RU2527088C1 - Production of cab carpet - Google Patents

Production of cab carpet Download PDF

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Publication number
RU2527088C1
RU2527088C1 RU2013108301/05A RU2013108301A RU2527088C1 RU 2527088 C1 RU2527088 C1 RU 2527088C1 RU 2013108301/05 A RU2013108301/05 A RU 2013108301/05A RU 2013108301 A RU2013108301 A RU 2013108301A RU 2527088 C1 RU2527088 C1 RU 2527088C1
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characterized
sheets
method according
cut
sheet
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RU2013108301/05A
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Russian (ru)
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RU2013108301A (en
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Сергей Игнатьевич Дрызлов
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Общество С Ограниченной Ответственностью "Нор-Пласт"
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Abstract

FIELD: machine building.
SUBSTANCE: granules of dynamically cured thermoplastic elastomer are extruded at 170°C to 210°C and pressure described by auger compression ratio of 2.7. Continuous melt sheet exiting from the extruder flat-slit head is cut to size required for placing onto female die. The next sheet is also placed onto the other free female die. Forming is performed at vacuum at 0.06 MPa, at least. Every cut-off sheet is formed with the help female die, each consisting of interconnected sheets made of aluminium, fibre boards of average density, steel as well as two sheets of veneer. Formed article is cut off to female die outline, cooled down and separated from female die as cab carpet.
EFFECT: higher efficiency of production, non-polluting process.
9 cl, 2 dwg, 1 ex, 1 tbl

Description

FIELD OF TECHNOLOGY

The invention relates to a method for manufacturing by extrusion-vacuum molding from a thermoplastic material of a floor mat for various vehicles.

BACKGROUND

It is known that thermoplastic materials include polymers that, when heated during processing, pass from a solid state to a liquid state, and when the material is cooled, a reverse transition to a solid state occurs. In addition, since thermoplastic elastomers are characterized by the absence of a three-dimensional crosslinked structure and a transition to a fluid state, this makes it possible to produce products from them by an extrusion method.

The term "floor mat" is used in the meaning of a tool placed on the floor of the passenger compartment or trunk of a car designed to protect against contamination and having a stable shape that repeats the shape of the surface to be protected, while having the elasticity inherent in the material from which it is made.

A known method, comprising mixing crushed rubber particles with a thermoplastic elastomeric material to obtain such a finished product as a floor mat [patent RU 2375390].

Known methods of manufacturing a rubber floor mat having a corrugated surface and stiffeners by injection molding [patent RU 11517 U, patent RU 41284 U, patent RU 111979 U1].

A known method of manufacturing a floor mat, comprising obtaining a blank of polyvinyl chloride by injection molding [patent RU 2444450].

However, injection molding technology is inefficient, given the cost of manufacturing steel molds, as well as the impossibility of further processing of technological waste in production.

Closest to the proposed technical solution according to the technical essence is a method of manufacturing from thermoplastic materials hollow core products by extrusion blow molding [a.s. SU 835795, publ. 06/07/1979], including extrusion and molding operations. The disadvantage of this method is that it allows you to get thin-walled hollow products, although of different geometric configurations with several grooves in 4-7 accuracy class. The known method [and.with. SU 835795] adopted as a prototype of the proposed technical solution.

SUMMARY OF THE INVENTION

The problem to which the invention is directed, is to develop a method for manufacturing floor mats from thermoplastic materials by continuous extrusion-vacuum molding.

The technical result achieved by using the invention is to increase the efficiency of manufacturing floor mats from thermoplastic material by continuous extrusion-vacuum molding, without reducing the quality of the product (compared with the cyclic injection molding process), due to the combination in the technology of using technological parameters, the sequence implementation of technological methods and their quantitative characteristics. It is important to note that the use of the invention improves the ecology of production, as it offers the reuse of industrial waste thermoplastic material in the total mass of primary material used.

To solve the problem and achieve the technical result, a method for manufacturing a floor mat for a vehicle from thermoplastic materials is proposed, including extrusion and molding operations, while extrusion under the influence of temperature from 170 ° C to 210 ° C and pressure, characterized by a compression ratio of the screw equal to 2.7, subjected to granules dynamically vulcanized thermoplastic elastomer, continuously emerging from the flat-slit head of the extruder, the melt of the workpiece which in the form of foxes This is cut after reaching the size necessary for further laying on the matrix, and the next, leaving the continuously working extruder head, the melt of the workpiece in the form of a sheet is also cut, laid on another free matrix, while vacuum molding is carried out under pressure not less than 0,0 6 MPa, moreover, each of the cut sheets of the melt billet is molded using matrices, each of which consists of series-connected sheets made of aluminum, a medium-fiber board otnostitsja, steel and two sheets of plywood, the molded article is cut along the contour of the matrix is cooled and separated from the mandrel as a floor mat.

In an additional aspect, the invention is characterized in that the granule size of a dynamically vulcanized thermoplastic elastomer is from 2 to 5 mm.

