CN109689337A - 片材料的制造方法和混合原料的混合方法 - Google Patents

片材料的制造方法和混合原料的混合方法 Download PDF

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CN109689337A
CN109689337A CN201680085962.9A CN201680085962A CN109689337A CN 109689337 A CN109689337 A CN 109689337A CN 201680085962 A CN201680085962 A CN 201680085962A CN 109689337 A CN109689337 A CN 109689337A
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raw material
mixed
sheet material
manufacturing
sheet
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CN109689337B (zh
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清水祥之
仁保博
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Kasai Kogyo Co Ltd
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Kasai Kogyo Co Ltd
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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    • B29C48/08—Flat, e.g. panels flexible, e.g. films
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
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  • Laminated Bodies (AREA)
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Abstract

本发明提供一种将第一原料(111)和含有第二原料(121)的第三原料(131)进行混合的混合原料(140)的制造方法。混合原料(140)作为再循环原料(141)以相对于第一原料(111)的再循环率r重量％混合到第一原料(111)中，对于第三原料(131)，在第二原料(121)的含量设定为X重量％，无限次重复混合第一原料(111)和第三原料(131)时的第二原料(121)相对于混合原料(140)的含量设定为A重量％时，将相对于混合原料(140)的比例设定为[A·X·(100‑r)]×10‑6重量％的第三原料(131)混合到第一原料(111)中。根据本发明，能够提供一种即使将混合原料进行再循环，物理性质也难以变化的混合原料的制造方法。

