JPH1132895A - Tufted mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a tufted mat which will not generate a large amount of toxic gas and is thus environmentally friendly. SOLUTION: A tufted mat 1 is formed with a pile 3 consisting of a base fabric 4 of nonwoven polyester and many pile threads 5 planted on the surface of the base fabric 4. A backing member 2 whose major component is an olefin resin including an amorphous alpha olefin resin and crystal propylene resin is stacked on the back face of the pile 3 with an adhesive layer 6 in between.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a greige machine in which a large number of pile yarns are planted on the surface of a base cloth,
The present invention relates to an improvement of a tufted mat on which a backing material is laminated.

[0002]

2. Description of the Related Art Generally, this kind of tufted mat is
It is widely used as a doormat for homes, stores, offices, etc., and is laid down by covering the back and edges of the synthetic fiber greige with a backing material mainly composed of various polymer materials in a frame shape. It has improved stability and appearance retention. This tufted mat is excellent in flexibility, layability, durability, antifouling property, sound insulation, and appearance retention, and also in various environments such as direct sunlight, rainy weather or from low to high temperatures. Over a wide temperature range.

In order to provide the tufted mat with unique and indispensable performance as described above, the main materials of the backing material are soft vinyl chloride resin (PVC), styrene-butadiene rubber (SBR), and styrene-butadiene-based. Synthetic rubber such as thermoplastic elastomer (SBS) or ethylene-vinyl acetate copolymer (EVA) is used.

FIG. 3 shows an example of a conventional tufted mat. In the tufted mat 51 shown in the figure, the greige 3 is composed of a base cloth 4 made of a non-woven fabric and the like and pile yarns 5 planted on the surface of the base cloth 4. Is the backing material 5 via the adhesive layer 56.
2 are stacked.

Conventionally, hard or soft PVC is mainly used as the backing material 52. This P
VC is excellent in durability, flexibility, or moldability, and is the most widely used material. Here, when hard PVC is used, since the backing material 52 does not contain a plasticizer,
Although irregularities such as embossing are provided on the bottom surface 52a of the backing material 52 to prevent slippage, it is hard and slippery in winter and the like. For this reason, a suction cup or the like must be provided on the bottom surface and fixed on the floor, resulting in a complicated configuration.

Therefore, at present, a backing material 52 made of a soft PVC in which a plasticizer is added to a raw material to give flexibility.
Is often used. When using this soft PVC,
A sol-like paste containing a plasticizer, such as phthalic acid esters such as dioctyl phthalate and diheptyl phthalate, is used as a molding raw material. A material 52 is obtained.

[0007]

However, in the case of the conventional tufted mat 51, the backing material 52 and the adhesive layer 56, which occupy most of the material, are mainly made of PVC, so that they are unnecessary. During incineration, toxic gases such as hydrogen chloride gas are generated in large quantities. Therefore, the generated hydrogen chloride gas has a serious problem of adverse effects on the global environment such as impairment of the health of workers, corrosion and deterioration of incinerators, and acid rain. It is being shunned for use as a backing material. When the soft PVC backing material 52 is used, it contains a plasticizer, so that the plasticizer may bleed out (exude) during use to alter or discolor the surface of a floor or the like. When embedding and disposing as waste, transfer of plasticizer and the like to soil becomes a problem. Furthermore, PVC
Since it has a weight (thickness: 2.2 mm) to make it less slippery and has a relatively large specific gravity, it requires labor to carry it during cleaning.

On the other hand, when synthetic rubber such as SBR or SBS is used for the backing material, the material viscosity at the time of melting is extremely large, so that the molding method is limited and the vulcanization step is required, so that the moldability is low. However, there is a disadvantage that the cost is poor and the economic efficiency is disadvantageous.

On the other hand, when EVA is used for the backing material,
VA has a relatively low melt viscosity and is excellent in moldability, but has the drawback that the softness and durability required for the backing material are poor, the coefficient of static friction is small, and the backing material becomes slippery.

[0010] The present invention has been made in view of the above-mentioned conventional problems, and it is a matter of course that the mat has the essential performance inherent in the mat. The purpose is to provide a tufted mat that is friendly to the global environment without doing so.

[0011]

Means for Solving the Problems The inventors of the present invention provided a backing material containing an olefin resin as a main component on the back surface of a greige machine comprising a base fabric and a number of pile yarns planted on the surface of the base fabric. The inventors have found that a laminated tufted mat can overcome the above-mentioned drawbacks of the conventional materials used so far, and have established the present invention. The olefin resin is not particularly limited, for example, polyethylene, polypropylene, polybutene-1,
Polyoctene-1 and the like can be mentioned, and these can be used alone or in combination regardless of whether they are crystalline or amorphous. Further, the backing material of the tufted mat is composed mainly of an amorphous alpha-olefin resin and a crystalline propylene resin.

