JP5650930B2 - Carpet and manufacturing method thereof - Google Patents

Description

The present invention relates to a carpet using a sealing layer having a small energy load in manufacturing and a manufacturing method thereof.

Conventionally, various materials are applied to the back surface of the carpet for sealing the surface pile layer. The purpose of the sealing is to prevent the carpet substrate from fuzzing.

On the other hand, in order to apply a carpet to various uses, for example, a tile carpet used in an office or a carpet used in a home, a backing layer suitable for each use has been developed, and the backing layer is used as a carpet substrate. By lining, the carpet according to various uses is used.

Here, what has been conventionally proposed as a backing layer of such carpet is a base resin made of a polymer material such as an ethylene / vinyl acetate copolymer, an ethylene / ethyl acrylate copolymer, or an olefin elastomer. For example, a composition comprising an ethylene / vinyl acetate copolymer / process oil / filler (Japanese Patent Laid-Open No. 55-71734), a copolymer of ethylene and vinyl acetate or ethyl acrylate / barium sulfate / plastic Using a composition comprising an agent (JP-A-56-53141), using an olefin elastomer / filler composition (JP-A-56-88464), and low-density polyethylene / barium sulfate. A composition using such a composition (Japanese Patent Laid-Open No. 57-139574) has been proposed.

However, such a conventional hot-melt type backing layer is suitable for various specific applications, but because it uses a polymer material as a base resin, it itself has poor penetration into the surface pile layer. In addition, since the melting temperature is high, the application time, that is, the time for infiltration, is short, and therefore, the effect of preventing fuzzing and the improvement of the pulling-out strength by sealing are not necessarily sufficient.

Therefore, when the above hot-melt type backing layer is applied to a substrate, a composition made of latex or emulsion of various polymer materials, typically a composition made of latex of carboxy-modified styrene / butadiene copolymer, is used. It has been proposed to apply to a carpet substrate in advance as a sealing layer.

However, when latex or emulsion is used, it is generally necessary to vulcanize or dry them after application, which requires a large apparatus for heating and drying the carpet, as well as high heating temperature and long heating time. For this reason, there is a concern about deterioration of the carpet base material, and workability and work efficiency are also lowered due to the addition of the heating step. Moreover, the use of latex or emulsion made of a polymer material necessitates a treatment facility for inevitably generated waste liquid, which is disadvantageous economically.
JP-A-55-71734 JP 56-53141 A JP-A-56-88464 JP-A-57-139574

In view of the above situation, the present invention is capable of providing a uniform seal sufficiently penetrating the surface pile layer, is excellent in the fuzz prevention effect (fuzz resistance) by the seal, and has a great amount of coating and heat when manufactured. The object is to provide a carpet that is not required and to propose a method of manufacturing the carpet.

As a result of intensive studies to solve such problems, the present inventors have found that a low-viscosity polyvinyl chloride resin having a viscosity of 5000 CPS or less and an inorganic component of 200 parts by weight or less with respect to 100 parts by weight of the polyvinyl chloride resin. By forming the sealing layer, it was found that the carpet was excellent in the fuzz prevention effect (fuzz resistance), does not require a great amount of coating and heat, and can be firmly adhered to the backing layer. . In order to achieve the above object, the present invention provides the following means.

[1] In a carpet composed of a surface pile layer made of a pile fabric in which a pile is planted on a base fabric, a sealing layer, and a backing layer, the sealing layer is formed of a low-viscosity polyvinyl chloride resin. The carpet characterized in that the low-viscosity polyvinyl chloride resin has a viscosity of 5000 CPS or less, and the inorganic component is 200 parts by weight or less with respect to 100 parts by weight of the polyvinyl chloride resin.

[2] The backing layer is composed of an intermediate layer made of a nonwoven or woven fabric of glass fiber or synthetic fiber, and a single layer or a plurality of resin layers made of a polyvinyl chloride resin and a filler. The carpet according to item 1 above.

[3] The carpet according to item 1 above, wherein the backing layer is composed of an intermediate layer made of a nonwoven fabric or a woven fabric of glass fiber or synthetic fiber, and a foamed resin layer or a nonwoven fabric layer having a cushioning property. .

