KR20110012495A - Flocking carpet and manufacturing method thereof - Google Patents

Abstract

PURPOSE: A flocking carpet and a manufacturing method thereof are provided, which can provided shape stability of the same level as a flocking carpet which uses glass cloth as a bubble layer. CONSTITUTION: A flocking carpet manufacturing method comprises: a step of coating the upper side of a bubble layer(110) consisting of polyester non-woven fabric or polypropylene non-woven fabric with adhesive; a step of forming a first layer(120) by transplanting one fiber on the upper side of the bubble layer coated with the adhesive; and a step of forming a support layer(160) in which a first polymer pad layer(130), a glass fiber layer(140), a second polymer pad layer(150) are laminated on the lower surface of the bubble layer in order.

Description

Flocking carpet and manufacturing method

The present invention relates to a flocking carpet and a method for producing the same, and more particularly, to a flocking carpet and a method for producing the froth, characterized in that the bubble layer is made of a polyester nonwoven fabric or a polypropylene nonwoven fabric.

Carpet has been used for indoor flooring for a long time. When the pile layer of the carpet is vertical or woven, the fibers constituting the carpet layer are looped or inclined upright. The density of the fibers is not high and there is a space between the fibers, such a carpet has a problem that is not beneficial to the human body to provide a space for hiding dust or ticks.

In order to solve this problem, Flocking Carpet has appeared, and Flocking Carpet has a flocking method in which yarns are erected vertically using static electricity. It features a high density structure of 80 million / m², more than ten times the carpet. This high density structure prevents the Flocking Carpet's compact structure from blocking contaminants, penetration of mites and bacteria, as well as cleaning of the carpet, thus solving concerns about hygiene of carpets. Its vertical structure makes it easy to loosen all like a regular carpet so you can always have new durability.

Regarding the flocking carpet, Korean Patent Publication No. 10-0785632 discloses a method of manufacturing the flocking carpet using a glass fiber fabric as a bubble layer, and FIG. 1 is a cross-sectional structure of a flocking carpet that is generally used. It is shown. As shown in FIG. 1, the general flocking carpet 100 includes a bubble layer 10 made of glass fiber fabric, and a pile layer 20 formed by planting nylon fibers on the upper surface of the bubble layer by flocking. ), And a support layer 160 having a form in which the first polymer pad layer 30, the glass fiber layer 40, and the second polymer pad layer 50 are sequentially stacked on the bottom surface of the bubble layer. However, when a conventional flocking carpet is already known on the floor, it is highly likely that the bubble layer made of fiberglass fabric will be exposed to the outside, although flocking using the bubble layer made of fiberglass fabric Carpet is excellent in form stability (dimension stability) but due to the high price of the glass fiber fabrics have a problem such as economical and causing tickling during work.

A closer look at the fiberglass fabric may show irritation, skin disorders and difficulty breathing if the fiber is inhaled or in contact with the respiratory tract, and may cause nausea, vomiting and diarrhea if ingested [Korea] Korea Occupational Safety & Health Agency, Material Safety Data Sheet on fiberglass fabrics]). In particular, considering that flocking carpets are mainly used in commercial facilities, government offices, hospitals, infant facilities, welfare facilities, etc., there is a need to change the fiberglass fabric of the bubble layer to a safer material.

The present invention is to solve the conventional problems, the present invention is the foam layer is made of a safer and more economical material than the glass fiber fabric, the shape stability of the same level as the flocking carpet using the glass fiber fabric as the bubble layer It is an object of the present invention to provide a flocking carpet having a (dimension stability) and a method for producing the same.

One object of the present invention is a bubble layer consisting of a polyester nonwoven fabric or a polypropylene nonwoven fabric; A pile layer made of fibers planted on the upper surface of the bubble layer by flocking; And a supporting layer having a form in which the first polymer pad layer, the glass fiber layer, and the second polymer pad layer are sequentially stacked on the lower surface of the bubble layer.

