CN1820683B - Composite forming carpet and its producing method - Google Patents
Composite forming carpet and its producing method Download PDFInfo
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- CN1820683B CN1820683B CN 200610025347 CN200610025347A CN1820683B CN 1820683 B CN1820683 B CN 1820683B CN 200610025347 CN200610025347 CN 200610025347 CN 200610025347 A CN200610025347 A CN 200610025347A CN 1820683 B CN1820683 B CN 1820683B
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Abstract
The composite formed carpet consists of a facing material layer and a bottom material layer. The facing material layer is made of polymer or mixture of styrene and rubber in the weight ratio of 70/30 to 90/10; and the bottom material layer is blended needle punched non-woven fabric of polyester fiber and low smelting point fiber in the weight ratio of 60/40 to 80/20in the needle punching density of 200-400 stitches/sq cm. The production process includes smelting and extruding the polymer for the facing material layer to form a membrane covering the surface of the bottom material layer to combine, far infrared heating, press forming inside mold, cooling to settle, punching, and installing corner parts. The product is environment friendly and erasable, and has high impact strength and less deformation. The production process has short procedure, high efficiency and low cost, and is especially suitable for producing small batch and complicated form carpets.
Description
Technical field
The present invention relates in the textile industry fabrics for industrial use manufacturing industry, composite forming carpet and manufacture method thereof are meant a kind of NEW TYPE OF COMPOSITE moulding carpet and manufacture method thereof especially.This carpet can be widely used in moulding carpet aspect in the interior trim of supporting main body in automobile and other fields.
Background technology
Along with the World Economics fast development, living standards of the people improve constantly, and automobile industry development is rapid, and car production is maked rapid progress, and vehicle is brought in constant renewal in.People are not only outward appearance, the comfortableness of upholstery, the globality, functional of beautiful design to the requirement of automobile, and have also proposed new requirement for the property easy to clean of automobile interior, promptly require car carpeting to be convenient to cleaning, arrangement.For reaching this purpose, usually the car owner can remove to lay in addition one deck polyvinyl chloride (PVC) material again on original car carpeting to the automobile remodeling factory after having purchased car, but such hand lay-up is not only time-consuming, effort, and owing to be the artificial laying in hand cutting back, therefore cause between PVC material and automobile profile and the originaling forming carpet and often can't fit preferably, occur being uneven and soaring phenomenon.
For addressing this is that, in recent years, usually adopt top layer PVC material and the bottom acupuncture lining way of moulding at twice in the industry, promptly first that bottom needle punched carpet (back of the body covers the moulding latex) is shaped, and then above by various means top layer PVC material being covered.Now domestic and international scientific worker is devoted to the research and development of the manufacture method of this PVC carpet, is summarized as follows:
1), Method for bonding behind the plastic uptake
Adopt elder generation respectively with behind moulding of bottom carpet and the top layer PVC material plastics sucking moulding, utilize adhesive to be bonded on top layer and bottom more at last.Because the plasticity of PVC material is on duty mutually, its processing range is very narrow, and is therefore higher to forming mould, plastic uptake device and plastic uptake technological requirement.And this kind method still can use for being capped the comparatively simple situation of profile, and for profile comparatively complicated just have a double layer material situation completely of fitting inadequately.
2) plastic uptake Method for bonding
Adopt earlier carpet to be placed on the plastics suction mould with forming, utilize then plastic uptake technology with top layer PVC material plastic uptake on the bottom carpet.This kind method has bigger improvement than the applying degree of the two layers of material of preceding a kind of method, but this kind method same exist be not suitable for the profile complexity, corner angle change situation greatly, and need two sleeve forming systems of processing, gross investment is bigger.
Yet, above-mentioned two kinds of processing methods all can be more much better than than the original way of the artificial laying of hand cutting, but because both all adopt the PVC of non-environment-friendly type as one of composite carpet raw material, thereby make this two method in process of production or in the use all because of the pernicious gas serious environment pollution of overflowing is arranged in various degree, influence health.
Summary of the invention
The purpose of this invention is to provide a kind of NEW TYPE OF COMPOSITE moulding carpet, to solve the above-mentioned problems in the prior art.This composite forming carpet of the present invention should have the characteristic except that having mill run, and it also should have good erosion-resisting characteristics, thermal contraction performance, can wipe examination performance and water resistance, and volatile matter nontoxic, that nothing influences environment distributes.
Another object of the present invention provides a kind of manufacture method of above-mentioned composite forming carpet.
Composite forming carpet provided by the present invention is made up of precoat and this two layers of material of initial bed.
In above-mentioned composite forming carpet, the surface density of two layers of material is respectively:
Precoat 1200～1600 grams/square metre
Initial bed 200～500 grams/square metre.
