JPS629022B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a novel method for producing a carpet tile, and more particularly, it relates to a method for producing a carpet tile containing (a) solvent-deasphalted asphalt, (b) a copolymer of an olefin and a polar monomer, and (c) a crystalline polyolefin. The present invention further relates to (d) a method for producing a carpet tile using a mixture containing an amorphous polyolefin as a backing material. Carpet tiles are square, rectangular, diamond-shaped, or more complexly shaped carpet tiles with an area of, for example, 0.05 to 2 m ² each. By using these in combination, it is possible to fill gaps. It can be placed on the floor without making it.
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, and they can be used in many combinations of shapes, colors, etc. to create carpets with a variety of textures. It also has the advantage of being able to 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 walked on. There are ways to do this, such as using adhesive or adhesive, and fastening with needles or rivets, but these methods are cumbersome to install.
It also has the disadvantage that it takes a lot of effort to replace it. As a solution to these drawbacks, a carpet tile is known in which a backing material gives the carpet tile its own weight, and the carpet tile has fixation (placeability) due to its own weight. This backing material also serves the purpose of imparting various properties to the carpet tile, such as thread removal prevention, dimensional stability, and elasticity. Therefore, the backing material for carpet tiles is
Of course, it must satisfy the required properties of general carpet backing materials, and furthermore,
It must also have numerability that allows it to be stabilized simply by placing it there. Moreover, this ease of placement must be provided without using expensive materials. Conventionally, known carpet backing materials include rubber latex, elastomer, synthetic resin, and asphalt. These are, for example, Special Publication No. 46-3839, Special Publication No. 48-20199
It is disclosed in Japanese Patent Publication No. 48-34556, Japanese Patent Publication No. 52-17851, and Japanese Patent Publication No. 53-4525. However, rubber latex systems require drying and vulcanization processes, which require a large amount of equipment and costs, and have disadvantages such as damage to the fiber base material due to prolonged exposure to high temperatures during these processes. Heat-melting types such as elastomer-based and synthetic resin-based materials have better performance than rubber latex-based materials, but are not preferred in terms of cost performance. In addition, although commonly available asphalts are inexpensive, they do not have sufficient hardness or load-bearing deformability, and when used as a backing material, they do not flow at room temperature.
This can cause migration and impair the aesthetic appearance of carpet tiles. The purpose of the present invention is to satisfy all performances such as hardness, deformability under load, and workability by using a backing material that combines the advantages of both synthetic resin backing materials and asphalt backing materials. Another object of the present invention is to provide a method for producing carpet tiles at low cost. The inventors of the present application have proposed a method for producing a carpet tile or a backing material composition that satisfies the above-mentioned objects, in which a composition containing amorphous polypropylene, a polyterpene resin, and a filler is used as a backing material. Manufacturing method (Unexamined Japanese Patent Publication 1973-
6127), a carpet tile backing composition comprising amorphous polypropylene, a low unsaturation rubber, a tackifier resin, and a filler, and optionally containing a small amount of a plasticizer. (Unexamined Japanese Patent Publication 1973-
No. 112591), and a method for manufacturing carpet tiles using blown asphalt and petroleum resin, or an asphalt-based composition in which these are further blended with styrene resin, as a backing material (Japanese Patent Application No. 32334/1983). The present invention provides a new method for producing carpet tiles having performance equivalent to or superior to the carpet tiles according to the above-mentioned application. The present invention provides (a) solvent-deasphalted asphalt 50-90
% by weight, (b) 2 to 40% by weight of a copolymer of olefin and a polar monomer, and (c) 2 to 40% by weight of a crystalline polyolefin.
