JP3385352B2 - Manufacturing method of foamed chip product having defibrated fiber surface layer - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foam chip product having a defibrated fiber surface layer.

[0002]

2. Description of the Related Art In the field of polyurethane molding, for example, waste polyurethane, which is the waste of foamed products, is reused. Generally, a polyurethane foam is formed by a crosslinking reaction of an isocyanate, and thus it is difficult to recycle it as a polyurethane material. Therefore, it has been conventionally proposed that a chip obtained by crushing polyurethane waste is mixed with an appropriate bonding agent to be molded into a predetermined shape. As one of these, cushion pad products used for cushion materials such as chairs and mattresses are known.

On the other hand, also with respect to the waste of textile products, a felt-like product is obtained by defibrating this with an anti-fluffing machine and molding it into a predetermined shape with an appropriate bonding agent. ing.

By the way, since the synthetic resin foam chips and the fluffy products are individually reused, their applications are currently limited to cushions and felts.

[0005]

Therefore, the present invention is
By using a combination of these synthetic resin foam wastes and anti-wool products that are wastes of textile products, it is lightweight and has high surface rigidity, and has excellent properties such as heat insulation and sound insulation / absorption characteristics. It is intended to propose a manufacturing method for a product. In particular, this invention intends to propose a manufacturing method capable of effectively and efficiently mixing defibrated fibers and an adhesive.

[0006]

[Means for Solving the Problems] That is, according to the invention of claim 1, a step of applying a urethane adhesive to mix chips of a soft or semi-hard synthetic resin foam and mixing them to obtain a foam chip body material, Preliminary disentanglement of the lumps of fiber by the first disentanglement machine, introducing the pre-disentangled disentanglement fiber into the mixer and mixing while applying urethane adhesive to it.
The defibrated fibers coated with the adhesive in the mixing step are further unraveled by a second defibrating machine, and the urethane-based adhesive is entangled in the defibrated fibers to apply the urethane-based adhesive to the defibrated fluff fibers. The step of mixing to obtain a defibrated fiber surface material, the foamed chip body material and the defibrated fiber surface material are laminated and arranged in a press mold, and water and heat are introduced into these to react the urethane adhesive. And a step of integrally press-molding into a predetermined shape, the method of manufacturing a foamed chip product having a defibrated fiber layer.

Further, the invention of claim 2 relates to the method of manufacturing a foamed chip product having a defibrated fiber layer which is integrally press-molded with a skin material or a backing material required in the press-molding step.

[0008]

DETAILED DESCRIPTION OF THE INVENTION The present invention will be described in detail below with reference to the accompanying drawings. FIG. 1 is a partial perspective view of an automobile floor mat product which is an example of the product obtained by the present invention, and FIG. 2 is a flow chart showing a manufacturing process of the automobile floor mat product.

The foamed chip product 10 according to the present invention, like the automobile floor mat product M illustrated in FIG. 1, compresses and solidifies a chip 21 of a soft or semi-rigid synthetic resin foam through an urethane adhesive. Foamed chip body layer 20
The main body layer 20 includes a defibrated fiber surface layer 30 obtained by compressing and solidifying defibrated fluff fibers 31 via a urethane adhesive.
And the surface layer 30 are integrally molded into a predetermined shape.

An automobile floor mat product M shown in FIG. 1 is placed on a floor plate of a vehicle compartment or the like. The upper surface 10A side is a flat defibrated fiber surface layer 30, and the lower surface side 10B is a foam chip body layer. The foamed chip body layer 20 is formed with a concavo-convex portion 25 that conforms to the concavo-convex shape of the floor plate of the passenger compartment. The flat defibrated fiber surface layer 30 on the upper surface 10A side is a dense layer in which the defibrated defibrated fibers 31 are compressed and solidified, and is lightweight but has firm rigidity. In this example, the defibrated fiber surface layer 30 has a thickness of 2 to 10 mm and a specific gravity of about 0.1 to 0.4. In addition, the foam chip body layer 2
Reference numeral 0 denotes a hardened layer obtained by compressing and solidifying a chip 21 of a soft or semi-hard synthetic resin foam, which is lightweight and has elasticity.
In this example, the foamed chip body layer 20 has a thickness of 10 to 50 mm, and the specific gravity varies depending on the compression molding portion.
It is about 0.05 to 0.15, and is about 0.1 on average.

