KR20230061096A - Carpet - Google Patents

Abstract

The present invention relates to a carpet and a manufacturing method thereof. The carpet of the present invention comprises: an upper part mat made of an eco-friendly fabric including equal to or more than one out of a PVC fabric, a cloth fabric, and a canvas fabric; and a flooring material attached to the upper part mat lower surface and formed of a film layer including equal to or more than one out of polyurethane, silicone, polyvinyl chloride (PVC), and polyester to have a non-slip function. An objective of the present invention is to provide the carpet which has environmentally friendly characteristics and can be reused, and the manufacturing method thereof.

Description

Carpet {Carpet}

The present invention relates to a carpet, and more particularly, an upper mat formed of eco-friendly fabric on the upper surface, an anti-slip flooring material applied to the lower surface, and low melting point (LM) fibers are used instead of general adhesives, thereby having eco-friendly characteristics and being reusable. It's about carpet.

In general, for the development of sports and physical development of citizens and students, there are indoor gym facilities in cities and local complex organizations or in each school.

In this indoor gym facility, not only athletic games but also various events are held where people gather.

However, since the floor of such a gym is made of an expensive high-end finishing material, when many people repeatedly enter the gym floor wearing general sneakers or shoes, the floor may be scratched and the floor of the high-end finishing material may be damaged. Therefore, the gym floor had to be renovated at great expense.

Therefore, in each school or local government, in order to prevent scratches on the floor of the gymnasium, when entering the floor, take off shoes or put corrugated cardboard or non-woven fabric on the floor before entering the floor. In addition, having them take off their shoes on the gym floor or put a protective cover on the floor would be very inconvenient for users, and the area around the gym was messy with cardboard or non-woven fabric. Due to pollution caused by the etc., it is difficult to reuse, leading to a problem that leads to resource waste.

Accordingly, it is necessary to develop a carpet capable of protecting the gym floor according to various events held in an indoor gymnasium, directly installing a game court line suitable for various sports games, and reusing the carpet.

As a prior art, there is Korean Utility Model Registration No. 20-0275131 "Carpet".

In order to solve the above problems, the present invention has an eco-friendly characteristic and can be reused by applying an upper mat formed of eco-friendly fabric on the upper surface, a non-slip flooring material on the lower surface, and using low melting point (LM) fibers instead of general adhesives. Its purpose is to provide a carpet and its manufacturing method.

In order to solve the above problems, the carpet according to an embodiment of the present invention is attached to an upper mat made of an eco-friendly fabric including at least one of polyvinyl chloride fabric, welfare fabric, and canvas fabric and the lower surface of the upper mat, It includes a flooring material formed of a film layer containing at least one of polyurethane, silicone, polyvinyl chloride, and polyester to have a non-slip function, and the upper mat and the flooring material are bonded with low melting point (LM) fibers.

In addition, the upper mat is characterized in that it has a dual structure including the polyvinyl chloride (PVC) fabric and further including the welfare fabric or canvas fabric.

In addition, the flooring material may further include a friction layer formed on a lower surface of the film layer and a protective layer formed on a lower surface of the friction layer to prevent damage to the friction layer.

In addition, the friction layer may include 8 to 12 parts by weight of a polymer, 1.5 to 3 parts by weight of a curing agent, 2 to 4 parts by weight of a viscosity modifier, and 1 to 2 parts by weight of a powder admixture.

In addition, the viscosity modifier may include at least one of polyvinyl alcohol having a molecular weight of 8,000 to 120,000 and polyvinylpyrrolidone having a molecular weight of 5,000 to 100,000.

In addition, the powder admixture may include at least one of glass fiber chop and diatomaceous earth.

In addition, the protective layer may include 20 to 35 parts by weight of cellulose, 50 to 60 parts by weight of alcohol, 45 to 55 parts by weight of distilled water, 0.1 to 0.5 parts by weight of a fluorine surfactant, and 0.8 to 1.7 parts by weight of a curing agent.