(A) described precoat is the amorphous polymer that formed by styrene monomer and rubber graft polymerization or the physical blending thing of polystyrene and rubber, promptly polystyrene copolymer or blend constituted.Described rubber is general purpose rubber, and preferred rubber is selected from butadiene rubber, neoprene, different third rubber, isoprene rubber or butadiene-styrene rubber, wherein butadiene-styrene rubber most preferably.
This melt index is 10～25, and wherein styrene monomer is the Main Ingredients and Appearance that constitutes precoat, also is the principal monomer that forms polystyrene copolymer, because its existence makes the whole fabric layer have good formability and erosion-resisting characteristics.Another component rubber, it can further improve precoat toughness and plasticity, and both fit fully further to guarantee the compound back of precoat and underlying material.The rubber addition is many more, and then toughness and plasticity are good more, but the typing effect is poor more, and promptly size and shape stability is poor more.Therefore the weight ratio of styrene monomer and rubber two components was advisable with 70: 30～90: 10.
(B) described initial bed is made of with low-melting fiber mixing needle punched non-woven fabrics polyester fiber.Wherein Main Ingredients and Appearance is polyester fiber (255～260 ℃ of a fusing point), it mainly is to strengthen shock-resistant, the tear-resistant main body of this moulding carpet, and another component low-melting fiber (125～175 ℃), be that polypropylene is that core, polyethylene are the tack composite fibre that skin is formed, it mainly plays bonding and composite consolidation.This fiber content is more little, and then forming stability is good more.But break easily in the place that corner angle change greatly, for reaching required effect, the weight ratio of polyester fiber and low-melting fiber two components was advisable with 60: 40～80: 20.In addition, the needling density that initial bed of the present invention promptly mixes needle punched non-woven fabrics also can influence the composite forming carpet overall processability, and density is high more, ultimate strength and tearing brute force are high more, and strain property is poor more, therefore, mixes the needle punched non-woven fabrics needling density and is controlled to be 200～400 pin/square centimeters.
Making the method for composite forming carpet of the present invention, is to be made up of following steps successively:
A) polystyrene copolymer or the blend that will be polymerized by styrene monomer and grafting rubbers earlier, form adding with particle has in the screw extruder of required compound width spout, be squeezed into membranaceous precoat through heating, fusion and with melt Conveying, be covered on the initial bed of required compound width, promptly be covered on the needle punched non-woven fabrics surface of forming by polyester and low-melting fiber.With precoat and the two-layer one that is composited of initial bed, form the composite carpet closely of fitting, and by the required sheet material that is cut to, standby.Technological parameter: extruder temperature is 200～280 ℃, the screw rod extrusion capacity be 1400～1800 the gram/square metre.
B) above-mentioned composite carpet sheet material is placed on the heating plate, the initial bed in its sheet material is positioned at the upper strata.Again it is sent in the conventional Far-infrared Heating equipment and heat.Technological parameter: heating-up temperature is 160～220 ℃, and be 70～120 seconds heat time heating time.
C) the above-mentioned composite carpet sheet material after will heating is displaced in the counterdie that is fixed on moulding press, puts down patrix, the matched moulds extrusion forming.For guaranteeing the typing cooling effect, upper and lower mould must lead to cooling water, makes the sheet material moulding in mould that is softening shape originally, behind cooling and shaping, composite forming carpet is fixed by the shape of mould.Technological parameter: briquetting pressure 0.6～1.0MPA, chilling temperature are 30～70 ℃, and shaping time is 80～100 seconds.
D) lift patrix, take out composite forming carpet, last by the unnecessary leftover pieces in profile requirement its edge of cutting that are capped thing, go out the corresponding mounting hole position with 200～260 ℃ of hot melt cutters, promptly make described composite forming carpet.
Effect of the present invention:
(a) precoat of the present invention's employing is polystyrene copolymerization body or mixture impact resistant material, do the skin-material except that having good toughness and processability, also good fine and close characteristic is arranged because of its surface, thereby having good erasable performance and a water resistance, material itself is that nontoxic nothing influences the compound that the volatile matter of environment distributes simultaneously.And primer has adopted polyester fiber and the mixed needle punched non-woven fabrics of forming of low-melting fiber; wherein; polyester fiber is that enhancing is shock-resistant; the main body of tearing; thereby can avoid surface material when die for molding because of excessive slippage occur vestige or even tear; another component low-melting fiber is a characteristic of utilizing its fusion at a certain temperature; both worked the adhesive effect of strengthening Polyester Fibers; improve the molding effect of composite carpet; can improve initial bed and the precoat adhesive power between two-layer again, in addition be capped the object plane type comparatively under the complicated situation initial bed and precoat still keep good fit-state.From finding out that the composite forming carpet that precoat+initial bed of the present invention is made not only has good erosion-resisting characteristics, thermal contraction performance, can wipe examination performance and water resistance, and is on-deformable good environmentally friendly machine.
