JP6669943B2 - テキスタイル製品の製造方法、それから取得可能な製品、および製品の再生方法 - Google Patents
テキスタイル製品の製造方法、それから取得可能な製品、および製品の再生方法 Download PDFInfo
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- JP6669943B2 JP6669943B2 JP2016517634A JP2016517634A JP6669943B2 JP 6669943 B2 JP6669943 B2 JP 6669943B2 JP 2016517634 A JP2016517634 A JP 2016517634A JP 2016517634 A JP2016517634 A JP 2016517634A JP 6669943 B2 JP6669943 B2 JP 6669943B2
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- polyester
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- D06N2201/02—Synthetic macromolecular fibres
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2201/00—Chemical constitution of the fibres, threads or yarns
- D06N2201/02—Synthetic macromolecular fibres
- D06N2201/0263—Polyamide fibres
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/061—Polyesters
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/065—Polyamides
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2205/00—Condition, form or state of the materials
- D06N2205/06—Melt
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2211/00—Specially adapted uses
- D06N2211/06—Building materials
- D06N2211/066—Floor coverings
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2213/00—Others characteristics
- D06N2213/02—All layers being of the same kind of material, e.g. all layers being of polyolefins, all layers being of polyesters
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2403/00—Details of fabric structure established in the fabric forming process
- D10B2403/01—Surface features
- D10B2403/011—Dissimilar front and back faces
- D10B2403/0111—One hairy surface, e.g. napped or raised
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2503/00—Domestic or personal
- D10B2503/04—Floor or wall coverings; Carpets
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2503/00—Domestic or personal
- D10B2503/04—Floor or wall coverings; Carpets
- D10B2503/041—Carpet backings
- D10B2503/042—Primary backings for tufted carpets
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/50—Improvements relating to the production of bulk chemicals