In addition, another object of the present invention (a) applying an adhesive to the upper surface of the bubble layer consisting of a polyester nonwoven or polypropylene nonwoven; (b) Flocking of any one of the fibers selected from the group consisting of nylon fibers, polyethylene fibers, rayon fibers, and mixed fibers thereof on the top surface of the bubble-coated bubble layer to form a pile layer Making; And a first polymer pad layer, a glass fiber layer, and a second polymer pad layer are sequentially stacked by coating the first polymer, the glass fiber fabric, and the second polymer on the lower surface of the bubble layer in which the fibers are implanted. Forming a support layer; wherein the first polymer and the second polymer of step (c) are made of polyvinyl chloride resin, styrene-butadiene rubber (SBR), natural rubber, polypropylene resin, and polyurethane resin. It can be achieved by providing a method for producing a flocking carpet, characterized in that any one selected from the group consisting of.

The present invention is preferably characterized in that the upper surface of the nonwoven fabric forming the bubble layer is coated with any one olefin resin selected from the group consisting of polyethylene resins, polypropylene resins, polyisobutylene resins, and mixed resins thereof. It is done.

Flocking carpet according to the present invention is because the bubble layer is made of polyester nonwoven fabric or polypropylene nonwoven fabric instead of conventional glass fiber fabrics, irritation, skin disorders, dyspnea, nausea, vomiting, diarrhea, etc. can be caused by the glass fiber It can be prevented in advance, and at the same time, has almost the same form stability (dimension stability) as the flocking carpet using the fiberglass fabric as the bubble layer. In addition, considering that the price of the polyester nonwoven fabric is about 2/5 of the price of the glass fiber fabric, the manufacturing cost is low, and thus it has a superior price competitiveness than the conventional flocking carpet.

One aspect of the present invention is a flocking carpet having a foam layer made of a material safer and more economical than a glass fiber fabric, and having almost the same level of form stability (dimension stability) as a flocking carpet using a fiberglass fabric as a bubble layer. It is about. Hereinafter, the flocking carpet according to the present invention will be described in detail with reference to the accompanying drawings.

According to Figure 2 showing a cross-sectional structure of the flocking carpet according to an embodiment of the present invention, the flocking carpet of the present invention is a bubble layer 110 made of a polyester nonwoven fabric or a polypropylene nonwoven fabric; Pile layer 120 made of fibers planted on the upper surface of the bubble layer by the flocking (Flocking); And a support layer 160 having a form in which the first polymer pad layer 130, the glass fiber layer 140, and the second polymer pad layer 150 are sequentially stacked on the bottom surface of the bubble layer.

Bubble layer

The nonwoven fabric forming the bubble layer is a structure in which polyester fibers or polypropylene fibers are bonded in a web form by one method selected from the group consisting of a spunbond method, a melt brown method, a needle punching method, and a water interlocking method. Phosphorous polyester nonwoven fabric or polypropylene nonwoven fabric is used. Preferably, PET (Polyethylene terphethalate) nonwoven fabric is used which is manufactured by spunbond method and has excellent strength. The basis weight of the nonwoven fabric constituting the bubble layer is characterized in that more than 60 g / ㎡, more preferably more than 80 g / ㎡, if the basis weight is less than 60 g / ㎡ the nonwoven fabric is too thin to coat the olefin on the top surface It becomes difficult to work, and there is a possibility that workability | operativity may be inferior in flocking the fiber (for example, nylon fiber) which forms a pile layer by flocking. The upper limit of the nonwoven basis weight is not limited, but will be limited by the raw material and manufacturing method of the nonwoven fabric.

The nonwoven fabric forming the bubble layer according to the invention is preferably coated on its upper surface with an olefin resin. The process of planting fibers (eg nylon fibers) on the top surface of the nonwoven fabric by flocking generally involves applying an adhesive to the top surface of the nonwoven fabric and then attaching the fibers (eg nylon fibers) on top of the static electricity. It consists of the process of fixing the fiber by using the chapter, when using the non-olefin coated nonwoven fabric, the adhesive flows down through the surface of the nonwoven fabric, which may cause a problem of increasing the amount of adhesive used. The olefin resin used to coat the upper surface of the nonwoven fabric may be any one selected from the group consisting of polyethylene resins, polypropylene resins, polyisobutylene resins, and mixed resins thereof, and is preferably convenient in workability. Polyethylene resins can be used.

