JPH07237237A - Chip forming and insulator material - Google Patents

Abstract

PURPOSE:To cause a block-type isocyanate to be thermally decomposed and cured to provide qualitative uniformity regardless of the type, mixing ratio, diameter of a crushed product, or the shape and thickness of a molding by uniformly mixing the crushed product with the block-type isocyanate uniformly, and heating the mixture also uniformly. CONSTITUTION:A crushed product mixture M is molded by compression between an outer die 12 and an inner die 13. In addition, a hot blast at approx. 150 deg.C is blown to the crushed product mixture M from a hot blast feeder pipe 14 through holes 12B, 13B in the molding faces 12A, 13A of both outer die 12 and inner die 13, with a concurrent action to heat the molding surfaces 12A, 13A by heaters 12D, 13D. The hot blast permeates the crushed product mixture M and is heated almost uniformly either directly or by the transferred heat of the hot blast. The block-type isocyanate is decomposed to regenerate an isocyanate group, and the isocyanate group reacts chemically with water mixed in the crushed product mixture M. Thus hexamethylenediisocyanate is bonded.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a chip forming method for binding a crushed product of a fiber or a plastic film into a predetermined shape with a binder and an insulator material produced by the chip forming method. Used as an insulator material for automobile interior materials.

[0002]

2. Description of the Related Art This type of chip molding is conventionally performed by a chip molding die (1) consisting of an outer mold (2) and an inner mold (3) as shown in FIG. Perforated plate at the bottom (4)
And a steam nozzle on the lower side of the perforated plate (4).
(5) is inserted. In order to perform chip molding with the above molding die (1), a mixture M prepared by adding and mixing urethane prepolymer as a binder to a crushed material such as fiber or plastic film is filled in the outer die (2) of the molding die (1). Then
While lowering the inner mold (3) to press the mixture M, the steam is jetted from the steam nozzle (5) and brought into contact with the mixture M through the perforated plate (4). Cure the urethane prepolymer. After molding, the obtained chip molded product is dried.

[0003]

However, in the above-mentioned conventional method, the steam is not evenly distributed in the mixture M, so that the curing of the urethane prepolymer in the mixture varies depending on the location, and the obtained molded product is obtained. There are problems that the physical properties become non-uniform and that it is necessary to dry the molded product after molding. In particular, if the mixture M is mixed with a crushed plastic film having a large crushing diameter that does not pass steam, or if there is a portion with a high compression ratio (for example, portion A in FIG. 9), the penetration of steam at this portion may occur. It is hindered and the urethane prepolymer does not cure smoothly.

[0004]

As a means for solving the above-mentioned conventional problems, the present invention mixes a pulverized product A, a block type isocyanate compound B, and a compound C having a functional group capable of reacting with an isocyanate group. Then, the block type isocyanate compound B is decomposed to regenerate an isocyanate group by filling the mixture in a molding die (11) and molding it into a predetermined shape and heating at a temperature not lower than the decomposition temperature. The present invention provides a chip forming method in which the mixture is cured by reacting with the compound C capable of reacting with the isocyanate group.

[Crushed Product] The crushed product A used in the present invention is a wood crushed product, a paper crushed product, a fiber crushed product, a plastic crushed product, a plastic film crushed product, a plastic foam crushed product, or two types thereof. The crushed product of the above laminated material is preferably a crushed product having a crushed diameter of 2 to 30 mm, more preferably 5 to 20 mm. These crushed products can be obtained from scraps of automobile interior materials and sheets, for example. That is, since the ceiling material of an automobile is composed of a base material such as a resin board, a cardboard, a synthetic resin-impregnated polyurethane foam, or a polystyrene foam and a skin material such as a nonwoven fabric, when the base material is a resin board from the scrap of the ceiling material. Can be crushed fiber, crushed paper and crushed fiber in the case of corrugated cardboard, crushed plastic foam and crushed fiber in the case of polyurethane foam or polystyrene foam. The dashboard can be felt and polyvinyl chloride. Since it is composed of a sheet, a crushed fiber and a crushed polyvinyl chloride sheet are obtained from the scrap of the dashboard, and a carpet for an automobile flooring is composed of a carpet body and a polyethylene film lined with the carpet body. , Crushed fiber and polyethylene film from the scrap of the carpet for automobile flooring Since a crushed product is obtained and the door trim is composed of a base material such as a hard board or a resin board and a skin material such as a non-woven fabric, when a hard board is used as a base material from the scrap of the door trim, a crushed wood material and a fiber crushed material are used. In the case of using a material or a resin board as a base material, a crushed fiber product is obtained, and since the sheet is composed of a pad made of polyurethane foam and a skin material such as a fiber knitted fabric, crushed polyurethane foam from scrap of the sheet. And a crushed fiber product are obtained.

