of the pulverized material to a very small level, which is inferior in the efficiency of recycling unnecessary materials, and is sufficient when the obtained sheet-like material is used as a backing material to line the carpet base material. There was a difficulty that I could not get the strength. Further, in the above method of binding the powder mixture sprinkled on the sheet in a heating furnace, when the backing material is constituted by the spreading layer by using the crushed material of the carpet unnecessary material as the waste material with the sheet as the carpet base material, There is a problem that the binding force between the material and the backing material is insufficient, and the pulling strength of the pile fiber or the like of the base material is poor.

[0004] On the other hand, in the preceding item you HirakiAkira 59-132581
The means for spraying the ground product of the carpet required material to the top coated with latex or synthetic resin emulsion on the back surface of the carpet base as by proposals, conventional carpet using a backing material such as common polyvinyl chloride resin Since it is a process means opposite to the manufacturing method of (1), that is, the method of applying the paste resin on the releasable belt and press-bonding the carpet base material on it, the existing manufacturing equipment cannot be used and it is enormous for new equipment. In addition to being costly, the resulting carpet has the drawback that the surface properties of the backing material are particularly degraded because the pulverized material is unevenly distributed on the surface of the backing material.

In view of the above-mentioned circumstances, the present invention provides a carpet in which a backing material mainly made of polyvinyl chloride is lined on the back surface of a carpet base material, and unnecessary materials for the carpet can be efficiently reused as raw materials, and at the same time, as a carpet. with sufficient general performance, yet prepared to accept the existing common carpet manufacturing equipment obtained Luka
-The purpose is to provide a method for producing pets .

[0006]

To achieve the above object, according to the Invention The, the inventions are on the back of the carpet cloth, polyvinyl chloride
Upper and lower layers of backing material made of nil resin are laminated
Is provided on the backing lower layer of the carpet unnecessary material
The crushed material is often unevenly distributed on the deep side of the lower layer.
A method of manufacturing a carpet that has continuous release characteristics
Apply polyvinyl chloride paste resin to the belt and
Forming a lower layer of a packing material, and then forming an uncured surface on the lower layer.
No carpet with a polyvinyl chloride resin backing layer
Was uniformly sprayed an average particle size less than 3mm pulverized by a main material
After that, further apply a polyvinyl chloride paste resin and
Form an upper layer of king material and place a carpet substrate on this upper layer.
A car characterized by heating and curing after crimping
To Pet of the method for manufacturing the gist is also of the.

[0007]

[Detailed structure and operation of the invention] produced by this inventions
The carpet, among polyvinyl chloride resins layer of 2-layer that make up the backing material, pulverized carpet unwanted material is contained in the resin layer located in a lower layer, i.e. the carpet back side of the upper layer in contact with the carpet cloth Since the resin layer does not contain the pulverized product, the joint portion between the carpet base material and the backing material is structurally similar to that of a normal carpet that does not use an unnecessary material. Therefore, in this carpet, the backing function of the backing material with respect to the base material is not affected by the use of unnecessary materials, the performance equivalent to that of the ordinary carpet can be ensured in terms of the yarn removal strength, and the dimensional stability and the like will be described later. In some cases, it may be improved due to the effect of mixing unnecessary materials.

Further, since the unnecessary material contained in the lower resin layer is unevenly distributed on the deep layer side of the layer, the surface characteristics of the backing material are not much different from those in the case where the unnecessary material is not contained. On the other hand, the contact performance equivalent to that of the ordinary carpet can be exhibited.

The carpet-free material used in the present invention is
Includes cut scraps produced during carpet production and used carpets that are discarded, but especially those that are lined with a backing material made of thermoplastic resin such as polyvinyl chloride.
Is used . As described above, such an unnecessary material is used as a pulverized product having an average particle size of 3 mm or less, and if it has a large average particle size, it causes pills due to the fibrous substance and deteriorates carpet quality. Is not preferable.

As the pulverized product, it is desirable to use the resin-rich component of the resin-rich component and the fiber-rich component which have been pulverized after the unnecessary material by air classification or the like. In addition, in order to increase the recovery rate of the resin-rich component in the above-mentioned air classification, it is preferable to use a crushed material of the unnecessary material having a mesh passage of 1 to 8 mm, more preferably 5 to 7 mm. Good. Then, the obtained resin-rich component is further subjected to secondary pulverization if necessary, and then subjected to 3
Those having an average particle size of less than or equal to mm, more preferably 0.
5 to 3 mm mesh passing material, optimally 0.5 to 1 mm
Use the mesh passing material.