A method for manufacturing a new carpet tile characterized by heating and melting it at 240°C, lining it with a carpet base material, and cutting or punching it as required after cooling, and (a) Solvent-deasphalted asphalt 50-90 (b) Copolymer of olefin and polar monomer 2-40% by weight, (c) Crystalline polyolefin 2-40% by weight
% by weight, and (d) amorphous polyolefin 2-40
% by weight, melted by heating to 100 to 240°C, lined with a carpet base material, cooled, and then cut or punched as required. The present invention will be explained in more detail below. Solvent-deasphalted asphalt (component (a)) in the present invention
is a precipitate (asphalt) obtained when petroleum distillation residue is extracted with a lower aliphatic hydrocarbon having 3 to 10 carbon atoms, such as propane, butane, or a mixture thereof. ) 40-80℃, penetration (150g, 5 seconds, 25℃) 100
It is preferable to have ˜0. These solvent-deasphalted asphalts have already been subjected to extraction treatment to remove components that are undesirable for carpet tile production, such as components that emit odors and components with low flash points.
Due to problems such as fluidity at room temperature, brittleness, and low softening temperature, it is not possible to satisfy the object of the present invention when used alone, and the following (b) to (c)
It is necessary to mix the ingredients. In this case, the amount of solvent-deasphalted asphalt blended is 50 to 90% by weight, preferably 60 to 80% by weight, based on the entire mixture. In the copolymer of olefin and polar monomer (component (b)) referred to in the present invention, the olefin is
_C2 - _C4 olefins can be used, preferably ethylene. As polar monomers, those that can be copolymerized with the above-mentioned olefin can be used, but vinyl acetate,
Preferred are ethyl acrylate, methyl acrylate, methyl methacrylate, acrylic acid, methacrylic acid, or two or more thereof. Preferred copolymers include ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, ethylene-methyl acrylate copolymer, and ethylene-ethyl acrylate-acrylic acid copolymer, especially ethylene-vinyl acetate copolymer. Vinyl acetate copolymer (EVA) and ethylene-ethyl acrylate copolymer (EEA) are preferred. These copolymers preferably have a polar monomer content of 5 to 30% by weight and a melt index of 0.2 to 400. If the content of the polar monomer exceeds this range, the solubility of the crystalline polyolefin in solvent-deasphalted asphalt will decrease. The amount of the copolymer of olefin and polar monomer to be blended is preferably 2 to 40% by weight, particularly 3 to 20% by weight, based on the entire mixture. If the blending amount is less than this range, the solubility of the crystalline polyolefin in solvent-deasphalted asphalt will decrease, and the softening point of the mixture will also decrease, which is not preferable. On the other hand, if the content exceeds this range, the mixture becomes soft and the deformability under load increases, which is not preferable. Crystalline polyolefin (component (c)) in the present invention
As the material, a _C2 to _C4 olefin homopolymer or copolymer can be used, and polyethylene is particularly preferred. The crystalline polyolefin preferably has a melt index of 0.1 to 100. The amount of crystalline polyolefin blended is preferably 2 to 40% by weight, particularly 3 to 20% by weight, based on the entire mixture. If the blending amount is less than this range, the softening point of the mixture will be lowered, and the hardness and load bearing capacity will be lowered at the upper limit of the practical temperature range, which is not preferable. On the other hand, if the blending amount exceeds this range, the melt viscosity of the mixture will increase and processability will decrease, which is not preferable. In the present invention, in addition to the above components (a) to (c), an amorphous polyolefin (component (d)) may be further blended as required. As the amorphous polyolefin in the present invention, a homopolymer or copolymer of _C2 to _C4 olefin can be used, and amorphous polypropylene, amorphous polybutene, and ethylene-propylene amorphous polymer are particularly preferred. . Amorphous polyolefins have an average molecular weight of 3000 to 300000, especially
A softening point of 10,000 to 150,000 is preferably 80 to 200°C, and materials in this range provide the mixture with low-temperature flexibility and bending resistance, and facilitate backing processing by appropriately controlling the melt viscosity. In addition, it assists the solubility of the crystalline polyolefin. When blending an amorphous polyolefin, its blending amount is 2 to 40% by weight, preferably 5 to 30% by weight, based on the entire mixture. In the present invention, it is also possible to further incorporate a filler into the backing material mixture. As the filler, fillers used for rubber and 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 Co., Ltd., published in 1971). Specifically, calcium carbonates, clays, silicas, carbon black, talc, barium sulfate, calcium sulfate, calcium sulfite,
Zinc white and the like are preferred. These fillers are preferred not only for the purpose of improving the softening point of the backing material mixture and lowering the price, but also for imparting self-weight to the backed carpet tile and making it easier to place it. In order to improve the softening point and specific gravity of the backing material mixture and to reduce the price, it is desirable to increase the amount of filler blended, but if the amount is too large, the viscosity of the composition when melted increases and processability decreases. In addition, the molded product becomes brittle against deformation and tends to crack. The blending amount of the filler is 10 to 400 parts by weight, especially 50 to 400 parts by weight, based on 100 parts by weight of the above-mentioned backing material mixture.
