JPH092128A - Manufacture of molded carpet - Google Patents

Manufacture of molded carpet

Info

Publication number
JPH092128A
JPH092128A JP7183599A JP18359995A JPH092128A JP H092128 A JPH092128 A JP H092128A JP 7183599 A JP7183599 A JP 7183599A JP 18359995 A JP18359995 A JP 18359995A JP H092128 A JPH092128 A JP H092128A
Authority
JP
Japan
Prior art keywords
resin layer
plastic resin
carpet
thermal plastic
foaming
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP7183599A
Other languages
Japanese (ja)
Inventor
Kazuo Tanabe
和雄 棚部
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ikeda Corp
Original Assignee
Ikeda Bussan Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ikeda Bussan Co Ltd filed Critical Ikeda Bussan Co Ltd
Priority to JP7183599A priority Critical patent/JPH092128A/en
Publication of JPH092128A publication Critical patent/JPH092128A/en
Pending legal-status Critical Current

Links

Landscapes

  • Passenger Equipment (AREA)
  • Carpets (AREA)
  • Laminated Bodies (AREA)

Abstract

PURPOSE: To provide moldability to a carpet main body by means of a forming thermal plastic resin layer, to allow it to serve as an insulator and to save man hours and material required, by forming a foaming thermal plastic resin layer on the back face of the carpet main body and also making the foaming thermal plastic resin layer to be heated, softened and foamed and also formed. CONSTITUTION: Solution of a foaming thermal plastic resin is pushed out through T die and applied to the back surface of a carpet main body so as to form a foaming thermal plastic resin layer 6. Then, when the foaming thermal plastic resin layer 6 is heated by means of any heater such as electric-heating type heater 8, an infra-red heater, and a high frequency heater, it is softened and foamed to be formed in a polyethylene foaming layer 7. During softened state of the thermal plastic resin foaming layer 7, a carpet main body 2 is formed by means of a cold press consisting of a lower mold and an upper mold.

Description

【発明の詳細な説明】Detailed Description of the Invention

【0001】[0001]

【産業上の利用分野】本発明は例えば自動車床敷用カー
ペット等に供される成形カーペットの製造方法に関する
ものである。
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a molded carpet for use in, for example, a carpet for automobile flooring.

【0002】[0002]

【従来の技術】従来の自動車床敷用カーペットは図6に
示すようにカーペット本体(2) の裏面にポリエチレン層
(3) をバッキングし、更に該ポリエチレン層(3) の下面
にインシュレーターとしてのフェルト(4) を接着した構
成、あるいは図7に示すようにフェルト(4) に代えてポ
リウレタン発泡体層(5) を形成した構成が提供されてい
る。
2. Description of the Related Art A conventional carpet for an automobile flooring has a polyethylene layer on the back surface of the carpet body (2) as shown in FIG.
(3) is backed and a felt (4) as an insulator is further adhered to the lower surface of the polyethylene layer (3), or a polyurethane foam layer (5) is used instead of the felt (4) as shown in FIG. A configuration is provided.

【0003】[0003]

【発明が解決しようとする課題】図6に示す構成の自動
車床敷用カーペット(1A)は カーペット本体(2) に成形
性を付与するために、該カーペット本体(2) の裏面にT
ダイから押出したポリエチレン溶融物を塗布し冷却する
ことによってポリエチレン層(3) をバッキングし、成形
の際にカーペット本体(2) のポリエチレン層(3) を加熱
軟化してフェルト(4) を載置した冷却型にセットしてプ
レス成形することによって製造され、図7に示す構成の
自動車床敷用カーペット(1B)では該カーペット本体(2)
のポリエチレン層(3) を加熱軟化して冷却型にセットし
てプレス成形し、次いでポリウレタン発泡成形型内に該
成形されたカーペット本体(2) を挿入し、該成形型にポ
リウレタン発泡体材料を注入してポリウレタン発泡体層
(5) を成形することによって成形される。しかしながら
いずれの方法においても工数が多く製造コトスおよび材
料コストが高くなると言う問題点がある。
The carpet (1A) for an automobile flooring having the structure shown in FIG. 6 has a T-shape on the back surface of the carpet body (2) in order to impart moldability to the carpet body (2).
The polyethylene layer (3) is backed by applying and cooling the polyethylene melt extruded from the die, and during molding, the polyethylene layer (3) of the carpet body (2) is softened by heating and the felt (4) is placed. The carpet body (2) of the carpet (1B) for an automobile flooring constructed as shown in FIG.
The polyethylene layer (3) is softened by heating, set in a cooling mold and press-molded, then the molded carpet body (2) is inserted into the polyurethane foam molding die, and the polyurethane foam material is put into the molding die. Injected polyurethane foam layer
Molded by molding (5). However, both methods have a problem that the number of steps is large and the manufacturing cost and the material cost are high.