Description

片材料的制造方法和混合原料的混合方法
技术领域
本发明涉及片材料的制造方法以及混合原料的混合方法。
背景技术
以往，车门内饰板、行李箱内饰板、后置物板等车辆用内装部件是使用片材料通过压制成型而制造的，该片材料是将以聚酯纤维等无纺布作为表皮材料贴合到聚丙烯树脂等片基材上的复合成型材料(参照专利文献1以及2)。
在该压制成型工序及其前后工序中，片材料由于切掉端部形成规定的形状或进行冲孔，因此产生端材。端材的比例在比例多的情况下为50％左右。
为此，虽然尝试了对端材进行再循环(再利用)，但是由于片材料的基材和表皮材料是不同的树脂材料，因此为了仅回收基材，需要进行分离、分类，从而增加了时间、成本。
现有技术文献
专利文献
专利文献1：日本专利特开平11-010717号公报
专利文献2：日本专利特开2002-292664号公报
另一方面，也考虑了在不将片材料分类为基材和表皮材料的情况下进行再循环，但是在这种情况下，由于再次使从包含再循环的端材的片材料排出的端材进行再循环，因此对于每次再循环，有时片材料(或者基材)中的原料比率发生变化，得不到期望的物理性质。
发明内容
因此，本发明是鉴于这样的情况而完成的，其目的在于提供一种即使将复合成型材料进行再循环，物理性质也难以发生变化的片材料的制造方法。
另外，本发明的另一个目的在于提供一种即使将混合原料进行再循环，物理性质也难以发生变化的混合原料的制造方法。
本发明是为了达到上述目的而提出的，(1)本发明所涉及的一个方式为将第二片贴合到第一片上的片材料的制造方法，包括：第一工序，所述第一工序为将所述片材料作为再循环原料而加以含有的第一原料片状挤出而形成所述第一片；和第二工序，所述第二工序为将由第二原料构成的所述第二片贴合到所挤出的所述第一片上，在所述第一工序中，所述再循环原料以相对于所述第一原料的再循环率r重量％被混合到所述第一原料中，当无限次重复所述第一工序以及所述第二工序时，所述第二原料相对于所述片材料的含量设定为A重量％时，在所述第二工序中，将相对于所述片材料的比例设定为[A·(100-r)]×10-4重量％的所述第二片贴合到所述第一片上。
(2)本发明所涉及的一个方式为将第一原料和第三原料进行混合的混合原料的制造方法，所述混合原料作为再循环原料以相对于所述第一原料的再循环率r重量％被混合到所述第一原料中，对于所述第三原料，在第二原料的含量设定为X重量％且无限次重复混合所述第一原料和所述第三原料时的所述第二原料相对于所述混合原料的含量设定为A重量％时，将相对于所述混合原料的比例设定为[A·X·(100-r)]×10-6重量％的所述第三原料混合到所述第一原料中。
发明的效果
根据本发明，能够提供一种即使将复合成型材料进行再循环，物理性质也难以发生变化的片材料的制造方法。
另外，根据本发明，能够提供一种即使将混合原料进行再循环，物理性质也难以发生变化的混合原料的制造方法。
附图说明
图1为说明内装部件的制造工序的概略图。
图2为表示片材料结构的截面图。
图3为说明本发明的实施方式1所涉及的片材料的制造方法的概略图。
图4为表示评价片材料的物理性质的结果的图。
图5为说明本发明的实施方式2所涉及的混合原料的制造方法的概略图。
符号说明
1 内装部件
2 端材
10 第一片、11 第一原料、12 第一成分、13 添加剂(滑石)
20 第二片、21 第二原料
30 片材料、31 再循环原料
111 第一原料、112 第一成分
121 第二原料
131 第三原料、132 第三成分
140 混合原料、141 再循环原料
200 制造装置
210 挤出成型机、211 挤出机、212 T型模头、213 供给料斗
220 贴合加工机、221 层压辊
230 切割机
240 压制成型机
300 搅拌机
具体实施方式
以下，基于附图详细说明用于实施本发明的方式(以下，称为“实施方式1”)。
(内装部件)
图1为说明内装部件的制造工序的概略图。
通常，车辆在室内侧安装有车门内饰板、行李箱内饰板、后置物板等内装部件1。对于该内装部件1，使用将第二片20贴合到第一片10而得到的片材料30，对应压制成型机240的由上模以及下模构成的成型模具而制造成具有凹凸或孔、开口等的各种形状。
在压制成型机240的压制成型工序中，在前处理工序以及后处理工序中，将不形成内装部件1的部分作为端材2从片材料30的原织物(原材料)中排出。通过将该端材2进行再循环(再利用)来制造新的片材料30。
(片材料)
图2为表示片材料结构的截面图。
片材料30为以第一片10作为片基材、以第二片20作为表皮材料而贴合的复合成型材料。由于第一片10的厚度为约0.5mm～6mm左右，第二片20的厚度为0.5mm～2mm左右，因此片材料30的厚度为1mm～8mm左右。第一片10以及第二片20的贴合重量比等在后面说明。
第一片10为将第一原料11片状挤出而形成的。在初期状态下，形成该第一片10的第一原料11由第一成分12构成，根据需要含有添加剂13等。在将端材2进行再循环的情况下，将端材2作为再循环原料31添加到该第一原料11中。
在这里，第一成分12例如为聚丙烯(PP)树脂等。另外，添加剂13为用于使成型、脱模性变好的滑石等。
第二片20形成为由第二原料21构成的纤维的无纺布片。形成该第二片20的第二原料21例如为聚酯(PET)树脂等。
(片材料的制造装置以及制造方法)
图3为说明本发明的实施方式所涉及的片材料的制造方法的概略图。
片材料30的制造装置200由挤出成型机210、贴合加工机220和切割机230构成。
在形成第一片10的第一工序S1中使用的挤出成型机210具备挤出机211和设置于挤出机211的出口侧前端的T型模头212。
挤出机211在上方具有供给挤出材料、即第一原料11的供给料斗213，在内部具有挤出第一原料11的未图示的螺杆。另外，挤出机211还具有加热、溶融第一原料11的未图示的加热器。
将所供给的第一原料11预先细化成碎片或者颗粒等的状态并混合。在含有以片材料30的端材2作为再循环原料31的情况下，也同样将第一原料11细化并混合。
T型模头212使由挤出机211挤出的第一原料11在宽度方向上扩展成型为片状，并从狭缝挤出。通过这种处理，挤出成型机210将第一原料11挤出成片状并形成第一片10。
接着，在贴合第一片10和第二片20的第二工序S2中使用的贴合加工机220具备一对层压辊221。
贴合加工机220将第一片10和第二片20夹持在该一对层压辊221之间并贴合。然而，层压辊221并不限于上下一对，也可以具备上中下三根。在这种情况下，可将第一片10夹持在中下的层压辊221之间，将第二片20从右侧送入上中的层压辊221之间，并将第一片10和第二片20夹持。
通过这种处理，贴合加工机220将第一片10和第二片20贴合，形成片材料30。此时，第一片10和第二片20总是以预先设定的一定的贴合重量比被贴合。
切割机230在上下具有切割刀，并以规定的长度切割片材料30。由此，片材料30变成规定长度的原织物。
(第一片以及第二片的贴合重量比)
在第一工序S1中，再循环原料31以相对于第一原料11的再循环率r重量％(以下，省略重量，简称为“％”)包含在第一原料11中。再循环率r根据内装部件1的种类等而不同，为20％～60％左右。
在这里，当将片材料30成型为内装部件1出厂时，将第二原材料21相对于片材料30的含量设定为A％，即将无限次重复第一工序S1以及第二工序S2时的第二原料21相对于片材料30的含量设定为A％时，在第二工序S2中，将相对于片材料30的比例设定为[A·(100-r)]×10-4％的第二片20贴合到第一片10上。
