JPS63249511A - Backing processing of carpet - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for lining carpets, particularly for fixing carpet piles, improving dimensional stability, adding weight and laying stability, This invention relates to a method for lining carpets with improved durability.

[Prior art] In the case of woven carpet, lining processing of carpet greige (Kibata) does not require lining processing, or
This can be done by sizing the inside of the cylinder with water-soluble glue, but for carpets such as tufted carpets and needle punch carpets, the normal backing method, in which a polymer latex emulsion compound is applied to the back side and dried to fix the pile, is used. The foam backing method involves mechanically foaming and applying a latex compound, drying it into a foam, and vulcanizing it.The secondary method involves laminating jute cloth, synthetic fiber fabric, non-woven fabric, etc. with a polymer latex emulsion compound and then drying it. Methods such as the backing method are generally widely used.

In recent years, we have also introduced tile carpets, which cut this carpet into 50cm square pieces and lay them out side by side, second car mats, which are partially laid inside cars, water spray mats, which are partially laid in the plumbing area of the home, and carpets that are laid out side by side. These carpets are now widely used as foot mats placed in entrances, artificial turf laid in sports facilities, etc.0.Such carpets have improved dimensional stability, adhesion to the floor, and durability. Due to increased demand for properties such as durability, processing methods that allow for greater thickness and weight have become more important.

Conventional processing methods for such thick and heavy carpets include polyvinyl chloride sol backing, rubber asphalt, hot melt processing of attack-tic polypropylene, press vulcanization of solid rubber, and extrusion of rubber/plastic sheets. Molding and laminating processes, or laminating processes of molded sheets using solvent glue, etc., are performed.

[Problems to be Solved by the Invention] However, these processing methods cannot be processed using processing equipment that uses polymer latex or emulsion formulations owned by carpet backing manufacturers.
New equipment is often required or productivity is significantly reduced.

In addition, since polyvinyl chloride sol and solvent are used, there are problems such as pollution and severe damage to piles caused by pressure bonding of rubber and plastic.

Also, in order to add thickness and weight to the carpet,
Backing processing by applying a large amount of a polymer latex emulsion compound using conventional equipment requires an excessive amount of time to dry the polymer latex emulsion compound, making it difficult to perform economically. is extremely difficult.

Furthermore, a second thick sheet is added to the carpet greige machine,
Alternatively, when laminating non-breathable sheets, if a conventional polymer latex emulsion compound is used, the secondary laminated sheet cannot be bonded in a dry state, so it must be laminated in a dry state. After that, it is necessary to remove moisture through the secondary base fabric, making it extremely difficult to dry and develop adhesive strength.

Using a polymeric latex emulsion formulation and utilizing conventional backing processing equipment owned by a carpey processing manufacturer, the inventors have developed a relatively inexpensive and convenient method for thickening We have conducted extensive research with the aim of providing a method for carpet lining that can simultaneously laminate a secondary laminated sheet with 'RQ' and fix the pile. As a means of laminating heavy molded sheets of fiber, rubber, or plastic, it can be used to press and vulcanize unvulcanized rubber, heat-press bond plastics, and attach hot-melt resin powder or sheets to the back of carpets. We considered lamination of sheets, pressure bonding of molded sheets after heating and melting, etc.
The adhesion of the carpet pile was insufficient, the adhesion was insufficient when laminating thick sheets, and the pile was severely damaged.

[Means for solving the problem] The inventors of the tree further investigated the method of laminating the backing sheet easily and efficiently and also fixing the pile together, and as a result, they discovered a method of adhesive resin emulsion and polymer latex. Apply a compound containing emulsion as the main ingredient to the back side of the carpet greige,
It was discovered that the above object could be achieved by laminating a backing sheet after drying and melting, and based on this knowledge, the present invention was completed.

In other words, 1. the present invention is to remove the hair from the back side of the carpet or from the hair I beforehand.
Softening point 150 on the back side of L-treated carpet
After applying an aqueous emulsion formulation containing an adhesive resin emulsion and a polymer latex emulsion at a temperature below 10°C, the coated surface is heated to dry the aqueous emulsion formulation and melt the surface. Immediately thereafter, the method for lining a carpet is characterized in that a molded sheet for lining is laminated to the welded area as it is or by heating the laminating surface of the sheet.

