JPH0365253B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for lining carpets. More specifically, the present invention relates to a method for lining carpets, particularly sound-insulating carpets for automobiles and tile carpets, in which the steps from kneading a thermoplastic resin and a filler to lining carpet material are performed in one step. Sound insulating carpets for automobiles are used for the purpose of reducing noise from outside, such as automobile engine noise, and improving indoor comfort. For this purpose, a backing material with sound insulation function is required. Since the sound insulation effect is proportional to the mass per unit area of the backing material, the backing material must be dense and have a certain thickness. Furthermore, the backing material is basically required to have functions such as reinforcing the carpet material, retaining the shape, preventing pile removal, and preventing shrinkage and elongation.
Although various lining materials with such functions have been considered, an economical method for lining them is not known. Tile carpet is made by laminating a relatively thick backing material on the back side of the original carpet to give it its own weight, and then cutting it into an appropriate size (for example, 0.05 to 2 m ² ) and shape. It can be placed on the floor. This backing material is required to have functions such as preventing the pile from falling out of the carpet material, preventing shrinkage and elongation, resistance to deformation under load, and ease of laying. Although various lining materials with such functions have been considered, an economical method for lining them is not known. Traditionally, the method for lining automotive carpets and tile carpets with sound insulation properties has been to first mix thermoplastic resin, fillers, and other additives with a Banbury mixer or a Farrel continuous mixer (FCM).
A method in which the pellets are kneaded and pelletized, and then the pellets are extruded into a sheet using an extruder equipped with a T-die and lined with a carpet (Japanese Patent Application Laid-open No. 71734/1983).
Another method is to dry blend resin pellets and kneaded pellets with resin, filler, and other additives that are compatible with the resin, and then extrude the kneaded product into a sheet using an extruder equipped with a T-die to line the carpet. (Japanese Unexamined Patent Publication No. 56-79033), the resin, metal oxide, and other additives are melt-mixed in a Banbury mixer, pelletized in an extruder, and then formed into a sheet in an extruder equipped with a T-die. Method of lining extruded carpet (Japanese Unexamined Patent Publication No. 135861/1983)
was known. As described above, the conventional lining method consists of two steps: preparing a kneaded material made of resin, filler, etc. in advance, and then extruding this kneaded material into a sheet using an extruder equipped with a T-die to line the carpet.
It was a carpet lining method that consisted of a step process. Therefore, the processing speed is slow, the physical properties of the carpet are deteriorated, and there are disadvantages in that it is extremely disadvantageous economically. In order to solve the above-mentioned drawbacks, the inventors of the present invention have conducted intensive studies on carpet lining methods, and as a result, we have developed a method for lining carpets, from kneading the resin and filler to extruding it into a sheet using a twin-screw kneading extruder in different directions. We have found a method that can omit the processing steps, increase the processing speed, improve the physical properties of the carpet, and back the carpet at low cost by performing the one-stage processing of lining the carpet material at the same time. That is, the present invention relates to thermoplastic resins and 5 to 80
% by weight (assuming the total as 100% by weight) of the filler was transferred from each metering feeder to the feed section with L/D of 5 to 10, the kneading section with L/D of 0.5 to 2, and the L/D of 0.5 to 2.
It is supplied to the feed section of a twin-screw extruder in different directions equipped with an extrusion section with a D of 5 to 20, extruded into a molten sheet from a T die provided at the tip of the extrusion section, and before the sheet is cooled and solidified, it is poured into a carpet. The present invention relates to a carpet lining method characterized by laminating the carpet on the back side of the original fabric using a pressure roll. Examples of thermoplastic resins used in the present invention include low-density to high-density polyethylene, ethylene-vinyl acetate copolymer (EVA), ethylene-based copolymers such as ethylene-ethyl acrylate, polypropylene (PP), and propylene. copolymers whose main component is polybutene, butene copolymers, olefinic resins such as ionomer resins whose main component is ethylene or propylene, polystyrene, styrene-butadiene copolymers, acrylonitrile-
Styrene resins such as butadiene-styrene terpolymer, methyl methacrylate-styrene copolymer, acrylic ester resins, acrylonitrile resins, vinyl chloride resins, polyester resins, polyacetal resins, polyamide resins, polycarbonates resins and the like are preferably used. These thermoplastic resins may be used in the form of particles such as pellets, powder, or flakes, and may be used alone or as a mixture of two or more. Examples of fillers used in the present invention include calcium carbonate, barium sulfate, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, fly ash, cement powder, metal powders such as iron, aluminum, and copper, iron oxide, aluminum oxide, metal oxides such as calcium oxide and mixtures thereof, and the most preferred fillers are calcium carbonate,
barium sulfate, hydrated alumina, and mixtures thereof. The addition ratio of filler to thermoplastic resin is 5
-80% by weight, preferably 15-75% (total 100% by weight). In order to obtain a carpet with excellent sound insulation properties, it is preferable to use a large amount of filler. In addition to the thermoplastic resin and filler, which are essential components, the present invention may also contain any known additives as necessary.
For example, inorganic short fibers (glass, asbestos, cotton powder, etc.), plasticizers, process oil, wax,
Asphalt, a blowing agent, a flame retardant, etc. can be blended. The bidirectional kneading extruder used in the present invention is an extruder equipped with a feed section, a kneading section, and an extrusion section equipped with a T-die. The L/D of the feed section is between 5 and 10. If the L/D is less than 5, it will not be possible to feed a stable material, and if the L/D is more than 10, heat will be intense and as a result, a stable material feed will not be possible. Can not. The kneading section has a kneading function, and in the extruder, materials are mainly kneaded by this section.
Therefore, it is appropriate that the kneading section is constituted by a member having an appropriate shape suitable for kneading, such as a rotor-shaped member. Depending on the type of member used in the kneading section, such as a rotor type member, it may be inappropriate to specify the kneading section shape by L/D. However, for example, L/D can be between 0.5 and 3. L/D of extrusion part with T die is 5
~20, and if it is less than 5, stable extrusion is not possible, and as a result, the thickness of the extruded backing material is not constant. Moreover, if the value exceeds 20, heat generation becomes severe and as a result, stable extrusion becomes difficult. The rolls used in the present invention are two rolls with a constant speed, and the rolls in direct contact with the molten sheet must have a cooling function using water or a refrigerant. The carpet material used in the present invention includes plain weave,
Any carpet material such as Wilton, tufted, needle punched, felt, etc. can be used. The carpet lining method of the present invention involves feeding a thermoplastic resin, a filler, and optionally additives from each feeder to a bidirectional twin-screw kneading extruder;
This is a one-step method in which melt-kneading and extrusion into a molten sheet are performed all at once, and the melt-extruded sheet is laminated on the back side of the original carpet using a pressure roll before being cooled and solidified. The temperature of the melt-extruded sheet can be changed depending on the type of resin, the amount of filler added, and the material of the carpet material, but it is 100 to 250°C, preferably 120 to 250°C, from the viewpoint of processing specific energy, carpet physical properties, etc. It is 200℃.
The thickness of the sheet laminated onto the carpet base fabric can be changed by adjusting the spacing between the T-die lips and the extrusion amount depending on the application, but for example, in the case of carpet lining, it is about 0.1 to 10 mm, preferably about 0.2 to 8 mm. . The thermoplastic resin, filler, and solid additives can be added to the kneading extruder using a generally known quantitative table feeder, screw feeder, rotary valve, or the like. In addition, among the additives, liquids such as process oil and plasticizer are injected into any location of the kneading extruder using a metering pump, such as the resin and filler feed section supply port, the center of the feed section, or the kneading section. be able to. The amount of the additive added is arbitrary, but preferably 2 to 50% by weight (based on the total composition as 100% by weight). The carpet lining method of the present invention can be applied to general carpets, tile carpets and automobile carpets, especially automobile carpets having sound insulation properties. As described above, since the carpet lining method of the present invention can omit processing steps, the processing speed is high, the physical properties of the carpet are improved, and the carpet can be manufactured at low cost. Next, the present invention will be explained based on examples. Examples 1 to 3 EVA (MI3, VA28%) 22wt%, calcium carbonate (Shiraishi Kogyo p-50) 70wt% and DOP (Sekisui Chemical) 8wt% as a plasticizer were added to each feeder, and EVA was a screw feeder. (manufactured by Kamanaga Seikosho), calcium carbonate with a table feeder (manufactured by Kouken), and DOP with a metering pump (manufactured by Nikkiso) with a width of 50 cm.
Different direction twin screw kneading extruder (TEX30 manufactured by Japan Steel Works, Ltd.) equipped with a T-die (feed part L/D=
10, Kneading section L/D = 3, Extrusion section L/D with T die
=10)), the kneading section temperature and the T-die temperature are changed to form a sheet, and before the sheet is cooled and solidified, the PP tufted carpet raw fabric (base fabric PP) and the sheet are cooled with water. The material was laminated with a pressure roll to a thickness of 1.5 mm to form a lining for a sound-insulating carpet for an automobile. Table 1 shows the physical properties of the laminated carpet. Comparative Examples 1 to 3 Using the same EVA, calcium carbonate, and plasticizer as in Example 1, one batch of 10 kg was kneaded at various temperatures for 15 minutes in a 10-pressure kneader in the same proportions, and the tank was overturned and discharged. The required time was measured. The molten mixture was rolled into a sheet having a width of 20 cm and a thickness of 2 mm using an 8-inch constant-velocity water-cooled roll and allowed to cool for 20 minutes.
Next, the sheets at room temperature are fed into a pelletizer (manufactured by Horai Tekko).
It was made into 4mm square pellets. The pellets are 50cm wide.
Using an extruder with a T-die (manufactured by Mitsuha Seisakusho), the temperature of the T-die is changed to form a sheet, and the sheet is immediately laminated to a thickness of 1.5 mm with a carpet material (base fabric PP) and a pressure roll to form a car. We processed the lining of the sound insulating carpet. The physical properties of the laminated carpet are shown in Table 1. In Examples 1 to 3, the carpet is lined in a one-stage process, so no discharge time is required, and even if the temperature of the kneading section changes, there is little effect on the physical properties of the carpet. On the other hand, in Comparative Examples 1 to 3, the time required for discharge was shortened by lowering the kneading temperature, but the kneading became insufficient and the physical properties of the carpet deteriorated. In addition, when the kneading temperature was increased, the physical properties of the carpet improved, but it took a long time to discharge the carpet.

