JPH0956567A - Carpet and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a recycled carpet formed by effectively utilizing the recycled stock from recovered carpets and a process for efficiently producing this carpet. SOLUTION: This carpet consists of a carpet base material 1 implanted with pile yarn 3 on a tufted base fabric 2, a sealing layer 14 formed on the rear surface of this carpet base material or this sealing layer 4 and a lining layer 5. At least one layer of the sealing layer 4 and the lining layer 5 is composed of a resin mixture into which the pulverized matter of the recovered carpets is incorporated at <=90wt.%, by which the carpet formed by using the recycled stock is obtd. The carpet is produced by subjecting the recovered carpets which are formed practically all of the thermoplastic sesin materials to a pulverization treatment to form the pulverized matter, incorporating this pulverized matter into the resin to form the resin mixture and forming at least one layer of the sealing layer 4 and the lining layer 5 by using the resin mixture as the stock.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carpet made of a recycled material which is effective for recycling recycled carpets such as used carpets, and an efficient method for producing the carpet.

[0002]

2. Description of the Related Art In recent years, regarding the problem of industrial waste, there are two needs: protection of the environment of the earth and efficient use of resources.
Its importance is increasing and many people are interested.

However, in the field of carpet,
Most of the used carpets are landfilled, and practical carpet recycling technology is still in the development stage.

As shown in FIG. 1, a typical carpet has a carpet base material 1 in which pile yarns 3 are planted in a tufting base cloth 2, a sealing layer 4 formed on the back surface thereof, and The backing layer 5 is formed on the back surface of the filling layer 4, and the backing layer 5 is provided as necessary in order to give the carpet cushioning and a feeling of weight.

Here, the pile yarn 3 determines the basic performance of the carpet, and the required performance depends on the respective carpet use such as home use, office use, hotel / theater use, car mat use and store use. The fibers satisfying both the price and the price are selected and used from a wide fiber group such as natural fibers, synthetic fibers such as polyester fibers and polyamide fibers.

As the tufted sack cloth 2, natural jute and polyester spunbond have been generally used, but polyester spunbond is now predominant.

Further, although the required performances of the filling layer 4 and the backing layer 5 differ depending on the place of use and the form of the carpet, the filling layer 4 for fixing the pile yarn 3 is used.
A resin such as polyethylene or polyester is used as the material of the above, and a resin such as polyvinyl chloride or neoprene rubber is used as the material of the backing layer 5 for cushioning and weight feeling.

[0008] Therefore, having a complicated structure using a wide variety of materials makes it more and more difficult to implement the recycling of carpet materials.

Conventionally, there have been some proposals as a method for recycling carpets. For example, as a method for recycling pile carpet, which is mainly composed of a synthetic polymer, the synthetic polymer is depolymerized to obtain a raw material (monomer).
A so-called chemical recycling method of recovering by returning to the above is proposed, for example, in Japanese Patent Application Laid-Open No. 5-117441.

According to the method disclosed in Japanese Patent Laid-Open No. 5-117441, a pile carpet is made into small pieces, and a small piece containing nylon 6 which is a material of pile yarn is made by a separator,
This is to separate ε-caprolactam, which is the raw material of nylon 6, by separating it into pieces containing other materials and subjecting the pieces containing nylon 6 to the depolymerization system.

[0011]

However, the pile carpet has a construction in which pile yarns are planted on a base fabric and a synthetic resin sealing layer or a sealing layer and a backing layer are formed on the back side thereof. Therefore, it is very difficult to separate only the pile yarn from the collected carpet.

Therefore, no matter how a separator such as a cyclone is used, a different material other than nylon 6 (specifically, polyester spun bond of the base cloth, a sealing layer or a backing layer) is used in the small pieces to be depolymerized. (Polyvinyl chloride, neoprene rubber, polyethylene, etc. in the layer) is difficult to sufficiently prevent, and it is difficult to depolymerize small pieces mixed with many different materials, and the recovery rate of ε-caprolactam is also low, Industrial implementation has been a challenge.