- Y02P20/582—Recycling of unreacted starting or intermediate materials
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/62—Plastics recycling; Rubber recycling
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/23907—Pile or nap type surface or component
- Y10T428/23979—Particular backing structure or composition
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/23907—Pile or nap type surface or component
- Y10T428/23986—With coating, impregnation, or bond
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/23907—Pile or nap type surface or component
- Y10T428/23993—Composition of pile or adhesive
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Carpets (AREA)
- Manufacturing Of Multi-Layer Textile Fabrics (AREA)
- Adhesives Or Adhesive Processes (AREA)
- Laminated Bodies (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Treatment Of Fiber Materials (AREA)
- Floor Finish (AREA)
- Adhesive Tapes (AREA)
- Decoration Of Textiles (AREA)
Description
(a)フロント表面とバック表面とを有するバッキングと、バッキング中に縫合されたヤーンと、を含む第1の中間製品を提供する工程であって、ヤーンがバッキング材料のフロント表面から延在する、工程と、
(b)加熱表面を有する物体に沿って、バック表面を前記加熱表面にプレスした状態で、第1の中間製品を供給することにより、中間製品中に存在するヤーンを少なくとも部分的に溶融してヤーンをバッキングに結合する工程であって、加熱表面にプレスされるバック表面の部分が、加熱表面に対して、カレンダー処理されたバック表面を有する第2の中間製品を提供するような相対速度を有する、工程と、
(c)寸法安定性キャリヤーシートを提供する工程と、
(d)カレンダー処理された表面とシートとの間にホットメルト接着剤を提供することにより第2の中間製品をキャリヤーシートに接合し、かつシートを第2の中間製品にプレスしてテキスタイル製品を形成する工程と、
を含む。
a)ポリエステルHMAテキスタイル製品を加熱してポリエステルを溶融および/または軟化させる工程と、
b)工程a)のポリエステルを押し出して押出し物を形成する工程と、
c)工程の押出し物を細断して回収ポリエステル材料を形成する工程と、
を含む。
a)使用済みの本発明に係るテキスタイル製品を提供する工程と、
b)テキスタイル製品の構成ポリマーの融解温度超の温度まで製品を加熱する工程と、
c)得られたポリマー溶融物を再使用する工程と、
を含む。
a)使用済みの本発明に係るラミネートテキスタイル製品を提供する工程と、
b)ホットメルト接着剤の軟化温度超ただしテキスタイル製品の中間製品およびキャリヤーシートの構成ポリマーの融解温度未満の温度まで製品を加熱する工程と、
c)キャリヤーシートから中間製品の接合を解除して再生されるそれぞれを個別に捕集する工程と、
を含む。
本発明でヤーン繊維(タフトとしても知られる)を構成すべく使用しうる好適な材料は、当業者に周知のヤーン材料から選択可能であり、たとえば、天然繊維(たとえば、ウール、コットン、および/またはジュート)、合成繊維(たとえば、ポリプロピレン、ポリアミド(たとえば、脂肪族ポリアミド、たとえば、ナイロン、たとえば、ナイロン6またはナイロン6−6)、およびポリエステル、および/またはアクリル)、および/または天然繊維および合成繊維のブレンド(たとえば、ウールブレンド、たとえば、ウール対合成繊維の80対20ブレンド)が挙げられる。
本発明で第1のヤーン担持材料(一次バッキングとしても知られる)を形成すべく使用しうる好適な材料は、ヤーンとして使用すべく以上に明記されたもののいずれか(さらには本明細書でポリマーRとして参照されるポリマーのいずれか)から選択可能である。