The blending amount of the pulverized product with respect to the polyvinyl chloride resin layer below the backing material is 5 to 2 in the resin layer.
It is preferable to set the range of 0% by weight, particularly preferably 10 to 15% by weight. If the amount is too small, the economical effect due to the use of unnecessary materials is poor, and if it is too large, interfacial peeling easily occurs. At the same time, it takes a long time to melt in the heating step performed in the final stage of production, resulting in a decrease in production efficiency. When an unnecessary material lined with a backing material made of polyvinyl chloride is mixed in the lower layer resin in an amount of 15% by weight or more, the polyvinyl chloride resin content in the entire pulverized product is 10% or more. It is better to be

By the way, although the carpet pulverized unwanted material formulated in the lower layer is integrated by melting with the pressurizing heat Kiyua Engineering of manufacturing the final stage with polyvinyl chloride lower layer, by air classification or the like, such as the Even in the separated resin-rich portion, it contains a considerable amount of non-melting fibrous material, and as a result of the fibrous material suppressing the expansion and contraction of the lower layer, the dimensional stability of the carpet may be improved as compared with the case where no unnecessary material is used. .

[0013] Incidentally, the backing material is in the carpet by the preparation of the invention may be composed only of the polyvinyl chloride resin layer of the upper and lower multilayer, but the purpose of dimensional stability improvement and reinforcement between the upper and lower resin layers It is more preferable that one or two intermediate base fabrics are interposed.

[0014] Figure 1 shows an example of the configuration of a mosquito over Bae <br/> Tsu preparative produced by this inventions. Reference numeral 1 in the drawing is a carpet base material in which piles 2 are planted on a primary base cloth 3, and is composed of upper and lower layers 4 and 5 made of polyvinyl chloride resin and an intermediate base cloth 6 interposed between both layers on the back surface thereof. The backing material 7 is lined. Then, in the lower layer 5 of the backing material 7,
The crushed material 8 having an average particle size of 3 mm or less of the carpet unnecessary material is unevenly distributed on the deep layer side, that is, on the interface side with the intermediate base cloth 6.

In the carpet having the above-mentioned structure, the paste resin for the lower layer of the backing material, the dispersion of the ground material of the carpet unnecessary material, and the paste resin for the upper layer of the backing material are sequentially applied on the releasable belt which continuously runs. According to the manufacturing method of the present invention, which performs pressure bonding of a carpet base material and heating cure.
Most of them orゝ can often easily continuous production efficiency while using the existing equipment Te.

The paste resin used to form the upper and lower layers of the backing material is an emulsion polymer of polyvinyl chloride and DO.
It is a paste-like material obtained by mixing a sol with a plasticizer such as P (dioctyl phthalate) with necessary additives such as a filler, a stabilizer, and a pigment, and gels by heating to form a uniform resin layer.

However, the crushed material of carpet unnecessary material is
Instead of being premixed in the paste resin for the lower layer, it is sprayed on the uncured surface of the lower layer of the backing material previously formed by coating as described above. This is because when the pulverized product is added to and mixed with the paste resin in advance, the mixture is remarkably made highly viscous (for example, when 10% by weight of the pulverized product is blended with the paste resin composition of Examples described later, the viscosity is several hundreds of thousands cps, Similarly 5% by weight
However, it is actually impossible to coat and form the resin layer with the coater.
It is considered that the cause of such increase in viscosity is that a large amount of the plasticizer in the paste resin is absorbed because the crushed material of the carpet unnecessary material is porous.

The amount of the above-mentioned pulverized material applied is the same as the amount of the pulverized material blended in the lower layer, but it is usually 1 kg per 1 m 2.
It is particularly preferable that the amount be 250 g or less.

