JPH1156585A - Slipproof carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a proper heat insulating characteristic and cushion property by sticking a woven fabric formed by using flat yarn consisting of a thermoplastic resin contg. a specific amt. of inorg. fillers for warp and weft and a foamed sheet body having a specific thickness to each other via an adhesive layer and laminating a slipproof resin layer on the rear surface of the foamed sheet body. SOLUTION: This carpet is a laminate comprising, successively from a front layer, the flat yarn woven fabric 2/the adhesive layer 4/the foamed sheet body 3/the slipproof resin layer 5. The woven fabric 2 is woven by using the flat yarn molded of the thermoplastic resin contg. 1 to 30 wt.% inorg. fillers as the warp and weft. The foamed sheet body 3 is a sheet-like material having flexibility and cushion property. The thickness thereof is set in a range from 1 to 15 mm. The foamed sheet body 3 is stuck and integrated to the flat yarn woven fabric 2 by the adhesive layer 4. The slipproof resin layer 5 consists of a film of >=0.5 in the coefft., of dynamic friction measured by JIS(Japanese Industrial Standard)-K 7125 and is formed at a thickness of 30 to 120 μm.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rug used exclusively for indoor floors, and more particularly, it has a natural grass texture,
The present invention relates to a rug having excellent heat retention and cushioning properties and having anti-slip properties.

[0002]

2. Description of the Related Art In recent years, especially in houses such as condominiums, rooms have been converted into Western rooms due to the tendency of westernization of life, and flooring (wood floor) has been promoted. On the other hand, it is also popular to change these ocean spaces between Japan and use them.
For that purpose, there is a method of laying Japanese flower arrangements and tatami mats on the flooring.

Hitherto, flower clusters and tatami mats have been made of natural grasses represented by rushes, but natural grasses have a favorable texture, but are inferior in abrasion resistance and durability because they are natural materials. In recent years, there have been attempts to substitute synthetic fiber materials due to problems such as the occurrence of pests. Taking rush as an example, a spiral-shaped tape-shaped synthetic resin with plastic streaks and a woven tatami surface structure (Japanese Utility Model Publication No. 55-132248), or a hollow cord with irregular wrinkles made of thermoplastic resin Imitation rush (Japanese Patent Application Laid-Open No. 63-274533) in which the body is irregularly converged and formed by passing through a narrow gap, or an artificial brush in which a thermoplastic resin film has an irregularly folded inner layer covered with a resin coating. Grass (Japanese Patent Laid-Open No. 6-41809) and the like are disclosed.

[0004] However, when a rug is woven using these synthetic resin fiber materials and used as a rug, the appearance is similar to that of a natural material, but the elasticity is poor, so that when a person behaves on the rug, it becomes slippery and falls. Then, the skin is damaged by friction with the rug, and the rug is not usually fixed to the floor, so it is easy to move, and when a person walks on it and a kicking action is added, the rug itself slides on the floor and moves, It has been pointed out that there is a risk of falling.

[0005]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention has a rug surface layer having a natural grass texture, a moderate heat retaining property and a cushioning property for giving a feeling of stepping pressure, and It is an object of the present invention to provide a rug having good slip resistance.

[0006]

SUMMARY OF THE INVENTION The present invention relates to a woven fabric using a flat yarn molded from a thermoplastic resin containing 1 to 30% by weight of an inorganic filler as a weft yarn, and a foam sheet having a thickness of 1 to 15 mm. Are bonded together via an adhesive layer, and a non-slip resin layer is laminated on the back surface of the foamed sheet. The anti-slip resin layer has a dynamic friction coefficient of 0.5 or more and a thickness of 3
Those having a diameter of 0 to 120 μm are preferred.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in FIG. 1, the rug of the present invention has a flat yarn woven fabric 2 / adhesive layer 4 /
It is a laminate composed of the foam sheet 3 / anti-slip resin layer 5. Hereinafter, each component will be described.

First, in the rug of the present invention, the surface layer is a woven fabric 2 woven using flat yarn molded from a thermoplastic resin containing 1 to 30% by weight of an inorganic filler as warp yarn.