[4] The carpet according to [1], wherein the backing layer is made of a nonwoven fabric or a woven fabric of natural fibers or synthetic fibers.

[5] The polyvinyl chloride resin forming the sealing layer is a polyvinyl chloride-vinyl acetate copolymer copolymer having a reduced viscosity (K value) of 60 to 75. carpet.

[6] After impregnating and coating the back surface of the surface pile layer with a coating amount of 100 to 800 g / m ² in a sol state at room temperature, the polyvinyl chloride resin forming the sealing layer is heated and solidified. A method for producing a carpet, characterized in that a sealing layer is formed by:

In the invention of [1], the sealing layer constituting the carpet is formed of a low-viscosity polyvinyl chloride resin having a viscosity of 2000 CPS or less and an inorganic component of 200 parts by weight or less with respect to 100 parts by weight of the polyvinyl chloride resin. Further, the carpet is excellent in the fuzz prevention effect (fuzz resistance) by applying a uniform seal sufficiently penetrating the surface pile layer.

In the invention of [2], the backing layer is composed of an intermediate layer made of nonwoven fabric or woven fabric of glass fiber or synthetic fiber, and a single layer or a plurality of resin layers made of polyvinyl chloride resin and a filler. It can be used as a tile carpet installed in an office or the like, and becomes a durable carpet with less fuzz.

In the invention of [3], the backing layer is composed of an intermediate layer made of a nonwoven fabric or a woven fabric of glass fiber or synthetic fiber and a foamed resin layer or a nonwoven fabric layer having a cushioning property. It can be used as a cushioned carpet, and it becomes a cushioned carpet with less fluff.

In the invention of [4], since the backing layer is composed of a nonwoven fabric or a woven fabric of natural fibers or synthetic fibers, it can be used as a carpet used at home or the like, and becomes a carpet with less fuzz.

In the invention of [5], since the polyvinyl chloride resin forming the sealing layer is made of a copolymer of polyvinyl chloride-vinyl acetate copolymer having a reduced viscosity (K value) of 60 to 75, the resin can be obtained at a relatively low temperature. Is cured, resulting in a carpet with excellent fuzz prevention effect (fuzz resistance) at a low processing temperature.

According to the invention of [6], the polyvinyl chloride resin for forming the sealing layer is impregnated and applied to the back surface of the surface pile layer at a coating amount of 100 to 800 g / m ² in a sol state at room temperature. With a small amount of coating, a large amount of heat is not required for heating and drying, and the sealing layer is excellent in fuzz prevention effect (fuzz resistance).

Hereinafter, an embodiment of a carpet according to the present invention will be described with reference to the drawings. For example, the carpet (1) according to the present invention is exemplified by the structure of claim 2. As shown in FIG. 1, the carpet (1) has a surface pile layer (2) composed of a pile fabric in which a pile is planted on a base fabric, and a low viscosity poly As a sealing layer (3) formed of a vinyl chloride resin, and a backing layer (4), an intermediate layer (5) made of a nonwoven fabric or a woven fabric of glass fiber or synthetic fiber, and a polyvinyl chloride resin and a filler. A plurality of resin layers (6) are laminated and integrated.

The surface pile layer (2) in the present invention is not particularly limited. For example, the surface pile layer (2) in which a pile is implanted on the surface of a carpet base material, tufted carpet, woven carpet, knitted carpet, electrodeposition carpet and the like. For example, it is preferable to use a tuft carpet in which pile yarn is planted on the base fabric by tufting or the like, and the pile form is not particularly limited, and any form such as a cut pile or a loop pile may be used.

As a pile material constituting the surface pile layer (2), a material generally used as a carpet material may be used. Natural fibers such as wool, hemp and cotton, polyamide fibers, polyester fibers, polyacrylic are used. And synthetic resin fibers such as polypropylene fibers and polypropylene fibers. Moreover, it is preferable to use the woven fabric and nonwoven fabric which consist of synthetic resin fibers, such as a polyester fiber and a polypropylene fiber, as the base fabric by which a pile is planted.

