JP3238468B2 - Formable rug - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a three-dimensionally moldable and recyclable rug, particularly a rug for automobiles and a method for producing the same.

[0002]

2. Description of the Related Art Currently available three-dimensional workable rugs are:
The individual components comprise more or less different types of synthetic resin or fiber composites. This kind of rug is mainly made of polyethylene terephthalate (PET), polyacrylate or polypropylene-fiber-containing PE.
Formable by applying a taffeta or needle fleece of T-mix to the back side coated with latex and then providing further layers of various materials to ensure mechanical stability and good installation behavior Some of them as composites are obtained in a number of process steps which are very expensive.

[0003] Not only is this type of rug expensive to manufacture, but also because of the combination of different types of materials, stamping debris, which can make up to 40% of the molding, can be reclaimed from the disposal of old automobiles. Has the drawback that it cannot be reused.

[0004]

It is therefore an object of the present invention to provide a rug which satisfies the following conditions: 1) The rug is made of the same type of material in order to be able to be reused. Must consist of a combination. 2) The back covering must be able to be processed at a heating temperature such that the rug surface is not disturbed. 3) The back coating must on the one hand be sufficiently flexible and, on the other hand, under the conditions of use and form-stable. 4) The rug must be easy to manufacture, avoiding fleece composite combinations.

[0005]

This object is achieved by a rug consisting of the following components: a) a rug surface made of partially crystalline polyolefin: b) a back surface made of a molding material containing the following components: Coatings: 10 to 95% by weight of one or more fully amorphous polyolefins of the following monomer composition 0 to 80% by weight of α-olefins of 4 to 10 carbon atoms, 20 to 100% by weight of propene and 20 Less than 5% by weight of ethene;-5 to 90% by weight of one or more partially crystalline polyolefins;-Up to 70% by weight of fillers; c) fleece, support grid, support fabric or support of partially crystalline polyolefin or glass. Back reinforcement in knitted state A flexible layer based on polyolefin without intermediate bonding on one or both sides with an adhesive, for example isotacticity German Patent Application DE 3,100,682 discloses a self-supporting polyolefin layer material which is based on a rigid support consisting of a polyolefin plate coated with a fabric or a fiber fleece made of k-polypropylene. is there. However, its stiffness realizes that its resonant vibration is in the audible range (ie, low sound absorption). Furthermore, they are not suitable as rugs because they cannot be precisely adapted to the floor geometry.

GB 2,072,578 discloses a sound absorbing rug whose back coating contains a substantial amount of polyolefin, synthetic rubber, petroleum and contains an inorganic filler. A significant disadvantage of this composition is that the very high melt viscosities of the polyolefin / synthetic rubber / filler combination must be reduced to a processing-technically appropriate degree by the addition of oil. However, the presence of oil is undesirable for a number of reasons. Of course, this is prone to sweating, which can cause significant fogging problems. Since the rug surface must be provided with latex prior to application to the backcoat, adhesion on the rug surface is also poor. In addition, the presence of oils and latex upon recycling is undesirable.

The specification does not mention whether the rug described therein can be formed into three-dimensional dimensions after its manufacture. In contrast, the rugs according to the invention can be reused without problems, can be processed three-dimensionally without difficulty, can be easily manufactured without the cause of fogging phenomena and have good flexibility and good soundproofing and sound-absorbing effects. Is shown.

As a material for the rug surface, use is made of isotactic polypropylene, which is particularly advantageous for reasons of good recyclability. Homo- and copolymers can be used. That is, it is particularly advantageous to use a homopolymer. According to the prior art, the polymer may contain commonly used amounts of pigments, stabilizers, processing aids, antistatics and the like.

For the back coating, a homopolypropylene such as atactic polypropylene may be sufficient as an amorphous polyolefin.
Alternatively, it can be used in the form of a copolymer. Particular preference is given to using atactic or polypropylene (APP) and / or binary or ternary copolymers consisting of monomers of butene-1, propene and possibly ethene. Copolymers of this kind can be obtained by the deliberate polymerization with Ziegler catalysts or their development, as described, for example, in DE 2,306,667 or DE 2,930,108. Can be manufactured by Generally, up to 25% of fully amorphous polyolefin (determined by X-ray diffraction)
Crystallinity.

In a particularly advantageous embodiment, 70 to 1
Softening point at 60 ° C (ring and ball method), 2,000 to 2 at 190 ° C
00,000 mPa. s melt viscosity (ASTM D 3
236-73), a density of 0.90 g / cm ³ and a
50 (0.1 mm) penetration 100/25/5 (DIN
52,010) is used. Particularly advantageous fully amorphous polyolefins are those having a softening point of 90 to 150 ° C and 5,000 to 1 at 190 ° C.
50,000 mPa. s melt viscosity and 15-40
(0.1 mm).

As partially crystalline polyolefins, it is possible in principle to use any polymers which are also suitable for the rug surface. However, high molecular weight PP
It is particularly advantageous to use random or block copolymers.

According to the prior art, at least a part of a sufficiently amorphous polyolefin and / or a partially crystalline polyolefin is radically grafted with a double bond-containing monomer having at least one functional group. Suitable polymer mixtures are described, for example, in DE-A-0,30
No. 9,674. This document is cited here.