Examples of the thermoplastic resin for forming the flat yarn include a polyolefin resin, a polyester resin, a polyamide resin, a polyvinyl chloride resin, a polyvinylidene chloride-vinyl copolymer, and the like. Polyolefin resins are preferred in terms of stable quality and economical mass production. As this polyolefin resin, specifically, high density polyethylene, medium density polyethylene, linear low density polyethylene, low density polyethylene,
Ultra-low density polyethylene, linear low-density polyethylene with metallocene catalyst, ethylene-vinyl acetate copolymer, polyethylene resin such as ethylene- (meth) alkyl acrylate copolymer, polypropylene, propylene-ethylene copolymer, Representative examples include polypropylene resins such as syndiotactic polypropylene, and these may be used alone or as a mixture of two or more. Among these, high moldability such as high-density polyethylene, polypropylene, and the like, which have good moldability of extrusion and hot stretching, and have a small decrease in mechanical strength and the like even if an inorganic filler essential for the present invention is compounded, Is most preferred.

[0010] By adding an inorganic filler to the thermoplastic resin to be molded, the flat yarn approaches the texture of natural grass from an artificial touch such as appearance, gloss and touch due to the synthetic resin. Examples of the inorganic filler include calcium carbonate, magnesium carbonate, titanium oxide, magnesium hydroxide, magnesium stearate, talc, zeolite, kaolin, bentonite, red iron oxide, and other inorganic pigments. Of these, calcium carbonate is particularly preferred.
Here, the compounding amount of the inorganic filler is 1 to 30% by weight, preferably 3 to 20% by weight, more preferably 5 to 10% by weight.
It is. That is, if the amount of the inorganic filler is less than 1% by weight, a shininess is produced and the texture is inferior, and if it is more than 30% by weight, poor dispersion tends to occur and moldability such as thread breakage tends to be deteriorated. The mechanical strength of the flat yarn is also significantly reduced.

A method for forming a flat yarn using a raw material resin containing a predetermined amount of an inorganic filler as described above can employ a general molding method. For example, a thermoplastic resin is charged into an extruder. By a single-layer or multiple-layer inflation method or T-die flat method, the film is extruded in a molten state from a die, cooled, slit into a film, and then hot-drawn by a hot plate contact method, a hot roll method, or a hot air oven method. It is stretched and oriented about 3 to 10 times in the longitudinal uniaxial direction by a method, and further subjected to a heat relaxation treatment to obtain a flat yarn. The flat yarn used in the present invention is different in width and thickness depending on required physical properties because it constitutes the surface layer of the rug, but when expressed as fineness, it is generally 50%.
0 to 5,000dr, from the viewpoint of formability and subsequent weaving efficiency
0-3,000dr is more preferable.

The obtained flat yarn is woven by a known sulzer type, air jet type, water jet type, rapier type loom or the like to form a woven fabric 2. The weaving structure is not particularly limited, and a typical plain weave, a twill weave, a mosaic weave, a gauze weave, an entangled weave and the like can be adopted.
Here, in weaving the flat yarn, one kind of flat yarn may be used for the warp and the weft, but the resin, the inorganic filler and the pigment, the yarn width, the yarn thickness and the fineness are changed. By combining two or more types of flat yarns at an arbitrary ratio, a new function or design can be imparted to the woven fabric. For example, what blended a flat yarn made of polyethylene resin and a flat yarn made of polypropylene resin on the warp yarn has the elasticity, compressive strain resistance, and bending resistance of polypropylene, and the flexibility and low temperature of polyethylene. It will have both adhesiveness.

Next, the foam sheet 3 to be bonded to the flat yarn woven fabric 2 is a sheet having flexibility and cushioning properties. Examples thereof include polypropylene, polyethylene, ethylene-vinyl acetate copolymer, and ethylene-
Acrylic acid copolymer, ethylene- (meth) alkyl acrylate copolymer, polystyrene, polyester, polyurethane or synthetic resin foam such as various elastomers,
Rubber materials such as natural rubber, styrene butadiene rubber, urethane rubber, and chloroprene rubber, and rubber foams may be used. Here, the thickness of the foam sheet 3 is 0.8 to 12 mm.
It is considered that the range is preferably within the range. In other words, in a typical in foam density 10 to 50 kg / m ³ at a level which is formed in expansion ratio can not be obtained a sufficient cushioning effect as rugs component is less than the thickness 0.8mm only Not manufacturing process Efficiency is poor because it is not strong enough to withstand tension.On the other hand, if the thickness exceeds 12 mm, it becomes too large as a roll and the workability deteriorates, and when it becomes a rug, the feeling of treading becomes heterogeneous .