The foamed chip product 10 is as follows.
Foamed chip body layer 2 obtained by compressing and solidifying a soft or semi-rigid synthetic resin foam chip 21 with a urethane adhesive.
0 and the defibrated fiber surface layer 30 obtained by compressing and solidifying the defibrated fluff fibers 31 via a urethane-based adhesive, they have the following product characteristics. a. The surface layer consists of a dense layer of fine, non-wool fibers that has been compressed and solidified, so it has rigidity, toughness, high shape retention, and is not easily deformed even when a large load is locally applied, and it has restorability. Is high. b. The surface layer consists of a compact layer of fine fluff fibers that has been compressed and solidified, so that it blocks heat and sound. c. On the other hand, since the main body layer is composed of a compression-solidified layer of a soft or semi-hard synthetic resin foam chip, it has elasticity (cushioning property). d. Since the main body layer is made of a layer of soft or semi-rigid synthetic resin foam chips that is compressed and solidified and a fine air layer is interposed, heat and sound are absorbed. e. Since the main body layer is made of a soft or semi-hard synthetic resin foam chip, the moldability is good. f. By combining the above a to e, it is possible to obtain a product having good moldability, high surface rigidity, and excellent heat insulation and sound insulation / absorption characteristics.

Next, a method of manufacturing the above foam chip product will be described with reference to FIG. This manufacturing method includes a step of obtaining a foamed chip body material, a step of obtaining a defibrated fiber surface material, and a step of integrally press-molding the foamed chip body material and the defibrated fiber surface material into a predetermined shape.

First, the foam chip body material will be described. The foam chip body material is made of a waste chip of a soft or semi-rigid synthetic resin foam such as urethane foam. Waste polyurethane foam discharged in the field of polyurethane molding is crushed into small pieces (chips) of about 5 to 20 mm by a crusher such as a drum chipper or a cutter. As the chip shape, there are a long thin shape and a substantially spherical shape depending on the crushing process. In addition, the synthetic resin foam is a mixture of soft and semi-rigid foam,
It can have an appropriate hardness. The mixing ratio in the examples is 50% soft and 50% semi-hard.

The foamed chip body material is weighed and mixed with a predetermined amount of urethane adhesive. At the time of this mixing, it is preferable to stir while spraying the urethane-based adhesive inside a mixer or the like.

Next, the defibrated fiber surface material will be described. Conventionally, it has been practiced to defibrate wastes of fiber products with a defibrating machine to make cotton-like defibrated products. Anti-wool fibers are used. Then, the fluff fibers and the adhesive are mixed, but it is not easy to apply and apply the liquid or mist adhesive to the cotton-like lumps of fine fibers. However, unless the adhesive is effectively applied to the fluffy fibers, the surface of the fiber layer is fluffed and fluffed after molding, or the fiber bundles are pulled out, which greatly impairs the commercial value. Therefore, the following mixing method is proposed.

That is, prior to the mixing of the fluff fibers and the adhesive, a lump of defibrated fibers weighed in a predetermined amount is preliminarily loosened by the first defibrating machine. By performing a preliminary loosening immediately before this adhesive mixing, the defibrated fibers that have been compressed and entangled by transportation or storage can be separated, and a large adhesive application space can be obtained. The coating can be performed effectively and efficiently.
This preliminary loosening is effectively used by a defibrating machine which is used in the defibrating step and which is composed of a defibrating drum having a large number of claw portions.