As described above, the carpet and its manufacturing method according to an embodiment of the present invention are eco-friendly by applying an upper mat formed of eco-friendly fabric on the upper surface, a non-slip flooring material on the lower surface, and using low melting point (LM) fibers instead of general adhesives. It has the advantage of being reusable by blocking the penetration of external contaminants and moisture.

In addition, since embossing is formed on the upper surface, there is an anti-slip effect, so that stability can be increased.

1 is a cross-sectional view showing a carpet according to an embodiment of the present invention.
Figure 2 is a cross-sectional view showing the detailed configuration of the interior material of Figure 1;
3 is a perspective view showing a state in which embossing is formed on the upper mat of FIG. 1;

Since the present invention can have various changes and various forms, specific embodiments will be described in detail in the text. However, this is not intended to limit the present invention to a specific form disclosed, and should be understood to include all modifications, equivalents, and substitutes included in the spirit and scope of the present invention.

Terms used in this application are only used to describe specific embodiments, and are not intended to limit the present invention. Expressions in the singular include plural expressions unless the context clearly dictates otherwise. In this application, terms such as "comprise" or "having" are intended to designate that a combination of features, numbers, steps, components, etc. described in the specification exist, but one or more other features or numbers, It should be understood that the presence or addition of combinations of steps, components, etc. is not precluded.

Unless defined otherwise, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by a person of ordinary skill in the art to which the present invention belongs. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with the meaning in the context of the related art, and unless explicitly defined in this application, it should not be interpreted in an ideal or excessively formal meaning. don't

Here, repeated descriptions, well-known functions that may unnecessarily obscure the subject matter of the present invention, and detailed descriptions of configurations are omitted. Embodiments of the present invention are provided to more completely explain the present invention to those skilled in the art.

Hereinafter, an embodiment of the present invention will be described in detail with reference to FIGS. 1 to 3 for explaining an embodiment.

1 is a cross-sectional view showing a carpet according to an embodiment of the present invention, FIG. 2 is a cross-sectional view showing the detailed configuration of the interior material of FIG. 1, and FIG. 3 is a perspective view showing embossing on the upper mat of FIG. 1 .

The carpet 1 according to an embodiment of the present invention protects the floor of an indoor facility such as a gymnasium and prevents problems caused by a slippery floor surface, thereby providing convenience to users and allowing them to use more safely. In addition, the carpet 1 may be used in various spaces, such as a carpet installed and used on the ground during an outdoor event, but is not limited thereto.

Referring to FIGS. 1 and 2 , a carpet 1 according to an embodiment of the present invention may include an upper mat 10 and a flooring material 20 .

First, the upper mat 10 may be made of an eco-friendly fabric including at least one of PVC fabric, welfare fabric, and canvas fabric.

At this time, the upper mat 10 is most preferably formed to have a double structure, but is not limited thereto.

More specifically, the upper mat 10 may have a dual structure including a polyvinyl chloride (PVC) fabric and further including a welfare fabric or a canvas fabric. By being formed in this way, the shape of the carpet 1 can be maintained for a long time, and durability can be increased.

At this time, the bonding between the fabrics constituting the double structure of the upper mat 10 may use low-melting fiber, but is not limited thereto, and an eco-friendly adhesive may be applied.

In addition, the upper mat 10 is subjected to finishing treatment such as corners through thermal welding, so that durability can be further maximized.

In addition, as shown in FIG. 3, the upper mat 10 may have a non-slip function by applying embossed embossing to the entire surface.

In addition, the upper mat 10 may have a size corresponding to the width and length of the space in which it is installed, and may be formed in various sizes without being limited thereto.

In addition, the upper mat 10 may be formed to a thickness of 0.2 to 0.8 cm, and most preferably formed to a thickness of 0.4 to 0.5 cm, but is not limited thereto.

At this time, if the upper mat 10 is formed to be less than 0.2 cm, the upper mat 10 may be torn or damaged, resulting in a problem of not being able to protect the floor. Not only does it fall off, but it also has the disadvantage of being difficult to store.

