JPH03112635A - Pile 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 (Field of Industrial Application) The present invention relates to tile carpets, and more particularly to tile carpets that have excellent resin permeability into the pile base and morphological stability, and have a low-cost backing structure. .

(Prior Art) Thermoplastic resins such as polyolefin resins and polyvinyl chloride resins have been commonly used as backing materials for tile carpets.

The structure of the backing layer is two-layered, with a non-woven fabric or fabric made of glass fiber or synthetic fiber interposed between them, or the amount of filler in the upper layer of the backing layer is reduced to reduce the amount of resin at the base of the pile. While improving permeability and preventing pile shedding, the amount of filler in the lower layer is increased to improve the degree of hardening of the backing layer and improve the form stability of the tile carpet.
has been proposed. (For example, JP-A-59-13
No. 5023, JP-A-61-119780).

(Problem to be solved by the invention) Such tile carpets are used in offices,
It is often used as flooring material in places where people walk frequently, such as hotels, stores, schools, and hospitals. Especially when it is used in places where heavy objects are placed or moved, shrinkage or warping may occur after installation. This may occur.

As a means to prevent this, polyvinyl chloride resin is used for the backing layer, and by increasing the amount of filler in the backing layer, the entire tile carpet is hardened, and at the same time, the weight is increased to improve the shape stability. is considered.

In this case, the vinyl chloride backing layer has a two-layer structure, and the upper layer contains a filler to sufficiently hold the pile threads of the carpet and prevent the pile, especially individual fibers, from coming off.
For example, in the upper layer of the backing layer, 300 parts or more of filler is added to 100 parts of vinyl chloride resin. Then, the viscosity of the resin increases and the permeability of the resin to the base of the pile deteriorates, causing problems such as threads coming out of the pile and a decrease in strength retention.

Particularly in the case of tile carpets, which are often installed in places where durability is required, such fuzz and loose threads are fatal defects for the product, and the permeability of the resin is an important requirement. It is.

Therefore, in general carpet tiles, the upper layer of the backing layer contains 300 parts or less of filler per 100 parts of vinyl chloride resin.
When adding 300 parts or more of filler to 00 parts,
It is necessary to interpose an adhesive between the pile fiber layer and the backing layer, which increases the cost.

The purpose of the present invention is to provide a tile carpet with good permeability of resin from the backing layer to the pile part and excellent morphological stability. This aims to improve the morphological stability and solve the above problems by mixing and using fillers with different particle sizes in a specific ratio.

(Means and effects for solving the problems) In order to achieve the above object, the present invention comprises a surface pile layer made of a pile fabric in which piles are planted on a base fabric, a polyvinyl chloride resin, a filler, etc. In the tile carpet, the backing layer is formed of two layers, an upper layer and a lower layer, and the upper layer is made of 300 to 450 parts by weight of filler per 100 parts by weight of polyvinyl chloride, and the lower layer is made of 300 to 450 parts by weight of filler per 100 parts by weight of polyvinyl chloride. Each contains 350 to 600 parts by weight of filler per 100 parts by weight of polyvinyl chloride, and the particle size of the filler is 150 to 2.
The composition of the carpet is a mixture of 00μ and 1 to 10μ in a ratio of 1:1 to 5:1.

The present invention will be explained in detail below along with its operation.

Fig. 1 is a joint cross-sectional view of the tile car vent of the present invention, which does not show the pile, 2 is the base fabric, 3 is the upper layer of the backing layer, 4 is the lower layer of the backing layer, and 5 is the middle of the backing layer. Each figure shows the base fabric.

The pile 1 forms the surface of the carpet, and the pile shape may be a loop, a cut, or a combination thereof. Further, pile formation can be achieved by any method such as tufting or needle punching.

As the material for the pile 1 to 5:1, all commonly used materials can be used, such as synthetic fibers such as nylon, acrylic, polyester, and polypropylene, and natural fibers such as wool. Further, as the pile material, these fibers may be used in combination, and further, functional fibers such as conductive fibers and antibacterial fibers may be used in combination.

As the base fabric 2, any material used for general carpets may be used, but it is necessary to perform high temperature treatment in the noking process, so from that point of view it is better to use a material that is not as heat resistant as polyester fiber Preferably, it is made of a superior fiber material.

The backing layer is mainly made of polyvinyl chloride resin and filler.
It has a two-layer structure with a base fabric 5 interposed between the backing layer, and the upper layer 3 contains 100 parts by weight of polyvinyl chloride, 70 to 120 parts by weight of a plasticizer, and 300 to 4 parts by weight of a filler.
It is blended at a ratio of 50 parts. In addition, the lower layer 4 contains 50 to 1 part of plasticizer per 100 parts by weight of polyvinyl chloride.
20 parts by weight of the filler and 350 to 600 parts by weight of the filler, and in both the upper layer 3 and the lower layer 4, the filler has a particle size of 150 to 200 μm and a filler of 1 to 10 μm.
They are mixed in the range of ~5:1.

As the filler, commonly used fillers such as calcium carbonate and talc are used.

In this case, if the amount of filler in the upper layer 3 is 300 parts or less, the hardness of the backing layer will decrease and the dimensional stability will deteriorate. If the amount exceeds 450 parts, the viscosity of the resin increases too much, resulting in poor processability and the formation of air bubbles and voids in the backing layer, which is not preferable.

The same applies to the lower layer part 4, but in the case of the lower layer part 4, there is no need to consider the permeability of the resin into the pile part, so the ``■'' of the filler is increased to improve the form stability of the backing layer. In particular it is possible to place the main 11J2.

The most important point in the present invention is that the shape of the filler is a mixture of coarse particles and fine particles.
It has been found that the permeability of the resin into the filler is improved and that an increase in viscosity can be suppressed even when the amount of filler is increased.

If a large amount of filler with a coarse (large) particle size, such as that used in -fm, is mixed into the resin, the filler will settle and separate from the resin layer. By combining fine fillers, it is possible to prevent the fillers from settling.

In the present invention, as a result of various studies on this formulation, the above-mentioned average particle diameter is 150 to 200/7,
It has been found that the desired effect can be obtained by mixing particles having an average particle diameter of 1 to 10 μm, preferably 3 to 5 μm, in a ratio of 11 to 5:1. In this case, if coarse particles of 200 μm or more are included, the granular filler may fall off from the cut surface of the tile carpet, which is not preferable.

Moreover, if it is less than 150μ, the viscosity will increase. Furthermore, if the particle size of the fine filler is 10 μm or more, the filler will settle when mixed with a resin, and if it is less than 1 μm, it will be difficult to compound and the problem of increased viscosity will occur.

When the fine particle ratio is set to 1 or more, the viscosity increases, and on the other hand, when it is set to 14 or less, the permeability deteriorates.

The intermediate base fabric 5 may be made of synthetic fibers such as polyester fibers or nylon fibers, but it has the heat resistance required as the intermediate base fabric 5 of the backing layer of the tile carpet, including the manufacturing process. A nonwoven fabric made of glass fiber is the most excellent in terms of chemical resistance, morphological stability, specific gravity, etc., and is therefore preferable.

The intermediate base fabric 5 may be inserted between the backing layers, and may be used in a composite form with other sheets if necessary.

The method for manufacturing the tile carpet of the present invention may be carried out according to a generally used manufacturing method. For example, a vinyl chloride composition for forming the lower layer is applied to a releasable belt, and then a glass fiber The nonwoven fabrics are laminated and impregnated. Next, a vinyl chloride composition for forming the upper layer is applied, and a surface pile layer is placed on top of it, followed by heat treatment to gel the vinyl chloride composition to form a backing layer and to integrate the whole. The carpet is then cut into predetermined dimensions to produce carpet tiles.

(Example) Hereinafter, the present invention will be explained in more detail with reference to Examples.

Tile carpets were manufactured according to the above-mentioned manufacturing method with the conditions of the upper layer and lower layer of the backing layer as shown in Table 1, and were used as Example 1, Example 2, Comparative Example 1, and Comparative Example 2.

As is clear from the same table, the conditions of the lower layer were common to each side, and the upper layer was varied in the amount of the desensitizer CD0P') and the coarse/fine ratio of calcium carbonate as a filler.

The results showed that Examples 1 and 2 were satisfactory in terms of fuzz resistance, suture removal strength, and filler sedimentation, but Comparative Example 1 in which the average particle size of the fine filler was 15μ In Comparative Example 2, the sedimentation of the filler was particularly significant, and the fuzz resistance was also unsatisfactory.

Table 1 Furthermore, the conditions of the lower layer were the same as in Example 1, the average coarse particle size of calcium carbonate, which is the filler in the upper layer, was 165μ and the average fine particle size was 5μ, and the ratio of coarse and fine particles was 2:l. , 3:
The ratio was changed to 1.5:1.4:1, and the other conditions were as shown in Table 2, resulting in Examples 3 to 6. In Example 6, the amount of calcium carbonate was specifically set to 450 parts, which is the upper limit of the present invention.

Although the coarse/fine particle ratio of calcium carbonate was changed to 2:1.3:1.5:1 in Examples 3 to 5, the fuzz resistance and
Both suture removal strength was good.

Further, although sedimentation was slightly inferior in Example-5, it did not pose a problem in processing. In Example 6, the amount of calcium carbonate added was increased to 450 parts, but the fuzz resistance, suture removal strength, and sinking strength were all satisfactory.

Table 2 (Effects of the Invention) As explained in detail below, the tile carpet of the present invention has excellent heat resistance because the backing layer is made of vinyl chloride, and furthermore, the upper layer of the backing layer Although it contains a high filler, it has excellent penetration into the resin twill part, making it possible to increase the hardness of the backing layer, resulting in good form stability and at the same time preventing fuzz and thread dropout. This can be prevented, and its effects are significant.

[Brief explanation of drawings]

The figure is a longitudinal cross-sectional view of the tile carpet of the present invention. Description of the main parts of the diagram 1-pile 2-Base fabric 3-(Backing layer) 2nd layer part 4-(Backing layer) Lower layer 5-(Backing layer) Intermediate base fabric Tezukuri City-IE'-JF (spontaneous) March 1990 1 [-1

Claims (1)

[Claims] A tile carpet consisting of a surface pile layer made of pile fabric with piles planted on the base fabric, and a backing layer made of polyvinyl chloride resin, filler, etc., where the backing layer has two layers, an upper layer and a lower layer. Furthermore, the upper layer contains 300 to 4 parts of filler per 100 parts by weight of polyvinyl chloride.
50 parts by weight, the lower layer contains 350 to 600 parts by weight of filler per 100 parts by weight of polyvinyl chloride,
and the particle size of the filler is 150-200μ and 1-1
A tile carpet characterized by a mixture of 0μ and 0μ in a range of 1:1 to 5:1.