JPS5847510B2 - carpet tile - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing carpet tiles.

More specifically, a composition containing 20 to 500 parts by weight of a filler to 100 parts by weight of a resin consisting of 97 to 40 parts by weight of amorphous polypropylene (abbreviated as APP) and 3 to 60 parts by weight of a polyterpene resin. The present invention relates to a method for manufacturing carpet tiles, which comprises heating and melting the tile, lining it on a carpet base material, and cutting or punching it after cooling.

Carpets are often used with a backing for the purpose of fixing the pile, providing cushioning properties, and making it easier to place the carpet.

For example, tufted carpets are backed with rubber latex to hold the pile in place.

In addition, vinyl chloride resin and polyethylene resin are also used as backing materials.

Asphalt has also been known as an inexpensive carpet backing material for a long time.

Furthermore, APP is already known as a component of carpet backing materials.

It is an object of the present invention to provide an improved method of manufacturing carpet tiles using APP as a component of the backing material.

Carpet tiles in the present invention are square, rectangular,
The rhombus and 《《《《《《《《《《《《《《《《《《《《《《《《《《》《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《《] surface area from 0.05m to 2m (0.05m~2m) It is something that can be done.

Compared to regular carpets, these carpet tiles have the advantage that they can be easily installed by simply arranging them on the floor and fixing them.
It also has the advantage of being able to create carpets with a variety of textures by combining the shapes and colors of the carpet tiles.

When these carpet tiles are laid on the floor, it is necessary that they adhere sufficiently to the floor and that part of them does not come off when walking.

There are ways to do this, such as using adhesives or pressure-sensitive adhesives, and fastening with needles or rivets, but these methods have drawbacks such as being troublesome to install and requiring time to reapply. There is.

According to the present invention, there is provided a carpet tile that gives its own weight to the carpet tile with the backing material and has fixation (placeability) due to its own weight.

More particularly, carpet tiles are provided with a backing or lamination of thickness between 0.5 and 20 mm on a carpet substrate.

In addition, the carpet tile referred to in the present invention includes paper, cloth made of natural or synthetic fibers, non-woven fabric, split cloth, etc. under the backing material.
It also includes laminated films made of resin.

Inexpensive asphalt composite is known as a backing material for carpet tiles that can be laid down, but backing with asphalt composite produces bad odors during processing, pollutes the manufacturing factory, and is difficult to mold. The carpet tiles themselves have problems, such as staining white walls and the like when installed, and cracking when installed on cold days or when subjected to rapid deformation.

It is known that compositions containing APP can also be used for similar purposes, but for example, compositions containing APP and a filler and a softening agent such as polybutene have sufficient elasticity near room temperature. Instead, it flows with a slight load,
It has the disadvantage of being easily deformed.

Furthermore, when cutting carpet tiles into specified shapes,
There is also a drawback that the composite material tends to adhere to the cutter blade, causing problems.

In addition, compositions containing APP and aliphatic petroleum resins are prepared by melting and mixing the adhesive for backing at high temperatures, and emit irritating odors and smoke during processing and molding for further lining. There is a tendency for objects to turn brown, which not only poses problems in processing, but also has the drawback of reducing the value of the product due to discoloration.

Furthermore, APP containing polybutene or aliphatic petroleum resin does not have sufficient ability to fix carpet piles.

The present invention was developed in order to comprehensively solve the problems of these carpet tile backing materials, their backings, and certain mold processing methods. 3 to 60 parts by weight,
Preferably, 120 to 2 parts of a filler containing 20 to 500 parts by weight, preferably 50 to 400 parts by weight of a filler, per ioo parts by weight of a resin component consisting of 5 to 50 parts by weight.
After uniformly heating and melting and mixing at a temperature of 50°C, preferably 130 to 200°C, the carpet base material is lined and laminated to a thickness of 0.5 to 20 mm, and after cooling, it is cut or punched into a predetermined shape. It is based on the discovery that carpet tiles can be produced at low cost and with excellent properties.

In other words, the present invention allows the processing conditions to be varied widely during the production of carpet tiles, especially during heating, dissolving and mixing the backing composition, and during backing processing, since no foul odor or irritating odor is generated, and there is no fear of discoloration or discoloration. Furthermore, the hue of the lining material can be freely selected, and excellent color tones can be obtained, thereby increasing the commercial value of the kai-shaped article.

Furthermore, the composition of the present invention can be made into a liquid having a viscosity suitable for processing simply by heating, and after melting and lining, lining can be easily completed by cooling.

