JPH0951844A - Carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obviate the deterioration of a surface fiber layer by heat and to reduce the weight equal to the weight of a foam lining material by forming a resin lining layer contg. a hollow packing material under this surface fiber layer. SOLUTION: The synthetic resin lining layer 4 of the upper layer is formed by a resin layer consisting of PVC paste, etc., similar to the synthetic resin lining layer 1 of a lower part as well. The hollow packing material 2 is packed at 10 to 60vol.% into the synthetic resin lining layer 4 of the upper part as well in the same manner as in the synthetic resin lining layer 1 of the lower part to impart the lighter weight and dimensional stability to the lining material. The synthetic resin lining layer 1 of the lower part and the synthetic resin lining layer 4 of the upper part are laminated, by which the resin lining layer 6 for tile carpets is obtd. The fiber surface layer, such as carpet fabric 9 formed by tufting a base fabric 7 with piles 8 is laminated on the resin lining layer 6 for tile carpets, by which the tile carpet 10 is obtd. The resulted carpet is compounded with the hollow packing material in the lining layer and is heated at <=170 deg.C and, therefore, the high temp. such as at the time of decomposing a chemical foaming agent is not needed and the damage to the piles by the heat is averted. Since the resulted lining layer contains the hollow packing material 2, the weight is reduced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a carpet,
Especially lightweight tile carpet (hereinafter referred to as TCP)
Regarding

[0002]

2. Description of the Related Art Conventionally, a carpet floor finishing material, in which a backing material obtained by adding a relatively large amount of a filler to a synthetic resin such as polyvinyl chloride (PVC) is laminated under a surface layer, JP-B-6.
JP-A-2-9012 and JP-A-5-132870 are known. In Japanese Examined Patent Publication No. 62-9012, a filler such as a car mat is added to a carpet.
No. 70 discloses a maximum of 90 with respect to 100 parts of backing resin.
It is a very high amount of filler when 0 parts by weight is blended.

[0003]

In particular, when a large amount of filler is mixed in the tile carpet backing material, the T
CP became heavy, and the transportability and workability deteriorated. Therefore,
In order to reduce the weight of the backing material, it has been studied to add a pyrolytic foaming agent to the backing material, but the foaming agent in the resin backing material decomposes the laminate of the surface fiber layer to form a foam. 1
When heated to 70 to 220 ° C., the pile was damaged by heat, and when too much heat was applied to the TCP, there was a defect that warp occurred.

[0004]

SUMMARY OF THE INVENTION It is an object of the present invention to solve the above-mentioned drawbacks and to provide a carpet which is lightweight, has good transportability and workability, and is particularly suitable for TCP. The gist of the present invention is a carpet characterized in that a resin backing layer containing a hollow filler is formed under a surface fiber layer. Hereinafter, the present invention will be described with reference to the drawings. "Figure 1"
Is a sectional view of the carpet of the present invention, and 1 is a lower resin backing layer. The resin backing layer is made of PVC paste, bitumen, ethylene-vinyl acetate copolymer (EVA), atactic polypropylene (APP), amorphous poly-α-
Hot melt resins such as olefins (APAO) are suitable. It can also be used for various emulsions and latexes.

A hollow filler 2 is filled in the resin backing layer. Examples of these hollow fillers include phyllite, shirasu balloon and glass balloon, and these hollow fillers are preferably filled at 10 to 60% by volume. The amount of these fillers corresponds to approximately 5 to 40% by weight. The hollow filler 2 has a small amount of oil absorption and therefore a small amount of plasticizer used, and the amount of plasticizer is less than 85 parts by weight based on 100 parts by weight of the resin. The backing material does not decrease in strength and does not bleed with the plasticizer. Moreover, since the amount of the plasticizer used is small, the amount is lighter and the cost can be suppressed. In the present invention, the low viscosity of the PVC paste mixture indicates the low oil absorption of the hollow filler. For example, a hollow filler having a volume ratio of 70 ml was mixed with 100 ml of the paste composition of "Table 1". The volume ratio is shown by weight (g) / air displacement density (g / ml).