Therefore, the present invention solves the above-mentioned problems in the prior art and makes it possible to easily and effectively recycle the collected carpets such as used carpets, and an efficient manufacturing method thereof. The primary purpose is to provide.

[0014]

In order to achieve the above object, a carpet made of a recycled material of the present invention (hereinafter referred to as a recycled carpet) is a carpet base material in which pile yarns are planted on a tufted sack cloth. And a carpet comprising a sealing layer or a sealing layer and a backing layer formed on the back surface of the carpet base material, at least one layer of the sealing layer and the backing layer is a powder granulated product of a carpet recovered product. It is characterized in that it is composed of a mixed resin mixture.

Further, the method for producing a recycled carpet of the present invention comprises a carpet base material in which pile yarns are planted in a tufted base cloth, and a sealing layer or a sealing material formed on the back surface of the carpet base material. In producing a carpet composed of a layer and a backing layer, a recovered carpet product, which is substantially entirely composed of a thermoplastic resin material, is granulated to form a granule, and the granule is a resin. It is characterized in that a resin mixture is mixed therein, and at least one of the filling layer and the backing layer is formed by using the resin mixture as a raw material.

[0016] In the recycled carpet, it is preferable that the mixing ratio of the powdered product of the recovered carpet in the resin mixture constituting at least one of the filling layer and the backing layer is 90% by weight or less.

In the carpet manufacturing method, the collected carpet is pulverized by a method in which the collected carpet is crushed as it is by a crusher or the like, and the collected carpet is press-melted to form a plate-like body, It is preferable to carry out a method of crushing after cutting into small pieces.

Further, it is preferable that substantially all of the recovered carpets subjected to the pulverization treatment are made of the same thermoplastic resin material.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail below.

Carpets are used in homes, offices, hotels,
It is widely used as a flooring material for theaters, automobiles, stores, etc. The cushioning property and the highness of the back surface are the main required functions.

However, since its bulkiness causes coarse dust and has been a bottleneck for recovery and recycling, it has been forced to carry out landfill treatment.

For the carpet having a high pitch, nylon 6, nylon 66, polyester,
Thermoplastic synthetic fibers such as polypropylene are commonly used.

The material for the sealing layer is a resin such as polyethylene, polyester or polyvinyl chloride, and the material for the backing layer is mainly polyvinyl chloride (PV
Resins such as C) and neoprene rubber are used respectively.

However, in the recycled carpet of the present invention, at least one of the filling layer and the backing layer is used.
Since the granular material obtained by subjecting the collected carpet to the granulation treatment is mixed in the layered resin material, the recycled material can be effectively and economically used.

That is, at least one of the filling layer and the backing layer is a resin composition obtained by mixing 90% by weight or less of the carpet recovered product powder granules in a resin such as polyethylene, polyvinyl chloride and neoprene rubber. Since it is composed of objects, the recovered carpet product can be effectively used as a part of the constituent material of the sealing layer and the backing layer, and the raw material cost of the carpet can be reduced.

The recycled carpet of the present invention can be efficiently manufactured by the following method.

In the method for manufacturing a recycled carpet of the present invention, first, a used carpet or a discarded carpet such as a defective product generated in the carpet manufacturing process is collected and granulated. As a means for this granulation, the recovered carpet product may be crushed as it is by a pulverizer or the like, but the recovered carpet product is press-melted to form a plate-like body, which is then cut into strips and then further mixed with It is preferable to grind by.

That is, the recovered carpet product is put into a heating and melting press device, all the components of the carpet base material are melted together, and cooled to a prescribed thickness.
Crimped to form a plate. After being shaped into a flat plate in this way, it is sent to a slitter and cut into strip-shaped strands with a maximum width of 3 mm or less by this slitter. Next, the cut strands are put into a strand cutter and cut into a desired length, and the finely-divided carpet pieces are then put into a pulverizing mixer to obtain a granulated product having a desired particle size.