[Detailed Description of the Invention] Any S Yuu 1 The carpet material used in the carpet lining processing method of the present invention is a tufted material that is produced by a machine at high speed and requires the fixation of pile or cotton. carpet,
needle punch carpen) and knitted carpet.

These carpet raw materials can be used as greige fabric, or
After hair-stopping treatment such as hair-stopping by applying and drying a Latinx fist emulsion formulation or hair-stopping by melting fibers, the carpent of the present invention is lined.

This type of hair fixing treatment performed in advance depends on the composition of the carpet and the degree of fixation force required, but since hair fixation is also done at the same time in the processing process of the present invention, a special treatment is required to simplify the process. It is not necessary to do this except in special cases.

The constituent components of the water-based emulsion compound applied to the back side of the emulsion-distributing car vent are mainly composed of an adhesive resin emulsion and a polymer latex emulsion.

1 Adhesive resins include rosin or its derivatives, petroleum resin, coumaron/indene resin, phenol resin, xylene resin, terpene Φ phenol resin, ethylene/vinyl acetate copolymer resin, polyamide! - There are resins, low molecular weight styrene resins, etc., and those with a softening point of 150°C or less are suitable. It can be used in the form of an emulsion in advance, or it can be emulsified or dispersed during formulation. These may be used alone or in combination.

In order for the dry film of the compound to soften and melt within 1σ sowing time and to exhibit adhesive properties, it is necessary to have a softening point of 150° C. or lower so as not to damage the fibers. Furthermore, by adding paraffin wax, plasticizer, etc. to the emulsion, softening and melting can be facilitated, melt viscosity can be lowered, and adhesion can be facilitated.

,, ;) - Latex/emulsion Polymer latex/emulsions include natural rubber latex and its modified latex, styrene-butadiene copolymer latex, acrylonitrile-butadiene copolymer latex, polybutadiene latex, and polyimpres. latex, polychloroprene latex, methyl methacrylate/butadiene copolymer latex, carboxyl-modified latex, acrylic ester,
Styrene copolymer emulsion, polyacrylic acid ester copolymer emulsion, ethylene/vinyl acetate copolymer emulsion, and copolymer emulsion with vinyl monooxide or vinylidene 31, poly1! ! Vinyl chloride or vinylidene chloride emulsion, vinyl chloride or vinylidene chloride/acrylic ester copolymer emulsion, vinyl inide or vinylidene chloride/ethylene copolymer emulsion, etc. are used alone or in combination.

In the present invention, good results can be obtained by using a rubber-based latex that has good compatibility with the adhesive resin and easily develops tackiness when melted, and a resin-based polymer emulsion that easily develops adhesive strength. can get.

height! In addition to the adhesive resin and polymer latex emulsion, the aqueous emulsion formulation used in the present invention contains crosslinking agents such as sulfur, zinc white, vulcanization accelerators, metal oxides, and melamine crosslinking agents. A 1F anti-aging agent, a filler, a stabilizer, a dispersant, an antifoaming agent, a flame retardant, a thickener, and the like are added as necessary.

Among these additives, thickeners are particularly effective additives for appropriately adjusting the permeability of the aqueous emulsion formulation and for uniformly coating the mixture.

■ The blending ratio of the above-mentioned adhesive resin and polymer latex emulsion is the dry weight! 5 ratio 10:90 to 70:3
0 is suitable, particularly preferably 20:80 to 50:5
It is 0. If the proportion of the adhesive resin is too high, the melt adhesive strength will increase, but the adhesive strength will be insufficient.

A continuous coating method using a combination of a rick roll and a doctor blade is suitable for applying the above-mentioned aqueous emulsion mixture to the back surface of the carpet greige, and most carpet processing manufacturers have this equipment.

The amount of coating Ia at this time varies depending on the type of carpet and laminated sheet, but the dry weight is 100 to 1500.
Approximately gr/m2 is appropriate.

Dry money! The aqueous emulsion mixture applied to the back side of the carpet is heated, dried, and then thermally melted.

To do this continuously for 10 hours, it is effective to directly heat the back of the carpet greige, which is flowing at a constant speed, using unit gas/Höner, which are arranged in succession.In addition, heating using electric heat, high frequency, hot air, etc. There is also a method, but it is not preferred because the heating efficiency is poor and the cost is high. Further, the heating is at a temperature above the melting temperature of the aqueous emulsion formulation, generally from 120 to 180°C, particularly from 130 to 180°C.
Preferably it is carried out at a temperature of 160°C.