(b) selected precoat polystyrene copolymer of the present invention or blend raw material are a kind of thermoplastic resins, and initial bed is slim needle punched non-woven fabrics, and both equal prices are cheap.And the color of precoat, style can arbitrarily be adjusted, and have easy selection and supporting main body interior trim tone, advantage that style is consistent, are cheap and good-quality supporting moulding ornament materials, and have lay convenient, the characteristic that is easy to produce in enormous quantities.
(c) manufacture method of composite provided by the present invention, changed the common mode of production, employing with the polymer particles of precoat by screw rod heating, fusion, carry, be squeezed into the membranaceous initial bed surface that is covered in, two-layer compound and one-time formed method, therefore in manufacture process of the present invention, just not needing to exist respectively two sleeve forming moulds, is one-shot forming after the heating; Used all moulds, equipment all can utilize original conventional moulding carpet manufacturing equipment, need not to append in addition the investment of this respect.Manufacture method flow process provided by the present invention is short, efficient is high, small investment, equipment are simple, the manufacturing of the multi-field moulding carpet of suitable especially the make rapid progress many kinds of small lot brought in constant renewal in and complex profile.
The specific embodiment
Embodiment 1
(A) composite forming carpet is specifically composed as follows:
Composite wood carpet sheet material precoat elects styrene monomer as and the butadiene-styrene rubber glycerol polymerization forms polystyrene copolymer, and the melt index of polymer particles is 15, and wherein styrene and rubber weight ratio are 85: 15.Initial bed is polyester fiber and low-melting fiber mixing needle punched non-woven fabrics, and wherein polyester fiber and low-melting fiber weight ratio are 70: 30, the needle punched non-woven fabrics surface density be 250 the gram/square metre, needling density 250 pin/square centimeters.
(B) concrete steps of above-mentioned composite forming carpet manufacturing are as follows:
(1) with the precoat polymer particle, add and have in the screw extruder of required compound width spout, fusion under 220 ℃ of temperature, melt is squeezed into to be equivalent to surface density be that 1400 gram/square metre membranaceous precoats are overlying on the initial bed needle punched non-woven fabrics of required compound width, the two-layer one that is composited of precoat and the initial bed composite carpet closely of fitting, and be cut into sheet material by required moulding specification requirement.
(2) above-mentioned composite carpet sheet material is placed on (initial bed upwards) on the heating table top, it is sent in the Far-infrared Heating baking oven commonly used and heats.Technological parameter: 160 ℃ of heating-up temperatures, 70 seconds heat time heating times.
The above-mentioned composite carpet sheet material that (3) will heat is displaced in the mould counterdie that is fixed on the moulding press, puts down patrix, the matched moulds extrusion forming.For guaranteeing its typing effect, the logical cooling water of mould is sheet material moulding in mould of softening shape originally up and down, after cooling composite forming carpet is fixed by the shape of mould.Technological parameter: briquetting pressure 0.65MPA, 45 ℃ of chilling temperatures, 70 seconds cool times.
(4) lift patrix, take out composite forming carpet, prescind the unnecessary leftover pieces in edge by the face type requirement that is capped thing.
(5) composite forming carpet that will prescind leftover pieces is placed on the punching die, goes out mounting hole site with 250 ℃ of hot melt cutters, promptly makes required product.
Claims (8)
1. composite forming carpet is characterized in that:
Be made up of precoat and this two layers of material of initial bed, the surface density of two layers of material is respectively: precoat be 1200～1600 grams/square metre, initial bed be 200～500 grams/square metre; Described precoat is the amorphous polymer that is polymerized by styrene monomer and grafting rubbers or the physical blending thing of polystyrene and rubber, and promptly the copolymer of polystyrene or blend constitute; Described initial bed is made of with low-melting fiber mixing needle punched non-woven fabrics polyester fiber.
2. composite forming carpet as claimed in claim 1, polymer or its melt index of blend of it is characterized in that constituting described precoat are 10～25, constituting the styrene monomer of precoat and the weight ratio of rubber two components is 70: 30～90: 10.
3. composite forming carpet according to claim 1, it is characterized in that wherein constituting the described rubber component of precoat is to be selected from butadiene rubber, neoprene, different third rubber, isoprene rubber or butadiene-styrene rubber.
4. as composite forming carpet as described in the claim 3, it is characterized in that wherein constituting rubber component is butadiene-styrene rubber.
5. composite forming carpet as claimed in claim 1 is characterized in that constituting the polyester fiber of above-mentioned initial bed and two component weight ratios of low-melting fiber are 60: 40～80: 20.
6. composite forming carpet according to claim 1, the low-melting fiber that it is characterized in that wherein constituting the initial bed component is to be that core, polyethylene are the tack composite fibre that skin is formed with the polypropylene, its fusing point is 125～175 ℃.