本発明でキャリヤーシートを形成すべく使用しうる好適な材料は、ヤーンおよびまたはヤーン担持材料として使用すべく以上に明記されたもののいずれか(さらには独立して、本明細書でポリマーRとして参照されるポリマーのいずれか)から選択可能である。
本明細書で用いられる場合、「接着剤」または「接着剤組成物」という用語は、本明細書で意図される使用に対して商業的に許容可能かつ実用性のある期間にわたり、周囲条件下で乾燥後に実質的にタック性を維持する(すなわち、タックフリーでない)任意の組成物を意味する。典型的な接着剤組成物は、表面に適用された後、少なくとも16時間にわたりタック性を維持しうる。タック時間は、便利には、本明細書に記載されるように測定されうる。
により表される。
それらは、60〜150℃、好ましくは75〜130℃の温度で適用可能である(溶融状態で);
150℃で500Pa・s未満、好ましくは<200Pa・sの粘度;
60〜130℃の融解温度(Tmとも記される);および/または
60〜130℃の結晶化温度(Tcとも記される);
TmおよびTcは、示差走査熱量測定(DSC)などの任意の好適な方法により取得されうる。サンプルの溶融および/または結晶化が温度範囲にわたり観測される場合、Tmおよび/またはTc値はこの範囲で観測されたピーク(最大)温度として記録される;
の1つ以上の(より好ましくはすべて)を呈する。
任意選択で、本発明に係るテキスタイル製品、たとえば、本発明に係るカーペットは、試験方法で以下の性質の1つ以上、さらなる任意選択で2つ以上、さらなる任意選択で3つ以上、さらなる任意選択で4つ以上、たとえば5つ以上、たとえばすべてを呈しうる。
(i)<10,000g水/m2/日の耐水性(米国繊維化学者色彩技術者協会(American Association of Textile Chemists and Colorists)(AATCC)試験方法127−2008に記載の静水圧試験で測定される)、
(ii)少なくとも20N、好ましくは>25N、より好ましくは>30Nのテキスタイル製品への繊維の接着(米国特許出願公開第2010−0098901号明細書(Dow Chemical)の段落[0071]およびASTM D1335に記載の「タフト結合」方法に類似した方法で繊維の除去に必要とされる平均力として測定され、ポンド力(lbf)からNに変換される)、
(iii)少なくとも0.2N/mm、好ましくは>0.3N/mm、より好ましくは>0.5N/mmの中間製品およびキャリヤーシートのドライラミネーション強度(米国特許出願公開第2010−0098901号明細書の段落[0072]およびASTM D3936に記載の「ドライラミネーション強度」方法に類似した方法で中間製品とキャリヤーシートと間の結合の強度の尺度として測定され、ポンド/インチ(lb/in)からN/mmに変換される)、
(iv)少なくとも0.05N/mm、好ましくは>0.10N/mm、より好ましくは>0.15Nの中間製品およびキャリヤーシートのウェットラミネーション強度(米国特許出願公開第2010−0098901号明細書の段落[0073]に記載の「ウェットラミネーション強度」方法に類似した方法で中間製品とキャリヤーシートと間の結合の強度の尺度として測定され、ポンド/インチ(lb/in)からN/mmに変換される)、
(v)200N以下、好ましくは<175N、より好ましくは<150Nの可撓性(「標準」条件、すなわち、50%の相対湿度(RH)および22.2℃で米国特許出願公開第2010−0098901号明細書の段落[0074]に記載の「ハンド」方法に記載されるようにテキスタイル製品のサンプルを1.3cm偏位させるのに必要とされる平均力として測定され、ポンド力(lbf)からNに変換される)、
(vi)20%未満、好ましくは10%未満、より好ましくは7%未満、最も好ましくは5%未満の低い収縮または膨張(−10℃〜40℃の温度範囲内でテキスタイル製品の任意の線寸法について)、
(vii)100〜150℃の温度で中間製品とキャリヤーシートとを接着するHMAの可逆的接着、および/または
(viii)1000g/m2未満、好ましくは<800g/m2、より好ましくは<600g/m2、さらにより好ましくは<400g/m2、さらにより好ましくは<350g/m2のHMAの層厚さ。
とくに指定がないかぎり、本明細書の試験はすべて、本明細書に定義されとおり標準条件下で行われる。
Tgは、50μlの標準TA Instrumentsアルミナカップを備えたTA Instruments DSC Q1000を用いてDSCにより測定された。流量は、50ml/minの窒素であった。また、サンプルは、20〜25℃の温度範囲で充填した。次いで、サンプルを−20℃に冷却し、−20℃でサンプルを5℃/minの速度で200℃に加熱した。Tgを実験的に測定できなかった場合、周知のフォックス式を用いて、ポリマーのTgを理論的に計算しうる。「n」個の共重合コモノマーを有するコポリマーのTg(ケルビン単位)は、各コモノマータイプのそれぞれのホモポリマーの重量分率「W」および式Tg値(ケルビン単位)により、式「1/Tg=W1/Tg1+W2/Tg2+..........Wn/Tgn」に従って与えられる。ケルビン単位の計算Tgは、容易に℃に変換されうる。
