JPS6034367B2 - Back surface finishing method for tufted carpet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention also includes a small amount of PVC plastisol (based on PVC acetate polymer paste resin).

The present invention aims to provide a tufted carpet at a low cost that has a smooth back surface without damaging the pile surface texture by effectively using adhesive and fixing the pile and eliminating unevenness caused by pile settling threads. be. Traditionally, tufted carpets have been finished by adding an appropriate foaming agent to vinyl chloride plastisol or carpoxyl modified S, B, R, latex, etc. to form a foam layer on the back surface.

However, the primary purpose of conventional foam finishes is to provide cushioning properties to tufted carpets.
In addition, it was a two-step process that required adhesive fixation of the pile with an undercoat such as non-foamed latex, which was not economical. In addition, a doctor knife method is used to apply a small amount of the applied latex, but when the doctor knife 1 comes in contact with the layer 13 of latex, etc., the back surface of the tufted carpet is compressed by the doctor base 2, so the layer 13 is made uniform. When the tufted carpet is unraveled, the pile filaments are raised due to the elastic recovery properties of the tufted carpet material, making it impossible to obtain a smooth coated back surface. Therefore, in order to form a smooth back surface of tufted carpet, it is necessary to
It was necessary to use foamable latex or the like in a volume greater than that required to fill the valley 4 caused by the undulations of the area. In addition, especially when a large amount of carboxyl-modified S, B, R, latex, etc. is used, a blister phenomenon occurs when the water contained therein is removed, which is undesirable. In addition, conventionally, when PVC plastisol is mechanically foamed using an OAKS mixer to finish the back surface of a carpet, the amount of filler added to 100 parts of PVC paste resin is limited to 30 to 5 yen, and if the amount exceeds that, the OAKS mixer generates heat and Since it turns into PVC plastisol, there are restrictions on reducing manufacturing costs by adding fillers.

The present invention aims to directly adhesively fix piles with foamable PVC plastisol without applying an undercoat, and to finish tufted carpets smoothly and inexpensively by using a small amount of this, and improves product performance, aesthetics, finishing equipment, It was completed after intensive comprehensive research into various factors such as foaming ratio.

That is, the present invention uses 1.0 parts of PVC plastisol containing 100 to 20 parts of a filler per 100 parts of PVC paste resin.
It is mechanically foamed 3 to 2 times, coated on the back side of the tufted carpet material with a coating of 0.5 to lk9/pillow using a low-fu coating method, and heat-treated.

In addition, as a method of mechanically low foaming, PVC plastisol is used as
As shown in Fig. 7, it is preferable to mechanically foam the foam to a ratio of 1.3 to 2 times using an Oaks mixer with a mixing head having a tooth ratio of 65 to 75:100. This low foaming rate is sufficient for fixing the pile 5, and since the foam increases in volume, it can be finished at a low cost. In addition, the finished surface conforms to the contact surface of the roller and the back surface is smooth, and since the pile can be sealed upward and coated without pinching, the pile will not sag and its texture will not be affected. .
The amount of application required to fill valley 4 is 0.5~lk9/
The thickness of the pile yarn is usually 1 to 2 meters, so adjust it within this range. To explain in more detail, the bulking agent can be used in large amounts because vinyl chloride plastisol is prepared by the following formulation.

PVC polymer paste resin and extender PVC paste resin...10 Ikaribe primary plasticizer...70
~12 Ikari Gun Secondary Plasticizer ・・・・・・・・・
...10-3 anchorage diluent...
・・・・・・・・・10～3 Anchor part heat stabilizer
......0.5-3 parts filler
・・・・・・・・・・・・・100-20 Anchor part Foam stabilizer for foaming ・・・・・・・・・・・1-5 parts In this case, the use of some coloring pigments is not prohibited.

In order to use a larger amount of bulking agent than is commonly used in conventional technology, the bulking agent must have thickening and oil absorbing properties to effectively increase the volume in order to prevent the Oaks mixer from generating heat. must be demonstrated.

Suitable fillers include "Honika○" and "CCR" (Shiraishi Calcium KK). In the practice of the present invention, the PVC plastisol has a viscosity (No. 3, &pm) of 3.00.
It must be adjusted to a ratio of 0 to 6.00, p, s, which is determined by the blending ratio of plasticizer and diluent.