Preferably it is 200 parts by weight. In the present invention, the carpet base material includes general carpets such as tufted carpet, woven carpet (Wilton or Axminster), and non-woven carpet (needle punch), as well as artificial grass made of polymeric materials such as polyamide and polyester. show. The temperature of the mixture is 100-240°C, preferably 120-240°C.
Carpet tiles can be manufactured by melting and mixing at 180°C, lining a carpet base material using a doctor knife coater method or roll coater method in the same temperature range, and cutting or punching as required after cooling. . If the melt mixing and backing temperatures are lower than the above range, a uniform backing material mixture will not be obtained and the adhesion to the carpet tile substrate will be insufficient. Further, there is no need to raise the temperature of melt-mixing and lining above the above range, which is undesirable from a commercial point of view as it requires excessive fuel costs. Furthermore,
High temperatures can also cause carpet tile substrates to shrink or become damaged. In the present invention, by further laminating a second base fabric such as natural or synthetic woven fabric, non-woven fabric, synthetic resin film, or paper, or a release material under the backing material, a carpet tile having more favorable properties can be obtained. It is also possible to manufacture The present invention will be explained in more detail below using Examples and Comparative Examples. Various backing material mixtures as shown in the table were prepared and used to manufacture carpet tiles. The details of the properties of the various components, the method of preparing the mixture, the method of manufacturing the carpet tile, and the various test methods are as follows.

[Table] <Mixture preparation method> Preparation method []: Place solvent-deasphalted asphalt in a mixing pot, or add amorphous polyolefin thereto as necessary, and heat and melt at 100 to 160°C. Next, add crystalline polyolefin and a copolymer of olefin and polar monomer,
℃ and stir until the added polymer particles disappear and dissolve. When the mixture becomes a homogeneous melt, adjust the temperature for backing processing. Preparation method []: A crystalline polyolefin and a copolymer of an olefin and a polar monomer are placed in a pressure kneader and heated and mixed at 140 to 160°C.
Next, the amorphous polyolefin and solvent-deasphalted asphalt are added little by little, heated and mixed, and when the mixture becomes a uniform melt, the temperature is adjusted to the lining processing temperature. <Manufacturing method for carpet tiles> Manufacturing method [ ] (doctor knife coater method): Place the carpet base material on a conveyor belt with the back side facing up, and apply a doctor knife coater while pouring the molten backing material mixture. Apply with a knife to a certain thickness, for example 1 to 5 mm. Next, if necessary, a second base fabric is bonded together and cut into a predetermined size and shape using a cutting machine to produce a carpet tile. Manufacturing method [ ] (Roll coater method): Two rolls are placed almost horizontally with a predetermined distance between them, and the carpet original fabric is applied from one of the upper sides, and the second base fabric or the carpet fabric is applied from the other upper side. A paper pattern is fed in, and a molten backing material mixture is poured between the paper patterns from above, while the rolls are rotated to form a carpet of a constant thickness. Next, the carpet tiles are manufactured by cutting into a predetermined size and shape using a cutting machine. <Various test methods> Softening point: Measured by the ring and ball method of JIS K 2531. 100
The temperature is preferably 110°C or higher, particularly 110°C or higher. Hardness: Measured at 25℃ using JIS K 6301 spring method. It is preferably 75 or more. Load capacity: Measured according to JIS K 2530 using a needle with a diameter of 1 mm with the tip cut into a flat end. 150g, 10 minutes, at 25℃
It is preferably 0.5 mm or less.
