JPH0450420B2 - - Google Patents

Description

[Detailed description of the invention]

[Industrial Field of Application] The present invention relates to a method for producing a shape-stable carpet tile that exhibits extremely little dimensional change and warping in response to changes in ambient temperature. [Prior art and its problems] Tile carpets are square, rectangular, diamond-shaped, or more complexly shaped carpets, each having an area of about 0.05 to ² m2. By using them in combination, they can be laid on the floor without creating any gaps.
These tile carpets have the advantage that they can be easily constructed by simply arranging them on the floor and fixing them, compared to regular carpets, and they can be made into carpets with various textures by combining many shapes, colors, etc. of the tile carpets. It also has the advantage of being easy to repair. When these tile carpets are laid on the floor, it is necessary that they adhere well to the floor and do not peel off when walking.For this reason, a relatively thick backing material gives the tile carpet its own weight, and its own weight It provides fixation (placeability). This backing material also has the role of imparting various properties to the tile carpet, such as thread removal prevention, shape retention, and floor placement. Conventional carpet tiles generally have a structure in which a backing material is laminated on a carpet base material, and a backing fabric is further laminated, and in some cases, the pile threads of the carpet base material are fixed. Some use adhesive for this purpose, while others do not use backing fabric. In this way, conventional tile carpets are rugs with various advantages, but the dimensions of conventional tile carpets are small due to changes in temperature due to seasonal changes and sudden changes in temperature caused by heaters or air conditioners. However, there was a drawback that changed. For this reason, even if the dimensions of a single tile carpet vary slightly, large deformations will occur in a large construction area for carpet tiles that are laid down by their own weight. In other words, when the temperature drops significantly, the slight contraction of the carpet tiles creates gaps between each carpet tile, which impairs the aesthetics and causes the tiles to move when walking, making it very uncomfortable to walk. . In addition, when the temperature rises significantly, the carpet tiles expand, and in extreme cases, the carpet tiles may bulge. As described above, the dimensional change of tile carpets due to temperature changes is said to be the biggest drawback of tile carpets, and there is an urgent need to solve this problem. In addition, because tile carpets are manufactured by laminating tile carpet base materials at high temperatures, tile carpets may warp at room temperature due to differences in the thermal deformation and residual strain of the combined base materials. Curling may occur, or even if there is no curling at room temperature, large curling may occur in high or low temperature atmospheres. When such warpage occurs, the tile carpet is lifted up, which not only impairs the aesthetic appearance but also poses a risk of tripping for pedestrians. It was also necessary to solve this recurring drawback at the same time. [Object of the Invention] The object of the present invention is to eliminate the above-mentioned drawbacks of conventional tile carpets, and to provide a tile carpet that has excellent dimensional stability, extremely little warping, and is stable in shape. be. [Summary of the Invention] That is, the present invention provides a carpet base material with (a) a first backing material made of a composition mainly composed of a thermoplastic material, and (b) an intermediate base fabric having a small linear expansion coefficient with respect to heat on the back side of a carpet base material. , (c) a second backing material made of a composition containing a thermoplastic substance as a main component; (d) a backing fabric laminated in sequence, and the (a) first backing material layer and (c) second backing material; The present invention relates to a method for producing a shape-stable carpet tile, characterized in that the weight ratio of the layers is 1.00±0.14. The carpet base material referred to in the present invention is not particularly limited, and may be formed from natural fibers such as wool, cotton, and linen, synthetic fibers such as polypropylene, polyester, polyamide, polyacrylate, and polyvinylidene chloride, and fiber materials such as flat yarn. These include woven carpets, knitted carpets, tufted carpets, needle punch carpets, etc., with tufted carpets and needle punch carpets being particularly preferred. It is also possible to use these carpet substrates which have been precoated with a latex type, a hot melt type adhesive based on ethylene-vinyl acetate copolymer, or a film precoated with low density polyethylene. The backing material used for the first and second backing materials in the present invention is a composition containing a thermoplastic substance as a main component. Examples of the thermoplastic substance include asphalt such as natural asphalt and petroleum asphalt;
Polyolefins such as polyethylene, polypropylene, ethylene-propylene copolymers, ethylene-butene copolymers, olefin-polar monomer copolymers such as ethylene-vinyl acetate copolymers, ethylene-acrylic acid ester copolymers, and polyvinyl chloride , chlorinated polymers such as chlorinated polyethylene can be used. In the present invention, when asphalt is used as the backing material, polyolefins such as polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-vinyl acetate copolymer,
Ethylene-polar monomer copolymers such as ethylene-acrylic acid ester copolymers, chlorinated polymers such as polyvinyl chloride and chlorinated polyethylene, styrene-butadiene copolymers (random, block), styrene-isoprene copolymers (random,
synthetic and natural rubbers such as block), butyl rubber, isoprene rubber, and chloroprene rubber.
~50% by weight is blended, and if necessary, an inorganic filler can be optionally blended. When polyolefin is used, waxes, low molecular weight polyolefins, petroleum resins, and inorganic fillers can be blended in an amount of 5 to 50% by weight based on 50 to 95% by weight of polyolefin. In addition, when using an ethylene-strength monomer copolymer, 10 to 90% by weight of the copolymer is mixed with 10 to 85% by weight of an inorganic filler, and 0 to 20% by weight of a softener and plasticizer that are liquid at room temperature. can do. Further, when using a chlorinated polymer, 5 to 80% by weight of a plasticizer and 0 to 80% by weight of an inorganic filler can be blended with respect to 10 to 90% by weight of the chlorinated polymer. In the present invention, the first backing material and the second backing material may be of the same type or may be of different types. In the present invention, when an asphalt-based, polyolefin-based, or ethylene-polar monomer copolymer system is used as the backing material, it can be prepared using a kneader, a Banbury mixer, a single-screw or twin-screw kneading extruder, and this is used as the first backing material. and the second
