JPH06199169A - Automobile carpet and manufacture thereof - Google Patents

Abstract

PURPOSE:To reuse an automobile carpet end material as backing resin by manufacturing a pellet after the carpet end material is pluverized and fiber is melted/ kneaded by a two-shaft extruder, and melting/laying/processing a blended pellet on the reverse of carpet gray goods by an extruder having a T die after this is blended with a virgin pellet. CONSTITUTION:An automobile carpet end material except EVA and vinyl chloride being reverse resin is pulverized, and fiber is melted/kneaded by a two-shaft extruder, and a pellet is manufactured, and a virgin pellet is blended with this pellet, and a blended pellet is melted/laid/processed on the reverse of a carpet gray goods by an extruder having a T die. This automobile carpet has a backing layer formed by melting/decomposing the automobile carpet end material except the EVA and the vinyl chloride being the reverse backing resin in virgin polyethylene resin. In this way, the carpet end material can be reused simply as a backing material.

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 an automobile carpet by effectively utilizing end pieces of an automobile carpet as a backing resin layer of the carpet.

[0002]

2. Description of the Related Art Japanese Patent Application Laid-Open No. Sho 5 has been proposed as a technique for effectively utilizing the end material of an automobile carpet as a backing layer of a carpet.
No. 8-139828 has a structure in which the resin layer on the back surface of the carpet has a structure in which finely divided fibers of trimming scraps of the carpet are uniformly dispersed. As a manufacturing method thereof, scraps of automobile carpet are crushed and melt-extruded. A block-shaped mass is formed, cooled and solidified, the mass is finely pulverized, virgin resin is mixed at any stage, melt-extruded and pelletized,
Lining using the pelletized material is disclosed.

Further, Japanese Patent Publication No. 61-390 discloses a method of extrusion coating at a temperature lower than the melting point of fibers of trimming waste of carpet and higher than the melting point of resin.

[0004]

Of the above-mentioned conventional methods, JP-A-58
No. 139828 has a problem that the process is complicated and the productivity is poor. In JP-B No. 61-390, the residual fibers are liable to be entangled and cause poor dispersion, probably because the residual fibers are relatively long. Therefore, problems such as film breakage are likely to occur in melt coating of a thin sheet of about 400 g / m ² .

[0005]

The present invention has been achieved as a result of studies aimed at solving the above-mentioned conventional problems. That is, the present invention relates to an automobile carpet having a backing layer in which the end material of an automobile carpet excluding EVA and vinyl chloride resin is melted and dispersed in a virgin polyethylene resin as the backing resin, and "the back resin is EVA and vinyl chloride. The end material of the automobile carpet excluding the resin is crushed, and the crushed material is melt-kneaded with the fibers by a twin-screw extruder to produce pellets.
A method for producing a carpet for an automobile, characterized in that an extruder with a die is used to perform melt coating on the reverse side of the carpet. This made it possible to easily reuse the carpet end material as the backing material.

The carpet backing materials used here are those whose backside resin is EVA and vinyl chloride resin, which have been excluded because they have insufficient heat resistance and are extremely thermally decomposed when melt-kneading the fibers in a twin-screw extruder. . Many use polyethylene resin as the backing resin. In addition, the end material of needle carpet using SBR latex or synthetic resin emulsion can also be used. The surface layer of the carpet is composed of a fiber layer of polypropylene, nylon, polyester or the like.

The crushing is of a rotary blade type, and the mesh to be used may be determined in relation to the crushing productivity and the biteability into the twin-screw extruder. Most preferred is 4-5 mm.
When crushed with a crusher, it is separated into light fiber and resin main part that passes through the mesh, but it is possible to mix most of the resin main part as recycled pellets in the virgin pellet, but it contains much fiber Although the compounding ratio of the compound becomes low, it can be compounded and used.

The biaxial extruder to be used has a slightly poor biteability with 100% pulverized product, so it is preferable to use a virgin resin blended for extruding, or to use a forced pushing type in which a screw or the like is attached to the hopper. . In addition, it is preferable that the two axes rotate in the same direction in terms of kneading.

It is preferable that the temperature is set so that the fibers are melt-kneaded and dispersed, and the screw is a shallow groove so that the kneading can be performed well.

The produced pellets may be blended with virgin pellets and extruded with an extruder equipped with a T-die for melt coating. The extrusion temperature is the same as that of polyethylene.
A product in which nylon and polyester fibers are melt-dispersed at the time of pellet production does not melt in this extruder, but melt-coating can be performed without any problem and a product having no quality problem can be produced. It is also necessary to sufficiently perform melt kneading in the twin-screw extruder to finely disperse the fiber melt. Next, the present invention will be described with reference to examples.

[0011]

[Examples] 50 g of carpet end material in which nylon pile of 500 g / m ² was tufted on a polyester spunbond base fabric of 120 g / m ² and polyethylene resin was melt-coated on the back side at 600 g / m ² 50 parts polypropylene polypropylene Cotton 252g / m ² , polyester-dyed cotton 108g /
m ² , SBR latex 80 g / m ² , polyethylene 4
A mixed product of 50 parts of end material of needle carpet made of 00 g / m ² is put into a crusher having a rotary blade with a 4 mm mesh and crushed, and the resin main part is then forcibly pushed in with a hopper. Same direction rotation 53mm
The temperature of the barrel part is set to 1 from the hopper side with a × 2 axial extruder.
The temperature was set to 20, 160, 200, 240, 270, 240 ° C., and the mixture was extruded at a screw rotation speed of 280 times / minute, cooled, and then cut into pellets. A continuous thick strand could be manufactured.

A mixture of 20 parts of the regenerated pellets, 80 parts of the regenerated pellets, and 50 parts of the regenerated pellets of 50 parts of the virgin pellets was used to extrude at a maximum temperature of 200 ° C. in a 65 mm extruder with a T die having a width of 70 cm and a lip gap of 1.2 mm.
/ M ² was melt-coated. It was possible to process without problems in the processing process, and there was obtained no problem in terms of quality and physical properties of the manufactured carpet.

[0013]

[Effects of the Invention] Carpet backing for automobiles which has no problem in terms of quality and cost of carpet end material

Claims (2)

[Claims] 1. An automobile carpet having a backing layer in which an end material of an automobile carpet excluding EVA and a vinyl chloride resin as a backing backing resin is melt-dispersed in a virgin polyethylene resin. 2. A backside resin excluding EVA and vinyl chloride resin, which is an end material of an automobile carpet is crushed, and the crushed material is melt-kneaded with fibers by a twin-screw extruder to produce pellets,
A method for producing a carpet for an automobile, which comprises blending virgin pellets with the pellets and subjecting the back surface of the carpet to melt coating with an extruder with a T-die.