The method of manufacturing the foam sheet 3 is as follows.
When a sheet is formed by using an extruder, a gas mixing method is generally used in which a gas or a physical foaming agent which is vaporized by heating is injected through an injection hole provided in the middle of the extruder. Examples of the physical foaming agent include an inorganic gas such as air, nitrogen, water, and carbon dioxide, and an organic foaming agent such as freon, butane, pentane, and hexane. Also, there is a foaming agent decomposition method in which a sheet is formed by previously kneading a thermally decomposable foaming agent that generates a decomposition gas by heating into a resin, and then heating it to a temperature higher than the decomposition temperature of the foaming agent. Examples of the thermal decomposition type foaming agent include azodicarbonamide, azobisformamide, dinitrosopentamethylenetetramine, toluenesulfonylhydrazide and the like.

The foam sheet 3 is integrated with the flat yarn woven fabric 2 by the adhesive layer 4. Specific methods include melt extrusion lamination using a sand resin, dry lamination, thermocompression lamination, urethane-based, vinyl-based, acid-based, epoxy-based adhesives and their powders or hot melt webs. However, a melt extrusion lamination method is most preferable because it can be easily processed at a high speed and has a wide width. In this case, as a material used for the sand resin, a resin of the same type or the same type as the two members or a polyolefin resin having a polar group is preferably used in order to firmly adhere the two members. Specific examples include ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, maleic anhydride-modified low-density polyethylene, low-density polyethylene, linear low-density polyethylene, and ethylene-propylene copolymer. Can be

Then, a flat yarn woven fabric 2 to be a surface layer
The back surface of the foamed sheet body 3 integrated with the adhesive layer 4 is coated with a resin having high frictional resistance in the form of a film. That is, by forming such an anti-slip resin layer 5 on the back surface of the rug, even if a person walks on the rug and the kicking action is applied, the back surface of the rug and the floor surface do not slide, and the slip resistance is improved. It is possible to obtain an excellent rug.
Here, JIS-K7
It is preferable that a film having a dynamic friction coefficient measured by 125 of 0.5 or more be used as the anti-slip resin layer 5.

The anti-slip resin layer 5 is made of ethylene-ethyl acrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-vinyl acetate copolymer, ethylene-
(Meth) alkyl copolymers, ethylene-based resins such as ethylene-propene copolymers, and styrene-based, polyester-based, polyurethane-based, thermoplastic elastomers such as polyether-based, and the like, the dynamic friction coefficient of the above-mentioned. What satisfies the range may be selected. Among these, ethylene-ethyl acrylate copolymer is most preferable from the viewpoint of heat resistance, processability, and the like.

The method of forming the anti-slip resin layer 5 includes a melt extrusion lamination method in which the back surface of the foamed sheet 3 is directly coated in a molten state, a dry lamination method in which a film formed in advance is laminated, and a thermocompression lamination. The law can be adopted. Here, the thickness of the anti-slip resin layer 5 varies depending on the density of the foamed sheet body 3 to be used and the use of the rug, but is preferably 30 to 120 μm, more preferably 50 to 80 μm.
It is said. That is, if the thickness is less than 30 μm, the adhesion is insufficient and the durability is inferior. On the other hand, if the thickness is more than 200 μm, the rigidity increases and folding becomes difficult, and the weight increases, which is uneconomical.

[0019]

【Example】

Test method 1. Dynamic friction coefficient: Based on JIS-K7125. 2. Slip resistance value: The rug was cut into 100 mm squares, and the non-slip surface of the sample was fixed on a flat plate with the non-slip surface turned upside down. put,
With a 1 kg weight placed on the center, the end of the sample piece was gently pulled in the horizontal direction, and the balanced tension was measured with a spring balance.