In an additional aspect, the invention is characterized in that the matrix is a prefabricated product consisting of sheets of aluminum glued together and medium density fiberboard, which are detachably connected to a sheet of steel and two sheets of plywood.

In an additional aspect, the invention is characterized in that the matrix sheets are joined by self-tapping screws.

In an additional aspect, the invention is characterized in that the matrix is made according to the profile of that part of the interior floor of each vehicle model that is covered with a floor mat.

In an additional aspect, the invention is characterized in that from 8 to 12 matrices are used simultaneously in the molding process.

In an additional aspect, the invention is characterized in that the cooling time of the molded product is from 3 to 10 minutes.

In an additional aspect, the invention is characterized in that the scraps of a dynamically vulcanized thermoplastic elastomer are crushed by crushing and reused with a dynamically vulcanized thermoplastic elastomer.

In yet a further aspect, the invention is characterized in that the crushed scraps of the dynamically vulcanized thermoplastic elastomer are used in quantity. not exceeding 20% of the total mass of raw materials used.

The essence of the proposed technical solution is illustrated by figures and an example.

Figure 1 presents the assembly process of the matrix for the manufacture of floor mat of the car by the proposed method.

Figure 2 shows the matrix assembly for the manufacture of floor mat car of the proposed method.

In figure 1 and figure 2, the following notation: 1 - aluminum sheet with corrugation; 2 - medium density fiberboard (hereinafter referred to as MDF board); 3 - steel sheet; 4 - plywood sheet; 5 - plywood sheet; 6 - insert with the designation of the brand of the car from aluminum sheet.

Example

A method of manufacturing a floor mat for a vehicle

The method is as follows.

As raw materials (granules of dynamically vulcanized thermoplastic elastomer), granules of a composite material based on polypropylene plasticized with dynamically vulcanized ethylene propylene rubber with a filler, or other polymer compositions processed by extrusion (hereinafter TPE), and having a size of from 2 to 5 mm and the following parameters are used : hardness 75 units ± 3 Shore A, elongation of at least 300%.

In the hopper of a 90 × 30 state-of-the-art PE extruder, TPE granules are loaded, which are extruded under the influence of temperature from 170 ° C to 210 ° C and pressure, characterized by a screw compression ratio of 2.7.

The melt emerging from the flat-slit head of the extruder (1.300-1.800 mm) in the form of a sheet is cut off after reaching the size necessary for further laying on the matrix. Moreover, the next, leaving the continuously working extruder head, the melt of the billet in the form of a sheet is also cut, laid on another free matrix, etc. Cut sheets are laid on a prefabricated matrix.

Thus, in the working area of the extruder can simultaneously be from 8 to 12 dies, and not one mold in the case of injection molding on injection molding machines.

The matrix is made (see Figure 1 and Figure 2) by gluing a sheet of aluminum with corrugation D16AT (1) with silicone glue and polished fiberboard MDF board (2), grade 1, thickness 16 mm, which are connected by self-tapping screws to a steel sheet 3, 2.0 mm thick (3), two sheets of plywood - FSF plywood sheet, grade 3/4, 12 mm thick (4 and 5); insert with the vehicle brand designation from aluminum sheet D16AT, thickness 2.0 mm (6).

Drawing the necessary images on the surface of the aluminum sheet (6) in the form of corrugation and the name of the car brand, the curved profile of the MDF sheets (2), plywood (4 and 5) are performed on CNC machines with programmed control using a 3D 3-D projection.

A preform sheet, which is a sheet of molten material having a uniform mass and dimensions sufficient for laying on a matrix with the necessary allowance at the edges of at least 2 cm, is subjected to molding.

In the process of vacuum molding, carried out under the influence of pressure of not less than 0.06 MPa, the blank sheet takes the form of a matrix.

After molding, the sheet is cut along the contour of the matrix and, after cooling for 3 to 10 minutes, is removed from the matrix in the form of a finished product - a floor mat.

The scraps of the dynamically vulcanized thermoplastic elastomer are crushed after cooling by crushing. In this case, the scraps are processed with the primary material in a ratio of 20/80.

The result is a floor mat satisfying consumer properties.

The tests of the selected materials for the manufacture of the matrix showed that they do not change their properties under the influence of the molding temperature. In this case, the material itself was not subjected to overheating, which did not lead to a possible warpage of the finished product.

It is important to emphasize the fact that a matrix made of the proposed material can be used up to reconditioning 2.000-3.000 times.

The table shows the indicators characterizing the floor mats made of TPE in accordance with the proposed technology, as well as the indicators of the floor rug made of rubber.

Table Name of indicator, units measuring TPE floor mat Rubber floor mat Shore A Hardness 75 units ± 5 75 units ± 5 Elongation at break,% not less than 300 250 Abrasion, mm cube no more than 300 400

Using the proposed technology provides products with high operational and functional capabilities, which can be used for a range of popular car brands. Moreover, as can be seen from the table, products obtained by the proposed method from TPE, in their properties are not inferior to floor mats made of rubber.