溶融粘度は、プレート/プレート25mmスピンドルを備えたAnton Paar Physica MCR301を用いてレオメーターにより測定した。測定時、窒素250ln/hオーバーフローを使用した。ギャップ距離を0.5mmに設定した。サンプルを200℃に加熱した。200℃で、冷却を4℃/minを開始する。冷却時、5s−1の剪断速度で粘度を測定である。
文脈上明らかに異なる記述がないかぎり、本明細書で用いられるポリマーまたはオリゴマーの分子量という用語は、重量平均分子量(Mwとも記される)を意味する。Mwは、任意の好適な従来の方法により、たとえば、気相クロマトグラフィー(GPC−以上に記載の方法GCMSと同様に行われる)によりおよび/または以下に記載のSEC方法により測定されうる。GPC方法が好ましい。数平均分子量(Mnとも記される)もまた、Mwと類似の方法により決定されうるかおよび/または理論的に計算されうる。
ポリマーのMwは、溶出液としてテトラヒドロフランを用いて、または溶出液として1,1,1,3,3,3ヘキサフルオロイソプロパノールを用いて、サイズ排除クロマトグラフィー(SEC)を用いて決定されうる。
SEC分析は、ポンプ、オートインジェクター、デガッサー、およびカラムオーブンを含めて、Alliance Separation Module(Waters 2690)を用いて行われた。溶出液は、1.0vol%酢酸が添加されたテトラヒドロフラン(THF)であった。注入量は、150μlであった。フローは、1.0ml/minに設定された。試験対象のサンプルは、40℃の温度でガードカラム(3μmPL)付きの3つのPL Mixed B SECカラム(Polymer Laboratories製)に適用した。検出は、示差屈折率検出器(410を灌水する)を用いて行った。サンプル溶液を8ml THF(+1vol%酢酸)中20mg固体の濃度で調製し、サンプルを24時間にわたり溶解した。500〜4,000,000g/molの範囲内の8つのポリスチレン標準(polymer standard services)を用いて校正を行った。三次校正曲線を用いてMillennium 32ソフトウェア(Waters)により計算を行った。取得されたモル質量は、ポリスチレン当量モル質量(g/mol)である。
SEC分析は、Waters Alliance2695(ポンプ、デガッサー、およびオートサンプラー)を用いてShodex RI101示差屈折率検出器およびShimadzu CTO 20ACカラムオーブンにより行った。溶出液は、0.2Mカリウムトリフルオロアセテート(KTFA)が添加された1,1,1,3,3,3ヘキサフルオロイソプロパノール(HFIP)であった。注入量は、50μlであった。フローは、0.8ml/minに設定された。ガードカラム(PFG PSS)付きの2つのPSS PFG Linear XLカラム(Polymer Standards Service)に40℃の温度で適用した。検出は、示差屈折率検出器により行った。サンプル溶液を2ml HFIP(+0.2M KTFA)中5mg固体の濃度で調製し、サンプルを24時間にわたり溶解した。500〜2,000,000g/molの範囲内の11のポリメチルメタクリレート標準(polymer standard services)を用いた校正を行った。三次校正曲線を用いてEmpower Proソフトウェア(Waters)により計算を行った。従来の校正を介してモル質量分布を取得し、モル質量はポリメチルメタクリレート当量モル質量(g/mol)である。
本明細書で用いられる場合、とくに文脈上異なる指定がないがきり、標準条件(たとえば、フィルムの乾燥用)とは、50%±5%の相対湿度、周囲温度(23℃±2°)、および0.1m/s(以下)のエアフローを意味する。
乾燥フィルムにコットンウール片(約1cm3、0.1g)を配置し、コットンウール片に直径4.8cmの1kgの錘を配置することにより(10秒間)、組成物がタック性を維持する時間(タック時間)を決定した。フィルム内またはフィルム上にいかなるのウールもマークも残存させることなく手で基材からコットンウール片を除去可能であった場合、フィルムはもはやタック性でないでない(タックフリー)と考え、フィルムがタックフリーになるのに要する時間をタック時間として記録する。
次に、以下の実施例を参照しながら、本発明を詳細に説明するが、これらの実施例は、例示を目的としたものにすぎず、限定を目的としたものではない。各成分の量は、以下の成分の全量を基準にして相対重量部として括弧内に与えられている。