[0006]

Table 1 PVC paste resin (Zeon 38J) 80 parts by weight PVC blend resin (Zeon 103ZA) 20 DOP (plasticizer) 80 Stabilizer (Ba-Zn liquid stabilizer) 1.0

The viscosity immediately after mixing the above-mentioned filler mixed paste at 20 ° C. with a BM type viscometer at 12 rpm is 20000 c.
It is preferably ps or less. By adding 10 to 60 parts by volume of the hollow filler to 100 parts by weight of the backing resin, dimensional stability and shape stability can be obtained. At this time, the amount of the filler in the backing material is 40 parts by weight. % Or less, it is possible to obtain a carpet that is lightweight and lightweight so that it does not warp and is easy to carry and construct.

The thickness of the lower backing material is preferably 1-10.
mm. The fiber layer 3 is interposed in the lower synthetic resin layer. The fiber layer is preferably a glass net of ^{20 to} 100 g / m ² , but a glass fiber non-woven fabric, synthetic fiber non-woven fabric such as polyester or polypropylene fiber may be used.
The upper synthetic resin layer 4 is formed on the lower resin layer.

Similarly to the lower layer, the upper synthetic resin layer 4 is made of PVC paste, EVA, APP, APAO, etc., preferably 1 to 1
It is formed of a resin layer with a thickness of 0 mm,
A fiber layer 5 of 100 g / m ² , preferably a polyester non-woven fabric, is interposed. Instead of the polyester non-woven fabric, other synthetic fiber non-woven fabric, glass non-woven fabric or glass net may be laminated.

Like the lower backing layer, the upper synthetic resin backing layer is also filled with 10 to 60% by volume of the hollow filler 2 to provide the backing material with light weight and dimensional stability. The lower synthetic resin backing layer and the upper resin backing layer 4 are laminated to obtain the TCP backing material 6. On the TCP backing material, a fiber surface layer of a carpet fabric 9 having tufted pile 8 on the base cloth 7 is laminated to obtain TCP 10 of the present invention.

In the carpet obtained by the present invention, since the backing layer is blended with the hollow filler and heated at 170 ° C. or lower, the high temperature which is required when the chemical foaming agent is decomposed is not required and the pile is not damaged by the heat. Since the backing layer thus obtained contains a hollow filler, it has the effect of reducing the weight. TC obtained
P is the pile thickness 1 to 10 mm, and the backing material thickness 1 to 1
At 0 mm, the total TCP is 1000 to 1600 g / m ² , which is 25 to 30% of that of the conventional backing material TCP.
light.

[0012]

By blending a hollow filler having a small oil absorption as a resin backing material for carpet, a lightweight carpet equivalent to a foam backing material can be obtained without deteriorating the surface fiber layer by heat.

[0013]

【Example】

[Example 1] "Table 2" on the release surface of the release substrate, P of formulation A
The VC paste layer was applied to a thickness of about 1 mm, a dimensionally stable substrate of glass non-woven fabric of 30 g / m ² was placed to impregnate the paste, and the PVC paste layer of "Table 3" formulation B was applied to a thickness of 1 mm. The following units are parts by weight.

[0014]

[Table 2]

[0015]

[Table 3]

4 mm thick on the applied PVC paste layer
Carrying a carpet rug with a thickness of 700g / m ²
After heat-gelling at 0 ° C. for 5 minutes to form a laminate, the laminate was cooled, the release substrate was peeled off, and the obtained sheet was wound. The wound sheet itself is also the floor covering material of the present application, but this sheet is unwound and cut into a tile of 50 × 50 cm by a cutting machine, and the total thickness is 6 mm,
A lightweight TCP of 657 g / m ² was obtained.

