JPH07279384A - Tile carpet and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide a tile carpet generating no upward warp by changing the heating density for composite fibers covered with a low-melting point cover material on a high-melting point core material in steps. CONSTITUTION:The first synthetic resin intermediate layer 2, a nonwoven fabric reinforcing material 3, and the second synthetic resin intermediate layer 4 are laminated in sequence on the pile back face of a fiber surface section 1, and a mesh reinforcing material 7 is laminated on a CP upper layer section 6 thus obtained. The reinforcing material 7 is covered with a low-melting point cover material on h high-melting point core material, and it has different heat treatment level so that the heating density is reduced in steps from the center toward the outside. The mesh reinforcing material 7 is provided on the back face of the CP upper layer section 6, and it is heated, pressurized, and laminated at the prescribed temperature to manufacture a tile carpet. The upper portion from the CP nonwoven fabric is warped upward, however the core material portion having a large residual shrinkage factor on the side edge of the mesh reinforcing material is shrunk when heated, the tensile force is balanced, and the problem of a warp on a CP sheet is solved.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tile carpet having excellent dimensional stability and no warp, and a method for producing the tile carpet.

[0002]

2. Description of the Related Art Various tile carpets have been conventionally known. In recent years, there is a demand for a type of tile carpet having a printed pattern. However,
Conventional tile carpets have insufficient dimensional stability and warpage prevention properties.For example, when printing a pile with a resin backing layer provided on the pile fabric, steaming of the printing paste, washing,
The tiles warp due to a process such as drying, and when the tiles contaminated by use are washed with water and dried, warping and shrinkage occur, and it has been desired to solve such problems. In order to solve such problems, a first synthetic resin intermediate layer, a glass fiber nonwoven fabric reinforcing material, a second synthetic resin intermediate layer, a heat-shrinkable mesh are disclosed under the fiber surface portion disclosed in Japanese Utility Model Publication No. 3-16536. A tile carpet has been developed in which a reinforcing material and a backing material are sequentially laminated, and a mesh reinforcing material is laminated on the upper surface of the backing material to the extent that it is not exposed on the bottom surface of the backing material, but the warped state of the tile after punching in a square shape There was a problem that it was not controlled depending on the place.

[0003]

SUMMARY OF THE INVENTION The object of the present invention is to solve the above problems and to provide a tile carpet which is excellent in dimensional stability, does not warp, and has excellent adhesion to the floor and laying property. To provide.

[0004]

SUMMARY OF THE INVENTION The present invention is a composite fiber in which a first synthetic resin intermediate layer, a non-woven fabric reinforcing material, a second synthetic resin intermediate layer, and a high melting point core material are coated under a fiber surface portion with a low melting point coating material. The present invention relates to a tile carpet and a method for manufacturing the tile carpet, wherein the mesh reinforcing material is laminated on the upper surface of the backing material.

The present invention will be described below with reference to the drawings. In FIG. 1, 1 is a fiber surface portion, and cut pile or loop pile is exemplified by tufted pile fabric such as wool, polyester, nylon and polypropylene. The fiber surface portion 1 may be provided with a stopper 5 on the back surface if desired.

Reference numeral 2 is a first synthetic resin intermediate layer, 3 is a nonwoven fabric reinforcing material, and 4 is a second synthetic resin intermediate layer. The intermediate layer 2 and the intermediate layer 4 are made of a foamed or non-foamed resin such as polyvinyl chloride (PVC), polyurethane, ethylene-vinyl acetate copolymer, or a resin containing an elastomer, and each thickness is preferably 1 to 4 mm. The non-woven fabric reinforcing material 3 is preferably a non-woven fabric of polyester, glass fiber or the like, and is preferably about ²⁰ to 120 g / m ² . This non-woven reinforcement provides dimensional stability and stiffness to the entire tile carpet.

When laminating the first resin intermediate layer 2 and below on the back surface of the greige, the pile fabric has been processed by being pulled outward by a tenter in advance and pulled in the directions of arrows a and a '. Layers of the first synthetic resin intermediate layer 2 and below are laminated on the back surface of the raw fabric. A stack of the pile 1 to the second synthetic resin intermediate layer 4 is referred to as a carpet upper layer portion (CP upper layer portion) 6 for convenience.

The mesh reinforcing material 7 is provided on the obtained CP upper layer portion 6.
Are stacked. In the mesh reinforcing material of the present invention, a core material having a high melting point is covered with a coating material having a low melting point. As a mode of this coating, a composite fiber 10 having a core 8-sheath 9 structure shown in a perspective view of FIG. 2 and a fiber 13 in which a core material 11 shown in a sectional view of FIG. be able to. The mesh reinforcing material is made of a core material having a high melting point, such as a warp and a weft, which is covered with a coating material having a low melting point.