The proposed technology using a continuous extrusion process can significantly increase production efficiency compared to the cyclic injection molding process. In addition, the proposed technology makes it possible to reuse industrial waste thermoplastic material.

Claims (9)

1. A method of manufacturing a floor mat for a vehicle from thermoplastic materials, including extrusion and molding operations, characterized in that the granules of dynamically vulcanized thermoplastic elastomer are subjected to extrusion under the influence of temperature from 170C ° to 210C ° and pressure, characterized by a compression ratio of the screw of 2.7 continuously leaving the flat-slit head of the extruder, the melt of the billet of which is cut off in the form of a sheet after reaching the size necessary for further laying on a trice, and the next, leaving the continuously working extruder head, the melt of the billet in the form of a sheet is also cut, laid on another free matrix, and the molding is carried out under vacuum at a pressure of at least 0.06 MPa, and each of the cut sheets of the melt billet is formed using matrices, each of which consists of series-connected sheets made of aluminum, medium-density fiberboard, steel, as well as two sheets of plywood, the molded product is cut along the contour of the mat Itza, cooled and separated from the mandrel as a floor mat.
2. The method according to claim 1, characterized in that the granule size of a dynamically vulcanized thermoplastic elastomer is from 2 to 5 mm.
3. The method according to claim 1, characterized in that the matrix is a prefabricated product consisting of sheets of aluminum glued together and medium density fiberboard, which are detachably connected to a sheet of steel and two sheets of plywood.
4. The method according to claim 3, characterized in that the matrix sheets are connected by self-tapping screws.
5. The method according to claim 1, characterized in that the matrix is made according to the profile of that part of the floor of the cabin of each car model, which is covered with a floor mat.
6. The method according to claim 1, characterized in that from 8 to 12 matrices are used in the extrusion-vacuum molding process.
7. The method according to claim 1, characterized in that the cooling time of the molded product is from 3 to 10 minutes.
8. The method according to claim 1, characterized in that the scraps of dynamically vulcanized thermoplastic elastomer are crushed by crushing and reused with dynamically vulcanized thermoplastic elastomer.
9. The method according to claim 8, characterized in that the crushed scraps of dynamically vulcanized thermoplastic elastomer are used in an amount not exceeding 20% of the total mass of raw materials used.
RU2013108301/05A 2013-02-25 2013-02-25 Production of cab carpet RU2527088C1 (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU174002U1 (en) * 2016-12-27 2017-09-25 Общество с ограниченной ответственностью "ДСК" Passenger carpet mat
RU2700533C1 (en) * 2018-12-11 2019-09-17 Общество с ограниченной ответственностью "НОВЛАЙН" Floor anti-skid car mat (versions) and corresponding manufacturing method thereof

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU835795A1 (en) * 1979-08-15 1981-06-07 Предприятие П/Я В-2913 Method and apparatus for making hollow continuous shapes of thermoplastic resins
RU93020106A (en) * 1993-04-19 1996-06-20 Казанское вертолетное производственное объединение Device for forming polymer composite materials
RU96522U1 (en) * 2010-05-17 2010-08-10 Вячеслав Сергеевич Анищенко Device for production of thermoplastic polymer products
RU2401740C2 (en) * 2005-07-22 2010-10-20 Эйрбас Дойчланд Гмбх Method of producing one- or multilayer fibrous workpiece in compliance with tfp-process
RU2444450C1 (en) * 2010-06-16 2012-03-10 Павел Юрьевич Буторин Method of fabricating floor mat
CN202573912U (en) * 2012-04-16 2012-12-05 芜湖尚唯汽车饰件有限公司 Car trunk carpet

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2085377C1 (en) * 1993-04-19 1997-07-27 Акционерное общество открытого типа "Казанский вертолетный завод" Apparatus for shaping polymer composite materials

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU835795A1 (en) * 1979-08-15 1981-06-07 Предприятие П/Я В-2913 Method and apparatus for making hollow continuous shapes of thermoplastic resins
RU93020106A (en) * 1993-04-19 1996-06-20 Казанское вертолетное производственное объединение Device for forming polymer composite materials
RU2401740C2 (en) * 2005-07-22 2010-10-20 Эйрбас Дойчланд Гмбх Method of producing one- or multilayer fibrous workpiece in compliance with tfp-process
RU96522U1 (en) * 2010-05-17 2010-08-10 Вячеслав Сергеевич Анищенко Device for production of thermoplastic polymer products
RU2444450C1 (en) * 2010-06-16 2012-03-10 Павел Юрьевич Буторин Method of fabricating floor mat
CN202573912U (en) * 2012-04-16 2012-12-05 芜湖尚唯汽车饰件有限公司 Car trunk carpet

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU174002U1 (en) * 2016-12-27 2017-09-25 Общество с ограниченной ответственностью "ДСК" Passenger carpet mat
RU2700533C1 (en) * 2018-12-11 2019-09-17 Общество с ограниченной ответственностью "НОВЛАЙН" Floor anti-skid car mat (versions) and corresponding manufacturing method thereof

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