JPS6119887A - Production of tile carpet having stable shape - Google Patents

Abstract

PURPOSE:To obtain a tile carpet having improved dimensional stability and stable shape with little warpage, by laminating a thermoplastic material on the rear of a carpet backing, intermediate base fabric having a low linear expansion coefficient thereon, and a rear base fabric further thereon one after another. CONSTITUTION:(A) The first backing material consisting of a composition consisting essentially of a thermoplastic material, e.g. asphalt, polyolefin, ethylene polar monomer copolymer, (B) an intermediate base fabric having a low linear expansion coefficient to heat (<=10<-6>), e.g. woven fabric or binding fabric consisting of glass fibers and further (C) the second backing material consisting essentially of the above-mentioned thermoplastic material at 1.00+ or -0.14 weight ratio of the materials (A) to (C) and (D) a rear base fabric, e.g. woven fabric and nonwoven fabric consisting of polyester or polyamide, etc., are laminated one after another on the rear of a tufted carpet and needle punched carpet backing formed from natural of synthetic fibers, etc.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing a tile carpet that is stable in shape and exhibits extremely little dimensional change and warping in response to changes in ambient temperature.

[Conventional technology and its problems]

Tile carpen) U, square, rectangle, diamond, or more complex shape, with an area of 0 for example.
．． They are plate-shaped carpets with a length of about 0.5 to 2 m, and by using them in combination, they can be laid on the floor without creating any gaps. These tile carpets have the advantage of being easier to install than regular carpets, just by arranging them on the floor and fixing them.Additionally, they can be used in many combinations of tile carpet shapes, colors, etc. to create a variety of carpet styles. It also has the advantage of being easy to repair. When carpet tiles are laid on the floor, they need to adhere well to the floor and not peel off when walking.For this reason, a relatively thick backing material is used to give the carpet tiles its own weight, and the carpet tiles need to be secured by their own weight. It gives a sense of gender.

The backing material of Sundako also has the role of imparting various properties to the tile carpet, such as thread removal prevention, shape retention, and bed placement.

Conventional tile carpets generally have a structure in which a backing material is laminated on a carpet base material, and a backing fabric is further laminated. There are some that use adhesive, and some that do not have a backing fabric.

In this way, conventional tile carpets are rugs that have various advantages, but they also suffer from changes in temperature due to seasonal changes,
Also, there is a disadvantage that the dimensions of conventional tile carpets change slightly when there is a sudden change in temperature caused by a heater or an air conditioner. For this reason, even if there is a slight change in the dimensions of a single carpet tile that is laid down by its own weight, it will result in a large deformation in a large construction area. In other words, when the temperature drops sharply, the slight contraction of the carpet tiles causes gaps between the carpet tiles, which impairs the aesthetic appearance and causes the tiles to move when walking, resulting in a very poor feeling of walking. Furthermore, when the temperature rises sharply, the carpet tiles expand, and in extreme cases, the carpet tiles may bulge. As described above, the dimensional change of tile carpets due to changes in temperature is said to be the biggest drawback of tile carpets, and there was an urgent need to solve them. Unfortunately, we cannot produce carpet tiles by laminating the base layers of carpet tiles at high temperatures.
Depending on the size of thermal deformation and residual strain of the combined base materials, tile carpets may warp at room temperature, or even if there is no warpage at room temperature, they may warp in high or low temperature atmospheres. Large collars may occur. If this kind of warping occurs, the carpet tiles will lift up and the aesthetic appearance will be spoiled, right? , there is a risk of injury to pedestrians.

This recurring drawback also needed to be resolved at the same time.

[Purpose of the invention]

An object of the present invention is to eliminate the above-mentioned drawbacks of conventional tile carpets, and to provide a shape-stable tile carpet with excellent dimensional stability and extremely little warping.