The defibrated fibers loosened in the preliminary loosening step are then introduced into a mixer such as a mixer and mixed and stirred with the urethane-based adhesive sprayed therein.

After the mixing step of the adhesive, the defibrated fibers coated with the adhesive are further subjected to a second defibrating machine to be loosened. By this step, the adhesive adhered to the surface of the defibrated fiber is sufficiently blended and entangled. Also in this entanglement step, the defibrating machine including the defibrating drum having a large number of claw portions described above is effectively used. The defibrated fiber surface material in which the adhesive is applied to the surface of each fiber through the above adhesive mixing step is weighed in a predetermined amount and then sent to the press molding step.

In the press-molding step, a predetermined amount of the foam chip body material and the defibrated fiber surface material, to which the urethane adhesive has been applied in the above-mentioned step, are laminated and pressed in the press mold. In this step, sufficient moisture and heat are applied so that the urethane-based adhesive applied to each material reacts. In the embodiment, although not shown, a steam ejection hole is formed in the lower mold, and the urethane adhesive is reactively cured by the steam during the compression molding by the upper mold. The steam ejected from the lower mold sufficiently spreads over the foam chip body material and the defibrated fiber surface material in the mold, and is solidified and molded into a predetermined shape integrally with a predetermined curing time. Needless to say, the lamination ratio and compression ratio of the foam chip body material and the defibrated fiber surface material are appropriately determined depending on the properties and physical properties of the molded product.

In this press molding, it is possible to integrally mold the skin material or the backing material used for the product. These skin materials or backing materials can be efficiently and integrally formed into a predetermined shape without requiring an adhesive. After press molding, the demolded molded product becomes a product through a necessary finishing process.

[0021]

As shown and described above, according to the present invention, the synthetic resin foam waste and the non-hairy product which is the waste of the textile product are used, and the weight is light and the moldability is good. A foamed chip product having a defibrated fiber surface layer having high surface rigidity and excellent properties such as heat insulation and sound insulation / absorption properties can be easily and easily manufactured. In particular, according to the present invention, it is possible to effectively and efficiently mix the defibrated fiber and the adhesive, which greatly affects the quality of the product.

[Brief description of drawings]

FIG. 1 is a partial perspective view of an automobile floor mat product which is an example of a product obtained by the present invention.

2 is a flow chart showing a manufacturing process of the floor mat product for automobiles of FIG. 1. FIG.

[Explanation of symbols]

10 Foam chip products 20 Foam chip body layer 21 Foam chip body material 30 defibrated fiber surface layer 31 Defibrated fiber surface material

─────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-6-346581 (JP, A) JP-A-6-101152 (JP, A) JP-A-7-48780 (JP, A) JP-A-60- 181352 (JP, A) Actual development Sho 61-169842 (JP, U) (58) Fields investigated (Int.Cl. ⁷ , DB name) B32B 1/00-35/00 B29B 17/00-17/02 C08J 11/00-11/28

Claims (2)

(57) [Claims] 1. A step of applying a urethane adhesive to mix chips of a soft or semi-hard synthetic resin foam to obtain a foam chip body material, and preliminarily loosening a lump of defibrated fibers by a first defibrating machine. Then
The defibrated fibers preliminarily loosened are introduced into a mixing machine and mixed while applying a urethane-based adhesive thereto, and the defibrated fibers coated with the adhesive in the mixing step are further defibrated by a second defibrating machine. A step of applying a urethane adhesive to the defibrated disentangled fibers by mixing them with a urethane-based adhesive to obtain a defibrated fiber surface material, and the foamed chip body material and defibrated fiber A defibrated fiber layer comprising a step of stacking the surface material in a press die and introducing moisture and heat into them to cause the urethane adhesive to react and press-mold integrally into a predetermined shape. Of a foamed chip product having the following. 2. The method for producing a foam chip product having a defibrated fiber layer which is integrally press-molded with a skin material or a backing material required in the press-molding step according to claim 1.