Conventionally, in order to improve the fuzz prevention effect (fuzz resistance) of carpet, 800 to 2000 g of carboxy-modified styrene / butadiene copolymer latex having a solid content concentration of about 50% is used as a sealing agent on the back surface of carpet base fabric. A carpet is widely used in which moisture is removed by coating with a large amount of resin / m ² and a large amount of heat, and a sealing layer (3) having a solid content of 400 to 1000 g / m ² is formed. .

In the present invention, the coating with a large amount of resin and the sealing process by drying with a large amount of heat are not performed, and the back surface of the surface pile layer (2) of the carpet, that is, the adhesive surface with the backing layer (5) has a room temperature. By laminating the sealing layer (3) made of a low-viscosity vinyl chloride resin, it has an effect of being excellent in fuzz prevention effect (fuzz resistance). Furthermore, it can be set as the carpet (1) which is excellent also in adhesiveness with the said backing layer (5), and was excellent in all of stationary stability, a shape and dimensional stability, and durability.

As the vinyl chloride resin used for the sealing layer (3) made of the low-viscosity vinyl chloride resin, it is necessary to use a vinyl chloride resin of 5000 CPS or less that contains almost no filler and filler. If it is the said viscosity range, low application | coating of 100-800 g / m < ² > of application quantity is possible with a roll coating application method, the drying process which requires a big calorie | heat amount is unnecessary, and a sealing layer (3 ) Can be formed. Furthermore, it can exhibit a sufficient pile sealing effect and suppress the fuzz phenomenon which is a cause of fluffing on the surface pile layer (2) surface. If the viscosity exceeds 2000 CPS, the penetration into the surface pile layer (2) is insufficient and the effect of preventing the pile is not exhibited, and the effect of preventing the pile is obtained even when the coating amount is less than 100 g / m ^2. When it exceeds 800 g / m ² , it takes a large amount of heat and time for curing, resulting in a heavy load construction method, and further, the carpet becomes heavy.

Further, the reduced viscosity (K value) of the polyvinyl chloride resin forming the sealing layer is preferably 60 to 75 from the viewpoint of permeability and workability. If it is less than 60, the strength of the sealing layer is insufficient, and the fuzz prevention effect (fuzz resistance) by the sealing becomes insufficient, and if it exceeds 75, the permeability is not exhibited. Furthermore, the polyvinyl chloride resin of the polyvinyl chloride resin forming the sealing layer having a vinyl acetate content of 3 to 6% can be suitably used from the viewpoint of permeability and workability. If the temperature is less than 3%, the curing temperature does not decrease, and if it exceeds 6%, the workability deteriorates.

The structure of Claim 2 in this invention is a structure used as a tile carpet mainly installed in an office etc., and the backing layer (4) of this structure is the intermediate | middle which consists of a nonwoven fabric or a woven fabric of a glass fiber or a synthetic fiber. It comprises a layer (5) and a single layer or a plurality of resin layers (6) made of polyvinyl chloride resin and a filler.

The intermediate layer (5) improves the shape and dimensional stability of the carpet, and examples thereof include non-woven fabrics, woven fabrics, and braided fabrics of glass fibers or polyester fibers, and monofilaments are irregularly arranged as the non-woven fabric. As the woven fabric, a bundle of monofilaments woven, and as the braided fabric, a bundle of monofilaments arranged vertically and horizontally and fixed with a binder can be used.

From the viewpoints of shape and dimensional stability, glass or polyester-based nonwoven fabric is preferred, and the glass or polyester-based nonwoven fabric improves the shape stability of the carpet by inserting it between the resin layers (6). is there. That is, the glass or polyester nonwoven fabric has a large contact area with the resin layer, and can effectively stabilize the shape of the carpet. Basis weight from this point is preferably in the glass system nonwoven fabric in the range of 15 to 60 g / ^{m 2,} the range of 20 to 100 g / ^{m 2} in the polyester nonwoven fabric. In any case, if the basis weight is lower than this range, the effect of dimensional stability is insufficient, and if the basis weight is higher than this range, any peeling between the resin layer and the nonwoven fabric is likely to occur.