[Summary of the invention]

That is, the present invention includes on the back side of the carpet base material: (a) a first backing material made of a composition containing a thermoplastic substance as a main component; (b) an intermediate base fabric having a small coefficient of linear expansion with respect to heat;
c) a second backing material made of a composition containing a thermoplastic as a main component; (d) a backing fabric layered in sequence; The present invention relates to a method for producing a shape-stable tile carpet characterized in that the weight ratio is 100±014.

The carpent base material referred to in the present invention is not particularly limited, and wool, wool,
Woven carpets, knitted carpets, tufted carpets, needle punched carpets, etc. made from natural fibers such as cotton and linen, synthetic fibers such as polypropylene, polyester, polyamide, polyacrylate, and polyvinylidene chloride, and fiber materials such as flat yarns. Carpets, especially tufted carpets and needle punch carpets, can be preferably used. It is also possible to use these carbent substrates which have been subjected to a Latinx pre-coat treatment, a pre-coat treatment with an ethylene-vinyl acetate copolymer hot melt type adhesive, a low-density polyethylene film, a mu pre-coat treatment, or the like.

The backing material used for the first and second backing materials in the present invention is a composition containing a thermoplastic substance as a main component. Examples of the thermoplastic substance include asphalt such as natural asphalt and petroleum asphalt, polyolefins such as polyethylene, polypropylene, ethylene-propylene copolymer, and ethylene-butene copolymer, ethylene-vinyl acetate copolymer, and ethylene-acrylic acid ester. Olefin-polar monomer copolymers such as copolymers and chlorinated polymers such as polyvinyl chloride and chlorinated polyethylene can be used.

In the present invention, when asphalt is used as the backing material, polyethylene,
Polyolefins such as polypropylene, ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-polar monomer copolymers such as ethylene-vinyl acetate copolymer, ethylene-acrylic acid ester copolymer, polyvinyl chloride, chlorine Chlorinated polymers such as polyethylene,
Styrene-butadiene copolymer (random, block)
, styrene-isoprene copolymer (random, block), synthetic rubber such as butyl rubber, imprene rubber, chloroprene rubber, and natural rubber in a weight ratio of 10 to 50%, and if necessary, an inorganic filler can be optionally blended. .

Well, if you use polyolefin, use polyolefin 5.
Waxes, low molecular weight polyolefins, petroleum resins, and inorganic fillers can be blended in an amount of 5 to 50% by weight based on 0 to 95% by weight.

However, when using an ethylene-polar monomer copolymer, 10 to 90% by weight of the inorganic filler is added to the copolymer.
85% by weight, and 0 to 20% by weight of a softener and plasticizer, which are liquid at room temperature, can be blended.

In addition, when using a chlorinated polymer, the chlorinated polymer 10 to
90% by weight of the plasticizer and θ to 80% by weight of the inorganic photonic agent.

In the present invention, the first backing material and the second backing material may be of the same type or may be of different types.

In the present invention, when an asphalt-based, polyolefin-based, or ethylene-polar monomer copolymer system is used as the backing material, it can be prepared using a kneader, a Banbury mixer, a single-screw extruder, or a twin-screw kneading extruder.
Used as a backing material and a second backing material, the total of which is 1
．． 5-8.0 klJ/rrl, preferably 20-6
．． Stack 0 kli/rrl. When the total thickness of the paulownia lining is smaller than 1.5 klt/m', it is not preferable because the placement stability due to its own weight deteriorates. 8.
If it is larger than 0 kg/d, it will be difficult to install it and it will be economically disadvantageous.

In the case of chlorinated polymers, polyvinyl chloride, plasticizers (
For example, DOP), a paste consisting of an inorganic filler is prepared, and this is applied to the carpent base material [1.5 to 8.0 kg
/ m' can be stacked.

The intermediate base fabric as used in the present invention may be any fabric having a small linear expansion coefficient with respect to heat, and the coefficient is 10-5 or less, preferably 10-6 or less. Examples include glass fiber, carbon fiber, and metal fiber.