Pile

The pile layer is formed by flocking fibers on the upper surface of the bubble-coated layer coated with an adhesive, and forms a surface of the carpet fabric and provides a cushioning effect to the carpet product. The fibers constituting the pile layer may be any one selected from the group consisting of nylon fibers, polyethylene fibers, rayon fibers, and mixed fibers thereof, and are preferably nylon fibers. Nylon fiber has a self-extinguishing property that can generate carbon dioxide by itself in the event of a fire, and when nylon fiber is used as the fiber constituting the pile layer, the flame resistance of the flocking carpet can be improved.

The length of the fibers constituting the pile layer is not particularly limited, but is preferably 1 to 5 mm, more preferably 2 to 4 mm. If the length of the fiber is less than 1 mm, the cushioning of the flocking carpet may be impaired. If the length of the fiber exceeds 5 mm, interference between the fibers may occur during the planting process due to flocking, and the fibers of the pile layer may be removed. Inclining in a direction or standing vertically may not be smooth.

The fineness of the fibers constituting the pile layer is not particularly limited, but is preferably 5 to 50 denier, more preferably 10 to 20 denier. If the fineness of the fiber is less than 5 denier, it may be too thin for flocking, and when the fineness of the fiber exceeds 50 denier, the number of fibers that can be planted per unit area of the bubble layer is limited, and the fiber of the pile layer is limited. There is a possibility that the water density is lowered and the characteristics expressed from the flocking carpet (blocking penetration of contaminants, ticks, blocking of breeding of bacteria, cleaning of water, etc.) may be lowered.

The number of flocked fibers in the pile layer is characterized in that more than 60 million, preferably more than 80 million per square meter area of the bubble layer, if the number of flocked fibers less than 60 million per square meter area of the bubble layer, the space between the fibers forming the pile layer increases (I.e., the density of fibers is lowered), the characteristics expressed from the flocking carpet (blocking penetration of contaminants, mites, blocking of breeding of bacteria, possible cleaning of water, etc.) may be deteriorated. There is no upper limit to the number of flocked fibers per square meter area of the bubble layer, but will be limited by the fineness, length and processing conditions of the flocking of the fibers constituting the pile layer.

Support layer

The support layer is formed by coating the first polymer, the glass fiber fabric, and the second polymer in order on the lower surface of the bubble layer into which the fibers are implanted, and the first polymer pad layer 130, the glass fiber layer 140, and the second polymer. The polymer pad layer 150 is stacked in order. The first polymer pad layer and the second polymer pad layer serve to maintain the shape of the flocking carpet, and the glass fiber layer imparts morphological stability (dimension stability) to the flocking carpet.

The first polymer and the second polymer used to form the first polymer pad layer and the second polymer pad layer are polyvinyl chloride resin, styrene-butadiene rubber (SBR), natural rubber, polypropylene resin, and polyurethane resin. It may be selected from the group consisting of, and it is preferable that it is a polyvinyl chloride resin in view of workability, economy, and versatility. In particular, the first polymer pad layer and the second polymer pad layer may be manufactured in the form of a foam, in which case the first polymer pad layer and the second polymer pad layer may be formed of a flocking carpet formed of glass fiber layers. Stability) and give elasticity when the user steps on the flocking carpet installed on the floor, thereby serving to keep the user's sense of comfort. When the flocking carpet is actually applied to the floor, it is divided into a tile type and a roll type. When the first polymer pad layer and the second polymer pad layer are non-foamed, the tile type is mainly a tile type. ), And in this case, the shape stability (dimension stability) is important, so a glass fiber layer should be formed between the first polymer pad layer and the second polymer pad layer. However, when the first polymer pad layer and the second polymer pad layer are in the form of a non-foaming body, the first polymer pad layer and the second polymer pad layer are mainly processed into a roll type. Even if the glass fiber layer is not formed between the polymer pad layer can serve as a support layer.