【0004】[0004]

【課題を解決するための手段】本発明は上記従来の課題
を解決するための手段として、カーペット本体(2) 裏面
に発泡性熱可塑性樹脂層(6) を形成し、該発泡性熱可塑
性樹脂層(6) を加熱軟化発泡せしめると共に所定形状に
成形する成形カーペット(1) の製造方法を提供するもの
である。
Means for Solving the Problems As a means for solving the above conventional problems, the present invention comprises forming a foamable thermoplastic resin layer (6) on the back surface of a carpet body (2), and forming the foamable thermoplastic resin layer. The present invention provides a method for producing a molded carpet (1), which comprises heat-softening and foaming a layer (6) and molding it into a predetermined shape.

【0005】本発明に用いられるカーペット本体はニー
ドルパンチカーペット、タフトカーペットの何れでもよ
い。また発泡性熱可塑性樹脂層はポリエチレン、ポリプ
ロピレン、エチレン−プロピレン共重合体、エチレン−
酢酸ビニル共重合体、ポリスチレン、ポリ塩化ビニル、
熱可塑性ポリエステル、熱可塑性ポリウレタン、熱可塑
性ポリアミド等の熱可塑性樹脂の溶液、エマルジョンあ
るいは溶融物に2,2’−アゾビスイソブチロニトリ
ル、アゾジカルボンアミド、p,p’−オキシビス(ベ
ンゼンスルホニルヒドラジド)、p,p’−オキシビス
(ベンゼンスルホニルセミカルバジド)、N・N’−ジ
メチル−N・N’−ジニトロソテレフタルアミド、ジア
ゾアミノベンゼン、1・1’−アゾビスホルムアミド等
の発泡剤、および所望なれば炭酸カルシウム、炭酸マグ
ネシウム、硫酸バリウム、硫酸カルシウム、酸化チタ
ン、酸化鉄、酸化亜鉛、アルミナ、シリカ、ケイ藻土、
石膏、タルク、クレー、マイカ、ケイ酸カルシウム、ベ
ンナイト、ホワイトカーボン、カーボンブラック、鉄
粉、アルミニウム粉、石粉等のフィラー、過酸化ベンゾ
イル、ジクミルパーオキサイド、t−ブチルパーオキサ
イド、2,5−ジメチル−2,5−ジ(t−ブチルパー
オキサイド)ヘキシン−3等のラジカル発生型の架橋剤
等を添加混合し、該カーペット本体裏面に塗布し、乾燥
あるいは冷却固化させることによって形成される。該発
泡性熱可塑性樹脂層は通常300〜800g/m2 、望
ましくは400〜600g/m2 の塗布量とされる。
The carpet body used in the present invention may be a needle punched carpet or a tufted carpet. The expandable thermoplastic resin layer is polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-
Vinyl acetate copolymer, polystyrene, polyvinyl chloride,
2,2'-azobisisobutyronitrile, azodicarbonamide, p, p'-oxybis (benzenesulfonylhydrazide) can be added to a solution, emulsion or melt of a thermoplastic resin such as thermoplastic polyester, thermoplastic polyurethane or thermoplastic polyamide. ), P, p′-oxybis (benzenesulfonyl semicarbazide), N · N′-dimethyl-N · N′-dinitrosoterephthalamide, diazoaminobenzene, 1.1′-azobisformamide, and the like, and a desired agent. Then calcium carbonate, magnesium carbonate, barium sulfate, calcium sulfate, titanium oxide, iron oxide, zinc oxide, alumina, silica, diatomaceous earth,
Fillers such as gypsum, talc, clay, mica, calcium silicate, bentonite, white carbon, carbon black, iron powder, aluminum powder, stone powder, benzoyl peroxide, dicumyl peroxide, t-butyl peroxide, 2,5- It is formed by adding and mixing a radical-generating cross-linking agent such as dimethyl-2,5-di (t-butylperoxide) hexyne-3, coating the mixture on the back surface of the carpet body, and drying or cooling to solidify. Foamable thermoplastic resin layer is usually 300 to 800 g / m 2, desirably a coating weight of 400-600 g / m 2.