Example 1 Polypropylene (MFR = 2.7 g / 10 min.) 9 as a thermoplastic resin
3% by weight, calcium carbonate as inorganic filler (average particle size =
3.6 μm) A resin composition consisting of 6% by weight and 1% by weight of a stem was charged into an extruder, a film was formed by an inflation method, and the film was slit into 6 pieces in the longitudinal uniaxial direction by a hot plate contact stretching method. After stretching twice, it was subjected to a heat relaxation treatment to produce a polypropylene flat yarn having a fineness of 1,250 dr. In addition, high density polyethylene (MFR = 2.0g / 10min.) 95
5% by weight, calcium carbonate (average particle size = 3.6 μm)
A resin composition comprising 0.5% by weight of a brown pigment is charged into an extruder, a film is formed by an inflation method, and the film is slit and stretched 5.5 times in a longitudinal uniaxial direction by a hot plate contact stretching method. Fineness after relaxation treatment
High-density polyethylene flat yarn of 1,500dr was manufactured. With this polypropylene flat yarn as the warp and the high density polyethylene flat yarn as the weft, with a Sulzer loom, 20 mm with a plain weave of 12 × 12 yarns / inch, 100 mm with a twill (1/3, 3/1) A dense woven fabric 2 with a lattice pattern was formed. The woven fabric 2 having a woven pattern as shown in FIG. 2 was obtained by the difference in the color tone between the warp and the weft and the difference in the weaving between the plain weave and the twill weave.

Next, as the foam sheet 3, a density of 25 kg / m
^{In step 3} , a 2.2 mm thick polyethylene foam sheet was selected and, when laminating with the above-mentioned woven fabric 2, an ethylene-vinyl acetate copolymer (MFR = 8.0 g / 10 min., VA content = 5% by weight) was sandwiched. The adhesive layer 4 having a thickness of 25 μm was formed by supplying the resin by the melt extrusion lamination method used for the resin, and the laminate was integrated.

Subsequently, an ethylene-ethyl acrylate copolymer (MFR = 5.0 g / 10 g) was provided on the foam sheet side of the laminate.
min., EA content = 9% by weight, dynamic friction coefficient = 0.75) to form a non-slip resin layer 5 by coating with a thickness of 60 μm by a melt extrusion lamination method, and after cutting to a size of 1.8 × 2.7 m. The periphery was wound with a narrow tape and sewn to obtain a rug of Example 1.

Comparative Example 1 The procedure of Example 1 was repeated except that a low-density polyethylene (MFR = 7.0 g / 10 min., Coefficient of dynamic friction = 0.40) was used instead of the anti-slip resin layer constituting the rug of Example 1. A rug was created as in.

Example 2 A woven fabric 2 used in Example 1, a foamed polypropylene sheet 3 (density 32 kg / m ³ , thickness 3.5 mm) as the foamed sheet ³ , and a linear low-density polyethylene (MFR = 8.5g / 10mi
n.), a thickness of 80 μm of an ethylene-propene copolymer (MFR = 6.0 g / 10 min., dynamic friction coefficient = 0.60) as the anti-slip resin layer 5.
A rug was prepared in the same manner as in Example 1 except for using the sheet.

Comparative Example 2 A low melting point polypropylene (MFR = 12.0 g / 10 min., Dynamic friction coefficient = 0.3) was used in place of the slip resistant resin layer constituting the rug of Example 2.
A rug was prepared in the same manner as in Example 2 except that the coating according to 5) was formed.

Table 1 summarizes the evaluation of the anti-slip performance of the rugs of Examples and Comparative Examples.

[0027]

[Table 1]

[0028]

As described above, the rug of the present invention is provided with a woven fabric using flat yarns containing a predetermined amount of an inorganic filler as warp yarns as a surface material. It has sufficient durability and bending resistance as well as insect and mold resistance, and has a heat insulating and cushioning property because the foam sheet is laminated in the middle, and the back side is coated with a slip resistant resin layer. There are slippery flooring and tatami mats,
It can be laid directly on the floor such as a vinyl chloride tile.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of a non-slip rug.

FIG. 2 is a partial plan view of a non-slip rug.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Rug 2 Woven fabric 3 Foam sheet body 4 Adhesive layer 5 Non-slip resin layer

Claims (2)

[Claims] 1. A woven fabric using a flat yarn formed from a thermoplastic resin containing 1 to 30% by weight of an inorganic filler as a weft and a foam sheet having a thickness of 1 to 15 mm are bonded together via an adhesive layer. A non-slip rug comprising a foamed sheet body and a non-slip resin layer laminated on the back surface. 2. The anti-slip resin layer has a dynamic friction coefficient of 0.5 or more,
The non-slip rug according to claim 1, which has a thickness of 30 to 120 µm.