For flocked carpets having a bubble layer of polyester nonwoven or polypropylene nonwoven, the strength of the nonwoven fabric (average basis weight is about 80 g / m2) is usually the strength of the glass fiber fabric (average basis weight is about 170 g / m2). Shape stability (dimension stability) may decrease. In order to compensate for this, the support layer according to the present invention includes a glass fiber layer in which a glass fiber fabric is impregnated between the first polymer pad layer and the second polymer pad layer. Unlike the bubble layer formed of the glass fiber fabric, the glass fiber layer according to the present invention is trapped in two polymer pad layers, and thus, when the flocking carpet is applied to the floor, the glass fiber layer is hardly exposed to the outside, and thus may be generated by the glass fiber. May prevent irritation, skin disorders, shortness of breath, nausea, vomiting and diarrhea. The glass fiber fabric used for the glass fiber layer according to the present invention is not particularly limited in basis weight, and may have a loose structure having a smaller number of wefts and warps per unit area than the glass fiber fabric used as a bubble layer in a conventional flocking carpet. . The basis weight of the glass fiber fabric used as the bubble layer in the conventional flocking carpet is about 170 g / ㎡, according to the present invention even when the glass fiber layer is formed of a glass fiber fabric having a smaller basis weight than the bubble layer It has almost the same form stability (dimension stability) as the flocking carpet used.

Another aspect of the present invention relates to a method for producing a flocking carpet, and the same parts as described above will be omitted.

Method for producing a flocking carpet according to the present invention comprises the steps of (a) applying an adhesive to the upper surface of the bubble layer 110 made of a polyester nonwoven fabric or a polypropylene nonwoven fabric; (b) The pile layer 120 is formed by flocking one of the fibers selected from the group consisting of nylon fibers, polyethylene fibers, rayon fibers, and mixed fibers thereof on the upper surface of the bubble-coated bubble layer. Forming); And (c) coating the first polymer, the glass fiber fabric, and the second polymer on the lower surface of the bubble layer in which the fibers are implanted in order, so that the first polymer pad layer 130, the glass fiber layer 140, and the second polymer It includes; forming a support layer 160 having a form in which the pad layer 150 is stacked in order.

The first polymer and the second polymer of step (c) is any one selected from the group consisting of polyvinyl chloride resin, styrene-butadiene rubber (SBR), natural rubber, polypropylene resin, and polyurethane resin The nonwoven fabric forming the bubble layer of step (a) may be coated with any one olefin resin selected from the group consisting of polyethylene resin, polypropylene resin, polyisobutylene resin, and a mixed resin thereof. It features.

The type of adhesive used in step (a) is not particularly limited, and preferably, polyurethane adhesives and acrylic adhesives may be used. In addition, the fiber forming the pile layer in step (b) is preferably a dyed (impregnated) fiber, but when it is planted on the top surface of the bubble layer can exhibit a color to increase the commerciality of the flocking carpet.

The manufacturing method of the present invention may further comprise the step of printing a pile layer 120 made of fibers planted on the upper surface of the bubble layer between the step (b) and (c), the desired pattern pile layer It is possible to increase the merchandise of the flocking carpet by printing on.

In the step (c) of the present invention, the process of coating the first polymer, the glass fiber fabric, and the second polymer on the lower surface of the bubble layer into which the fibers are planted is performed in a die coater, comma coater, blade coater, gravure coater, etc. And a comma coater is particularly advantageous for coating solutions or pastes with high viscosity.

Hereinafter, the present invention will be described in more detail with reference to Examples. However, the following examples are only intended to clarify the present invention, but the scope of the present invention is not limited thereto.

One. Flocking Carpet  Produce

Example 1.

A foam layer was prepared by coating a polyethylene resin on the upper surface of the spunbond PET nonwoven fabric (Basic weight: 80 g / m 2) by a laminating method. Polyurethane adhesive is applied to the upper surface of the bubble layer, and nylon fibers (length: 2-4 mm, fineness: 10-20 denier) are attached thereto, and then the bonded fibers are vertically oriented using a high voltage electrostatic generator. It was planted and the pile layer was formed. The pile layer is dyed (printed) with a rotary screen printer (printing speed: 12 m / min), and a PVC resin and glass fiber fabric (PVC) is applied to the lower surface of the bubble layer using a comta coater (coating speed: 3 m / min). Basis weight: 150 g / ㎡), and then coated with a PVC resin to form a support layer to prepare a flocking carpet.

Comparative Example 1.

Flocking carpet was prepared under the same conditions as in Example 1, except that a glass fiber fabric (a basis weight: 170 g / m 2) not coated with a polyethylene resin on the upper surface was used as a bubble layer.