[Table] Examples 4 to 6 Low density polyethylene (Nisseki Chemical J79, MI45)
70wt%, calcium carbonate (Asahiko powder K300) 30wt%
A sound insulating carpet for an automobile was lined in the same manner as in Example 1 except that the kneading temperature was changed. Table 2 shows the physical properties of the laminated carpet. Comparative Examples 4 to 6 Using the same low-density polyethylene and calcium carbonate as in Example 4, one batch of 8 kg was kneaded at various temperatures for 10 minutes in the same ratio using an intensive mixer (D-10 manufactured by Japan Steel Works, Ltd.). The liquid was discharged using a drop door, and the time required for discharge was measured. The molten mixture was rolled using an 8-inch uniform water-cooled roll to a width of 20 cm and a thickness of 2 mm.
After being rolled into a sheet and left to cool for 20 minutes, it was made into 4 mm square pellets using a pelletizer (manufactured by Horai Tekko). The pellets were extruded into a sheet with a thickness of 0.5 mm using an extruder with a width of 50 cm T die (manufactured by Mitsuha Seisakusho), and the sheet was lined on a carpet. Table 2 shows the physical properties of the carpet.
It was shown to. In Examples 4 to 6, the carpet is lined in one step, so no discharge time is required, and even if the temperature of the kneading section changes, the physical properties of the carpet are less affected.
On the other hand, in Comparative Examples 4 to 6, the time required for discharge was shortened by lowering the kneading temperature, but the kneading became insufficient and the physical properties of the carpet deteriorated. In addition, when the kneading temperature was increased, the physical properties of the carpet improved, but it took a long time to discharge the carpet.