The resin layer (6) is a layer for forming the shape of the carpet, and the resin used is a plasticizer such as PVC sol made of a polymer of polyvinyl chloride-vinyl acetate copolymer and DOP (dioctyl phthalate). A paste-like product in which required additives such as a filler, a stabilizer, and a pigment are blended with a mixture sol and gelled by heating to form a homogeneous resin layer.

The coating amount of the resin layer (6) is suitably 300~4000g / ^{m 2.} When the coating amount is 300 to 4000 g / m ² , a large energy is not required and a dimensional stable backing layer is obtained. Below this range, formation as a strong layer is difficult, and above this range, formation as a layer becomes difficult.

The structure of Claim 3 in this invention is a structure used as a cushioning carpet mainly installed in a school facility etc., and the backing layer (4) of this structure is made of glass fiber or synthetic fiber. It is comprised by the intermediate | middle layer (5) which consists of a nonwoven fabric or woven fabric of a fiber, and a foamed resin layer or nonwoven fabric layer (7) with cushioning properties.

The said intermediate | middle layer (5) improves the shape and dimensional stability of a carpet similarly to the structure of Claim 2, Comprising: The nonwoven fabric, woven fabric, braided fabric, etc. of glass fiber or a polyester fiber are mentioned.

As the foamed resin layer or the nonwoven fabric layer (7) having cushioning properties, as the foamed resin layer, polyurethane-based elastic foam, which is a molded product that generates bubbles and has characteristics such as light weight, heat insulation, and elasticity, is used. Among the foams, polyurethane-based elastic foams are suitable for reasons such as ease of production, foaming magnification, ease of changing condition settings, and versatility. Due to the cushioning property of the polyurethane elastic foam, a lightweight and comfortable carpet can be obtained.

The polyurethane elastic foam has a thickness of 2.0 to 7.0 mm, more preferably 3.0 to 5.0 mm. If it is less than 2.0 mm, the cushioning property is lowered, and if it exceeds 7.0 mm, it becomes bulky, and a large step is formed at the boundary with the surrounding area where the carpet is not provided. Further, the compression elastic modulus is 80 to 97%, and if it is less than 80%, comfortable walking ability is lowered, and if it exceeds 97%, cushioning ability is lowered.

Moreover, as a nonwoven fabric layer, the nonwoven fabric which consists of synthetic fiber etc. or natural fiber etc. is used. Examples of the material used include polyester fibers, nylon fibers, synthetic fibers such as polyolefin fibers, and natural fibers such as wool and cotton, or a mixture of a plurality of natural fibers. Polyester fibers with little dimensional change due to heat are preferable. Examples of the nonwoven fabric include short fiber felts, needle punched nonwoven fabrics, chemical bond nonwoven fabrics, and the like, and needle punched nonwoven fabrics are preferable in consideration of cushioning properties.

Moreover, if the said nonwoven fabric is 2.0-7.0 mm in thickness, it will become the said nonwoven fabric layer (7) with the cushioning property suitable for a walk, and if it is this range, it will be a dimension suitably for a carpet (1). Stability and cushioning properties can be imparted. Preferably it is 4.0-6.0 mm. If the thickness is less than 2.0 mm, suitable dimensional stability and cushioning properties cannot be obtained, and if it exceeds 7.0 mm, walking becomes unstable carpet (1). Moreover, if it is this range, a weight will be 100-800 g / m < ² >, and it will become a carpet (1) which was remarkably reduced in weight compared with the conventional carpet, and the ease of construction and conveyance was improved.

Moreover, in the said nonwoven fabric (7) with a cushioning property, the carpet (1) which a cushioning property expresses by the structure where the fiber is entangled three-dimensionally, and can ensure lightweight and comfortable walkability is obtained. . The compression elastic modulus of the cushioning nonwoven fabric (7) is 80 to 97%. If it is less than 80%, the comfortable walking performance is lowered, and if it exceeds 97%, the cushioning property is lowered.

The structure of Claim 4 in this invention is a structure of the carpet mainly used at home etc., and the backing layer (4) of this structure is comprised with the nonwoven fabric or woven fabric of a natural fiber or a synthetic fiber. Examples of the material used include natural fibers such as hemp, and synthetic fibers such as polyester fibers, nylon fibers, and polyolefin fibers, and a woven fabric of hemp fibers having excellent shape retention is preferable.