As an example of the production of the mesh reinforcing material in the present invention, a high melting point resin such as polyester is melt-spun from a nozzle spinneret, and a low melting point resin such as polyolefin is melt spun from immediately next to the high melting point resin to be coated. By extruding the low melting point resin into a single fiber, a fiber having a core-sheath structure or a sandwich structure is obtained. A woven fabric is prepared by weaving about 50 to 1000 denier yarns of this fiber, and at the intersection of the woven fabrics, the outer sheath material portions are fused to each other with an embossing hot press roll or the like to obtain a mesh reinforcing material. In the present invention, the core material is a heat-shrinkable material,
In addition to the above polyesters, nylon is indicated.

As a preferred embodiment of the present invention, a mesh reinforcing material having a different heat treatment degree in which the heating density is gradually reduced from the center to the outside is used. Such a mesh reinforcing material is obtained, for example, by passing it through a heating roll 14 as shown in FIG. In this roll, the center 15 has the highest heating density, the heating density gradually decreases toward the both ends, and the heating density at the ends 16 becomes the weakest. Depending on the area and embossing depth of the heated part by passing through the roll,
The heating density of the central part of the roll is high, the heating density of both ends is low, and the mesh heated at the central part of the roll has a large amount of coating material adhered at the mesh intersection points and has a small residual shrinkage ratio, and is heated at the end part of the roll. The mesh material has a low degree of fusion of the covering material and a high residual shrinkage ratio of the core material.

The CP upper layer thus obtained is preliminarily prepared as shown in FIG.
The mesh-shaped reinforcing material is laminated by heating with an embossing roll indicated by 1) to increase the heating density in the center and gradually lowering the heating density toward the periphery. FIG. 5 is a diagram of the residual shrinkage rate of the obtained mesh reinforcement material. In the high heating density portion at the center of the width, the mesh portion is fixed in large quantity, and the residual shrinkage rate is low. On the other hand, the peripheral edge portion of the reinforcing material has a low heating density, and the mesh portion has a high heat fixing density and a large residual shrinkage ratio.

When the mesh reinforcing material having the above structure is provided on the back surface of the CP upper layer portion 6 and laminated under heat and pressure at 130 to 200 ° C., the tile carpet of the present invention shown in FIG. 6 is obtained.
At this time, the portion of the CP above the nonwoven fabric is warped in the directions of arrows A and A shown in FIG. This is when laminating the resin layer on the tuft machine that constitutes the part above the nonwoven fabric,
This is because the tufting machine is tensioned outward by a tenter and then laminated with the resin layer, and when the laminated body is heated, the tuft portion contracts inward, so that warpage occurs. On the other hand, in the above mesh reinforcing material, the core material portion having a large residual shrinkage ratio at the side edge is shrunk by heating at the time of heating, and the outer covering material portion has few mesh intersections fixed beforehand. The reinforcing material shrinks, resulting in a balanced tension and the problem of warping of the CP sheet is solved.

Reference numeral 11 denotes a synthetic resin lining material such as PVC, polyurethane, ethylene-vinyl acetate resin, etc., which is as thin as 0.1 to 1 mm, and is formed on the lower surface of the mesh reinforcing material 10. This backing material is preferably laminated to the extent that the mesh reinforcing material 10 is not exposed. Thus, it is desirable that the mesh reinforcing material 10 is provided at a position as close to the bottom surface of the tile carpet as possible in order to prevent the warp. After laminating this very thin backing material on the mesh reinforcing material, the sheet-like CP is punched out to a predetermined size and the tile carpet (T
CP) is obtained.

[0014]

In general, the warp stress of tile carpet can be explained as follows. That is, as shown in FIG. 6, the upper portion of the tile carpet with the nonwoven fabric reinforcement 3 as a boundary is
In the pretreatment process such as dyeing and sealing, the fiber surface portion that has been strained by being pulled outward by a pin tenter or the like and warped as shown by arrow A in FIG. Trying to become.

On the other hand, in the lower portion of the tile carpet, the heat-shrinkable mesh reinforcing material 10 exerts a downward force as indicated by an arrow stress B in the gelation process. The state of warpage is determined by the magnitude relationship between the forces of A and B. If A> B, the warp occurs, and if A <B, the warp occurs.

In the fiber surface portion 1, the degree of strain differs between the central portion in the width direction and the side edge portions, and the side edge portions often have large strain. Therefore, even if a conventional mesh reinforcing material having a uniform residual shrinkage ratio is used, the warped state after punching differs depending on the location, and A> B occurs at the side edge portion, often resulting in upward warpage.