7. composite forming carpet as claimed in claim 1 is characterized in that, constitutes the needle punched non-woven fabrics that mixes of described initial bed by polyester fiber and low-melting fiber, and its needling density is 200～400 pin/square centimeters.
8. make the method for the described composite forming carpet of claim 1, it is characterized in that this method may further comprise the steps composition:
A) copolymer or the blend of the polystyrene that will be polymerized by styrene monomer and grafting rubbers earlier, form adding with particle has in the screw extruder of required compound width spout, be squeezed into membranaceous precoat through heating, fusion and with melt Conveying, be covered on the initial bed of required compound width, with precoat and the two-layer one that is composited of initial bed, the formation composite carpet closely of fitting, and by the required sheet material that is cut to, technological parameter: extruder temperature is 200～280 ℃, the screw rod extrusion capacity be 1400～1800 the gram/square metre;
B) above-mentioned composite carpet sheet material is placed on the heating plate, the initial bed in its sheet material is positioned at the upper strata, and it is sent in the conventional Far-infrared Heating equipment again and heat technological parameter: heating-up temperature is 160～220 ℃, and be 70～120 seconds heat time heating time;
C) the above-mentioned composite carpet sheet material after will heating is displaced in the counterdie that is fixed on moulding press, puts down patrix, the matched moulds extrusion forming, upper and lower mould leads to cooling water, cooling and shaping, technological parameter: briquetting pressure 0.6～1.0MPA, chilling temperature is 30～70 ℃, and shaping time is 80～100 seconds;
D) lift patrix, take out composite forming carpet, last by the unnecessary leftover pieces in profile requirement its edge of cutting that are capped thing, go out the corresponding mounting hole position with 200～260 ℃ of hot melt cutters, promptly make described composite forming carpet.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 200610025347 CN1820683B (en) | 2006-03-31 | 2006-03-31 | Composite forming carpet and its producing method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 200610025347 CN1820683B (en) | 2006-03-31 | 2006-03-31 | Composite forming carpet and its producing method |
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| CN1820683A CN1820683A (en) | 2006-08-23 |
| CN1820683B true CN1820683B (en) | 2010-10-20 |
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| CN 200610025347 Active CN1820683B (en) | 2006-03-31 | 2006-03-31 | Composite forming carpet and its producing method |
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Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101046033B (en) * | 2007-04-24 | 2010-05-19 | 江苏中联地毯有限公司 | Composite knitted automobile carpet and its making process |
| CN101524239B (en) * | 2008-03-07 | 2011-08-03 | 吴莹旭 | Environmental protection type nonwoven needle punched carpet and manufacturing method thereof |
| CN101476218B (en) * | 2009-01-21 | 2011-07-20 | 江阴市华方新技术科研有限公司 | Method for processing needle-punched carpet needle tail wool stub |
| CN105058945B (en) * | 2015-07-27 | 2017-05-31 | 无锡吉兴汽车声学部件科技有限公司 | A kind of manufacturing process of sound-absorbing car carpeting high |
| CN110722853A (en) * | 2019-10-29 | 2020-01-24 | 山东省寄生虫病防治研究所 | Compound layer rubber carpet for repelling mosquitoes and preparation method thereof |
| CN110757811A (en) * | 2019-10-29 | 2020-02-07 | 上海允泉新材料科技有限公司 | Sportswear composition and method for producing the same |
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|---|---|---|---|---|
| US3957554A (en) * | 1973-05-24 | 1976-05-18 | Conwed Corporation | Attachment of net to non-woven blanket without adhesive |
| CN2490022Y (en) * | 2001-06-29 | 2002-05-08 | 十堰市金利威汽车装饰材料公司 | Composite carpet |
| CN1410246A (en) * | 2001-09-25 | 2003-04-16 | 上海汽车地毯总厂 | Method of producing composite material for decorating automobile inside |
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2006
- 2006-03-31 CN CN 200610025347 patent/CN1820683B/en active Active
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3957554A (en) * | 1973-05-24 | 1976-05-18 | Conwed Corporation | Attachment of net to non-woven blanket without adhesive |
| CN2490022Y (en) * | 2001-06-29 | 2002-05-08 | 十堰市金利威汽车装饰材料公司 | Composite carpet |
| CN1410246A (en) * | 2001-09-25 | 2003-04-16 | 上海汽车地毯总厂 | Method of producing composite material for decorating automobile inside |
Non-Patent Citations (3)
| Title |
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| 石化部科技情报研究所.国外合成橡胶工业技术概况.合成橡胶工业1.1978,(1),68-83. * |
| 麦华生等.非织造轿车地毯复合材料比热性能的测试与研究.上海纺织科技33 7.2005,33(7),20-22. |
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