在普通片材料30的制造方法中，最初设定第一片10和第二片20的贴合重量比，但是如果将片材料30的端材2保持原样进行再循环并使用，则由于第二原料21的含量A徐徐上升，高于规定的含量，因此制造了与设计的物理性质偏离的片材料30。
例如，如果以第一片10:第二片20＝90:10之比贴合片材料30，并将再循环率r设定为50％，则理论上无限次之后，第二原料21的比例会上升至20％并从最初的状态翻倍。
在片材料30的物理性质偏向不好的方向时，不能使内装部件1出厂。相反地，在片材料30的物理性质偏向好方向时，虽然能够使内装部件1出厂，但是相对应地第二原料21被额外使用，由此，材料费变得浪费。
因此，在本发明实施方式所涉及的片材料30的制造方法中，如上所述，从最终的状态逆向运算来设定第一片10和第二片20的最初贴合重量比。
通过以这种方式设定第一片10和第二片20的贴合重量比，由于第二原料21的含量徐徐上升，接近规定的含量，因此能够制造设计的物理性质的片材料30。
例如，如果将出厂的内装部件1中的第二原料21的含量A设定为15％，将再循环率r设定为50％，则理论上最初的片材料30的贴合重量比以第一片10:第二片20＝92.5:7.5贴合就可以。
而且，在第一次再循环之后，第二原料21相对于片材料30的含量A1变为：
A1＝7.5+(7.5/100)×(92.5)×(50/100)＝10.97％。
在第二次再循环之后，第二原料21相对于片材料30的含量A2变为：
A2＝7.5+(7.5/100)×(92.5)×(50/100)1+(7.5/100)×(92.5)×(50/100)2＝12.70％。
在第n次再循环之后，第二原料21相对于片材料30的含量An变为：
An＝7.5+(7.5/100)×(50/100)1×(92.5)+(7.5/100)×(50/100)2×(92.5)+…
+(7.5/100)×(50/100)n×(92.5)％。
在这里，如果n变为无限大∞，则第二原料21相对于片材料30的含量A∞变为：
A∞＝7.5/[1-(50/100)]＝15.00％。
并且，A3＝13.57％，A4＝14.00％，A5＝14.22％，A6＝14.33％，A7＝14.38％，A8＝14.41％，第六次循环之后的A6约相当于A∞的值的96％。此后，由于第二原料21相对于片材料30的含量An逐渐接近15.00％，因此最终成为变动约为4％。
(片材料的物性)
图4为表示评价片材料的物理性质的结果的图。
为了评价片材料30的物理性质，将对长度(挤出，MD)方向和宽度(TD)方向进行弯曲试验，以求取弯曲弹性模量。
基于该试验结果，片材料30的弯曲弹性模量在再循环次数为第六次或者第七次附近稳定，没有发生急剧变化。如上所述，再循环次数在第六次或者第七次时，第二原料21相对于片材料30的含量A6、A7约为A∞值的96％，可以说成由于第二原料21的含量的变动变小。理论上，第二原料21相对于片材料30的含量A约为A∞值的96％是第四次再循环时，但是在第5次循环时，由于某种理由TD方向的弯曲弹性模量减小，因此安全起见，将第六次或第七次之后的片材料30成型的内装部件1出厂即可。
如上所述，实施方式1所涉及的片材料30的制造方法为将第一片10贴合到第二片20上的片材料30的制造方法，包括：第一工序S1，将含有片材料30作为再循环原料31的第一原料11片状挤出而形成第一片10；和第二工序S2，将由第二原料21构成的第二片20贴合到所挤出的第一片10上，在第一工序S1中，将再循环原料31以相对于第一原料11的再循环率r重量％混合到第一原料11中，当无限次重复第一工序S1以及第二工序S2时的第二原料21相对于片材料30的含量设定为A重量％时，在第二工序S2中，将相对于片材料30的比例设定为[A·(100-r)]×10-4重量％的第二片20贴合到第一片10上。
由此，即使使用将贴合第一片10和第二片20的片材料30的端材2再循环而得的再循环原料31来形成第一片10，由于第二原料21相对于片材料30的含量A变为规定值，因此也能够按照设计的物理性质制造片材料30。
另外，由于将片材料30的端材2进行再循环，因此能够消除与内装部件1的制造相伴的废弃物。进而，在将片材料30的端材2进行再循环时，不需要对第一片10和第二片20进行分离、分类，从而能够削减与之相应的工序、装置以及人员。
接下来，对实施方式2进行说明。
图5为说明本发明的实施方式2所涉及的混合原料的制造方法的概略图。
在实施方式1中，将再循环技术应用于片材料的制造方法，但是在实施方式2中，将再循环技术应用于混合原料的制造方法的情况进行说明。
混合原料140为用搅拌器300将第一原料111和含有第二原料121的第三原料131混合而制造的。
第一原料111、第二原料121、第三原料131可以为液体，也可以为粉末，或者可以为在溶融时呈现流动性的固体，例如，可为实施方式1中所记载的树脂材料，另外，对其种类也并不特别限定于药液、涂布液体、食品、复合树脂等，只要通过液体之间的混合，液体和粉末的混合等能够均一扩散即可。
然而，第三原料131包括第三成分132，与第三成分132不同的第二原料121的含量设定为X重量％(以下，省略重量，简称为“％”)。
混合原料140在混合后被消耗，残余的混合原料140作为再循环原料141以相对于第一原料111的再循环率r％被再次混合到第一原料111中。再循环率r为5％～60％左右，但是没有特别限定。第一原料的残余为第一成分112。
此时，当使用混合原料140时，第二原料121相对于混合原料140的含量设定为A％时，即将无限次重复再循环混合时的第二原料121的含量设定为A％时，将相对于混合原料140的比例设定为[A·X·(100-r)]×10-6重量％的第三原料131混合到第一原料111中。
例如，如果将消耗的混合原料140中的第二原料121的含量A设定为20％，再循环率r设定为10％，第三原料131中的第二原料121设定为80％，则理论上最初的混合原料140以第一原料111:第三原料131＝85.6:14.4贴合即可。
如上所述，实施方式2所涉及的混合原料140的制造方法为将第一原料111和含有第二原料121的第三原料131进行混合的混合原料140的制造方法，混合原料140作为再循环材料141以相对于第一原料111的再循环率r重量％被混合到第一原料111中，对于第三原料131，第二原料121的含量为X重量％，当无限次重复混合第一原料111和第三原料131时，第二原料121相对于混合原料140的含量设定为A重量％时，将相对于混合原料140的比例设定为[A·X·(100-r)]×10-6重量％的第三原料131混合到第一原料111中。
由此，即使将混合第一原料111和含有第二原料121的第三原料131的混合原料140消耗，使用将残余的混合原料140再循环而得的再循环原料141来混合新的混合原料140，由于第二原料121相对于混合原料140的含量变为规定值，因此也能够按照设计的物理性质制造混合原料140。
(变形例)
在上述实施方式1中，虽然使用片材料30制造了内装部件1，但是也可以制造其他部件。另外，第一片10可以为发泡片材，第二片20可以为纺布而不是无纺布，也可以为片材或薄膜材。
上述实施方式2的混合方法可以作为片材料30的制造方法适用于实施方式1的挤出材料混合。在这种情况下，片材料30通过将第一片10和由多种成分构成的第二片20贴合而形成。
并且，本发明并不限于上述实施方式，在能够实现本发明目的的范围内的变形、改进等均包括在本发明中。