The ceiling material and the door trim surface material may be lined with a wadding material such as polyethylene foam, polypropylene foam or polyurethane foam. In this case, in addition to the above, a plastic foam material may be used. A crushed product can also be obtained. In the present invention, in addition to the scraps of the automobile interior materials and sheets, scraps of packaging materials,
Crushed materials obtained from clothing scraps, construction material scraps, etc. can also be used.

[Block type isocyanate compound B] The block type isocyanate compound B used in the present invention is, for example, tolylene diisocyanate, paraphenylene diisocyanate, toluene diisocyanate, hexamethylene diisocyanate, naphthalene diisocyanate,
Polyphenyl isocyanate such as diphenyl diisocyanate, diphenyl methane diisocyanate, dimethyl diphenyl diisocyanate, dimethyl diphenyl methane diisocyanate, dimethoxy diphenyl diisocyanate, chlorophenyl diisocyanate, chlorophenylene diisocyanate, phenylene diisocyanate, tetramethyl biphenylene diisocyanate, xylylene diisocyanate, or the polyvalent isocyanate and polyethylene glycol. , Acidic sodium sulfite, an aromatic secondary amine in the isocyanate group of the urethane prepolymer having isocyanate groups at both ends obtained by addition reaction with a compound having a hydroxyl group such as polypropylene glycol,
It is obtained by adding a masking agent such as a tertiary alcohol, amide, phenol, lactam, heterocyclic compound, hydrocyanic acid, and sulfite. Specific examples of such a masking agent include phenol and malonic acid. Examples thereof include diethyl ester, acetoacetic acid ester, acetylacetone, hydrocyanic acid, and acidic sodium sulfite. The block type isocyanate compound is decomposed by heating at a predetermined temperature to regenerate an isocyanate group.

[Compound C Reactive with Isocyanate Group] The compound C capable of reacting with an isocyanate group used in the present invention reacts with an isocyanate group regenerated from the above block type isocyanate compound to polymerize the isocyanate compound. It is a three-dimensional one. Examples of such a compound C include water, alcohols, fatty acids, amines, amides, compounds having active hydrogen such as urea, which are conventionally used as curing agents for isocyanate compounds, or hydroxyl groups, amino groups,
There are synthetic resins or rubbers having a functional group having active hydrogen such as an amide group and a carboxyl group. If these are specifically illustrated, for example, water, triethylamine, diethanolamine, diisopropylamine, stearylamine, methanol, ethanol, isopropanol, n-
Butanol, ethylene glycol, propylene glycol, glycerin, polyethylene glycol, polypropylene glycol, acetic acid, oxalic acid, maleic acid, citric acid,
Examples thereof include stearic acid, acetic acid amide, atearyl acid amide, acrylic resin containing a hydroxyl group, amino group, amide group, carboxyl group and the like, synthetic rubber and the like.

[Compounding] The pulverized product A, the block type isocyanate compound B, and the compound C capable of reacting with the isocyanate group are mixed in a mixing tank or the like.
The mixing ratio is the hardness desired for the resulting chip molding,
It should be adjusted according to the physical properties such as elasticity. However, the usual compounding ratio is 5 to 50 for the compound B in the mixture.
%, And compound C is about 1 to 50% by weight.