[0017]

[Example 2] A synthetic resin of "Table 4" formulation C, which had been hot-melted in advance, was applied to the back surface of the carpet greige to a thickness of 0.5 mm, and a glass net of 30 g / m ² was placed and impregnated,
Furthermore, 0.6 mm of hot melt resin of “Table 5” formulation D
It was applied thickly, and a 30 g / m ² non-woven fabric was placed and impregnated.

[0018]

[Table 4]

[0019]

[Table 5]

Further, a hot-melt layer having a composition E of "Table 6" which had been hot-melted in advance was applied thereon to a thickness of 0.9 mm, and the laminate obtained by cooling was wound up to obtain a roll carpet. .

[0021]

[Table 6]

The above sheet was cut into a 50 × 50 cm tile by a cutting machine, and the total thickness was 6 mm and 591 g / 50 cm × 5.
A lightweight TCP of 0 cm of the present invention was obtained.

[0023]

[Comparative Example 1] Carbide 30 was used in place of the hollow filler of Formula A.
TCP was obtained by the same method except that 0 part was compounded and 250 parts of calcium carbonate was compounded instead of the hollow filler of compound B.

[0024]

[Comparative Example 2] Instead of the hollow fillers of Formula C, Formulation D and Formulation E of Example 2, 100 parts of calcium carbonate and 200 parts of carbon dioxide were used.
Parts were obtained in the same manner as in Example 2 except that 300 parts of calcium carbonate was added.

[0025]

[Comparative Example 3] Example 1 TCP was obtained by mixing 60 parts of DOP and 2 parts of a foaming agent without adding a hollow filler in place of the preparations A and B, and gelled by heating at 200 ° C. .

[0026]

[Comparative Example 4] Instead of blending A and blending B of Example 1, 60 parts of DOP was added without blending a hollow filler, 7 parts of a silicone type foam stabilizer was blended, and air was preliminarily enclosed by a foaming machine. TC with a backing material obtained by heating and gelating the mechanical foam
P was obtained.

The TCPs obtained in Examples 1 and 2 are
The dimensional stability was good, the workability was light, the backing material was formed at low temperature, and the pile was not damaged. On the other hand, since Comparative Examples 1 and 2 were heavy, they had poor workability and transportability. In Comparative Example 3, the pile was damaged by heat because it foamed by heating when the backing material was formed. Since Comparative Example 4 uses an expensive silicone type foam stabilizer, the cost of the obtained TCP was 1.28 times that of the TCP of the present invention.

[0028]

EFFECT OF THE INVENTION Since the backing material is lightweight, a carpet such as TCP having good transportability and workability was obtained. Upon forming the backing, a carpet with no damage to the pile was obtained. The cost of the carpet was low compared to the cost of the mechanical foam backing. A carpet with excellent sound insulation and heat insulation was obtained. It was excellent in dimensional stability and shape stability.

[Brief description of drawings]

FIG. 1 is a sectional view of the carpet of the present application.

[Explanation of symbols]

2 ... Hollow filler 6 ... Resin backing layer 3, 5 ... Fiber layer
7 ... Carpet base fabric 8 ... Pile 10 ... Carpet

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Seiji Endo 5-125 Higashiarioka, Itami-shi, Hyogo Tori Co., Ltd. (72) Inventor Haru Yoshikawa 5-125 Higashiarioka, Itami-shi, Hyogo Tori Co., Ltd.

Claims (5)

[Claims] 1. A carpet having a resin backing layer containing a hollow filler formed under a surface fiber layer. 2. The carpet of claim 1 wherein the hollow filler is one of phyllite, shirasu balloon or glass balloon. 3. The backing layer contains 10 to 6 hollow fillers.
Carpet according to claims 1 and 2 filled with 0% by volume. 4. The weight of the backing layer is 600 to 1400 g /
The carpet according to claims 1 to 3, which is m ² . 5. The carpet according to claim 1, wherein the carpet has a tile shape.