After the upper and lower layers of the backing material are formed and the carpet base material is pressure-bonded as described above, the upper and lower layers are cured by heating and curing according to a conventional method. Cut according to size or shipping form. Here, the above heating curing does not require special means and conditions, and is 150 to 190 as usual.
The heating may be performed at 5 ° C. for about 5 to 15 minutes. Then,
Port of pulverized carpet unwanted material by the heat curing
Integrated with lower layer resin Li vinyl chloride resins components are melted,
It constitutes a single layer with the lower layer resin.

[0020] Figure 2 is equipment to be applied to the production method of the present invention
Show the usage scenario. In the figure, 9 is a releasable belt that runs endlessly in one direction at a constant speed.
Lower layer resin supply pipe 10a, coater 11a, quantitative spraying device 12, intermediate base cloth sticking roller 13 in order from the upstream side of travel
a, a pressing roller 13b, an upper layer resin supply pipe 10b, a coater 11b, and a press roller 14 are installed.

In the above apparatus configuration, first, the polyvinyl chloride paste resin 5a for the lower layer is continuously drawn out on the belt 9 from the supply pipe 10a at a constant ratio, and the lower layer having a thickness of usually about 1 to 3 mm is applied by the coater 11a. Molded to 5. Then, sprinkling apparatus 12 by Ripori vinyl chloride on the surface of the lower layer 5
Le resin backing material average particle size less than 3mm pulverized material 8 of unnecessary material obtained from mosquito Pe' bets with are continuously uniformly quantitatively sprayed, adhered intermediate fabric 6 at the roller 13a on the sprayed surface Then, the pressure roller 13b is adjusted by clearance or pressure and pressure-bonded.

The pressing roller 13b presses the intermediate base cloth 6 against the lower layer 5 to wet the intermediate base cloth 6 with the paste resin 5a of the lower layer 5 by utilizing the capillary phenomenon, so that the intermediate base cloth 6 and the lower layer 5 are separated from each other. The air between the two is eliminated to bring them into close contact with each other in a wet state, and the function of preventing interfacial peeling between the two in the manufactured carpet is fulfilled. However, if the intermediate base cloth 6 is pre-wetted with a plasticizer or a surfactant,
This pressing roller 13b can be omitted.

On the intermediate base cloth 6 thus adhered, a polyvinyl chloride paste resin 4 for the upper layer above the supply pipe 10b.
a is continuously derived at a constant ratio, is formed into an upper layer 4 having a thickness of usually about 1 to 3 mm by a coater 11b, and the carpet base material 1 is further laminated on the surface of the upper layer 4 and pressure-bonded by a press roller 14. , A laminated carpet stock can be obtained. Thus, the resulting carpet raw is subjected to heat curing described above is guided to the heat treatment furnace (not shown), made the cut into the required size, if desired after cooling products
It

[0024]

EXAMPLES Examples and comparative examples of the present invention will be specifically described below.

Examples 1 to 3 A polyvinyl chloride resin composition having the following composition was used as a paste resin for forming upper and lower layers of a backing material, and a backing material lower layer was prepared by the manufacturing method using the manufacturing apparatus shown in FIG. The composition of FIG. 1 in which the crushed material of the following unnecessary carpet material is contained in the lower layer in an amount of 10% in Example 1, 5% in Example 2, and 15% in Example 3 Manufactured carpet. In addition, Examples 1-3
The thickness of the upper and lower layers of the backing material was set to 1.7 mm, and the supply amount of the paste resin for the lower layer was increased / decreased according to the difference in the compounding amount of the crushed material of the carpet unnecessary material.

<Paste resin composition> Polyvinyl chloride resin 100 parts by weight Dioctyl phthalate 100 parts by weight Calcium carbonate 400 parts by weight Stabilizer 2 parts by weight Face agent 2 parts by weight Bubble preventer 5 parts by weight <Crushed material of carpet-free material> Using the cut end material of the carpet lined with a backing material made of polyvinyl chloride resin on the base cloth with flocked pile,
The pulverized product was passed through a mesh of 5 to 7 mm and separated into a resin-rich component and a fiber-rich component by air classification, and the resin-rich component (resin content recovery rate of 70 to 90% by weight) was further pulverized. A portion of the pulverized material that passed through the mesh of 0.5 to 1 mm was used for compounding into the lower layer of the backing material.

Comparative Example Carpets were produced in the same manner as in Examples 1 to 3 except that the crushed material of the unnecessary material for the carpet was not mixed with the lower layer of the backing material. The thickness was set to 1.7 mm, which is the same as in Examples 1 to 3, by increasing the supply amount in proportion to the non-compounding of the pulverized material.