However, since the plasticizer is related to the texture (hardness, stickiness) of the back surface of the tufted carpet product, it must be prepared using a secondary plasticizer. Next, the formulation preparation will be specifically illustrated and explained.

PVC-acetate co-polymer paste resin “PCX” (manufactured by Sumitomo Chemical KK) ・・・6 anchor PVC bulking paste resin “RX” (manufactured by Sumitomo Chemical KK)
... 4 Anchor primary plasticizer general-purpose plasticizer "DOP" (manufactured by Kyowa Hakko KK) ... 8 Anchor part low-temperature melting plasticizer "DBP" (manufactured by Kyowa Hakko KK)
・・2 parts Secondary plasticizer “PansoLV Ichi” (manufactured by Chiyoda Trading KK) ・-20 parts Heat stabilizer “KS-2000F” ・1 part Diluent “Isobar M” (manufactured by Esso Kagaku KK) )． ...15 parts extender "Honika ○" (manufactured by Shiraishi Calcium KK) ---150 parts foam stabilizer "SH1250" (manufactured by Toray Silicon KK) ...24 parts When using a large amount of extender and achieving low foaming with an OAKS mixer However, the above-mentioned formulation is necessary to prevent sedimentation of the filler and to prevent changes over time in the foamed cells or to stabilize them.
The number of teeth 10 on the second mixer head 7, 8, and 9 is 6, which has a mutual foaming effect in terms of uniformity of foaming cells and workability.
Preferably, as shown in FIGS. 5, 6, and 7, the tooth arrangement ring 11 of the mixer head 8 with the smaller number of teeth should be placed second from the outer ring. The third tooth ring, and the two tooth ring rings of the other mixer heads 7 and 9 that are numbered between the third and fourth tooth ring are revived, and each number (mixer head 7, 8, 8
and 9), set the ratio of the number of teeth to 7:10.

In order to make the Oaks mixer 12 more general-purpose, the number of teeth on both sides of the intermediate rotating mixing head 8 shall be reduced, and in this case, the intermediate mixing head may be replaced with other mixing heads 7 and 9 that do not rotate. When the number is approximately the same, this can be used as an oak mixer for high foaming of 4 to 5 times.

In this way, a tufted carpet with a smooth back surface can be obtained depending on the interaction effects of the plastisol preparation, foaming device, foaming ratio, coating amount, and coating device.

The tufted carpet according to the present invention is
The back surface is smooth, requiring less amount of twill adhesive used for adhesion to the floor surface, making it flexible and easy to work with, and since it is processed using a low-fu coat method, the pile texture is not affected and it is wash resistant. There are also additional practical benefits such as good ventilation.

[Brief explanation of drawings]

Fig. 1 is a sectional view showing the relationship between a doctor knife, a tufted carpet material, and a doctor base, Fig. 2 is a sectional view of a tufted carpet using the doctor knife method, and Fig. 3 is a sectional view of a tufted carpet material. Figure 4 is a cross-sectional view of the tufted carbide material and rollers in the low-fu coat method, Figure 5 is a cross-sectional view of the oak mixer, Figure 6 is a front view of the mixer head, and Figure 8 is the mixer head. FIG. 1...Doctor knife, 2...Doctor base, 3...
...Pile next thread, 4...Valley, 5...
...Pile, 6...Lofu, 7,8,9...Mixer head, 10...Teeth, 11...Tooth arrangement ring, 12...Oaks mixer, 13・・・・・・
...PVC layer. Chrysanthemum - Younger Brother's Drawing - Drawing 3 - Drawing 10 - Obsolete Rainbow Hana - Genkyo - Drawing 8

Claims (1)

[Claims] 1. 100 parts of an extender for 100 parts of PVC paste resin.
A tufted carpet characterized in that PVC plastisol containing ~200 parts is mechanically foamed 1.3 to 2 times and applied to the back side of the tufted carpet material at a rate of 0.5 to 1 kg/m^2 using a roller coating method. Back finishing method. 2. The method for finishing the back surface of a tufted carpet according to 1 above, characterized in that the vinyl chloride plastisol is prepared according to the following formulation. PVC/vinyl acetate copolymer base resin and base resin for expanding PVC...100 parts Primary plasticizer...70-1
20 parts Secondary plasticizer...10-30 parts Diluent...10-30 parts Heat stabilizer...0.5-3 parts Extending agent...100-200 parts Foam stabilizer...1-5 parts