2. Flocking Carpet  Property measurement

Formulation number, dimensional stability per unit area of the bubble layer of the flocking carpet prepared in Example 1 and Comparative Example 1 was measured and the results are shown in Table 1 below. The measurement of the dimensional stability was performed by the method of KSK 2621 7.8. Specifically, the samples 50 cm long and 50 cm long were left in water for some time, taken out, dried in a drier, and the dimensional change was calculated by the following equation.

Dimensional change (%) = absolute value of (I-Io) * 100 / Io

Where Io is the length of the original sample and I is the sample length after drying.

division Number of plantings per unit area of bubble layer (number / ㎡) Dimensional change amount (%) Example 1 80 million 0.15 Comparative Example 1 80 million 0.1

As shown in Table 1, the flocking carpet of Example 1 exhibited excellent morphological stability (dimension stability) as in the flocking carpet of Comparative Example 1.

Figure 1 shows a cross-sectional structure of a general flocking carpet having a bubble layer made of a glass fiber fabric, Figure 2 shows a cross-sectional structure of a flocking carpet according to an embodiment of the present invention.

Claims (12)

Bubble layer 110 made of polyester nonwoven or polypropylene nonwoven; Pile layer 120 made of fibers planted on the upper surface of the bubble layer by the flocking (Flocking); And And a support layer (160) having a form in which the first polymer pad layer (130), the glass fiber layer (140), and the second polymer pad layer (150) are sequentially stacked on the bottom surface of the bubble layer. The flocking carpet according to claim 1, wherein the nonwoven fabric forming the bubble layer is coated with an olefin resin on an upper surface thereof. 3. The flocking carpet according to claim 2, wherein the olefin resin is any one selected from the group consisting of polyethylene resin, polypropylene resin, polyisobutylene resin, and mixed resins thereof. The floc according to any one of claims 1 to 3, wherein the fibers constituting the pile layer are any one selected from the group consisting of nylon fibers, polyethylene fibers, rayon fibers, and mixed fibers thereof. King carpet. The flocking carpet according to claim 4, wherein the fibers constituting the pile layer have a length of 1 to 5 mm and a fineness of 5 to 50 denier. The lower flocking carpet according to claim 4, wherein the number of flocked fibers in the pile layer is 60 million or more per square meter area of the bubble layer. The flocking carpet according to any one of claims 1 to 3, wherein the basis weight of the nonwoven fabric constituting the bubble layer is 60 g / m 2 or more. The method of claim 1, wherein the first polymer pad layer and the second polymer pad layer comprise polyvinylchloride resin, styrene-butadiene rubber (SBR), natural rubber, polypropylene resin, and polyurethane. Flocking carpet, characterized in that made of any one polymer selected from the group consisting of a resin. 10. The flocking carpet according to claim 9, wherein the first polymer pad layer and the second polymer pad layer are in the form of a foam. (a) applying an adhesive to the top surface of the bubble layer (110) consisting of a polyester nonwoven or a polypropylene nonwoven; (b) The pile layer 120 is formed by flocking one of the fibers selected from the group consisting of nylon fibers, polyethylene fibers, rayon fibers, and mixed fibers thereof on the upper surface of the bubble-coated bubble layer. Forming); And (c) coating the first polymer, the glass fiber fabric, and the second polymer on the lower surface of the bubble layer into which the fibers are implanted, in order, so that the first polymer pad layer 130, the glass fiber layer 140, and the second polymer pad Forming a support layer 160 having a form in which the layers 150 are stacked in order; The first polymer and the second polymer of step (c) is any one selected from the group consisting of polyvinyl chloride resin, styrene-butadiene rubber (SBR), natural rubber, polypropylene resin, and polyurethane resin Method for producing a flocked carpet. The non-woven fabric of claim 10, wherein the nonwoven fabric forming the bubble layer of step (a) has any one olefin resin selected from the group consisting of polyethylene resins, polypropylene resins, polyisobutylene resins, and mixed resins thereof. Method for producing a flocking carpet, characterized in that coated with. The method according to any one of claims 10 to 11, further comprising the step of printing a pile layer (120) made of fibers planted on the upper surface of the bubble layer between the steps (b) and (c). Method for producing a flocking carpet, characterized in that.

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