Claims (2)

1.一种片材料的制造方法，为将第二片贴合到第一片的片材料的制造方法，其特征在于，包括：
第一工序，将所述片材料作为再循环原料而加以含有的第一原料片状挤出而形成所述第一片；和
第二工序，将由第二原料构成的所述第二片贴合到所挤出的所述第一片，
在所述第一工序中，所述再循环原料以相对于所述第一原料的再循环率r重量％被混合到所述第一原料中，
在无限次重复所述第一工序以及所述第二工序时的所述第二原料相对于所述片材料的含量设定为A重量％时，
在所述第二工序中，将相对于所述片材料的比例设定为[A·(100-r)]×10-4重量％的所述第二片贴合到所述第一片。
2.一种混合原料的制造方法，为将第一原料和含有第二原料的第三原料进行混合的混合原料的制造方法，其特征在于，
所述混合原料作为再循环原料以相对于所述第一原料的再循环率r重量％被混合到所述第一原料中，
对于所述第三原料，在第二原料的含量设定为X重量％，无限次重复混合所述第一原料和所述第三原料时的所述第二原料相对于所述混合原料的含量设定为A重量％时，
将相对于所述混合原料的比例设定为[A·X·(100-r)]×10-6重量％的所述第三原料混合到所述第一原料中。
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