As fillers, for example, chalk, talc, mica, barite, similar rock crushed materials, glass fibers and / or
Alternatively, glass spheres can be used. It is particularly advantageous to use chalk and / or barite. The average particle size should not exceed 150 μm.

The molding composition for the back coating can be produced from the components by any customary method, in particular by melt mixing. Generally, the back coating has a thickness of about 0.2 to about 5 mm.

[0015] The back coating generally contains an embedded fleece, support grid, support fabric or knit. Suitable materials are the same polymers that can also be used for the rug surface.

The composite can be produced in various ways, for example by calendering or coating. It can be obtained particularly advantageously by extrusion coating. After production and possibly cutting, the composite can be three-dimensionally formed, for example by pressing or vacuum forming. For this purpose, the composite is first passed through a hot zone which has been brought to a temperature which has softened the back coating but the fibers on the rug surface are still shape-stable.

A rug of this kind is particularly suitable for use in motor vehicles. In this way, the composite can be easily adapted to the outer space of the leg space or the trunk room. The cuttings or the entire molding can be easily reused. For this purpose, the materials are customarily ground and fed to an extruder, where further substances may be incorporated. The resulting material can be used, for example, for back coatings. Since only the same type of thermoplastic polymer is contained, neither delamination nor staining is observed.

[0018]

EXAMPLE 100 percent polypropylene - taffeta consisting homopolymer - velor (360g / m ²⁾ (not latex coating to the back surface is required to provide a brushed) 4 with a width of 2m It has a fiber raising height of 0.5 mm and a fineness of 17 dtex. Use this.

This taffeta-velor is wrapped with three rolls
Ging-Scroll low on calender (operating width 2.40m)
Supplied from Then passed the first roller
Later, from the extruder through a wide nozzle, 33 1/3%
Random copolymer (VESTOLEN P 840)
0), 33 1/3% of amorphous directly polymerized
Tactic-Polypropylene (VESTOPLAST)
891) and 33 1/3% barite batch (70 weight
% Barite and 30% polypropylene-homopoly
And a molten film consisting of VESTO
60 g / m consisting of LEN A 6012 ^TwoHeavy poly
Olefin net (Lattice size 1.2 × 1.5m
m) while simultaneously supplying
Supply. In this case, as the extruder, dynamic mixer, melting
Pump, static mixer and flexible lip nozzle (2.20
screw extruder with an operating width of 2.20 m)
(120 mmφ screw diameter) is used. GRAGE
Combine the composites through a calendar.

By preparing the glazing roll gap 10% thinner than the total thickness of the composite to be formed,
Sufficient composite bonding is achieved. The rugs thus produced can be supplied to the thermoforming process as rolled products or in mold sizes.

[0021] Starting from the molding process roll roller coverings complex is conveyed and the forming location held by the sutured thien supply means (Kettenzufuehrung).

The heating step is carried out by infrared radiation below the melting range of the fiber surface on the longitudinal heat regulating means, which can be controlled separately on both sides, so that it is not thermally damaged.
Then, a clear contour with no problem is formed by press molding. The stamping of the molded body is performed in this press molding step.

The stamping waste (about 40% by weight) is used as a component of the back coating in another product mixture of the same kind.
The amount of calculation of the individual first components of the back coating (4 in total)
8% by weight) for a corresponding amount of ground chopping. In this case, a qualitatively equivalent complex is obtained.

[0024]

[0025]

[0026]

────────────────────────────────────────────────── ─── Continued on the front page (72) Inventor Eduard Winkel, Germany, Dorsten 1, Handelstraße, 129 (56) References JP-A-1-104886 (JP, A) (58) Fields studied .Cl. ⁷ , DB name) D06N ^7/ 00-7/06 B32B 27/00-27/42

Claims (8)

(57) [Claims] 1. A rug surface consisting of the following components: a) a partially crystalline polyolefin: b) A backcoat consisting of a molding composition containing the following components: from 10 to 95% by weight of one or more of the following monomer compositions: 0 to 80% by weight of α-olefins having 4 to 10 carbon atoms, 20 to 100% by weight of propene and less than 20% by weight of ethene; one or more partial crystals of 5 to 90% by weight -Up to 70% by weight of filler; c) bedding consisting of a backing in the form of a fleece, supporting grid, supporting fabric or knitting made of partially crystalline polyolefin or glass. 2. The rug according to claim 1, wherein independently of each other, the partially crystalline polyolefin component of the rug surface, the back coating and / or the back reinforcement comprises polypropylene. 3. The rug according to claim 2, wherein the polypropylene is a homo- or copolymer. 4. Use of atactic or polypropylene (APP) and / or two- or three-component copolymers of butene-1, propene and possibly ethene monomers as fully amorphous polyolefins for the backcoat. The rug according to any one of Items 1 to 3. 5. The process according to claim 1, wherein chalk, talc, mica, barite, similar crushed rocks, glass fibers and / or glass spheres are used as fillers for the back coating. Rug. 6. The method for producing a rug according to claim 1, wherein the back coating is provided by extrusion coating and then calendered. 7. The composite according to claim 6, wherein the composite is then three-dimensionally molded.
The method described in. 8. A method of using the rug according to any one of claims 1 to 5 for an automobile.