The backing material comprising an amorphous alpha-olefin resin and a crystalline propylene resin as a main component in the present invention means 10 to 50% by weight, preferably 20 to 40% by weight of the amorphous alpha-olefin resin based on the entire backing material. %, A crystalline propylene resin of 10 to 50% by weight, preferably 20 to 40% by weight, and an inorganic filler represented by calcium carbonate of 0 to 60% by weight, preferably 20 to 40% by weight.

The amorphous alpha-olefin resin in the present invention is a copolymer of 40 to 99% by weight of propylene and 1 to 40% by weight of ethylene and / or butene-1 at random using a special catalyst. It was made. This amorphous alpha-olefin resin has a crystallinity of 10% or less according to a DSC method, and is a polymer having a very low crystallinity as compared with a normal polyolefin. Also, 1
The melt viscosity at 90 ° C. is in the range 3000 to 30000 centipoise.

The amorphous alpha olefin resin is one of the olefin resins and the main component is propylene. Therefore, the amorphous alpha olefin resin has an affinity such that it is completely compatible with the crystalline propylene resin. Rigidity can be adjusted without significantly reducing cohesion. As described above, the compounding ratio of the amorphous alpha-olefin resin to the entire backing material is 10 to 50% by weight, preferably 20 to 50% by weight.
４０40% by weight. At this time, if the amount is less than 10% by weight, the flexibility and elasticity of the backing material decrease, and if the amount is more than 50% by weight, distortion and deformation when a concentrated load is applied to the backing material become remarkable.

The crystalline propylene resin in the present invention is obtained by randomly copolymerizing 80 to 99% by weight of propylene and 1 to 10% by weight of ethylene.
Is a material known as so-called random type polypropylene having a melt flow rate (MFR) of 1 to 30. As described above, the compounding ratio of the crystalline propylene resin to the entire backing material is 10 to 50% by weight, preferably 20 to 40% by weight. At this time, if the amount is less than 10% by weight, distortion and deformation when a concentrated load is applied to the backing material become remarkable, and if it is more than 40% by weight, the flexibility and elasticity of the backing material decrease.

The present invention further provides an ethylene copolymer obtained by copolymerizing 50 to 99% by weight of ethylene with 1 to 50% by weight of an alpha olefin such as propylene, butene-1, and octene-1. MFR at 190 ° C is 1
The copolymer in the range of 10 to 10 is added to the entire backing material by 2%.
0% by weight or less can be added. By adding this ethylene-based copolymer to a kneaded product of an amorphous alpha-olefin resin and a crystalline propylene resin, the overall melt viscosity can be increased and the moldability can be improved, and the strength and durability of the kneaded material can be improved. It also has the effect of increasing However, if this ethylene-based copolymer is added in an amount of 20% by weight or more based on the entire backing material, the melt viscosity becomes too large and the moldability deteriorates.

The inorganic filler represented by calcium carbonate used in the present invention includes calcium carbonate, magnesium carbonate, magnesium sulfate, barium sulfate, magnesium hydroxide, aluminum hydroxide, glass powder and the like. Of these, calcium carbonate is particularly preferred in terms of economy and moldability. The compounding ratio of the inorganic filler to the entire backing material is 0 to 60% by weight, preferably 2% by weight.
0 to 40% by weight. If the amount is less than 20% by weight, the feeling of weight, and hence the stability required for laying down the tufted mat, will be reduced, and the economy will be poor. On the other hand, if the content is more than 40% by weight, the material strength of the backing material decreases, the viscosity of the backing material at the time of melting increases, and molding processing becomes difficult.

Thus, the amorphous alpha-olefin resin, the crystalline propylene resin, the inorganic filler, and, if necessary, the ethylene copolymer, the colorant, and the processing aid are kneaded with a Banbury mixer, and the mixture is extruded. Into pellets. Next, the pellets are melted, bonded to a green machine, and if necessary, subjected to secondary processing such as punching into a product shape to obtain a tufted mat covered with a backing. That is, in the tufted mat according to the present invention, by backing and laminating a backing material mainly composed of an amorphous alpha-olefin resin and a crystalline propylene resin on a greige machine, flexibility, laying stability, durability, and protection are improved. It is possible to improve soiling, sound insulation, appearance retention, and the like, reduce performance changes in various environments or over a wide temperature range, and reduce the amount of harmful gas generated during combustion.