Since it is preferable that the recovered carpet can be melted without being carbonized even if it is heated in the step of pulverizing as described above or in the step of further backing treatment, substantially all of the material is a thermoplastic resin. It is preferable that

The grain shape of the powder granules obtained from the recovered carpet should be as small as possible, and the thermoplastic resin (polyethylene, polyvinyl chloride, neoprene rubber, etc.) which is the original constituent material of the sealing layer and the backing layer ( Hereinafter, mixing with a resin) is more uniform, which is preferable.

A step of forming a filling layer or a backing layer on the surface of the carpet base material is generally called a backing step. The resin used in this backing process, for example, a polyvinyl chloride paste sol, may contain, for example, heavy carbon calcium as an extender.

Next, the powder granules of the recovered carpet product obtained by the above granulation are added to the tank in which the above-mentioned paste sol is mixed, and mixed and stirred to make the resin and the granules uniform. A mixed resin mixture (mixed paste sol) is used and backing is performed using this to form a filling layer and a backing layer. At this time, the amount of the powdered product of the carpet recovered product added to the resin mixture is 90% by weight or less, preferably 50 to 80% by weight, based on the resin mixture.

The backing process for forming the filling layer or the backing layer on the back surface of the carpet base cloth is the same as the usual backing process except that the above mixed paste sol is used as the paste sol (for example, polyvinyl chloride paste sol). Do the same.

When the backing layer is formed by using the mixed paste sol to which the powder and granules are added, the mixed paste sol is applied to the front and back surfaces of the reinforcing intermediate substrate (for example, glass fiber base cloth), and one side thereof is applied. The carpet base material is attached to the side, and the intermediate base material and the sealing layer are adhered to the back surface of the carpet base material by heating, drying and cooling. On this occasion,
The reinforcing intermediate base material may be provided as necessary.

A backing layer made of a resin may be provided on the back side of the filling layer, if necessary. However, the resin material is mixed with the powdered granules of the recovered carpet by the same method as described above. You may let me. In addition, the thickness of the filling layer may be increased so as to have the function of the backing layer.

Then, the desired recycled carpet can be obtained by cutting into a desired size and shape.

Conventionally, since the collected carpets are bulky, there is no effective cutting / separating method, and because they are bulky, it is difficult to reprocess them, and most of them are landfilled. However, according to the present invention, It becomes possible to solve the above problems and recycle the entire carpet without separating it.

[0038] If possible, the recovered carpet material is made of a thermoplastic resin material of which the pile yarn, tufted base cloth, sealing layer and backing layer are substantially all of the same type, for example, substantially all polyester type material. Or, it is preferable that substantially all of the material is made of nylon because the melting points of all the materials are similar, and by constructing in this way, workability when making the recovered carpet into a plate shape. And a uniform plate-like product can be obtained, and the powdered product obtained by melting and pulverizing the product becomes more uniform, and the mixing with the resin can be more uniform. Therefore, it is preferable.

[0039]

EXAMPLES The constitution and effects of the present invention will be further described below with reference to examples.

Nylon 6 chips having a relative viscosity of nitric acid of 2.80 are spun, stretched and crimped by a usual method to obtain a fineness of 2600 denier and a filament number of 100,
Field cross section, hollow, hollow ratio 13 ± 3%, crimp elongation 24
± 7% nylon 6 crimped yarn was produced for the pile yarn.

On the other hand, polyethylene terephthalate was melted, jetted at high speed, and laminated by a usual method to produce a sheet-shaped polyester spunpond base fabric, which was once wound up on a roll.

Then, the above polyester spunpond base cloth is passed through an impregnating device to apply a thermosetting urethane resin on the surface, and the tufted base cloth having a surface roughness Rmax of 0.8 mm and a basis weight of 120 g / m ^2. Got

By tufting the nylon 6 crimped yarn onto the tufted sack fabric, the pile length is 5.5 m.
A loop pile carpet base fabric having m, stitch 12, and basis weight of 1000 g / m ² was obtained.