1) Stand-up J A molded backing sheet is attached to the surface of the film of the aqueous emulsion mixture on the back side of the carpet heated and melted in this way, either as it is or after its adhesive surface is heated. Please note that the seat is heated.

It is preferable to carry out the heating to such an extent that the surface thereof melts.

This lamination is generally performed following drying and melting of the aqueous emulsion, but if necessary, coating IH5 of the aqueous emulsion, drying, melting of the coated surface, and pasting of the backing sheet may be performed as separate processes. You can also do it.

' fchi sheet The molded sheet for backing includes polyvinyl chloride sheet, polyethylene sheet, polypropylene sheet, rubber asphalt sheet, polybutadiene resin sheet, thermoplastic rubber sheet, ethylene/vinyl acetate copolymer resin sheet, and foamed sheets of these sheets. Heat-meltable sheets such as cross-linked polyethylene sheets, vulcanized rubber sheets, polyurethane sheets, and foamed sheets thereof; woven fabrics of natural fibers such as shoots, synthetic fibers such as polypropylene fibers, polyester fibers, and glass fibers; Includes non-woven fabrics. The thickness of the sheet is usually 0.5~711mm, preferably 1~
It is 5mm.

These backing sheets preferably have heat-melting properties. When using such heat-melting sheets, a water-based emulsion compound is applied to the back side of the carpet to form a film, and this adhesive resin and high-temperature adhesive resin are used. The bonding surface of the backing sheet is attached to the molten surface of the molecular resin either as is or after the surface is heated and melted.

At this time, the carpet and sheet to be bonded can be bonded more firmly by pressing and bonding them together. Such lamination is generally accomplished by passing the carpet and backing sheet together between two appropriately spaced press rolls, one above and the other.

Immediately after crimping, the carpet is cooled by blowing cold air or passing through a cold air circulation chamber to complete the backing process.

This prevents the carpet from deforming during the backing process.

Therefore, it is necessary to stretch both widthwise ends using a tenter.

The backing processing method of the present invention can be carried out using the processing equipment already owned by carpet processing manufacturers, so it is possible to efficiently laminate various backing materials, and at the same time, it is possible to make carpet hair stopper. can be done.

Carpets processed using this backing method depend on the type of backing sheet, but are commonly used with secondary carpets. In addition to cloth-covered carpets, it can be used in a wide range of applications such as tile carpets, car interior carpets, water mats, artificial turf, sports rugs, etc., to improve the dimensional stability of the carpet and to keep it flat on the floor. The carpet can have excellent properties such as heat insulation, sound insulation, durability, and cushioning properties when using a foam sheet.

[Example] Next, examples of the present invention will be described.

Embodiment 1 FIG. 1 shows an embodiment of a carpet lining processing apparatus used in the carpet lining processing method of the present invention.

l is the tufted carpet greige, a is sent out in the direction of the arrow while returning it, and 2 is an aqueous emulsion formulation in the bath, containing Super Ethyl 7303E (50% of rosin acid ester with a softening point of 70-80°C). Emulsion, made by Arayo Kagaku ■) 70iT (Q part, JSR0
5B+ (Styrene-butadiene copolymer latex 1 Japan Synthetic Rubber Co., Ltd. 5u) 145 xui and 1 part by weight of an 80% emulsion of styrenated phenol and 3 parts by weight of a 30% aqueous solution of Emulgen 913 (nonionic activator, Kako [J)] were mixed. Then, the viscosity was reduced to 20,000 with Aron 20L (sodium polyacrylate, manufactured by Toago I & Co., Ltd.) and water.
cps, the total solid content was adjusted to 55%.

3 is a rotating coating roller with a large diameter.

It has a width larger than a carpet. While rotating, the application roller lifts a portion of the aqueous emulsion formulation 3 and rubs it onto the back side of the advancing carpet, thereby coating the aqueous emulsion formulation on the back side of the carpet.

The applied aqueous emulsion formulation is scraped off with a doctor blade number 4 to adjust the amount of application and at the same time promote penetration into the carpet pile. The amount of coating can be adjusted by changing the rotational speed of the coating roller 3, the pressing angle and strength of the carpet, and the pressing method of the doctor blade.

5 is a unit type gas burner arranged over a sufficient length in the width direction and the traveling direction of the carpet, and the density and height of the gas burner 5 is enough to heat the aqueous emulsion mixture on the carpet surface; The temperature can be regulated.Therefore, under this unit type gas burner 5, a carpet l coated with the aqueous emulsion formulation 2 is placed.
In the first half of the process, the water in the aqueous emulsion is evaporated off to form a film, which is partially melted by the heat.