[Molding] Molding is performed by a molding die (1
In 1), the mixture is molded and heated above the decomposition temperature of compound B to cure the mixture. In the above molding, if desired, the molding die (11) has a sound insulation material (17, 18).
You may also insert a cover material. Such sound insulation material (1
7,18) include felt, asphalt sheet,
There are rubber asphalt sheets, polyvinyl chloride sheets, non-woven fabrics, or laminated materials of two or more of these sound insulation materials (17, 18), and examples of the covering materials include carpets, non-woven fabrics, fiber knitted fabrics, synthetic leather, etc. .

[0011]

In the present invention, the ground product A, the block type isocyanate compound B and the compound C capable of reacting with an isocyanate group are easily and uniformly mixed. When the mixture is molded and heated to a temperature above the decomposition temperature, heat is conducted into the mixture and the blocked isocyanate compound B
Is thermally decomposed to regenerate the isocyanate group, and the isocyanate group and the compound C react with each other to cause the isocyanate to be polymerized and three-dimensionalized to be cured. When the compound C is a synthetic resin, the isocyanate reacts with the synthetic resin to form a crosslink and cure.

[0012]

1 to 4, there is shown a first embodiment of the present invention. In the figure, the molding die (11) is composed of an outer die (12) and an inner die (13), the outer die (12) is provided with a porous surface (12B) on the die surface (12A), and the die surface (12A). A hot air passage (12C) communicating with the perforation (12B) is provided inside the hot air passage (12C), and a hot air supply pipe (14) is connected to the hot air passage (12C).
Heater (12D) is installed inside 2C) and the inner mold (13)
The mold surface (13A) of the is provided with a porous (13B), the mold surface (13A)
A hot air passage (13C) communicating with the perforation (13B) is provided inside the hot air supply pipe (15) in the hot air passage (13C).
And a heater (13D) is arranged inside the hot air passage (13C).

In the outer mold (12) of the mold (11), polyester non-woven fabric (18, 18) is provided on both sides as a sound insulating material prior to molding.
The polyvinyl chloride sheet (17) to which was adhered was inserted, and malonic acid was added to the crushed product A (mixed crushed product of crushed fiber and polyethylene film) obtained from scraps of carpet for automobile flooring. 30% by weight of hexamethylene diisocyanate B (with a decomposition temperature of 130 to 140) blocked by diethyl ester is added and 40% by weight of water C is further mixed in to prepare a ground mixture M.

As shown in FIG. 2, the pulverized material mixture M is pressed between the outer die (12) and the inner die (13) to be molded. Then, the mold surfaces (12A, 13A) are heated by the heaters (12D, 13D), and the crushed mixture M is heated from the hot air supply pipes (14, 15) to the mold surfaces of the outer mold (12) and the inner mold (13). Hot air of 150 ° C. is blown through the pores (12B, 13B) of (12A, 13A). The hot air permeates into the pulverized mixture M, the pulverized mixture M is heated substantially uniformly by the hot air or by heat transfer from the hot air, and the block type isocyanate B is decomposed to regenerate the isocyanate group. The isocyanate group reacts with the water C mixed in the pulverized mixture M, and thus hexamethylene diisocyanate B is polymerized and three-dimensionalized to bind the pulverized mixture M. The ground mixture M
Excess water contained therein is removed by hot air during the molding. Heating of the above-mentioned compression molding is done in the inner mold (13) and the outer mold
(12) Only one side may be used.

In this way, an insulator material (16) as shown in FIG. 3 is obtained, and a polyvinyl chloride sheet (17) which is a sound insulating material is formed on the insulator material (16) via a nonwoven fabric (18). At the same time, it is crimped. As shown in FIG. 4, the insulator material (16) is attached to a carpet (19) for automobile flooring via a polyethylene film (20),
It is used as a sound insulation material (16) for the carpet (19).