After lining is completed, the backing material has appropriate strength and elasticity, so it can be easily cut into a predetermined shape of carpet tile using a cutter or the like.

The carpet tiles manufactured according to the present invention have excellent dimensional stability, excellent bending resistance that does not easily crack due to deformation, and have sufficient pile fixation for tufted carpet base materials. It indicates gender.

Furthermore, since it has a suitable amount of elasticity, it feels good when walking, and does not crack even when handled in winter.

Furthermore, since inexpensive APP is used, inexpensive carpet tiles can be provided.

APP as used in the present invention is mainly composed of amorphous polypropylene with an atactic structure. Specifically, APP is produced as a by-product during the production of crystalline polypropylene, and contains about a few percent of crystalline polypropylene. This includes those who are doing so.

Furthermore, polypropylene production involves copolymerizing propylene with a small amount of ethylene, etc., and by-products of the production of these copolymers are also included.

These APPs have an average molecular weight of about 3,000 to 30,000
0, and the present invention has an average molecular weight of 5000 to 1.
00000 is desirable.

In addition, the polyterpene resin referred to in the present invention refers to terpene compounds obtained from natural plants, particularly α-pinene, β-pinene, dipentene, dipentene obtained by dimerization of isoprene, etc., either alone or in combination with a small amount of other species. A resin-like material obtained by polymerizing with heat or a catalyst in the presence of a polymerizable monomer or (and) a non-reactive solvent, and has a softening point of usually 80 to 140 by the ring and ball method.
It is in the range of ℃.

Currently, they are commercially available in Japan under the names of YS Resin PX (manufactured by Yasuyu Kogyo), Picolite α (manufactured by Esso Chemical), Picolite S (manufactured by Esso Chemical), etc.

These resins can be used alone or in combination.

In the present invention, the weight ratio of APP as a resin component and polyterpene resin (APP/polyterpene) is 97.
It is in the range of /3 to 40/6o.

If the ratio is larger than 977'3, the above-mentioned effect will not be observed, while if the ratio is smaller than 40/60, the book backing composition will be stiff and have poor elasticity, causing cracks etc. when deformed. It becomes easier to do.

In addition, it tends to be slightly colored in hue, which also causes disadvantages such as being disadvantageous in terms of price.

In the production method of the present invention, the (APP/polyterpene) ratio is 97.
/3 to 40/60, preferably 95/5 to 5 0/5
This is based on the new finding that if a composite having a range of 0 is used, carpet tiles with stable workability even at high temperatures and excellent hue and physical properties after backing can be obtained.

As the filler used in the present invention, any filler used for rubber or plastics can be used.

These fillers are, for example, those described in Sections 11 and 12 of "Handbook of Rubber and Plastic Compounded Chemicals" (Rubber Digest, published in 1966).

Specifically, carbon black may be used, but in order to provide various hues, a white filler is preferable, and moreover, an inexpensive filler is preferable.

Therefore, calcium carbonates, clays, silicas,
Talc, barium sulfate, calcium sulfate, calcium sulfite, zinc white, and the like are preferred.

These fillers are needed not only to improve the softening point of the backing composition and to reduce its price, but also to give the backed carpet tile its own weight and make it easier to lay.For this purpose, at least APP, It is necessary to use 20 parts by weight, preferably 50 parts by weight or more, per 100 parts by weight of the resin made of polyterpene resin.

In order to improve the softening point and specific gravity of the lining composition and to reduce the price, it is desirable to increase the amount of filler blended.
If the amount is too large, the viscosity of the filler will increase when melted, reducing processability, and the molded product will become brittle against deformation and tend to crack, so the amount of filler blended is 100 parts by weight of resin. 500 parts by weight, preferably 400 parts by weight
The weight part is the limit.

Particularly when the amount of filler is large, it is desirable to use APP with a low average molecular weight.

In addition, the composition used in the present invention may contain a small amount of anti-aging agent, coloring agent, or other tackifying agent other than the polyterpene resin in a small amount of 0 to 5 parts by weight per 100 parts by weight of a certain resin from the APP or polyterpene resin. Softeners such as agent resins and liquid polybutene,
Oils, waxes, etc. can be added as necessary.

These backing composites in the present invention have a 120 to 2
It can be prepared by mixing relatively easily at a temperature range of 50°C, preferably 130 to 200°C.

As for the filler, it is preferable that a resin component consisting of APP or polyterpene resin is melted and then added and mixed little by little.