【table】

[Table] Comparative Examples 7 to 8 In Example 1, a single-screw kneading extruder (50 mm extruder L/D22 manufactured by Tanabe Plastics Co., Ltd., feed 9D, compression
3D, Metaling 10D, Madotsuku 2D) and twin-shaft co-directional kneading extruder (PCM30 manufactured by Ikegai Iron Works Co., Ltd.)
The carpet lining process was carried out in exactly the same manner as in Example 1, except that . That is, in the single-screw kneading extruder, lumps of filler were observed in some parts of the extruded sheet, and a sufficient kneading effect could not be obtained and a uniform sheet could not be obtained. Further, although the biaxial kneading extruder had a kneading effect, stable extrusion performance could not be obtained in T-die extrusion, and the thickness of the extruded sheet was not uniform. Example 7 Using the same method as in Example 1, apply 180 mm to the carpet original fabric.
The backing material for tile carpet was laminated to a thickness of 3.5 mm at a temperature of °C. This was then cut into a size of 500mm x 500mm and made into carpet tiles. The obtained tile carpet is 1
Although it was a step process, the following good physical properties were obtained. Suture removal strength 2.4Kg/Main heating dimensional stability 60℃×24hr, 20℃×24hr)
+0.02% Water immersion (20℃ x 1hr) Drying (20℃ x 24hr) Dimensional stability -0.03% Load deformation (10Kg/cm ² x 40℃ x 24hr)
Good placement only due to pile deformation

Claims (1)

[Scope of Claims] 1. Thermoplastic resin and 5 to 80% by weight (total
Fillers (as 100% by weight) were transferred from each metering feeder to a different direction twin screw kneading extruder equipped with a feed section with an L/D of 5 to 10, a kneading section and an extrusion section with an L/D of 5 to 20. Supplied to a feed section and extruded into a molten sheet form from a T die provided at the tip of the extrusion section,
1. A method for lining a carpet, which comprises laminating the sheet on the back side of a carpet material using a pressure roll before the sheet is cooled and solidified. 2. The method according to claim 1, wherein the carpet is a sound insulating carpet for an automobile. 3. The method according to claim 1, wherein the carpet is a tile carpet.