【0006】上記カーペット本体裏面に形成された発泡
性熱可塑性樹脂層は該熱可塑性樹脂の軟化点以上でかつ
該発泡剤の分解温度以上の温度に加熱されると軟化発泡
する。そして該発泡性熱可塑性樹脂層が発泡しかつ軟化
状態を維持している間に所定形状に成形する。成形は通
常冷間プレス成形、真空成形等が適用される。
The expandable thermoplastic resin layer formed on the back surface of the carpet body is softened and foamed when heated to a temperature above the softening point of the thermoplastic resin and above the decomposition temperature of the foaming agent. Then, the foamable thermoplastic resin layer is molded into a predetermined shape while foaming and maintaining the softened state. Cold press forming, vacuum forming, etc. are usually applied for forming.

【0007】[0007]

【作用】本発明ではカーペット本体(2) の成形性は発泡
性熱可塑性樹脂層(6) によって付与されるので、カーペ
ット本体(2) にポリエチレン層をバッキングする必要は
ない。更に該発泡性熱可塑性樹脂層(6) は加熱軟化発泡
させ成形した後は熱可塑性樹脂発泡層(7) となるので、
フェルトやポリウレタン発泡体等のインシュレーターを
別材として接着あるいは成形する必要はない。
In the present invention, since the moldability of the carpet body (2) is provided by the expandable thermoplastic resin layer (6), it is not necessary to back the polyethylene layer on the carpet body (2). Further, since the foamable thermoplastic resin layer (6) becomes the thermoplastic resin foam layer (7) after being softened and foamed by heating and molded,
It is not necessary to bond or mold an insulator such as felt or polyurethane foam as a separate material.

【0008】[0008]

【実施例】本発明の一実施例を図1〜図4によって説明
すれば、(2) はポリプロピレン繊維からなるニードルパ
ンチカーペットである本体であり、該カーペット本体
(2)の裏面にはポリエチレン65重量%、炭酸カルシウ
ム30重量%、発泡剤としてアゾジカルボンアミド4重
量%、架橋剤としてのジクミルパーオキサイド1重量%
の混合物である発泡性熱可塑性樹脂の溶融物がTダイか
ら押出され500g/m2 の塗布量で塗布され、発泡性
熱可塑性樹脂層(6) が形成される。
EXAMPLE An example of the present invention will be described with reference to FIGS. 1 to 4. (2) is a main body which is a needle punched carpet made of polypropylene fiber.
65% by weight of polyethylene, 30% by weight of calcium carbonate, 4% by weight of azodicarbonamide as a foaming agent, and 1% by weight of dicumyl peroxide as a crosslinking agent on the back surface of (2).
The melt of the expandable thermoplastic resin, which is a mixture of the above, is extruded from the T-die and applied at an application amount of 500 g / m 2 , whereby the expandable thermoplastic resin layer (6) is formed.

【0009】上記裏面に発泡性熱可塑性樹脂層(6) を形
成したカーペット本体(2) を成形する場合には、図2に
示すように例えば電熱式加熱装置(8) 、遠赤外線加熱装
置、高周波加熱装置等の加熱装置によって該発泡性熱可
塑性樹脂層(6) がアゾジカルボンアミドの分解温度(1
75℃)以上になるように加熱され(例えば200℃,
1分間)、該発泡性熱可塑性樹脂層(6) が軟化されかつ
発泡され、熱可塑性樹脂発泡層であるポリエチレン発泡
層(7) となる。
When the carpet body (2) having the foamable thermoplastic resin layer (6) formed on the back side is molded, as shown in FIG. 2, for example, an electric heating device (8), a far infrared heating device, The expandable thermoplastic resin layer (6) is heated by a heating device such as a high frequency heating device to decompose the azodicarbonamide (1
Heated to above 75 ° C (eg 200 ° C,
For 1 minute), the foamable thermoplastic resin layer (6) is softened and foamed to become a polyethylene foam layer (7) which is a thermoplastic resin foam layer.