A second embodiment of the present invention is shown in FIGS. The forming die (21) shown in the figure consists of an outer die (22) and an inner die (23), and the heating wire is inside the die surfaces (24A, 24B) of the outer die (22) and the inner die (23). (25,25) are arranged respectively. In the outer mold (22), as shown in FIG. 5, a crushed product of the crushed product of the carpet for automobile flooring and the crushed product of the polyurethane foam of the pad of the sheet scrap is mixed in a weight ratio of 2: 1. 35% by weight of tolylene diisocyanate B blocked with acetylacetone and 15% by weight of polypropylene glycol C are mixed and mixed in the product mixture M.

As shown in FIG. 6, the pulverized material mixture M has an outer mold.
(22) and the inner mold (23) are compression-molded. At this time, the mold surfaces (24A, 24B) of the outer mold (22) and the inner mold (23) are heated by the heating wire (25, 25). Heated to 170 ° C. The pulverized mixture M is thus heated by the mold surfaces (24A, 24B) of the outer mold (22) and the inner mold (23), and the block type isocyanate compound B is decomposed to regenerate the isocyanate group. Reacts with the hydroxyl groups of polypropylene glycol C, and thus tolylene diisocyanate B polymerizes with polypropylene glycol C and becomes three-dimensional to bind the pulverized mixture M.

In this way, the insulator material (26) shown in FIG. 7 is obtained. As shown in FIG. 8, the insulator material (26) is attached to the dashboard (27) and used as a dashboard insulator material. To be done.

[0019]

INDUSTRIAL APPLICABILITY In the present invention, the pulverized product A and the block-type isocyanate B can be uniformly mixed, and the heating can be performed uniformly on the mixture. The block type isocyanate B can be thermally decomposed and cured to produce an insulator material having uniform physical properties regardless of the diameter, the shape, the thickness, etc. of the molded product, and the molding time is longer than that of the conventional steam curing method. It can be greatly shortened and the drying process can be omitted. Also, with the conventional steam curing method, it is possible to mix crushed plastic film with a large diameter that blocks steam, so it is possible to reuse the waste material of plastic film laminated materials such as carpet for automobile flooring, It is also possible to insert a sound insulating material such as a vinyl sheet into the molding die.

[Brief description of drawings]

 1 to 4 show a first embodiment of the present invention.

FIG. 1 Cross-sectional view before molding

[Fig. 2] Side sectional view during molding

[Fig. 3] Side sectional view of insulator material

FIG. 4 is a vertical sectional view of a carpet for automobile flooring. FIGS. 5 to 8 show a second embodiment of the present invention.

[Fig. 5] Side sectional view before molding

[Fig. 6] Side sectional view during molding

[Fig. 7] Side sectional view of insulator material

[Figure 8] Dashboard vertical section

FIG. 9 is a side sectional view of a conventional example during molding.

[Explanation of symbols]

 11,21 Mold 12,22 Outer mold 13,23 Inner mold 12A, 13A, 24A, 24B Mold surface 14,15 Hot air supply pipe 16,26 Insulator material 17,18 Sound insulation material 25 Heating wire M Grinded mixture

─────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] July 6, 1994

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be amended] Title of invention

[Correction method] Change

[Correction content]

[Title of Invention] chip molding method and the insulator over <br/> material

Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display area B29L 31:58

Claims (3)

[Claims] 1. A pulverized product A, a block type isocyanate compound B, and a compound C having a functional group capable of reacting with an isocyanate group are mixed, and the mixture is filled in a molding die to be molded into a predetermined shape and decomposed. By heating at a temperature equal to or higher than the temperature, the block type isocyanate compound B is decomposed to regenerate the isocyanate group, and the regenerated isocyanate group and the compound C capable of reacting with the isocyanate group are reacted to cure the mixture. Chip forming method characterized in that 2. An insulator material comprising a chip molded product manufactured by the method according to claim 1. 3. An insulator material in which a sound insulation material is attached to the chip molded product manufactured by the method according to claim 1.