Glass fibers are particularly preferred, and woven fabrics in which bundled yarns formed from these fibers are plain weave, twill weave, patterned weave, leno weave, satin weave, and cloths in which bundled yarns are bonded in a network shape with a binder without weaving, and A nonwoven fabric is used that is dispersed in a random direction to a uniform thickness and bonded with a binder. Also, the basis weight is 10 to 1. oo
o! ! /m', preferably] 5-800! J/m.

The backing fabric as used in the present invention refers to a woven fabric made from the same fiber material as the carpet base material, a fabric bonded without weaving into a mesh shape using a binder or heat fusion, and a fabric in which fibers are randomly arranged in a uniform thickness. using a nonwoven fabric bonded to In particular, woven fabrics and nonwoven fabrics formed from polyester fibers, polyamide fibers, polypropylene fibers, and mixed fibers thereof are preferred.

The basis weight of the backing fabric is 10 to 500 g/m, preferably 15 to 400 g/rrl.

The method for manufacturing the shape-stable tile horn vent of the present invention will be explained.

FIG. 1 is a schematic diagram showing an example of the method for manufacturing a tile carpet according to the present invention, in which a carpet base material 1 pulled out from a carpet base material supply section 2 by a conveyor 3 and transported is ” A first backing material 7 made of a composition based on a thermoplastic material (excluding a pasty composition of polyvinyl chloride) disposed on two sides.
) is laminated to a predetermined thickness by T-die extrusion at a temperature of 100 to 250°C using a coke 6 such as a doctor blade or a calendar roll coater, and then laminated to a predetermined thickness from the intermediate base fabric supply section 4 parallel to the upper surface of the first backing material. The intermediate base fabric 5 that has been guided is laminated using a pressure roll 8, and then a second backing material 10 made of a composition containing a thermoplastic material as a main component is extruded on top of the intermediate base fabric 5 using a T-guid extrusion under the same conditions, and then the second backing material 10 is extruded using a doctor blade or a doctor blade. After being laminated to a predetermined thickness by a coater 9 such as a calendar roll coater, the back base fabric 13 guided parallel to the upper surface of the second backing material from the back base fabric supply section 12 is laminated by a pressure roll 1 to a predetermined thickness. A method of forming a laminated carpet strip I4 having a thickness and predetermined properties (1 to 1), and then passing through a cooling device 15 and a cutting device 16 in subsequent steps to obtain a desired tile carpet 17 will be described.

At this time, it is effective if the weight ratio of the first backing material layer and the second backing material layer is in the range of 1.00 d: 0.14, but the desired weight is equivalent. In the case of a paste-like compound consisting of crushed polyvinyl chloride, a plasticizer, and an inorganic photonic agent, it is spread evenly on the backing fabric using a doctor blade at room temperature to form a second backing material layer, and then an intermediate layer is applied on top of this. The base fabric was layered and preheated at 180°C in a heating oven for 5 ml, and then the paste mixture was evenly spread to form the first backing material layer.The carpet base material was layered and heated in a heating oven. The mixture is further heated at 180°C for 100ml to gel and integrate. In this case as well, the layers are laminated so that the weight ratio of the first backing material layer and the second backing material layer is in the range of 100 to 4. The product obtained by laminating in this way is cut into a suitable size to make a tile carpet.

〔Effect of the invention〕

It has been found that excellent dimensional stability can be imparted by inserting an intermediate base fabric with a small linear expansion coefficient against heat. Furthermore, it has been found that laminating a backing fabric improves warpage and acts as an auxiliary to improve dimensional stability. In other words, the intermediate base fabric used in the present invention has a very small linear expansion coefficient against heat, which is much smaller than that of the carpet base material, backing material, and back base fabric conventionally used for tile carpets. By using this together, the dimensional change of the tile carpet due to temperature changes becomes very small. In other words, the backing material used for tile carpets is melted at a temperature of 100 to 250°C and laminated with the carpet base material and backing fabric that have been heated at room temperature or slightly warmed, so it is best when cooled to room temperature. Since it is the backing material that retains most of the distortion, inserting the intermediate base fabric used in the present invention in the middle of this backing material is very helpful in improving dimensional stability. . However, if the intermediate base fabric is inserted between the backing materials and the carpet base material is simply laminated on one side of the backing material, warping will normally occur to the back side of the carpet base material. In order to prevent this, if the backing fabric is laminated on the opposite side of the carpet base material, the warping will be eliminated, especially if the backing fabric is made of a fiber material that is the same or has a linear expansion coefficient similar to that of the base fabric material of the carpet base material. We found that using a backing fabric was highly effective. It was also found that this effect improved dimensional stability.