It is preferably 1.0 mm or less at 100 g, 3 minutes, 45°C. Bending resistance: A sample was formed into a sheet with a thickness of 2 mm, and the bending resistance was evaluated by bending the sample at a predetermined temperature by 180° around a rod with a diameter of 6 mm as a central axis. ×: wave-broken, △:
Items with cracks, ○: Items with no cutting or cracks. Melt viscosity: Measured using a rotational viscometer. It is preferably 100,000 cp or less at 150°C. It is preferably 10,000 cp or less at 200°C. Dimensional stability: A carpet tile cut into 30cm squares was heated in air at 60°C for 2 hours, and the dimensional change after heating was measured (-) indicates contraction, (+) indicates expansion. ±0.1%
It is preferable that it is below. Pull-out strength: A single carpet tile pile is pulled at 20°C, and the strength at which the thread pulls out from the backing material is measured using a tensile tester. 2.5
It is preferable that it is more than Kg/pile. Example 1 shows that propane-deasphalt asphalt (component
(a)), ethylene-vinyl acetate copolymer (component (b))
This is an example of production according to the present invention in which a carpet tile is lined with a backing material mixture consisting of and crystalline polyethylene (component (c)). The backing material mixture satisfies the required values for all properties of softening point, hardness, load resistance, bending resistance, and melt viscosity, and carpet tiles manufactured using this mixture as the backing material have good dimensional stability and thread removal strength. It showed very good properties. In Examples 2 to 4, propane-deasphalt (component (a)), ethylene-vinyl acetate copolymer or ethylene-ethyl acrylate copolymer (component
(b)), crystalline polyethylene (component (c)) and amorphous polypropylene (component (d)) is a production example according to the invention in which a carpet tile is lined with a backing material mixture consisting of crystalline polyethylene (component (c)) and amorphous polypropylene (component (d)). As in Example 1, the backing material mixture satisfied the required values in all properties, and the carpet tiles manufactured using this mixture as the backing material exhibited excellent dimensional stability and thread removal strength, and exhibited extremely good properties. Ta. Comparative Examples 1 and 2 are examples in which a mixture containing no crystalline polyolefin (component (c)) was used. Since the softening point and load resistance of the backing material mixture were low, carpet tiles manufactured using the same also had problems with dimensional stability and could not be used favorably. Comparative Example 3 is an example in which a mixture containing no copolymer of olefin and polar monomer (component (b)) was used. In this case, the compatibility between the propane-deasphalted asphalt and the crystalline polyolefin is insufficient, resulting in a non-uniform mixture, resulting in poor bending resistance and dimensional stability, making it impossible to put it to practical use.

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Claims (1)

[Scope of Claims] 1 (a) Solvent-deasphalted asphalt 50 to 90% by weight, (b) Copolymer of olefin and polar monomer 2
~40% by weight, and (c) crystalline polyolefin 2~40% by weight. After heating and melting at 100~240°C, line the carpet base material, and after cooling, cut or punch out as required. A novel carpet tile manufacturing method featuring: 2 (a) Solvent-deasphalted asphalt 50-90% by weight, (b) Copolymer of olefin and polar monomer 2
A mixture containing ~40% by weight, (c) 2-40% by weight of crystalline polyolefin, and (d) 2-40% by weight of amorphous polyolefin is heated to 100-240°C and melted, and then lined onto a carpet base material. A novel method for manufacturing carpet tiles, which is characterized in that, after cooling, cutting or punching is performed as required.