Next, a method for coating and impregnating the surface pile layer (2) with the sealing layer (3) of the present invention will be described. Although this method is not particularly limited, it is appropriate to adopt a roll coating method, which is usually a known coating method, in view of the low viscosity of the filler.

That is, according to the roll coating method, the coating material is rotated and brought into contact with the sealing material of the present invention in a sol state at room temperature to form a thin film of the sealing material on the coating roll, and this surface pile moves separately. It can be transferred onto the layer (2) and impregnated. The sealing layer of the present invention can be easily impregnated by such a method.

After applying and impregnating the sealing material, the backing material according to the application, such as tile carpet, is thermocompression bonded before the sealing material is dried and solidified, or after heat curing, thereby producing a carpet as a product for a specific application. .

In addition, the carpet (1) of this invention is not specifically limited to what is manufactured with the said manufacturing method.

Examples of the present invention will be described below.

<Materials used> Surface pile layer: Nonwoven fabric (carpet base material) of polyester fiber having a basis weight of 90 g / m ² , and pile yarn made of nylon fibers tufted into a loop pile (pile basis weight 610 g / m ² ) : Non-woven fabric made of glass fiber (weight per unit: 35 g / m ² ) Backing layer: Mixture sol of PVC sol made of polymer of polyvinyl chloride-vinyl acetate copolymer and plasticizer such as DOP (dioctyl phthalate), filler, A composition that contains the required additives such as stabilizers and pigments Sealing layer: low-viscosity polyvinyl chloride resin

<Example 1> In a carpet processing machine, an upper and lower 3500 g / m ² polyvinyl chloride resin sheet sandwiched between glass nonwoven fabrics having a basis weight of 35 g / m ² is placed on a releasable belt and heated, and then separately. , Pile with low viscosity polyvinyl chloride resin (viscosity 1500 CPS, calcium carbonate containing 120 parts by weight with respect to 100 parts by weight of polyvinyl chloride resin) 300 g / m ² as a sealing layer It is applied to the back surface of the surface pile layer made of fabric, and the surface pile layer is heated and cured at 150 ° C. for 3 minutes, then thermocompression bonded at a temperature of 160 ° C. with a pressure roll, and finally cut into a square of 500 mm square, Carpet was manufactured.

<Example 2> Except that a low-viscosity polyvinyl chloride resin (viscosity 1800 CPS, calcium carbonate contained 120 parts by weight with respect to 100 parts by weight of polyvinyl chloride resin) was used as a sealing layer, the same as Example 1 And got a carpet.

<Example 3> Except that a low-viscosity polyvinyl chloride resin (viscosity 1000 CPS, calcium carbonate contained 120 parts by weight with respect to 100 parts by weight of polyvinyl chloride resin) was used as a sealing layer, the same as Example 1 And got a carpet.

<Example 4> Except that a low-viscosity polyvinyl chloride resin (viscosity 1500 CPS, calcium carbonate contained 180 parts by weight with respect to 100 parts by weight of polyvinyl chloride resin) was used as the sealing layer, the same as Example 1 And got a carpet.

<Example 5> Except that a low-viscosity polyvinyl chloride resin (viscosity 1800 CPS, calcium carbonate contained 80 parts by weight with respect to 100 parts by weight of polyvinyl chloride resin) was used as the sealing layer, the same as Example 1 And got a carpet.

<Comparative Example 1> Carpeting was carried out in the same manner as in Example 1 except that 800 g / m ² of SBR latex having a solid content concentration of about 50% was applied and dried as a sealing layer in a process separate from the carpet processing machine. Got.

<Comparative Example 2> Except that a low-viscosity polyvinyl chloride resin (viscosity 2500 CPS, calcium carbonate contained 120 parts by weight with respect to 100 parts by weight of the polyvinyl chloride resin) was used as the sealing layer, exactly the same as Example 1. And got a carpet.