Used as lining material, total weight is 1.5-8.0Kg/
m ² , preferably 2.0 to 6.0 Kg/m ² . When the total weight of the backing material is less than 1.5 kg/m ² , it is not preferable because the placement stability due to its own weight deteriorates.
Moreover, if it is larger than 8.0Kg/m ² , it will be difficult to lay it and it will be economically disadvantageous. In addition, in the case of chlorinated polymers, polyvinyl chloride,
Prepare a paste consisting of a plasticizer (e.g. DOP) and an inorganic filler, and apply it to the carpet base material at a rate of 1.5~
8.0Kg/ ^m2 can be laminated. The intermediate base fabric used in the present invention may be any material that has a small linear expansion coefficient against heat, and the coefficient is 10 ^-5
It is preferably 10 ⁻⁶ or less. Examples include glass fiber, carbon fiber, and metal fiber.
Glass fibers are particularly preferred, and woven fabrics made of bundled yarns such as plain weave, twill weave, simiyaori, leno weave, satin weave, etc.; A nonwoven fabric is used that is dispersed in a random direction to a uniform thickness and bonded with a binder. Also, the basis weight is 10 to 1000g/m ² , preferably 15
~800g/ ^m2 . The backing fabric as used in the present invention refers to a woven fabric formed from the same fiber material as the carpet base material, a fabric bonded without weaving into a network using a binder or heat fusion, and a fabric in which fibers are randomly arranged in a uniform thickness. using a nonwoven fabric bonded to Especially polyester fiber, polyamide fiber,
Woven and nonwoven fabrics formed from polypropylene fibers and mixed fibers thereof are preferred. The basis weight of the backing fabric is 10 to 500 g/m ² , preferably 15 to 500 g/m 2
It is 400g/ ^m2 . The method for manufacturing a shape-stable carpet tile of the present invention will be explained. FIG. 1 is a schematic diagram showing an example of the tile carpet manufacturing method according to the present invention, in which a carpet base material 1 is drawn out from a carpet base material supply section 2 by a conveyor 3 and is transported. The first backing material 7 (excluding the paste-like composition of polyvinyl chloride) made of a composition mainly composed of a thermoplastic substance disposed above the
T-die extrusion at a temperature of 250℃, doctor blade,
Alternatively, after laminating to a predetermined thickness with a coater 6 such as a calendar roll coater, the intermediate base fabric 5 guided in parallel to the upper surface of the first backing material from the intermediate base fabric supply section 4 is laminated with a pressure roll 8, A second backing material 10 made of a composition containing a thermoplastic material as a main component is again extruded through a T-die under the same conditions and laminated to a predetermined thickness using a coater 9 such as a doctor blade or a calendar roll coater. The back base fabric 13 guided in parallel to the upper surface of the second backing material from the back base fabric supply section 12 is laminated by the pressure roll 11 to form a laminated carpet strip material 14 having a predetermined thickness and properties, and then a subsequent process. At the cutting device 1 via the cooling device 15.
6 shows a method of obtaining the desired tile carpet 17 through 6. At this time, it is effective if the weight ratio of the first backing material layer and the second backing material layer is in the range of 1.00±0.14, but it is preferable that the weight ratio is equal. Also polyvinyl chloride,
In the case of a paste-like compound consisting of a plasticizer and an inorganic filler, it is spread evenly on the backing fabric using a doctor blade at room temperature to form the second backing material layer, and then the intermediate fabric is layered on top of this and heated in a heating oven. After preheating at 180°C for 5 minutes in a heating furnace, spread the paste mixture evenly on top of it to form the first backing material layer, layer the carpet base material, and further heat at 180°C in a heating furnace.
Heat for 10 minutes to gel and integrate. In this case as well, the weight ratio of the first backing material layer and the second backing material layer is
Laminate so that the range is 1.00±0.14. The product obtained by laminating in this way is cut into a suitable size and used as a tile carpet. [Effects of the Invention] It has been found that excellent dimensional stability can be imparted by inserting an intermediate base fabric having a small linear expansion coefficient against heat. It has also been found that laminating a backing fabric improves warping and helps improve dimensional stability. In other words, the intermediate base fabric used in the present invention has a very small linear expansion coefficient against heat, which is much smaller than that of the carpet base material, backing material, and back base fabric conventionally used for tile carpets. By using cloth in combination, the dimensional change of the tile carpet due to temperature changes is very small. In other words, the backing material used for carpet tiles is 100
Because the carpet base material and backing fabric are melted at a temperature of ~250°C and then heated at room temperature or slightly warmed, it is the backing material that retains the most distortion when cooled to room temperature. Therefore, inserting the intermediate base fabric used in the present invention in the middle of this backing material is very useful for improving dimensional stability. However, if the intermediate base fabric is inserted between the backing materials and the carpet base material is simply laminated on one side of the backing material, curling will normally occur to the back side of the carpet base material. In order to prevent this, if the backing fabric is laminated on the opposite side of the carpet base material, the warpage will be eliminated, and especially if the backing fabric is laminated on the opposite side of the carpet base material, We found that using a backing fabric was highly effective. It was also found that this effect improved dimensional stability. [Examples] The present invention will be explained in more detail below using Examples and Comparative Examples. Examples 1 to 6 On the back side of a tufted carpet or needle punch carpet, various backing materials (first) shown in Table 1 and an intermediate base fabric made of glass fiber were laminated, and the same backing material was also laminated. The material (second) and various backing fabrics were laminated and cut into a predetermined size to obtain a tile carpet. For these, room temperature is 20℃
Using this as a standard, we determined the rate of change in dimensions and the state of warping in an atmosphere where the temperature was raised or lowered by 40°C. As shown in Table 2, the results show that the dimensional change rate is extremely small, indicating good dimensional stability and no warping at all, which poses no practical problems. I found out.