以下に記載の標準的なポリエステル合成を用いて、ポリエステルを調製した。
実施例Aのポリエステル接着剤を用いて、以下のナイロンタフトカーペットタイルを作製しうる。ナイロン−6繊維をナイロン−6一次バッキングに織成する。国際公開第2012/076348号パンフレット(Niaga)に記載の超音波結合方法により、繊維ループを固着する。繊維ループが依然として熱いうちに(150℃)、120〜150℃の温度で適用された実施例1で調製された溶融結晶性ポリエステル接着剤を用いて、ポリエステルのキャリヤー層を一次バッキングに装着する。リサイクル可能な耐久性ナイロン−6カーペットタイルが取得される。
ナイロン−6タフトおよびナイロン−6一次バッキングをポリエステルタフトおよびポリエステル一次バッキングに置き換えて、実施例1と同様にポリエステルタフトを有するカーペットタイルを作製することが可能である。その結果、ポリエステルのみからなる耐久性のリサイクル可能なラミネートカーペットタイルが得られる。100〜120℃に加熱してポリエステル接着剤を軟化させ、かつキャリヤーからタフトおよび一次バッキングを分離することにより、ポリエステルタイルをリサイクルすることが可能である。代替的に、カーペットタイルがポリエステル成分のみを有するため、任意選択で、ポリエステルの分解に用いられるいずれの公知の方法による分離工程を用いることなく、リサイクル可能である。
ポリエステル接着剤Aのみによりタフトを永久的に結合させるように、国際公開第2012/076348号パンフレットに記載の超音波結合方法を省略した以外は、実施例1に記載されるのに同様にナイロンポリエステルカーペットタイルを作製する。しかしながら、リサイクル可能な得られたカーペットタイルは、機械的負荷下でタフトが容易に除去されるため、不十分な耐久性を有する。
本発明に係るテキスタイル製品のさらなる実施例(実施例3〜5)は、以下の表2にある。
PEを作製するために使用した他の成分の全質量の6質量%の量で添加された5−(ソジオスルホ)イソフタル酸(SSIPA)の追加の成分から作製された半結晶性スルホ官能性ポリエステルをホットメルトグルーとして使用して、実施例3に対して記載されたようにテキスタイル製品を作製した。そのような半結晶性スルホ官能性PEグルーは、テキスタイル製品中の静電荷の蓄積を低減するという追加の利点を有しうると考えられる。
Claims (29)
- テキスタイル製品の製造方法であって、
(a)フロント表面とバック表面とを有するバッキングと、前記バッキング中に縫合されたヤーンと、を含む第1の中間製品を提供する工程であって、前記ヤーンが前記バッキング材料の前記フロント表面から延在する、工程と、
(b)加熱表面を有する物体に沿って、前記バック表面を前記加熱表面にプレスした状態で、前記第1の中間製品を供給することにより、前記第1の中間製品中に存在する前記ヤーンを少なくとも部分的に溶融して前記ヤーンを前記バッキングに結合する工程であって、
前記加熱表面にプレスされる前記バック表面の部分が、前記加熱表面に対して、カレンダー処理されたバック表面を有する第2の中間製品を提供するような相対速度を有する、工程と、
(c)寸法安定性キャリヤーシートを提供する工程と、
を含む方法において、
(d)前記カレンダー処理された表面と前記シートとの間にホットメルト接着剤を提供することにより前記第2の中間製品を前記キャリヤーシートに接合し、かつ前記シートを前記第2の中間製品にプレスして前記テキスタイル製品を形成する工程、
をさらに含むことを特徴とし、
前記ホットメルト接着剤がポリマーPを含み、前記ヤーン、前記第1の中間製品、前記第2の中間製品および前記キャリヤーシートが、それぞれ独立して、少なくとも1種のポリマーRを含む、方法。 - 前記ホットメルト接着剤が、ホットメルト接着剤組成物の少なくとも50重量%の量でポリマーPを含み、かつ/または
前記ヤーン、前記第1の中間製品、前記第2の中間製品、および前記キャリヤーシートが、それぞれ独立して、少なくとも1種のポリマーRを含み、
前記ポリマーPおよび/またはいずれかのポリマーRが、独立して、重縮合、環状モノマーの開環重合、および/または段階成長重合の方法により取得されるおよび/または取得可能である、請求項1に記載の方法。 - 前記ヤーン、前記第1の中間製品、前記第2の中間製品、および前記キャリヤーシートのそれぞれに対する前記ポリマーRのいずれかが同一の材料を含む、請求項2に記載の方法。
- 前記ポリマーPおよび/またはいずれかの前記ポリマーRが、結晶性ポリマーを含み、かつ少なくとも5J/gの融解エンタルピー(ΔHm)を有する、請求項2または3に記載の方法。
- 前記ポリマーPおよび/またはいずれかの前記ポリマーRがアモルファスポリマーを含む、請求項2〜4のいずれか一項に記載の方法。
- 前記ポリマーPおよび/またはいずれかの前記ポリマーRが、(コ)ポリアミド、(コ)ポリエステル−アミド、それらの混合物、および/またはそれらのコポリマーからなる群から選択される1種以上のポリマーおよび/またはコポリマーである、請求項2〜5のいずれか一項に記載の方法。