[0019]

Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 is an external view showing a tufted mat according to one embodiment of the present invention, and FIG.
FIG. 4 is a partial cross-sectional view taken along line A-A. However, the same components as those of the conventional tufted mat shown in FIG. 3 are denoted by the same reference numerals, and detailed description thereof is omitted. In each figure,
Reference numeral 1 denotes a tufted mat, and a backing material 2 is laminated on the back surface of the greige machine 3 via an adhesive layer 6. Greige 3
Is composed of a base cloth 4 made of a nonwoven fabric made of polyester and a pile thread 5 made of nylon pierced through the base cloth 4 and planted.

The backing material 2 is formed wider than the greige machine 3, and the protruding portion around the greige machine 3 is an edge 7. The backing material 2 is made of, for example, an amorphous alpha-olefin resin (here, polypropylene, polyethylene,
And a polybutene-1 copolymer), a crystalline olefin resin (here, crystalline polypropylene was used), heavy calcium carbonate as a filler, a coloring agent and other additives. These composition ratios are the same as in Example 1 described later, and 35% by weight of an amorphous alpha-olefin resin, 35% by weight of a crystalline propylene resin,
Based on 35% by weight of heavy calcium carbonate.

The backing material 2 contains an amorphous alpha-olefin resin and a crystalline propylene resin, both of which are olefin resins, as a main component (subtotal 59% by weight), of which a relatively large amount of the amorphous alpha-olefin resin is contained. Have been. The properties of the backing material 2 were as follows. Specific gravity (g / cm ³ ) = 1.20, surface hardness (JI
SA) = 72, tensile strength (kg / cm ² ) = 75, tensile elongation (%) = 900, tear strength (kg / cm 2) = 30.

That is, the backing material 2 has excellent properties such as a lower specific gravity and a larger surface hardness, tensile strength, tensile elongation, and tear strength than the conventional backing material containing vinyl chloride resin as a main component. I have. In addition, since the backing material 2 contains a large amount of amorphous alpha-olefin resin, the softening point is about 130 to 140 ° C., and the melt flow rate (MFR; g / 10 min; 190 ° C.) is also about 5 And the sheet is easily formed under ordinary extrusion molding conditions. In addition, since a change in hardness due to temperature is small, a plasticizer such as a phthalate ester is not required.

The backing material 2 has a smaller thickness and weight than the conventional backing material, and the unevenness of the bottom surface 2a is formed rough. Nevertheless, since it has a moderate surface tackiness, it has a sufficiently large frictional resistance to a floor or the like and exhibits a non-slip property. Since the amorphous alpha olefin resin can be obtained at low cost as a by-product of the production of the crystalline olefin resin, the tufted mat 1 using this
Will also be cheaper. On the other hand, the adhesive layer 6 is obtained by applying a pre-coat material containing an olefin resin emulsion as a main component to the back surface of the greige machine 3 and drying it. Thereby, the greige fabric 3 and the backing material 2 can be firmly and firmly adhered to each other, and a product having excellent durability can be obtained. The adhesive layer 6
Also has a function of stopping the removal of the pile yarn 5.

Next, a method of manufacturing the tufted mat 1 having the above-described configuration will be described. First, on the back of the long greige machine 3, the above-mentioned pre-coated material is dried at about 170 g / m2.
Apply evenly at a density of ² . Next, the greige 3 after the application is heated at about 140 ° C. for 10 minutes, and the precoat material is dried to form the adhesive layer 6. The greige 3 after drying is
Cut to shape. On the other hand, the raw material pellets for the backing material are put into an extruder to be heated and melted, and then continuously extruded into a sheet shape, and run on a belt conveyor in a molten state, for example. Then, the upper surface of the backing material 2 is heated by the heating means disposed above the belt conveyor.

Subsequently, the greige machines 3 cut into a predetermined size and shape as described above are sequentially placed on the upper surface of the running backing material 2 one by one. Further, the whole of the greige machine 3, the adhesive layer 6, and the backing material 2 are heated by a heating means arranged below the belt conveyor to impart adhesiveness to the adhesive layer 6, and are then pressed by a pressure roller above the belt conveyor. The whole of the greige machine 3, the adhesive layer 6, and the backing material 2 are pressed toward the belt conveyor. Then, the greige 3 is bonded to the backing material 2 via the adhesive layer 6. Thereafter, the lining material 2 is cooled to a temperature close to room temperature by a cooling roll or the like, and the backing material 2 is cut in a state where the edge 7 is left on the periphery of the greige machine 3. As a result, a tufted mat 1 with an edge is obtained.