APP itself is not sufficiently stable against heat, and long-term heating can cause molecular chain scission and decomposition, so it is desirable to avoid heating more than necessary.

Backing to carpet base material can be done within the above temperature range, but if the temperature is too high, problems such as shrinkage and melting may occur when synthetic fibers such as polypropylene are used as part of the carpet base material. It may also cause.

Manufacture carpet tiles by uniformly laminating the backing material to a thickness between 0.5 and 20 mm on the carpet base fabric in this temperature range, and cutting or punching it into a predetermined shape after cooling. I can do it.

Carpet substrates that can be lined using the manufacturing method of the present invention include tufted carpets, woven carpets, knitted carpets, 21-dollar punch carpets, and 21-dollar felt carpets made of natural or synthetic fibers. , Feltnato non-woven type carpet, etc., and can be applied to all carpet base materials.

Although the present invention will be described in detail with reference to Examples above, the present invention is not limited thereto.

Example 1-5 As APP, a by-product of crystalline polypropylene production with an average molecular weight of about 30,000 was used, and as polyterpene resins, YS resin PXIOOO (softening point 100°C),
The effect of adding polyterpene resin was investigated using Picolite S-100 (softening point: 100°C) and heavy calcium carbonate as a filler.

In addition, as comparative samples, aliphatic petroleum resin (softening point: iooo°C) and liquid polybutene (
A case was also investigated using an average molecular weight of 1200).

After melt-mixing the backing string composition at about 160°C and making it uniform, the melt viscosity (160°C, B-type viscometer), needle size (ASTM-D-1 3 2 1), and specific gravity of the composition were determined. The prepared paste was then laminated to a thickness of 5 mm on a tufted carpet base material made of a jute base fabric tufted with nylon pile.

After cooling, a 50 mm square test piece was cut out and a pile pull-out test (fixability) was conducted.

Similarly, a rectangular test piece with a width of 25 mm and a length of 150 mm was cut out and subjected to a 1800 bending test, and the bending resistance of the composition was evaluated by the number of bends until cracking occurred.

The test results are shown in Table-1.

As is clear from the results in Table 1, it can be seen that when polyterpene resin is added to APP alone, the fixing properties and bending resistance of pile clothing* are greatly improved.

It is also clear that aliphatic petroleum resins generate a pungent odor, color the composition brown, and have inferior pile fixing power compared to polyterpene resins.

On the other hand, polybutene was still inferior in that it increased the needle size of the composition, making it easily deformable, and did not improve the fixing force of the pile.

From the above results, it is clear that the resin component made of APP/polyterpene resin is an excellent component that meets the purpose of the present invention.

On the other hand, when the (APP/polyterpene) ratio is lower than 40/6 o (for example, Comparative Example 2), the bending resistance rapidly decreases,
It is clear that this would be inconvenient for this purpose.

It is clear that adding a filler increases the specific gravity, lowers the needle size, and improves the pile fixing properties, but it is also clear that if the filler is added too much, the bending resistance becomes poor.

Example 6 A backing composite having the following composition was prepared.

APP-A (average molecular weight approximately 30,000) APP-B (approximately 1ooo0) Polyterpene resin-A (YS resin PXIOOO) (parts by weight) 70 20 10 Liquid polybutene (molecular weight 1200) Physical properties of the composition itself and the composition of the composition itself The product was tested in the same manner as in Example 1 on carpet backing as shown below and the results were as follows.

This composition was laminated on a tufted carpet made of pure wool using a polypropylene nonwoven fabric as a backing fabric at about 160° C. to a thickness of about 4 mm.

After cooling, it was cut into squares of 50Cr/L x 50C1rL to obtain carpet tiles.

In this carpet tile, the fluidity of the backing composition was also appropriate, and it penetrated into the back surface of the carpet to some extent and did not pass through the base fabric to the outer surface, and the fixation of the pile was sufficient.

When this carpet tile was laid on the floor, it was easy to install and had sufficient installation properties, no adhesive was required during installation, and it did not peel up when walking after it was laid.

It also felt good when walking on it, making it an excellent carpet tile.

Claims (1)

[Claims] 1 A composition containing 20 to 500 parts by weight of a filler to 100 parts by weight of a resin consisting of 97 to 40 parts by weight of amorphous polypropylene and 3 to 60 parts by weight of a polyterpene resin is heated and melted. 0.5-20mm on the base material
A method for manufacturing carpet tiles with excellent laying properties, which is characterized by laminating the backing to a thickness of 100 ml, cooling it, and then cutting or punching it as required.