Thus, the upper mat 10 has the advantage of being formed to the above thickness, as well as protecting the floor on which it is installed, and also being able to easily store it by rolling it up when not in use.

The flooring material 20 is formed to have a non-slip function through a shape feature such as a non-slip protrusion or a material feature, and is attached to the lower surface of the upper mat 10 to prevent the carpet 1 from being pushed. Accordingly, it is possible to reduce the possibility of an accident such as injury caused by pushing of the carpet 1 .

The flooring material 20 may be formed of a film layer containing at least one of polyurethane, polyvinyl chloride (PVC), silicone, and polyester, but is not limited thereto.

The flooring material 20 is most preferably bonded to the upper mat 10 using low-melting fiber, but is not limited thereto and various adhesives may be applied.

In addition, the flooring material 20 may further include a friction layer and a protective layer.

The friction layer is attached to the lower surface of the film layer to increase the frictional force of the bottom surface of the flooring material 20, thereby increasing the anti-slip effect of the carpet 1.

The friction layer may include 8 to 12 parts by weight of a polymer, 1.5 to 3 parts by weight of a curing agent, 2 to 4 parts by weight of a viscosity modifier, and 1 to 2 parts by weight of a powder admixture, and 10 to 11 parts by weight of a polymer and 2.2 to 2.5 parts by weight of a curing agent. It is most preferable to include 2.8 to 3.1 parts by weight of a viscosity modifier and 1.7 to 1.9 parts by weight of a powder admixture.

Polymer refers to a high molecular weight compound containing a plurality of repeating units in its structure, and may include one or more of polyvinyl acetate, polyurethane, epoxy, linear low density polyethylene, polyorganosiloxane, and ethylene vinyl acetate copolymer. .

When the polymer is added in an amount of less than 8 parts by weight, it is difficult to harden and thus it is difficult to improve the frictional force, and if it exceeds 12 parts by weight, the polymer remaining after curing may exist, which is not preferable.

The polyvinyl acetate resin is produced by radical polymerization of vinyl acetate as a raw material using an alcohol-based solvent and benzoyl peroxide as a radical initiator, and may be mixed with a curing agent to impart bonding strength between the friction layer and the film layer.

또는 그 이상의 고온에서 작업하는 것이 조성물의 결속력 및 유연성을 좋게 하며, 혼합이 잘 되게 할 수 있어 가장 바람직한 온도이나, 이에 한정되지 않는다.In addition, the polyvinyl acetate resin has a temperature of at least 60 to 65

Working at a high temperature higher than or equal to is the most preferable temperature because it improves the coherence and flexibility of the composition and enables good mixing, but is not limited thereto.

Polyurethane resin is a polymer used to improve tensile strength, chemical resistance, and abrasion resistance. The hard segment using glycol and amines, the soft segment using polymeric glycol, and polyisocyanate are the main raw materials. It can be manufactured using Polyurethane synthesis is synthesized by one of the one-shot method in which a mixture of polyurethane glycol and chain extender reacts with polyisocyanate at once, and the prepolymer method in which polyisocyanate is reacted in excess and then chain extension is performed again. can do.

In addition, polyurethane resin has excellent tensile strength, chemical resistance and abrasion resistance, so it can be used as elastomer, flexible foam, rigid foam, plastic, paint, adhesive, and synthetic leather. It is commonly used in almost all fields of polymer materials such as

Epoxy resin has excellent mechanical strength such as chemical resistance, durability, and water resistance, and has characteristics of high hardness.

The linear low-density polyethylene resin has a density lower than 0.94 among polyethylene resins, and has characteristics of the low-density polyethylene resin, but is characterized in that the molecular structure is linear.

Polyorganosiloxane is a type of silicone and refers to a polymer having a siloxane bond substituted with organic groups as a main axis.

Ethylene vinyl acetate copolymer resin is a thermoplastic polymer material prepared by addition polymerization of ethylene and vinyl acetate.