【table】

[Table] Comparative Examples 1 to 5 Various backing materials shown in Table 2 were applied to the back side of the tufted carpet without inserting an intermediate base fabric,
Furthermore, the various tile carpets obtained by laminating the backing fabric are 40°C higher than the room temperature of 20°C.
The rate of change in dimensions and the presence or absence of warping in an atmosphere where the temperature was raised or lowered were determined. As shown in Table 2, the results were very large values, which could cause problems in practice. However, the names of each material are abbreviated as follows. Ethylene-vinyl acetate copolymer: EVA Ethylene-ethyl acrylate copolymer: EEA Polypropylene: PP Low-density polyethylene: LDPE Polyvinyl chloride: PVC Dioctyl phthalate: DOP Calcium carbonate: Charcoal

【table】 [Brief explanation of the drawing]

FIG. 1 is a schematic diagram showing an example of the method for manufacturing a tile carpet according to the present invention. DESCRIPTION OF SYMBOLS 1... Carpet base material, 2... Carpet base material supply part, 3... Conveyance conveyor, 4... Intermediate base fabric supply part, 5
... Intermediate base fabric, 6, 9... Coater, 7... First backing material, 8, 11... Pressure roll, 10... Second backing material, 12... Back base fabric supply section, 13... Back base fabric, 14...
Laminated carpet strip material, 15... Cooling device, 16... Cutting device, 17... Tile carpet.

Claims (1)

[Scope of Claims] 1. On the back side of the carpet base material, (a) a composition mainly consisting of a thermoplastic material selected from asphalt, polyolefin, olefin-polar monomer copolymer, and chlorinated polymer; (b) glass fiber with a small linear expansion coefficient against heat;
Selected from woven fabrics, bonded fabrics, and non-woven fabrics made of carbon fibers or metal fibers, with a basis weight of 10~
1000 g/m ² , (c) a first base fabric comprising a composition based on a thermoplastic material selected from asphalt, polyolefin, olefin-polar monomer copolymer and chlorinated polymer; (d) backing fabrics selected from woven fabrics, bonded fabrics and non-woven fabrics of polyester fibers, polyamide fibers, polypropylene fibers or glass fibers are sequentially laminated, and said (a) first backing material layer and ( c) Manufacture of a shape-stable carpet tile, characterized in that the weight ratio of the second backing material layer is 1.00±0.14, and the total amount of the first backing material and the second backing material is 1.5 to 8.0 Kg/ ^m2 . Method. 2. The manufacturing method according to claim 1, wherein the carpet base material is a tufted tile carpet or a needle punch carpet.