On the other hand, 6 is a soft polyvinyl chloride sheet with a thickness of 2.5H, which is a backing sheet, and is unwound in the direction of the arrow.
The bonding surface of the polyvinyl chloride sheet 6 is heated in the melting zone where the Uni/Togas Henner 7 is arranged to partially melt the surface, and the back surface is heated between the upper and lower pressure rollers 8a and 8b. Pass it through the carpet and press it together.

The carpet with the soft polyvinyl chloride sheet 6 pasted thereon is sufficiently cooled by passing through a chamber/tube 9 in which cold air is circulated, and then wound up by a single winding roller 1O.

The carpet pile backed in this manner was sufficiently adhered to the carpet base fabric, and the polyvinyl chloride sheet 6 was sufficiently bonded to the back surface of the carpet, making it usable for practical use.

Example 2 Instead of the polyvinyl chloride sheet 6 of Example 1, RB 1
12 (1 (polybutadiene resin 1 manufactured by Nippon Synthetic Rubber ■), TR100O (: (styrene/butadiene block combination compound, manufactured by Nippon Synthetic Rubber ■), filler, and plasticizer are kneaded to make a sheet with a thickness of 2.5 m + *. The molded product was laminated together in the same manner as the backing sheet of Example 1 to obtain a good backing carpet.

Example 3 In the same process as in Example 1, Alcon emulsion AP100I (softening point 10
50% emulsion of hydrogenated petroleum resin at 0℃, Arayo Chemical ■
) 70 parts by weight, JSRO5B1100 parts by weight, and JSR
Mix 60 parts by weight of 0897 (carboxyl-modified styrene-butadiene latex, manufactured by Japan Synthetic Rubber @), 5 parts by weight of 1 (H aqueous solution) of sodium tripolysulfate, and 5 parts of modified 30% aqueous solution of sodium dodecylbenzenesulfonate. death,
Thoroughly disperse and mix 100 parts by weight of heavy calcium carbonate powder, then add 20 L of Aron and water to obtain a viscosity of 20,000 c.
ps, and the total solid content θoz was adjusted.

Further, as the facing sheet 6, a foamed urethane sheet having a thickness of 3Illl was used. However, in this case, the gas burner 7 was not used.

The pile of the carpet lined with the foamed urethane sheet 6 was sufficiently fixed, and the foamed urethane and the carpet greige were sufficiently bonded to each other, so that the carpet was sufficiently durable for practical use.

Example 4 Example 3 except that a polyester woven base fabric was laminated as the backing sheet 6 instead of the foamed urethane sheet.
When carried out under the same conditions as above, it was possible to produce a tufted carpet backed with a synthetic fiber base fabric that was suitable for practical use.

[Effects of the Invention] The carpet lining processing method of the present invention can process a variety of backing materials efficiently by using the processing equipment already owned by carpet processing manufacturers. The hair of the carpet can be fixed at the same time as lamination, and the backing carpet can be manufactured simply and economically.

Further, the carpet produced by the carpet lining processing method of the present invention can be a carpet that is excellent in dimensional stability, fit on the floor, heat insulation, sound insulation, durability, etc.

It can be used in a wide range of applications such as carpet tiles, car interior carpets, water mats, artificial turf, and sports rugs.

It is extremely useful industrially.

[Brief explanation of drawings]

FIG. 1 shows an embodiment of a carpet lining processing apparatus used in the carpet lining processing method of the present invention. 1: Tufted carpet greige 2: Aqueous emulsion compound 3: Application roller 4: Doctor blade 5: Unit type gas burner 6: J-beating sheet 7: Uni/ ) gas burner 8a
: Upper pressure roller 8b: Lower pressure roller

Claims (1)

[Claims] After applying an aqueous emulsion formulation containing an adhesive resin emulsion with a softening point of 150°C or less and a polymer latex emulsion to the greige back side of a carpet or the greige back side of a carpet that has been pre-treated with hair locking, the coated surface is heated. , the aqueous emulsion composition is dried and its surface is melted, and immediately after that, a molded sheet for lining is directly applied to the melted surface.
Alternatively, a carpet lining processing method characterized in that the sheets are laminated by heating the laminating surfaces thereof.