By preparing a polymer comprising one or more of the resins listed above, it can be used as a suitable polymer for the friction layer.

The curing agent cures the polymer, and is most preferably used in an amount of 1.5 to 3 parts by weight, but is not limited thereto.

If less than 1.5 parts by weight of the curing agent is used, the polymer does not cure well and uncured polymer remains, making it difficult to form a friction layer. Residual curing agent may adversely affect the physical properties of the carpet.

At this time, a silane coupling agent may be used as the curing agent, (3-aminopropyl)trimethoxysilane, N-[3-(trimethoxysilyl)propyl]ethylenediamine, N-[3-(trimethoxysilyl) )propyl]ethylenediammonium chloride and (N-succinyl-3-aminopropyl)trimethoxysilane.

The viscosity modifier is capable of adjusting the viscosity to form the thickness of the friction layer and increasing bonding strength with a powder admixture to be described below, and may include at least one of polyvinyl alcohol and polyvinylpyrrolidone.

At this time, it is most preferable that the viscosity modifier is 2 to 4 parts by weight, and if it is less than 2, the effect of the viscosity modifier is insignificant, and if it exceeds 4 parts by weight, not only does not cure as a whole, but also the coating is not smoothly performed due to the high viscosity. There are downsides to not having

At this time, the molecular weight of polyvinyl alcohol used as the viscosity modifier is 8,000 to 120,000, and the molecular weight of polyvinylpyrrolidone is most preferably 5,000 to 100,000, but is not limited thereto.

When the molecular weight of polyvinyl alcohol and polyvinylpyrrolidone is less than the lower limit, the effect of the viscosity modifier is insignificant, and when it exceeds the upper limit, the viscosity increases too much, making it difficult to mix each material in forming the friction layer. However, there is a disadvantage in that the thickness of the friction layer becomes excessively thick.

The powder admixture is for adding frictional force to the friction layer, and may include at least one of glass fiber chops and diatomaceous earth.

At this time, the powder admixture is most preferably added in an amount of 1 to 2 parts by weight, but is not limited thereto.

In addition, when the powder admixture is added in less than 1 part by weight, the effect of the powder admixture is insignificant, and when it exceeds 2 parts by weight, a problem in that the powder admixture is not mixed well as a whole may occur. As a result, the powder admixture in a state that is not mixed with the polymer and the curing agent may remain and form agglomerated parts, and there is a disadvantage in that curing is not performed in the corresponding part.

The glass fiber chop is a composite material formed by molding glass fibers in a chopped form, and may include 1 to 3 parts by weight.

At this time, when the amount of glass fiber chop is less than 1 part by weight, the effect of increasing the frictional force due to glass fiber chop is insufficient, and when it is more than 3 parts by weight, mixing between components of the friction layer may be hindered, thereby deteriorating physical properties of the friction layer.

In addition, the glass fiber chop may be formed in a size of 0.1 to 0.5 mm in length, and most preferably formed in 0.2 mm, but is not limited thereto.

At this time, when the length of the glass fiber chop is less than 0.1 mm, it is difficult to obtain a frictional force enhancing effect, and when the length exceeds 0.5 mm, the floor surface on which the carpet 1 is installed may be damaged due to the glass fiber chop, which is not preferable.

Diatomaceous earth is intended to further enhance the durability of the friction layer by controlling the humidity of the carpet 1 and improving the binding force between the friction layer components, and may be included in an amount of 3 to 5 parts by weight.

At this time, when the amount of diatomaceous earth is less than 3 parts by weight, it is difficult to exhibit the above effect, and when it is greater than 5 parts by weight, the mixing of the composition of the friction layer is not performed well, and the bonding force of the friction layer may be lowered.

The protective layer is applied to the lower surface of the friction layer to prevent damage to the friction layer, and may include cellulose, alcohol, distilled water, a fluorosurfactant, and a curing agent.

At this time, the protective layer may also be formed on the upper surface of the upper mat 10 to protect the surface of the upper mat 10, but is not limited thereto.