Therefore, the mesh reinforcing material of the present invention, that is,
Consisting of a composite fiber in which a high-melting-point core material is coated with a low-melting-point coating material, the heating density is changed stepwise, the heating density is high in the central part in the width direction, and the side edges are heat-treated in a low state,
As a result, when a mesh reinforcement having a small residual shrinkage ratio in the central portion and a large side edge portion is used, the stress A in the upper layer portion of the tile carpet and the stress B in the lower layer portion are balanced, and even after punching, it can be taken anywhere. A tile carpet without warpage can be obtained.

As described above, the mesh reinforcing material composed of the composite fiber in which the high-melting-point core material is coated with the low-melting-point coating material is heat-treated with a heating roll having a different heating density distribution,
A mesh reinforcement having a desired residual shrinkage can be obtained, and the warped state of the tile carpet can be freely controlled.

[0019]

EXAMPLES Examples will be described below.

Example 1 A raw fabric obtained by tufting nylon filaments on a polyester nonwoven fabric was dyed by a continuous dyeing machine and dried by a tenter. At this time, the greige machine was pulled outward in the width direction.

Next, the heating density is high in the central portion in the width direction,
A mesh reinforcing material composed of a polyester core-polyethylene sheath composite fiber was heat-treated with a heating embossing roll at 210 ° C. designed so that the heating density gradually decreased as it moved to the side edge.

Then, on the releasable conveyor belt, from the bottom, the backing material resin layer of compound A 0.5 mm, the mesh reinforcing material, the second synthetic resin intermediate layer 1.0 mm, and the glass fiber of 50 g / m ² Non-woven fabric reinforcement, first synthetic resin intermediate layer 1.5mm,
Then, the tuft greige machine was laminated, heated and gelled at 190 ° C., and punched into 50 cm squares. At this time, the residual shrinkage of the mesh reinforcement material occurs, and the force to become the warp of the upper part of the tile carpet and the force to become the warp of the lower part of the tile carpet cancel each other out, resulting in a tile carpet without warping. It was

Formulation A Vinyl chloride resin 100 parts by weight Plasticizer (DOP) 80 parts by weight Calcium carbonate 300 parts by weight Stabilizer 1 part by weight Pigment 0.5 parts by weight

[0024]

According to the method of the present invention, the distortion of the portion of the CP above the nonwoven fabric is suppressed at any position in the width direction, and TCP having no warp can be obtained regardless of the cutting position of the sheet. TCP has good dimensional stability and can be satisfactorily constructed without warping.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a tile carpet.

FIG. 2 is a perspective view of a mesh reinforcing material having a core-sheath structure.

FIG. 3 is a cross-sectional view of a mesh reinforcing material having a sandwich structure.

FIG. 4 is a diagram showing a distribution of heating densities of heating rolls having different heating densities in a stepwise manner.

FIG. 5 is a diagram showing the distribution of residual shrinkage of the mesh reinforcing material in the width direction.

FIG. 6 is a cross-sectional view of the tile carpet of the present invention.

[Explanation of symbols]

 1 Fiber Surface Part 2 First Synthetic Resin Intermediate Layer 3 Nonwoven Fabric Reinforcing Material 4 Second Synthetic Resin Intermediate Layer 6 Carpet Upper Layer 7 Mesh Reinforcing Material 8 High Melting Point Core Material 9 Low Melting Point Coating Material 10 Mesh Reinforcing Material 11 Core Material 12 Coating Material 13 Sandwich structure mesh reinforcing material 14 Heating roll 15 Central portion in the width direction with high heating density 16 Side edge in the width direction with low heating density

Claims (4)

[Claims] 1. A first synthetic resin intermediate layer below the fiber surface portion,
A non-woven fabric reinforcing material, a second synthetic resin intermediate layer, and a mesh reinforcing material composed of a composite fiber in which a high melting point core material is covered with a low melting point coating material are laminated, and the mesh reinforcing material is laminated on the upper surface of the backing material. And tile carpet. 2. The tile according to claim 1, wherein the mesh reinforcing material is a mesh reinforcing material which has been previously heated to a high density in the central portion in the width direction and then subjected to heat treatment in a state where the heating density decreases as it moves to the end portion. carpet. 3. A mesh made of fibers in which a first synthetic resin intermediate layer, a non-woven fabric reinforcing material, a second synthetic resin intermediate layer, and a high melting point core material are coated with a low melting point coating material on a fiber surface portion with the back side facing up. A method for producing a tile carpet, comprising laminating a reinforcing material and a backing material, and heating and gelling. 4. A backing material, a mesh reinforcing material made of fibers obtained by coating a high melting point core material with a low melting point coating material on a releasable material, a second synthetic resin intermediate layer, a non-woven fabric reinforcing material, and a first synthetic resin intermediate material. A method for producing a tile carpet, comprising laminating a layer and a fiber surface portion, gelling by heating, and then releasing from a releasable material.