JPS6032995Y2 - Synthetic resin material - Google Patents

Description

[Detailed Description of the Invention] The present invention relates to a carpet-like synthetic resin material suitable for use as rugs such as automobile floor mats and other materials.

For example, there are various types of car floor mats on the market that are made for a fee, but they are luxurious, have a good feel, and are otherwise made of natural or synthetic resin fibers such as woven, knitted, or non-woven fabrics, and the back side is made of synthetic resin. So-called carpet mats are preferred, which are made from a reinforced backing with rubber or the like, or from a base sheet whose surface is treated with flocking.

However, in the above-mentioned conventional materials, the upper layer, such as a woven fabric, and the backing or base layer are made of different materials, so a large amount of trimming waste is generated during the molding process of articles made from these materials. It is impossible to recycle this material, for example, by melting it and using it as a raw material for manufacturing the material, and in most cases it is disposed of as is.

Therefore, this has a large impact on product cost.

This proposal was proposed in view of the above, and provides a carpet-like fabric in which all of the waste materials from the molding process can be completely recycled and used as raw materials for manufacturing the fabric. The fibrous upper layer 1 (hereinafter referred to as the carpet layer) of woven fabric, knitted fabric, non-woven fabric, flocked fabric, etc. is made of thermoplastic resin fiber, and the backing or base layer 2 (hereinafter simply referred to as the backing layer) is made of thermoplastic resin fiber. ) is the same thermoplastic resin as layer 1, the amount of date in layer 1 is Ag/d, and the amount of resin in layer 2 is B9/rd.
, When the trimming waste rate during fabric molding is 0%, (A + B) It features a synthetic resin base.

In other words, the synthetic resin base of the present invention (1) Since the carpet layer 1 and the backing layer 2 are made of the same thermoplastic resin, the waste material discharged during the molding process of the fabric can be completely melted and remanufactured. It can be reused as the material for the backing layer 2 of the fabric.

(2) In this case, since the mutual resin amounts per unit area of the carpet layer 1 and the backing layer 2 were set to the above relationship, the molten resin material used as the material for forming the backing layer 2 was approximately 1
00% utilization.

For example, the material resin for layers 1 and 2 is polypropylene resin (specific gravity 0.92), and the basis weight A of layer 1 is 250 y/m.
The amount of resin B in layer 2 is 304 f/d (thickness 0.35 mm)
, when the trimming waste material rate C is 55%, the amount of molten resin per unit area d of waste material is (2501304f) xs5
/loo = 3o5g, which is approximately the same as the resin amount B = 3049/rd per unit area of the backing layer 2, so it can be used as a forming material for the backing layer 2 with almost no excess or deficiency. .

Similarly, for example, if the date amount A of layer 1 is 350 f/d, the resin amount B of layer 2 is 331 y/rrt (thickness 0.36 mm), and the waste material rate C is 50%, the amount of molten resin per unit area of the waste material is is (350f+33HF) X50/100=34
19, which substantially matches the resin amount B=331 g/lyf per unit area of the backing layer 2, so that it can be used as a forming material for the backing layer 2 with almost no excess or deficiency.

That is, all of the waste materials can be almost completely recycled, so product costs can be significantly reduced and resources can be saved.

(3) Layer 1 and layer 2 may be bonded together using adhesive, but since layer 1 and layer 2 are made of the same thermoplastic resin, it is easy to use a heat fusion method without using adhesive. A strong bonding process is possible.

(4) Since the upper layer 1 is made of fibrous material such as woven fabric, knitted fabric, non-woven fabric, flocked fabric, etc., it has the same luxuriousness, tactility, texture, etc. as conventional carpet materials.

(5) Since the entire body is thermoplastic, thermoforming method (vacuum forming method,
A molded product having a desired shape can be easily manufactured by a pressure molding method, a hot press method, etc.).

It has great features such as these, and its intended purpose is well related. For example, it is effective when used as a material for automobile carpet mats, etc., where products of the same shape are produced in large quantities and the waste rate is always approximately constant.

[Brief explanation of the drawing]

The drawing is a cross-sectional view of an example of the synthetic resin fabric of the present invention. 1 is a carpet layer such as woven fabric, and 2 is a backing layer.

Claims (1)

[Scope of Claim for Utility Model Registration] A fibrous upper layer 1 made of thermoplastic resin fiber such as woven fabric, knitted fabric, non-woven fabric, flocked fabric, etc., and a backing or base layer 2 made of the same thermoplastic resin as the fibrous upper layer. The amount of resin in the fibrous upper layer 1 is Ag/rIt1, or the amount of resin in the base layer 2 is Bg/rd. When the trimming waste rate during molding of the synthetic resin base is 0%, the mutual relationship per unit area of both layers 1 and 2 is such that (A + B)XC/100 is approximately B. Synthetic resin material with a set amount of resin.