<Comparative Example 3> Except that a low-viscosity polyvinyl chloride resin (viscosity 1800 CPS, calcium carbonate contained 300 parts by weight with respect to 100 parts by weight of the polyvinyl chloride resin) was used as the sealing layer, exactly the same as Example 1. And got a carpet.

<Comparative example 4> Implemented except that 70 g / m ² of low-viscosity polyvinyl chloride resin (viscosity 1500 CPS, calcium carbonate contained 120 parts by weight with respect to 100 parts by weight of polyvinyl chloride resin) serving as a sealing layer was applied. A carpet was obtained exactly as in Example 1.

<Comparative Example 5> Implemented except that 900 g / m ² of low-viscosity polyvinyl chloride resin (viscosity 1500 CPS, calcium carbonate contained 300 parts by weight with respect to 100 parts by weight of polyvinyl chloride resin) serving as a sealing layer was applied. A carpet was obtained exactly as in Example 1.

Each carpet obtained as described above was examined for fuzz resistance, dimensional stability test, and production rationality based on the following evaluation methods. The results are shown in Table 1.

(Fuzz resistance) A 300 gram load is applied to the wear wheel and rotated 20 times to visually evaluate the fuzz resistance. Grades 5 to 1 were judged according to the criteria table, and grades 4 and above were accepted. Judgment standard table grade 5: Pile form is almost the same as before the test. Grade 4: Slightly fuzzy. 3rd grade: Fluff observed on the same circumference of the sample. Second grade: Fluff is generated in a bundle of fibers and changes in pile form are observed. 1st grade: Those that do not retain the original shape of the pile.

(Production rationality) According to the number of processes and the amount of heat used, the low load method was marked as ◯, and the high load method was marked as x.

As is clear from Table 1, all the carpets of Examples 1 to 5 obtained carpets that were excellent in fuzz resistance and excellent in production rationality and could be fully used.

On the other hand, the carpet of Comparative Example 1 was inferior in fuzz resistance and production rationality, and the carpet of Comparative Example 2.3 did not have good performance with respect to fuzz resistance.

It is a schematic sectional drawing of the carpet which concerns on one Embodiment (structure of Claim 2) in this invention. It is the schematic of the manufacturing apparatus of the carpet of this invention concerning one Embodiment (structure of Claim 2) of this invention.

DESCRIPTION OF SYMBOLS 1 ... Carpet 2 ... Surface pile layer 3 ... Sealing layer 4 ... Backing layer 5 ... Intermediate layer 6 ... Resin layer which consists of a polyvinyl chloride resin and a filler 7 ... Heat treatment area

Claims (3)

A surface pile layer made of a pile fabric in which a pile is planted on a base fabric;
A sealing layer on the lower surface of the surface pile layer ;
A backing layer on the underside of the sealing layer ;
With
The sealing layer is formed of a low-viscosity polyvinyl chloride resin comprising a polyvinyl chloride-vinyl acetate copolymer copolymer having a reduced viscosity (K value) of 60 to 75, and the low-viscosity polyvinyl chloride resin has a viscosity of 5000 CPS or less. and Ri der than 200 parts by weight per 100 parts by weight of the inorganic component is polyvinyl chloride resin,
The backing layer includes two resin layers on the bottom surface of the sealing layer, and an intermediate layer made of a glass-based nonwoven fabric or a polyester-based nonwoven fabric interposed between the two resin layers,
Basis weight of the glass-based nonwoven fabric of the intermediate layer is 15 to 60 g / m ^2, the basis weight of the polyester nonwoven fabric is 20 to 100 g / m ^2,
Carpet characterized by that. The two resin layers are made of a foamed resin layer, and the foamed resin layer is made of a polyurethane elastic foam having a thickness of 2.0 to 7.0 mm and a compression elastic modulus of 80 to 97%. The carpet according to claim 1. A method for producing a carpet according to claim 1 or 2,
Polyvinyl chloride resin for forming the second stopper layer at room temperature of the sol state, after impregnation applied to the back surface of the surface pile layer at a coverage of 100 to 800 g / m @ 2, by heat curing to solidify, the eye A method for producing a carpet, characterized in that a stop layer is formed.