- 前記ポリマーPおよび/またはいずれかの前記ポリマーRがポリエステルおよび/またはポリアミドである、請求項6に記載の方法。
- 前記ポリマーPおよび/またはいずれかの前記ポリマーRがポリエステルである、請求項7に記載の方法。
- 請求項1〜8のいずれか一項に記載の方法から取得されるおよび/または取得可能なテキスタイル製品。
- (a)ポリエステルカーペットタイル、
(b)前記キャリヤーシートとしてナイロン層ならびに前記第1の中間製品および/または第2の中間製品としてポリエステル層を含むラミネート織りカーペット、ならびに/あるいは
(c)前記キャリヤーシートとしてならびに/または前記第1の中間製品および/もしくは前記第2の中間製品として少なくとも1つ、好ましくは少なくとも2つのポリエステル層を含むラミネート織りカーペット、
からなる群から選択される、請求項9に記載のテキスタイル製品。 - 請求項9または10に記載のテキスタイル製品を製造するための、ホットメルト接着剤の使用。
- 使用済みの請求項9または10に記載のテキスタイル製品を受け取る工程と、前記バッキングが前記シートから接合を解除されるまで前記製品を加熱する工程と、前記シートから前記バッキングを分離する工程と、前記バッキングおよび前記シートを再使用する工程と、を含む、テキスタイル製品のリサイクル方法。
- 前記ホットメルト接着剤を加熱して前記バッキングから前記シートの接合を解除する工程と、前記シートと前記バッキングとを2つの個別のストリームで収集する工程と、前記個別のストリームをそれらの融解温度よりも高い温度にさらに加熱してリサイクルされたポリマーを取得する工程と、前記取得されたポリマーを再使用する工程と、を含む、請求項12に記載の方法。
- 使用済みの請求項9または10に記載のテキスタイル製品を受け取る工程と、前記製品を溶融する工程と、前記取得されたポリマーを再使用する工程と、を含む、テキスタイル製品のリサイクル方法。
- 前記溶融が1回の溶融工程で行われ、かつ前記方法が前記溶融と前記再使用との間の分離工程なしで行われる、請求項14に記載の方法。
- 前記テキスタイル製品の前記ポリマーPおよび/またはいずれかの前記ポリマーRが重縮合物である、請求項12〜15のいずれか一項に記載の方法。
- 請求項16に記載の方法で取得された未変性または化学変性および/もしくは機械変性のリサイクル重縮合物を含むテキスタイル製品。
- 請求項12〜16のいずれか一項に記載の再生方法により取得されるおよび/または取得可能な再生テキスタイル製品。
- 前記第1の中間製品の前記ヤーンが前記バック表面からも追加的に延在する、請求項1〜8のいずれか一項に記載のテキスタイル製品の製造方法。
- 前記ホットメルト接着剤が、1mm未満、好ましくは0.5mm未満の厚さを有する層として提供される、請求項2〜8または19のいずれか一項に記載のテキスタイル製品の製造方法。
- 前記ポリマーPおよび/またはいずれかの前記ポリマーRが、100℃未満のガラス転移温度を有する、請求項2〜8または19もしくは20のいずれか一項に記載のテキスタイル製品の製造方法。
- 前記ポリマーPおよび/またはポリマーRが結晶性ポリマーとアモルファスポリマーとの混合物を含む、請求項2〜8または19〜21のいずれか一項に記載のテキスタイル製品の製造方法。
- 前記ポリマーPが150℃で<500Pa・sの溶融粘度を有する、請求項2〜8または19〜22のいずれか一項に記載のテキスタイル製品の製造方法。
- カーペット、カーペットタイル、ラグ、および/またはマットである、請求項9または10に記載のテキスタイル製品。
- 前記バッキング、前記ヤーン、および前記ホットメルト接着剤、ならびに任意選択で前記キャリヤーシートが同一タイプのポリマーを含む、請求項9もしくは10または24のいずれか一項に記載のテキスタイル製品。
- 床カバーとしての、請求項9もしくは10または24もしくは25のいずれか一項に記載のテキスタイル製品の使用。
- テキスタイル製品を床に適用する方法であって、請求項9もしくは10または24もしくは25のいずれか一項に記載のテキスタイル製品を床に適用する工程と、前記テキスタイル製品を前記床に固定する工程と、を含む、方法。
- 請求項9もしくは10または24もしくは25のいずれか一項に記載のテキスタイル製品および/または請求項27に記載の方法により取得されるおよび/または取得可能なテキスタイル製品で覆われた床。
- ホットメルト接着剤を適用するためのヘッドを有することを特徴とする、請求項9もしくは10または24もしくは25のいずれか一項に記載のテキスタイル製品を製造するためのデバイス。
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