This loop pile carpet base cloth is subjected to a usual continuous dyeing method for dyeing and finishing, and then polyvinyl chloride is applied and formed on the back surface of the base cloth as a sealing layer and a backing layer, respectively, to obtain the final pile. Carpet product (length: 500 m, width: 2 m) was finished.

This pile carpet was put to practical use for 3 months and then collected.

The recovered carpet was placed in a heating and melting press apparatus, treated at 260 ° C. for 10 minutes, and then cooled to obtain a plate-like material having a thickness of 3 mm.

Then, the plate-like material is passed through a slitter for 2
mm band-shaped strand. This strand is cut with a strand cutter into 2 mm long pieces,
Further, it was placed in a pulverizing mixer and treated for 30 minutes to obtain a powder granule.

Next, 50 parts by weight of the obtained powder granules is added to 50 parts by weight of the polyvinyl chloride resin in the backing step,
A resin mixture (mixed paste sol) was mixed therein.

Using this mixed paste sol and the above-mentioned loop pile carpet base cloth, a tile carpet made of a recycled material was manufactured by the following method.

After applying the mixed paste sol to the back surface of the carpet base cloth, the resin is gelated in an oven dryer,
After cooling and fixing, a resin layer having a thickness having a function of a backing layer as well as a function of a sealing layer was formed on the back surface of the carpet base cloth.

After that, the tile carpet was cut into a length of 50 cm square. The obtained tile carpet made from recycled materials is used on the floor 1 of an office building.
It was laid on 000 m ² , and no abnormalities were found in the cushioning property and the dimensional stability even after the lapse of 3 months, and it was a carpet comparable to an ordinary carpet.

[0052]

EFFECTS OF THE INVENTION By using a recycled material obtained from a collected carpet item such as the carpet using the recycled material of the present invention, it is possible to easily recycle the collected carpet item and also to achieve an economical effect by cost reduction. Can be achieved.

In addition, according to the method for producing a recycled carpet of the present invention, the entire collected carpet is granulated and reused as a carpet raw material without separating it, so that a carpet using recycled materials can be efficiently produced. Therefore, the process can be simplified and the cost can be reduced.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a carpet using recycled material of the present invention.

[Explanation of symbols]

 1 Carpet base material 2 Tufted sack cloth 3 Pile thread 4 Filling layer 5 Backing layer

Claims (6)

[Claims] 1. A carpet comprising a carpet base material in which pile yarns are planted in a tufted sack cloth, and a sealing layer formed on the back surface of the carpet base material or a sealing layer and a backing layer. A carpet characterized in that at least one of the filling layer and the backing layer is made of a resin mixture in which a powdered product of a recovered carpet product is mixed. 2. The mixing ratio of the carpet recovered product granules in the resin mixture forming at least one of the filling layer and the backing layer is 90% by weight or less. carpet. 3. A carpet comprising a carpet base material in which pile yarns are planted in a tufted sack cloth, and a sealing layer formed on the back surface of the carpet base material or a sealing layer and a backing layer. In doing so, substantially all of the recovered carpet product made of a thermoplastic resin material is granulated to form a granulated product, and the powdered product is mixed into a resin to form a resin mixture, A method for producing a carpet, comprising forming at least one of the filling layer and the backing layer using a resin mixture as a raw material. 4. The method for producing a carpet according to claim 3, wherein the powdered granules are powdered granules produced by directly crushing a recovered carpet product. 5. The powdery granules are manufactured by press-melting a recovered carpet product into a plate-like body, then cutting the pieces into fine pieces, and then pulverizing the pieces. The method for manufacturing a carpet according to claim 3. 6. The production of carpet according to any one of claims 3 to 5, characterized in that substantially all of the carpet-recovered products subjected to the pulverization treatment are composed of the same thermoplastic resin material. Method.