The carpets produced in the above Examples and Comparative Examples were tested for carpet performances such as fuzz resistance, yarn pulling strength and dimensional stability. The results are shown in Table 1 together with the blended amount of the crushed material of the material not requiring carpet with respect to the lower layer of the backing material. Each test item was examined by the following method.

<Fuzz resistance> A load of 300 is applied to the carpet surface using a wear wheel with needles.
The holding property of the pile filament was examined by determining whether or not the fluff can be removed by rubbing at 20 rpm. The evaluation was ◯: good, ×: poor.

<Pull-out Strength> The pile-drawing strength (kgf / piece) of the pile yarn was measured in accordance with JIS L 1021.

<Dimensional stability> (A) ... Carpet 60 ° C. → 40 ° C. → 0 ° C. → −20 ° C.
→ After each temperature was maintained at 20 ° C. for 2 hours, the temperature was maintained for 2 hours, and then the vertical and horizontal dimensions were measured, and the values in comparison with the dimensions before the temperature change were shown as the average values in the vertical and horizontal directions.

(B) ... 90 kg load on the carpet surface
After the chair caster to which was added was rotated 2000 times, the vertical and horizontal dimensions were measured, and the values in comparison with the dimensions before rolling were shown by the average values in the vertical and horizontal directions.

[0033]

[Table 1] From the results of Table 1, carpet thus obtained in this invention is, despite the use part of the carpet unnecessary material raw material compared to the same structure of the carpet without using the unnecessary material, equivalent It is clear that the above-mentioned general performance is provided and that the dimensional stability is particularly excellent, and the dimensional stability (B) test shows that delamination does not occur.

[0034]

According to the present invention, as a carpet in which a backing material mainly composed of polyvinyl chloride is lined on the back surface of a carpet base material, the raw material thereof is a cut end material at the time of carpet production, a defective product, a used carpet, etc. In addition to efficiently reusing the unnecessary carpet materials,
Cars that are comparable to those that do not use the above-mentioned unnecessary materials in general performance such as fizz resistance, dimensional stability, and delamination resistance.
Can produce a pet, it can contribute greatly to the reduction of waste disposal costs and resource conservation and pollution prevention me also.

Particularly according to the present invention, no carpet is required
Polyvinyl chloride resin backing material as crushed material
Since we use materials obtained from the unnecessary carpet materials,
In the lower layer of backing material made of polyvinyl chloride resin
In the heating process, the above pulverized product melts with the lower layer resin.
Integrate and form a single layer with it. Therefore,
King material can be made to have sufficiently good delamination resistance
With the fibrous material dispersed in the lower layer,
The dimensional stability of pets can be further improved.

Furthermore, according to the manufacturing method of the present invention,
Most of the carpet manufacturing equipment of
-Adding a quantitative spraying device for crushed pet-free material
The most common existing carpet because it can be implemented
Utilizing the manufacturing equipment as it is, the carpet
Producing carpets that make effective use of essential materials at low cost
it can.

[Brief description 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 a configuration example of an apparatus used for manufacturing the carpet.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Carpet base material 4 ... Backing material lower layer 4a ... Lower layer paste resin 5 ... Backing material upper layer 5a ... Upper layer paste resin 7 ... Backing material 8 ... Carpet unnecessary material crushed material 9 ... Releasing belt 12 ... Quantitative spraying device

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location D06M 15/248

Claims (1)

[Claims] On the back of 1. A carpet cloth, the Po Li and the backing material layer made of vinyl chloride resins and the lower layer is laminated
Provided, in the backing layer, flour <br/> grinds carpet unwanted material A method of manufacturing a <br/> carpets made are contained unevenly many deep inside side of the lower layer, a continuously running The pace of polyvinyl chloride on the release belt
Resin to form a backing material lower layer, and then
Polyvinyl chloride resin backing layer on the uncured surface of the lower layer
Powder with an average particle size of 3mm or less
After evenly distributing the crushed material, paste of polyvinyl chloride is further added.
Apply resin to form the upper layer of backing material, and
After crimping the carpet base material to the
And a method for manufacturing a carpet characterized by: