JPH08312117A - Interior material - Google Patents

Abstract

PURPOSE: To prevent deformation, and reuse wastes, by superposing a backing material laminated with the upper layer, intermediate layer, and lower layer, on the surface layer and making these respective layers bear a specified quantity of short fiber composed of wastes or the like. CONSTITUTION: A surface layer 6 is laminated on a backing layer 4 composed of a synthetic resin bearing short fiber (f). The short fiber (f) made of a ground fiber interior material of tilecarpet or the like is charged in the backing material 4. And more short fiber (f) than the upper layer 1 and the lower layer 3 is charged in the intermediate layer 2 so that the quantity of short fiber in the intermediate layer is 1-80% and the quantity of short fiber in the upper and lower layers is 0-30%. As the backing material 4 is divided into three layers, it is formed to have an even thickness. And as the charged quantity in the intermediate layer 2 is more than that of other layers, the dimensional stability is increased and also the surface of surface layer 6 becomes flat and smooth. In this way, warping-up is prevented and dimensions are stabilized and a large quantity of waste materials can be reused.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to carpets, particularly tile carpets, and interior materials such as vinyl flooring materials and wall covering materials, and more particularly to interior materials containing a synthetic resin and short fibers as a backing material.

[0002]

2. Description of the Related Art At present, fiber interior materials, which occupy an important position as a type of interior materials, are generally incinerated or landfilled when they are used up and discarded. In the case of incineration, there is a risk that toxic gas will be generated, and in the case of landfill, it is difficult to secure a disposal site.

Therefore, it has been practiced to pulverize the discarded fiber interior material to some extent, mix it with the backing layer of another interior material, and reuse it. (Actual development 59-132
(No. 581, No. 59-132582, Shokai)

However, these have only one layer containing the crushed fiber interior material, the amount of the crushed fiber interior material that can be filled is limited, and the shape stability such as warpage is poor, and the size is further increased. The stability was also unsatisfactory. In addition, the finish as a product was not beautiful because it contained fibers and lacked smoothness.

[0005]

DISCLOSURE OF THE INVENTION An object of the present invention is to provide an interior material having at least an intermediate layer of an interior material backing material, which is filled with short fibers, to prevent warpage and to have further excellent dimensional stability. (EN) Provided is an interior material in which a crushed fiber interior material is filled into a lining material to reuse a discarded fiber interior material and to increase the amount of reuse.

[0006]

DISCLOSURE OF THE INVENTION The present invention is an invention that solves the above-mentioned problems and is composed of a backing material in which a surface layer, an upper layer, an intermediate layer and a lower layer are laminated, and at least the backing material intermediate layer has short fibers. The interior material is characterized in that the content of the short fibers is higher in the backing material intermediate layer than in the backing material upper layer and the backing material lower layer.

The present invention will be described with reference to the drawings. FIG.
Is an interior material of the present invention, 1 is a backing material upper layer, 2 is a backing material intermediate layer, and 3 is a backing material lower layer. These one, two,
The backing material layer 4 is formed by stacking 3 in order from the top. This backing material layer 4 is formed of synthetic resin such as PVC, PE, PP, APAO, and hot melt resin. Also,
The backing material layer 4 contains short fibers. The short fibers include synthetic fibers such as nylon and polyester, natural fibers such as wool, and inorganic fibers such as glass fibers. These short fibers can be used as piles contained in carpet waste, base cloth, and crushed materials of fiber reinforcement.

In the present invention, a particularly important point is that the lining material is filled with a crushed material of a fiber interior material such as a tile carpet as much as possible and is recycled, which is useful from the viewpoint of environmental protection. . As shown above, the backing material layer 4 is divided into an upper layer, an intermediate layer, and a lower layer, and the intermediate layer is filled with more staple fibers than the upper layer and the lower layer.
The amount of fibers in the middle layer is 1 to 80%, and the amount of fibers in the upper and lower layers is 0.
~ 30% contamination.

By thus dividing the backing material layer 4 into three layers, a thick sheet having a uniform thickness and a total thickness (3.5 mm or more) can be produced.

The filling amount of short fibers in the upper and lower layers 3 of the backing material is 20% or less, preferably 10%. By making the fiber filling amount of the backing material lower layer 3 smaller than that of the intermediate layer 1, dimensional stability is obtained, and when the filling fiber contains glass fiber, the fiber content of the lower layer 3 is reduced. This prevents the construction worker from scratching. Moreover, the surface smoothness of the surface layer can be obtained by making the fiber filling amount of the upper layer smaller than that of the intermediate layer.

Furthermore, since the embossing 5 is applied to the surface of the interior material of the present application by a known method such as passing through an embossing roll, it does not slip even when placed. Therefore, the construction can be simplified.

As the surface layer 6, a sheet using a synthetic resin as shown in FIG. 2, a carpet fabric as shown in FIG. 3, a woven fabric, a non-woven fabric, etc. can be used. Not limited. As a result, it can be applied to a wide variety of interior materials.

[0013]

EXAMPLES Next, examples will be described. The structure of this embodiment is shown in FIG.

[Compound]

[Table 1] (Unit: wt%) Backing material Surface layer Upper layer Intermediate layer Lower layer PVC resin 70 25 15 25 TCP scraps 0 10 45 10 Plasticizer 27 15 10 15 Calcium carbonate 0 47 47 28 47 Stabilizer 3 2 1.8 2 Pigment 0 1.0 0.2 1.0 Printed layer Printed sheet ― ― ― Sheet thickness (mm) 0.5 0.5 1.5 1.0 1.0 However, TCP scrap is 10 mesh after crushing tile carpet. Through a sieve, and the fiber content is about 10% by weight. The existing surface layer was used.

[Manufacturing Method] According to the composition and sheet thickness shown in Table 1, the upper layer, the intermediate layer and the lower layer of the backing material are manufactured by calendering. Then, the surface layer, the upper layer of the backing material, the intermediate layer, and the lower layer are laminated in this order from the top, and the laminating roll (150-
(160.degree. C.), followed by thermocompression bonding, and then the back surface was embossed with an embossing roll to complete the interior material of the present application.

[0014]

Comparative Example Next, a comparative example will be described.

[Compound]

[Table 2] (Unit: wt%) Surface layer Intermediate layer Lower layer PVC resin 58.1 25.6 25.6 TCP scraps ― ― ― Plasticizer 21.3 11.4 11.4 Calcium carbonate 14.6 58.5 58.5 Stabilizer 4.0 3.3 3.3 Pigment 2.0 1.2 1.2 Sheet thickness (mm) 0.3 1.2 0.5

[Manufacturing Method] The surface layer, the intermediate layer and the lower layer having the above composition are manufactured by calendering. Then, the surface layer, the intermediate layer, and the lower layer were laminated in this order, and thermocompression bonded by a laminating roll to manufacture a sheet of a comparative example.

[0015]

[Comparison between Examples and Comparative Examples] A comparison of physical properties between Examples and Comparative Examples is shown below. Example 1 Comparative Example 1 Total thickness (mm) 4.42 2.02 Residual dent rate (%) 3.70 4.90 Heat expansion / contraction rate V (%) -0.393 -0.393 H (%) +0. 023 +0.129 Heating warp V (%) +1.5 +7.7 H (%) +1.5 +4.2 Absorption expansion and contraction rate V (%) +0.059 -0.485 H (%) +0.033 +0.179 Absorption warpage V (%) -0.9 -9.1 H (%) 0 0 The methods of measuring various physical properties are shown below. Total thickness measurement Under a room temperature of 20 ± 2 ° C. and a humidity of 65 ± 10% (hereinafter referred to as standard conditions), a test piece of 50 mm × 50 mm is adjusted for 1 hour,
Then the thickness is measured. The adjustment is performed in the same manner as in the measurement of the residual indentation rate, and then a load of 0.56 kgf / mm ² is applied for 10 minutes, and the thickness 60 minutes after the application of the load is released is measured. Then, the residual depression rate is calculated by the following formula. Heat expansion / contraction ratio Samples are adjusted for 12 hours or more under standard conditions, then 300m
Cut into m × 300 mm. The piece is placed horizontally in an oven at 80 ± 2 ° C. with the surface facing up and heated for 6 hours. Then, the sample is adjusted under standard conditions for 1 hour, and the length of the sample thereafter is measured. Then, it is calculated by the following formula. Perform the same test as the heating warp and measure the warp at the center of each side of the test piece. Water absorption expansion / contraction rate A test piece 303 mm × 303 mm is adjusted for 12 hours or more under standard conditions, and the length is measured. Then, the test piece is immersed in a water absorption tank (water temperature 20 ± 1 ° C.) for 72 hours, and then the time is adjusted under standard conditions to measure the length. The water absorption expansion / contraction rate is calculated by the following formula. Perform the same test as the water absorption warp, and measure the center warp of each side of the test piece.

[Operation of the Invention] The interior material of the present invention comprises the backing material layer containing short fibers, and further comprises a backing material layer in each of three layers having different short fiber ratios, a backing material upper layer and a backing material intermediate layer. The laminated structure of the layers and the lower layer of the backing material does not cause warpage, which is important for interior materials, and has excellent physical properties such as dimensional stability. Further, by blending the fiber filler in the upper layer, the intermediate layer and the lower layer, the discarded tile carpet scraps and the like are most utilized.

[0017]

EFFECTS OF THE INVENTION The backing material layer has a three-layer structure, each layer contains short fibers, and the short fiber content of each layer is different. It has excellent physical properties such as properties. Laying can be done by embossing the surface. It can be applied to a wide variety of interior materials by changing the surface layer. Waste of tile carpets and other textile interior materials,
A large amount of the interior material lining material layer of the present application is filled with a large amount of waste, and the amount of waste such as landfill and incineration is reduced, which is effective in terms of environmental protection.

[Brief description of drawings]

FIG. 1 Interior material of the present invention

FIG. 2 Interior material of the present invention (surface layer: PVC clear layer +
Print layer)

FIG. 3 Interior material of the present invention (surface layer: carpet raw material)

[Explanation of symbols]

1 ... Lining material upper layer 2 ... Lining material intermediate layer 3 ... Lining material lower layer 4 ... Lining material layer 5 ... Back surface embossing 6 ... Surface layer 6 '... Surface layer (PVC clear Layer + printing layer) 6 "... Surface layer (carpet green) 7 ... Interior material of the present invention 8 ... PVC clear layer 9 ... Printing layer 10 ... Interior material of the present invention (surface layer: PVC clear) Layer +
Printing layer) 11 ... Pile 12 ... Nonwoven fabric 13 ... Interior material of the present invention (surface layer: carpet greige)

[Procedure amendment]

[Submission date] August 10, 1995

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be amended] Detailed explanation of the invention

[Correction method] Change

[Correction content]

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to carpets, particularly tile carpets, and interior materials such as vinyl flooring materials and wall covering materials, and more particularly to interior materials containing a synthetic resin and short fibers as a backing material.

[0002]

2. Description of the Related Art At present, fiber interior materials, which occupy an important position as a type of interior materials, are generally incinerated or landfilled when they are used up and discarded. In the case of incineration, there is a risk that toxic gas will be generated, and in the case of landfill, it is difficult to secure a disposal site.

Therefore, it has been practiced to pulverize the discarded fiber interior material to some extent, mix it with the backing layer of another interior material, and reuse it. (Actual development 59-132
(No. 581, No. 59-132582).

[0004]

However, these have only one layer containing the pulverized fiber interior material, the amount of the pulverized fiber interior material that can be filled is limited, and the shape stability such as warpage occurs. However, the dimensional stability was not satisfactory. In addition, the finish as a product was not beautiful because it contained fibers and lacked smoothness.

[0005]

SUMMARY OF THE INVENTION It is an object of the present invention to provide an interior material having at least an intermediate layer of an interior material backing material with short fibers to prevent warpage and further having good dimensional stability,
Further, by filling the ground material lining material with the crushed fiber interior material, it is possible to reuse the discarded fiber interior material and to provide an interior material in which the reuse amount can be increased. The invention of the present application is constituted by a backing material in which a surface layer and an upper layer, an intermediate layer, and a lower layer are laminated in the invention which solves the above-mentioned problems, and at least the backing material intermediate layer contains short fibers, and the content of the short fibers. The gist is an interior material characterized in that the backing material intermediate layer is more than the backing material upper layer and the backing material lower layer.

The present invention will be described with reference to the drawings. FIG. 1 is a sectional view of the interior material of the present invention, in which 1 is a backing material upper layer, 2 is a backing material intermediate layer, and 3 is a backing material lower layer. The backing material layer 4 is a laminate of these upper layer, intermediate layer and lower layer.
Becomes This backing material layer 4 is made of polyvinyl chloride (PV
C), polyethylene (PE), polypropylene (P
P), amorphous poly-α-olefin (APA
O) and other synthetic resins such as hot melt resin, and the backing material layer 4 contains short fibers f. The short fibers include synthetic fibers such as nylon and polyester, natural fibers such as wool, and inorganic fibers such as glass fibers. These short fibers can be used as piles contained in carpet waste, base cloth, and crushed materials of fiber reinforcement. The surface layer 6 is laminated on the backing material layer 4 to form the interior material 7 of the present invention.
Is obtained.

In the present invention, a particularly important point is that the lining material is filled with a crushed material of a fiber interior material such as a tile carpet as much as possible and is recycled, which is useful from the viewpoint of environmental protection. . As shown above, the backing material layer 4 is divided into an upper layer, an intermediate layer and a lower layer, and the intermediate layer is filled with more short fibers f than the upper layer and the lower layer. The amount of short fibers in the middle layer is 1 to 80%, and the amount of short fibers in the upper and lower layers is 0 to 30%. By dividing the backing material layer 4 into three layers in this manner, a thick sheet having a uniform thickness, preferably a total thickness of 3.5 mm or more, can be produced.

In the upper layer 1 and the lower layer 3 of the backing material, the filling amount of short fibers is preferably 20% or less, more preferably 1%.
0% or less. By making the fiber filling amount of the backing material lower layer 3 smaller than that of the intermediate layer 2, dimensional stability is obtained, and when the filling fiber contains glass fiber, the fiber content of the lower layer 3 is reduced. This prevents the construction worker from scratching. Further, by making the fiber filling amount of the upper layer 1 smaller than that of the intermediate layer, the surface smoothness of the surface layer 6 can be obtained. Further, the surface layer 6 may be appropriately provided with an embossed pattern. Furthermore, by embossing 5 on the surface (rear surface) of the interior material backing material of the present application, which is adhered to the base material, by passing it through an embossing roll or the like, there is no displacement even when laid down and the construction is simplified. You can

FIG. 2 is a sectional view of the interior material of the present invention of another embodiment, and FIG. 3 is a sectional view of the carpet according to the present invention. In FIG. 2, 1 is a backing material upper layer, 2 is a backing material intermediate layer, 3 is a backing material lower layer, 4 is a backing layer, f is a short fiber, and a transparent resin layer 8 and a pattern layer 9 are laminated as a surface layer 6 ′. The interior material 10 is created. The pattern layer 6 may be a printed pattern, or an irregular pattern such as a marble pattern or a plain colored pattern. In FIG. 3, the pile 11 is tufted onto the base fabric 12 to form a pile greige 6 ″, which is laminated with the backing 4 to obtain the carpet 13.

[0010]

[Example] In the constitution of "Fig. 2", each of the surface layer and the backing layer was formed with the composition as shown in "Table 1".

[0011]

[Table 1] (Single
(Rank: weight%)Lining material Surface layer Upper layer Middle layer Lower layer PVC resin 70 25 15 25 TCP waste 0 10 (1) 45 (4.5) 10 (1) Plasticizer 27 15 10 15 Calcium carbonate 0 47 28 47 Stabilizer 3 2 1.8 2  Pigment 0 1.0 0.2 1.0 Sheet thickness (mm) 0.5 0.5 1.5 1.5 1.0 However, TCP scrap is crushed tile carpet
And passed through a 10-mesh sieve. TCP
The amount in the brackets in the scrap column is the total amount of short fibers (unit:
% By weight).

The upper layer, the intermediate layer and the lower layer of the backing material having the composition and the sheet thickness shown in "Table 1" were prepared by calendering,
150-160 for each surface layer, printing layer, and backing material layer
The laminate was heated and pressure-bonded with a laminating roll at ℃, and further embossed with an embossing roll on the lower surface of the lower layer of the backing layer to obtain the interior material of the present application.

[0013]

[Comparative example]

[Table 2] (Unit: wt%) Surface layer Intermediate layer Lower layer PVC resin 58.1 25.6 25.6 TCP scraps ― ― ― Plasticizer 21.3 11.4 11.4 Calcium carbonate 14.6 58.5 58.5 Stabilizer 4.0 3.3 3.3 Pigment 2.0 1.2 1.2 Sheet thickness (mm) 0.3 1.2 0.5

A surface layer, an intermediate layer, and a lower layer having the composition of "Table 2" were produced by calendering and heat-pressed with a laminating roll to produce a sheet floor material of a comparative example.

[0015]

Table 3 Examples Comparative Examples Total thickness (mm) 4.42 2.02 Residual dent rate (%) 3.70 4.90 Heat expansion / contraction rate V (%) -0.393 -0.393 H (%) +0.023 +0.129 Heating warp V (%) +1.5 +7.7 H (%) +1.5 +4.2 Water absorption expansion / contraction rate V (%) +0.059 -0.485 H (%) +0.033 +0 .179 Water absorption warp V (%) -0.9 -9.1 H (%) 0 0

The performance comparison between the example and the comparative example is shown in "Table 3". In the example, although the total thickness is thicker than that of the comparative example, the short fibers are 1.0% by weight in the upper layer, 4.5% by weight in the intermediate layer, and 1.0% in the lower layer.
Since it is mixed by weight%, the residual dent is slightly excellent, and the heating and water absorption expansion / contraction rate and the warp are excellent. Particularly, the value of the example is about 20% for the heating expansion / contraction rate (horizontal direction) of the comparative example. The warpage was 20 to 40%, the water absorption expansion / contraction rate was 10 to 20%, the water absorption warpage V (vertical direction) was 10% or less, and H was 0, and extremely excellent performance was obtained.

The methods for measuring various physical properties are shown below. Total thickness measurement Under a room temperature of 20 ± 2 ° C. and a humidity of 65 ± 10% (hereinafter referred to as standard conditions), a test piece of 50 mm × 50 mm is adjusted for 1 hour,
Then the thickness is measured. The adjustment is performed in the same manner as in the measurement of the residual indentation rate, and then a load of 0.56 kgf / mm ² is applied for 10 minutes, and the thickness 60 minutes after the application of the load is released is measured. Then, the residual depression ratio is calculated by the following "Formula 1".

[0018]

(Equation 1)

Heat expansion / contraction rate Samples were conditioned for 12 hours or more under standard conditions, then 300 m
Cut into m × 300 mm. The piece is placed horizontally in an oven at 80 ± 2 ° C. with the surface facing up and heated for 6 hours. Then, the sample is adjusted under standard conditions for 1 hour, and the length of the sample thereafter is measured. Then, it is calculated by "Equation 2".

[0020]

(Equation 2)

The same test as the heating warp is conducted, and the warp at the center of each side of the test piece is measured. Water absorption expansion / contraction rate A test piece 303 mm × 303 mm is adjusted for 12 hours or more under standard conditions, and the length is measured. After that, the test piece is immersed in a water absorption tank (water temperature 20 ± 1 ° C.) for 72 hours, and then the time is adjusted under standard conditions to measure the length, and the water absorption expansion / contraction rate is calculated by “Equation 3”.

[0022]

(Equation 3)

The same test as the water absorption warpage is conducted, and the center warpage of each side of the test piece is measured.

[0024]

INDUSTRIAL APPLICABILITY The interior material of the present invention comprises three layers having a short fiber content in the backing material layer and a backing material layer in each layer and having different short fiber ratios, that is, an upper layer, an intermediate layer and a lower layer. The structure and the maximum content of short fibers in the intermediate layer show the characteristic that the interior material does not warp, and have excellent physical properties such as dimensional stability. Further up,
By incorporating the fiber filler also in the intermediate layer and the lower layer, the discarded tile carpet waste and the like are most utilized.

[0025]

EFFECTS OF THE INVENTION The backing material layer has a three-layer structure, each layer contains short fibers, and the short fiber content of each layer is different. It has excellent physical properties such as properties. Waste of tile carpets and other textile interior materials,
A large amount of the interior material lining material layer of the present application is filled with a large amount of waste, and the amount of waste such as landfill and incineration is reduced, which is effective in terms of environmental protection. Laying can be done by embossing the back of the lining material. It can be applied to a wide variety of interior materials by changing the surface layer.

[Procedure Amendment 2]

[Document name to be amended] Statement

[Name of item to be corrected] Brief description of the drawing

[Correction method] Change

[Correction content]

[Brief description of drawings]

FIG. 1 is a sectional view of an interior material of the present invention.

FIG. 2 is a sectional view of an interior material according to another embodiment of the present invention.

FIG. 3 is a sectional view of a carpet of the present invention.

[Explanation of reference numerals] 1 ... upper layer of backing material 2 ... intermediate layer of backing material 3 ... lower layer of backing material 4 ... backing material layer 5 ... back surface embossing 6 ... front surface layer 6 '... Surface layer (PVC clear layer + printing layer) 6 "... Surface layer (carpet green) 7 ... Interior material of the invention 11 ... Pile 12 ... Nonwoven fabric 13 ... Carpet f of the invention f ... Short fiber

[Procedure 3]

[Document name to be corrected] Drawing

[Correction target item name] All drawings

[Correction method] Change

[Correction content]

FIG.

[Fig. 2]

[Figure 3]

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display location E04F 15/16 8702-2E E04F 15/16 A

Claims (5)

[Claims] 1. A backing material in which a surface layer, an upper layer, an intermediate layer and a lower layer are laminated, and at least the backing material intermediate layer contains monofilaments, and the content of the monofilament is in the backing material intermediate layer. The interior material is characterized by having more than the upper layer of the backing material and the lower layer of the backing material. 2. The interior material according to claim 1, wherein a crushed material of carpet waste is mixed in the backing layer. 3. The interior material according to claim 1, wherein the single fiber is a crushed carpet pile product and / or a crushed glass fiber product. 4. The interior material according to claim 1, wherein the backing layer intermediate layer is filled with 1 to 80% by weight of monofilament. 5. The interior material according to claim 1, wherein 0 to 30% by weight of monofilament is added to the upper and lower layers of the backing layer.