JPH05254369A - Moldable floor rug - Google Patents

Abstract

PURPOSE: To obtain a floor rug which is recyclable and can be easily manufactured, by constituting the floor rug with the surface thereof made from a partially crystalline polyolefin and with the back covering thereof made from a molding material containing a specific component. CONSTITUTION: A floor rug has the surface thereof formed from a partially crystalline polyolefin and the back covering thereof formed from 0-80 wt.% of α-olefin having the number of carbons of 4-10; 20-100 wt.% of propene; 20 wt.% or less of ethene; 5-90 wt.% of one or more kinds of a partially crystalline polyolefin; and at most 70 wt.% of a filler. A back reinforcing material is used which is made from a partially crystalline polyolefin or glass and is in the state of a fleece, supporting-lattice,-textile, or -knitting. The manufacture of this floor rug is such that at first the back covering is provided by extrusion covering, and then it undergoes a calendering fabrication. This rug is suitable for use in a motor vehicle, and a composite therefrom is readily adaptable for a foot space or a trunk room.

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 an automobile rug, and a method for producing the same.

[0002]

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

This kind of rug is not only expensive to manufacture, but also a combination of different types of materials, so that the debris which can account for up to 40% of the molding is also a waste of old automobile waste treatment. The molded member of No. 1 also has the drawback that it cannot be reused.

[0004]

The object of the present invention is therefore to provide a rug which fulfills the following conditions: 1) The rug is of the same type of material in order to be reusable. It must consist of a combination. 2) The back coating must be processable at a heating temperature that does not damage the rug surface. 3) The back coating must be sufficiently flexible on the one hand and shape stable under the conditions of use on the other hand. 4) Rugs should be easy to manufacture while avoiding fleece composite combinations.

[0005]

This problem is solved by a rug composed 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 sufficiently amorphous polyolefins of the following monomer composition 0 to 80% by weight C4 to C10 alpha-olefins, 20 to 100% by weight propene and 20 Less than wt% ethene; 5 to 90 wt% of one or more partially crystalline polyolefins; up to 70 wt% fillers; c) fleeces, supporting grids, supporting fabrics or supports of partially crystalline polyolefin or glass. Back reinforcement in the form of a knitted fabric A flexible layer based on polyolefin without intermediate bonding with adhesive on one or both sides, for example isotactic A self-supporting polyolefin layer material based on a rigid support consisting of a polyolefin sheet coated with a woven or fibrous fleece made of polypropylene is known from DE-A-3,100,682. is there. However, its rigidity realizes that its resonant vibrations are within the audible range-ie, its low sound absorption. Moreover, they are not suitable as rugs because they cannot fit precisely to the floor geometry.

British Patent No. 2,072,578 discloses a sound absorbing rug whose back coating contains a significant amount of polyolefin, synthetic rubber, petroleum and an inorganic filler. A significant drawback of this composition is that the very high melt viscosity of the polyolefin / synthetic rubber / filler combination must be reduced by the addition of oil to a processing-technically appropriate degree. However, the presence of oil is undesirable for many reasons. Of course, this is prone to sweating, which can lead to significant fogging problems. Adhesion on the rug surface is also poor because the rug surface must be provided with latex before it is applied to the backcoat. Furthermore, the presence of oils and latices is undesirable during recycling.

There is no mention in the specification of whether the rug described therein can be formed into three-dimensional dimensions after its manufacture. In contrast, the rug of the present invention can be reused without problems, can be processed three-dimensionally without difficulty, can be easily manufactured without causing a fog phenomenon, and has good flexibility and good soundproofing and sound absorbing effects. Indicates.

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

Amorphous polyolefins, such as atactic-polypropylene homo-
Alternatively, it can be used in the form of a copolymer. Particular preference is given to using binary or ternary copolymers of atactic polypropylene (APP) and / or butene-1, propene and optionally ethene monomers. Copolymers of this kind are obtained by the intentional polymerization with Ziegler catalysts or their development, as described, for example, in German Patents 2,306,667 or 2,930,108. Can be manufactured by Generally up to 25% fully amorphous polyolefin (as measured by X-ray diffraction)
It has a crystallinity of.

In a particularly advantageous embodiment, 70 to 1
Softening point of 60 ° C (ring and ball method), 2,000 to 2 at 190 ° C
0,000 mPa.s. s melt viscosity (ASTM D 3
236-73), a density of 0.90 g / cm ³ and 5
50 (0.1 mm) penetration 100/25/5 (DIN
52,010) with a sufficiently amorphous polyolefin. Particularly preferred fully amorphous polyolefins have a softening point of 90-150 ° C, 5,000-1 at 190 ° C.
50,000 mPa. s melt viscosity and 15-40
It has a penetration of (0.1 mm).