〔Example〕

The present invention will be explained in more detail below using Examples and Comparative Examples.

Examples 1 to 6 On the back side of a tufted carpet or needle punch carpet, the various backing materials (first) shown in Table 1 and an intermediate base fabric made of glass fiber were laminated, and the same backing material (first) was laminated. 2) and various backing fabrics were laminated and cut to a predetermined size to obtain a tile carpet. For these, the rate of change in dimensions and the state of warpage were determined in an atmosphere where the temperature was raised or lowered by 40°C, with room temperature 20°C as a reference. As shown in Table 2, the results show that the dimensional change rate is extremely small, indicating good dimensional stability, and that no curling occurs at all, so there is no problem in practical use. I found out something.

Comparative Examples 1 to 5 Various tile carpets obtained by applying the various backing materials shown in Table 2 to the back side of a tufted carpet without inserting an intermediate base fabric, and further laminating the back base fabric were as follows: The rate of change in dimensions and the presence or absence of warpage were determined in an atmosphere in which the temperature was raised or lowered by 40°C, with the room temperature being 20°C. The results are shown in Table 2 [As shown in Table 2], the values were extremely large and could cause problems in practice.

However, the names of each material are abbreviated as follows.

Ethylene-vinyl acetate copolymer: EVA ethylene-
Ethyl acrylate copolymer: EEA polypropylene: PP low density polyethylene
: LDPE polyvinyl chloride : p
vc dioctyl phthalate: DOP calcium carbonate: Charcoal

[Brief explanation of the drawing]

FIG. 1 is a schematic diagram showing an example of the method for manufacturing a tile carpet according to the present invention. 1. Carpent base material, 2. Carpent base material supply section, 3
- Conveyor, 4 - Intermediate base fabric supply section, 5... Intermediate base fabric, 6.9... Coater, 7 First backing material, 8.1
1. Pressure roll, 10.. Second backing material, 12. Back base fabric supply section, 13.. Back base fabric, 14. Laminated carpet strip material, 15. Cooling device, 16.. Cutting device, 17. tile carpet.

Claims (5)

[Claims] (1) On the back side of the carpet base material, (a) a first layer consisting of a composition mainly composed of a thermoplastic substance;
a backing material, (b) an intermediate base fabric having a small linear expansion coefficient with respect to heat, and (c) a second material made of a composition containing a thermoplastic substance as a main component.
A backing material, (d) a backing fabric is sequentially laminated, and the weight ratio of the (a) first backing material layer and (c) second backing material layer is 1.00±0.14. A method for producing shape-stable carpet tiles. (2) The method for manufacturing a tile carpet according to claim 1, wherein the carpet base material is a tufted carpet or a needle punch carpet. (3) The method for manufacturing a tile carpet according to claim 1, wherein the thermoplastic material is selected from asphalt, polyolefin, ethylene-polar monomer copolymer, and chlorinated polymer. . (4) The method for manufacturing a tile carpet according to claim 1, wherein the intermediate base fabric is a woven fabric, a bonded fabric, or a nonwoven fabric made of glass fiber. (5) The method for manufacturing a tile carpet according to claim 1, wherein the backing fabric is a woven fabric or a nonwoven fabric made of polyester fibers, polyamide fibers, polypropylene fibers, or mixed fibers thereof. .