More specifically, the protective layer may include 20 to 35 parts by weight of cellulose, 50 to 60 parts by weight of alcohol, 45 to 55 parts by weight of distilled water, 0.1 to 0.5 parts by weight of a fluorine surfactant, and 0.8 to 1.7 parts by weight of a curing agent.

Cellulose serves as a binder so that a transparent coating can be made on the friction layer, and may include one or more of methyl cellulose, carboxylmethyl cellulose, ethyl cellulose, and hydroxypropyl cellulose, and hydroxypropyl cellulose is most preferably used. .

At this time, when the cellulose is less than 20 parts by weight, the coating on which the protective layer is formed is not made, and when it exceeds 35 parts by weight, the coating is not made smoothly due to the cellulose and the thickness is not preferred.

The fluorosurfactant is for improving the coatability of the protective layer, and when the protective layer is coated on the friction layer by adding the fluorosurfactant, it can be uniformly coated.

More specifically, the surface tension of the protective layer can be reduced through the fluorosurfactant, leveling properties can be obtained during coating, and problems such as bubbles can be suppressed.

When the fluorosurfactant is less than 0.1 part by weight, the effect due to the fluorosurfactant is insignificant, and when it exceeds 0.5 part by weight, it is not preferable because it may affect the physical properties of the protective layer.

The curing agent is to cure the protective layer, and is most preferably used in an amount of 0.8 to 1.5 parts by weight, but is not limited thereto.

If less than 0.8 parts by weight of the curing agent is used, the protective layer does not harden well and the friction layer protection effect is insignificant, and if it exceeds 1.5 parts by weight, the coating may not be smooth due to rapid curing.

At this time, a silane coupling agent may be used as the curing agent, (3-aminopropyl)trimethoxysilane, N-[3-(trimethoxysilyl)propyl]ethylenediamine, N-[3-(trimethoxysilyl) )propyl]ethylenediammonium chloride and (N-succinyl-3-aminopropyl)trimethoxysilane.

In addition, the protective layer may further include a UV stabilizer.

The UV stabilizer is added to inhibit photodegradation by ultraviolet rays when the protective layer is exposed to the external environment, and is most preferably 1 to 1.5 parts by weight, and when the amount is less than 1, the effect of the UV stabilizer is negligible. UV stabilizers may affect the coating mixture, which is undesirable.

At this time, the UV stabilizer is most preferably added by selecting one or more of benzoxazine-based compounds, benzotriazole-based compounds, and HALS-based compounds, but is not limited thereto.

The protective layer thus formed is coated on the lower surface of the friction layer to protect the floor material, thereby increasing durability of the carpet 1 .

Hereinafter, the present invention will be described in more detail by examples.

However, the following examples are only to illustrate the present invention, and the content of the present invention is not limited by the following examples.

[Example]

[Example 1]

Manufactures a carpet including an upper mat formed of a double structure including polyvinyl chloride (PVC) fabric and canvas fabric, and a flooring material attached to the lower surface of the upper mat and formed of a film layer containing polyurethane to have a non-slip function. did

[Example 2]

A carpet was manufactured in the same manner as in Example 1, except that a friction layer was further formed on the flooring material.

At this time, the friction layer is prepared by including 10 parts by weight of a polymer, 2.3 parts by weight of a curing agent, 2.9 parts by weight of a viscosity modifier (polyvinylpyrrolidone having a molecular weight of 8,000), and 1.8 parts by weight of a powder admixture (glass fiber chops having a length of 0.2 mm). did

[Example 3]

A protective layer was further formed on the carpet of Example 2 to manufacture a carpet.

At this time, the protective layer was prepared by including 27 parts by weight of cellulose, 55 parts by weight of alcohol, 51 parts by weight of distilled water, 0.3 parts by weight of a fluorosurfactant and 1.2 parts by weight of a curing agent.

[Comparative Example 1]

The same carpet as in Example 2 was prepared except that the polymer was 5 parts by weight.