The tufted mat 1 obtained as described above
Does not use chlorine-containing materials,
Hydrogen chloride gas (gas detector tube analysis: below the detection limit) is hardly generated during incineration, and NOx (gas detector tube analysis) and smoke density (based on ASTM-E-662) are less than half that of conventional mats. became. In addition, since the plasticizer is not used, the floor surface is not naturally deteriorated or discolored due to seepage of the plasticizer. Therefore, it can be used as a flooring or plumbing place of a general household or a second mat of a car, as a matter of course, for use in an office or a factory.

Further, since the backing material 2 has an appropriate surface tackiness, the backing material 2 is not slippery on the floor and stays at the position exactly, so that the bottom surface 2a of the backing material 2 does not form much unevenness. You may. Even after molding, embossing or engraving can be easily performed only by applying heat to the surface. By the way, once molded from a vinyl chloride resin, surface molding is not easy. in addition,
Unlike the conventional mat, the weight of the backing material 2, that is, the thickness (about 1.8 mm) can be small because it is not necessary to increase the weight of the backing material 2 in order to secure the slip resistance. Therefore, it is possible to obtain a thin, lightweight one that is not slippery.

The adhesive layer 6 is not limited to the olefin resin emulsion as a main component, but may be formed by, for example, applying and drying a precoat material containing an acryl resin emulsion as a main component. Absent.

The olefin resin is not limited to propylene resin. For example, even when polyethylene, polybutene-1, octene-1 or the like is used as a backing material, no harmful hydrogen chloride is generated during incineration.

[0030]

EXAMPLES Examples of the backing material used in the tufted mat of the present invention will be described with reference to comparative examples. "Materials used" Amorphous alpha olefin resin (APAO) Propylene / ethylene copolymer, 190 ° C viscosity: 850
1. “Centipoise”, “UT2385” manufactured by Ube Lexen Amorphous alpha-olefin resin (APAO) Propylene-butene-1 copolymer, 190 ° C viscosity: 85
"UT2780" manufactured by Ube Lexen, 00 centipoise. 3. Crystalline propylene resin (PP) Ethylene content: 3% by weight, MFR: 1.0, Ground polymer “B-221” Ethylene copolymer (ethylene / propylene rubber:
4. EPR) MFR: 4.0, "P-0480" manufactured by Mitsui Petrochemical. BF-300 made of calcium carbonate (charcoal) Shiraishi calcium

[Test Method] A pressure kneader heated to 190 ° C. using an amorphous alpha-olefin resin, a crystalline propylene resin, an ethylene-based copolymer, and calcium carbonate at a predetermined mixing ratio as shown in the table below. And kneaded. After measuring the melt flow rate of each of these kneaded materials, a sample sheet having a thickness of 2 mm was prepared by hot pressing and subjected to a mechanical test. The surface hardness, tensile strength, tensile elongation, and tear strength of the sample sheet thus obtained were measured. The results of these measurements are shown in the table below.

"Results of Evaluation of Physical Properties"

In the evaluation results in the above table, ○ indicates good, and × indicates poor. That is, as is clear from the evaluation results in the above table, it can be understood that the compounding ratio of the amorphous alpha-olefin resin and the crystalline propylene resin is too small or too small, and the slipperiness and the mechanical strength are inferior. .

[0034]

As described above, according to the tufted mat according to the present invention, the backing material occupying most of the constitution is mainly composed of the olefin resin and does not contain the halogen which is a harmful gas source. No harmful hydrogen chloride gas or the like is generated during incineration, and a product that is extremely friendly to the global environment can be provided.

As the olefin resin of the backing material,
When amorphous alpha-olefin resin and crystalline propylene resin are the main components, light-weight products can be easily manufactured due to characteristics such as good moldability, hardness independent of temperature, non-slip properties, and no plasticizer. It does not cause deterioration or discoloration of floors and other surfaces, and there is no need to worry about the transfer of plasticizers to soil even in the case of landfill disposal.

[Brief description of the drawings]

FIG. 1 is an external view showing a tufted mat according to an embodiment of the present invention.

FIG. 2 is a partial sectional view taken along line AA in FIG.

FIG. 3 is a partial side sectional view showing a conventional tufted mat.

[Explanation of symbols]

 Reference Signs List 1 tufted mat 2 backing material 3 greige machine 4 base cloth 5 pile yarn

Claims (2)

[Claims] 1. A tough characterized in that a backing material containing an olefin resin as a main component is laminated on a back surface of a greige machine comprising a base fabric and a number of pile yarns planted on the surface of the base fabric. Ted mat. 2. The tufted mat according to claim 1, wherein the olefin resin contains an amorphous alpha-olefin resin and a crystalline propylene resin as main components.