As the partially crystalline polyolefin, it is possible in principle to use any polymer which is 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 portion 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, for example, German Patent Application Publication No. 0,30.
No. 9,674. This document is incorporated herein by reference.

Examples of fillers include chalk, talc, mica, barite, similar ground stones, 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 backcoat molding composition can be produced from the components by any customary method, in particular by melt mixing. Generally, the backside coating has a thickness of about 0.2 to about 5 mm.

The backcoat contains a generally embedded fleece, support grid, support fabric or support knit. Suitable materials are the same polymers that can be used on 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 manufacture and optionally cutting, the composite can be three-dimensionally shaped, for example by pressing or vacuum forming. For this purpose, the composite is first passed through a shaped body into a hot zone which is at a temperature which softens the back coating but the fibers of the rug surface are still shape-stable.

Rugs of this type are particularly suitable for use in motor vehicles. In this way the composite can be easily adapted to the leg space or the outer contour of the luggage compartment. The debris or the entire molded part can easily be reused. For this purpose, the materials are customarily ground and fed to the extruder, in which case further substances may be incorporated. The material obtained can be used, for example, for back coating. Since it contains only the same type of thermoplastic polymer, neither delamination nor stain formation 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 rolled into a three-roll roll
Aging-calender (operating width 2.40 m) and scroll roll
Supplied from Ra. Then passed the first roller
Later, from the extruder through a wide nozzle, 33 1/3% la
And dam copolymer (VESTOLEN P 840
0), 33 1/3% of amorphous directly polymerized polymer
Tactic-Polypropylene (VESTOPLAST
891) and 33 1/3% barite batch (70
% Barite and 30% polypropylene-homopoly
A melted film consisting of
60 g / m consisting of LEN A 6012 ²Heavy poly
Olefin net (grid size 1.2 x 1.5 m
m) at the same time while supplying rug velor to the back side
Supply. In this case, as extruder, dynamic mixer, melting
Pump, static mixer and flexible lip nozzle (2.20
single screw extruder with an operating width of 2.20 m)
(120 mmφ screw diameter) is used. Grage
-Combine the complex through a calendar.

By preparing the glazing roll gap wo 10% thinner than the total thickness of the composite to be made,
Sufficient composite bonding is achieved. The rug thus produced can be supplied to the thermoforming process as a roll product or in the size of a mold.

Forming process Starting from the roll roller, the rug composite is held by a stitched chain feeding means (Kettenzufuehrung) and conveyed to the forming station.

Since the heating step is carried out by infrared rays below the melting range of the fiber surface on the longitudinal heat adjusting means which can be controlled separately on both sides, it is not thermally damaged.
A problem-free contour-shaping is then carried out by pressing. The stamping of the molded body is performed in this press molding process.

Stamping debris (about 40% by weight) is used as a component of the backcoat in another product mixture of the same type.
In doing so, the calculated amount of each first component of the backside coating (total 4
8% by weight) is replaced with a corresponding amount of milled chips. In this case, a qualitatively equivalent complex is obtained.

The present invention relates to a rug according to the claims and a method for producing the rug, and includes the following as an embodiment. 1) Independently of one another, the rug according to claim 1, wherein the partially crystalline polyolefin component of the rug surface, the back coating and / or the back reinforcement comprises polypropylene.

2) The rug as described in 1 above, wherein the polypropylene is a homo- or copolymer. 3) Use of atactic-polypropylene (APP) and / or binary or ternary copolymers of the monomers butene-1, propene and optionally ethene as the sufficiently amorphous polyolefin of the backcoat. The rug according to 1 or 2 above.

4) Use of chalk, talc, mica, barite, similar crushed rock, glass fibers and / or glass spheres as the back coating filler. The rug described in.

Claims (4)

[Claims] 1. A surface of a rug consisting of the following components: a) a partially crystalline polyolefin: b) a backcoat consisting of a molding material containing the following components: 10 to 95% by weight of one or more of the following monomer compositions sufficient: Amorphous polyolefin 0 to 80% by weight C4 to C10 α-olefin, 20 to 100% by weight propene and less than 20% by weight ethene; -5 to 90% by weight of one or more partial crystals Polyolefins; -up to 70% by weight of fillers; c) rugs consisting of a fleece of partially crystalline polyolefin or glass, a supporting grid, a back reinforcement in the form of a supporting woven or supporting knit. 2. A method for producing a rug according to claim 1, characterized in that the back coating is provided by extrusion coating and then calendering. 3. The composite is then three-dimensionally molded.
The method described in. 4. A method of using the rug according to claim 1 in an automobile.