[Comparative Example 2]

The same carpet as in Example 2 was manufactured except that the length of the glass fiber chop was 0.05 mm.

[Comparative Example 3]

The same carpet as in Example 3 was prepared except that the cellulose was 18 parts by weight.

[Experimental Example] Anti-slip and durability evaluation of carpet

Non-slip performance evaluation

Anti-slip performance was evaluated by measuring the coefficient of friction at room temperature. At this time, a coefficient of friction of 2.5 or more is indicated by ◎, 2.0 or more and less than 2.5 by ○, 1.5 or more by less than 2.0 by △, and less than 1.5 by Х.

durability evaluation

After 1000 hours or more of the salt spray test, durability was evaluated by observing whether peeling of the flooring material occurred. At this time, if the occurrence of the peeling phenomenon occurs after 1500 hours or more of the salt spray test, ◎, 1000 hours or more and less than 1500 hours ○, 500 hours or more and less than 1000 hours △, if less than 500 hours, Х showed up

The results are shown in Table 1.

Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 Anti-slip performance ○ ◎ ◎ ○ ○ ○ durability ○ ○ ◎ ○ ○ ○

As shown in Table 1, it was confirmed that Examples 1 to 3 and Comparative Examples 1 to 3 had excellent anti-slip performance and durability.

Comparing Examples 1 and 2, it can be seen that the anti-slip performance of Example 2 is better than that of Example 1. On the other hand, as a result of comparing Example 2 with Comparative Examples 1 and 2, in the case of Comparative Examples 1 and 2, the weight part of the polymer and the length of the glass fiber chop were different from those of Example 2, so the effect of increasing the anti-slip performance was not exhibited. I was able to confirm what was missing.

In addition, when comparing Examples 2 and 3, it can be seen that the durability of Example 3 is better than that of Example 2. On the other hand, as a result of comparing Example 3 and Comparative Example 3, in the case of Comparative Example 3, it was confirmed that the effect of increasing durability did not appear due to the weight part of cellulose being different from that of Example 3.

As above, a specific part of the contents of the present invention has been described in detail, for those skilled in the art, these specific descriptions are only preferred embodiments, and the scope of the present invention is not limited thereby. It will be clear. Accordingly, the substantial scope of the present invention will be defined by the appended claims and their equivalents.

1: carpet
10: upper mat
20: flooring

Claims (7)

An upper mat made of eco-friendly fabric including at least one of polyvinyl chloride fabric, welfare fabric, and canvas fabric, and
A flooring material attached to the lower surface of the upper mat and formed of a film layer containing at least one of polyurethane, silicone, polyvinyl chloride, and polyester to have a non-slip function,
The carpet, characterized in that the upper mat and the floor material are bonded with low melting point (LM) fibers.
According to claim 1,
The upper mat,
A carpet characterized in that it has a dual structure including the polyvinyl chloride (PVC) fabric and further including the welfare fabric or canvas fabric.
According to claim 1,
The flooring material is
A friction layer formed on the lower surface of the film layer and
The carpet further comprises a protective layer formed on a lower surface of the friction layer to prevent damage to the friction layer.
According to claim 3,
The friction layer,
A carpet comprising 8 to 12 parts by weight of a polymer, 1.5 to 3 parts by weight of a curing agent, 2 to 4 parts by weight of a viscosity modifier and 1 to 2 parts by weight of a powder admixture.
According to claim 4,
The viscosity modifier,
A carpet comprising at least one of polyvinyl alcohol having a molecular weight of 8,000 to 120,000 and polyvinylpyrrolidone having a molecular weight of 5,000 to 100,000.
According to claim 4,
The powder admixture,
A carpet comprising at least one of fiberglass chop and diatomaceous earth.
According to claim 3,
The protective layer,
A carpet comprising 20 to 35 parts by weight of cellulose, 50 to 60 parts by weight of alcohol, 45 to 55 parts by weight of distilled water, 0.1 to 0.5 parts by weight of a fluorosurfactant and 0.8 to 1.7 parts by weight of a curing agent.

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