【0010】該熱可塑性樹脂発泡層(7) が軟化状態を維
持している間に該カーペット本体(2) は図3に示すよう
に下型(9A)と上型(9B)とからなる冷却プレス型(9) にセ
ットされ、自動車床形状に適合する形状に冷間プレス成
形される。
As shown in FIG. 3, the carpet body (2) is cooled by a lower mold (9A) and an upper mold (9B) while the thermoplastic resin foam layer (7) is maintained in a softened state. It is set in the press mold (9) and cold press-formed into a shape that matches the shape of the automobile floor.

【0011】このようにして図4に示すようなカーペッ
ト本体(2) の裏面にインシュレーターとしてのポリエチ
レン発泡層(7) が形成された自動車床敷用カーペット
(1) が製造される。
In this way, a carpet for an automobile flooring in which a polyethylene foam layer (7) as an insulator is formed on the back surface of the carpet body (2) as shown in FIG.
(1) is manufactured.

【0012】上記実施例以外、図5に示すようにカーペ
ット本体(2) の裏面には不織布(10)を介して発泡性熱可
塑性樹脂層(6) が形成されてもよい。
In addition to the above embodiment, as shown in FIG. 5, a foamable thermoplastic resin layer (6) may be formed on the back surface of the carpet body (2) via a nonwoven fabric (10).

【0013】[0013]

【発明の効果】本発明では発泡性熱可塑性樹脂層により
カーペット本体に成形性が付与され、かつ該発泡性熱可
塑性樹脂層は成形後熱可塑性樹脂発泡層となりインシュ
レーターとして作用するから、製造する際の工数や材料
が節減され、極めて安価な製品を提供出来る。
INDUSTRIAL APPLICABILITY In the present invention, the foamable thermoplastic resin layer imparts moldability to the carpet body, and the foamable thermoplastic resin layer becomes a thermoplastic resin foamed layer after molding and acts as an insulator. The number of man-hours and materials can be reduced, and extremely inexpensive products can be provided.

【図面の簡単な説明】[Brief description of drawings]

図1〜図4は本発明の一実施例を示すものである。 1 to 4 show one embodiment of the present invention.

【図1】カーペット本体断面図[Figure 1] Cross section of the carpet body

【図2】発泡性熱可塑性樹脂層加熱工程の説明図FIG. 2 is an explanatory diagram of a foamable thermoplastic resin layer heating step.

【図3】成形工程の説明図FIG. 3 is an explanatory diagram of a molding process

【図4】自動車床敷用カーペットの断面図FIG. 4 is a cross-sectional view of a carpet for automobile flooring.

【図5】他の実施例のカーペット本体断面図FIG. 5 is a sectional view of a carpet body of another embodiment.

【図6】従来例の自動車床敷用カーペットの断面図FIG. 6 is a cross-sectional view of a conventional carpet for automobile floor covering.

【図7】他の従来例の自動車床敷用カーペットの断面図FIG. 7 is a cross-sectional view of another conventional carpet for automobile flooring.

【符号の説明】[Explanation of symbols]

1 成形カーペット 2 カーペット本体 6 発泡性熱可塑性樹脂層 7 熱可塑性樹脂発泡層 8 加熱装置 9 プレス型 1 Molded carpet 2 Carpet body 6 Foamable thermoplastic resin layer 7 Thermoplastic resin foamed layer 8 Heating device 9 Press type

Claims (2)

【特許請求の範囲】[Claims] 【請求項1】カーペット本体裏面に発泡性熱可塑性樹脂
層を形成し、該発泡性熱可塑性樹脂層を加熱軟化発泡せ
しめると共に所定形状に成形することを特徴とする成形
カーペットの製造方法
1. A method for producing a molded carpet, characterized in that a foamable thermoplastic resin layer is formed on the back surface of a carpet body, and the foamable thermoplastic resin layer is heat-softened and foamed and molded into a predetermined shape.
【請求項2】該熱可塑性樹脂はポリオレフィンである請
求項1に記載の成形カーペットの製造方法
2. The method for producing a molded carpet according to claim 1, wherein the thermoplastic resin is polyolefin.
JP7183599A 1995-06-26 1995-06-26 Manufacture of molded carpet Pending JPH092128A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP7183599A JPH092128A (en) 1995-06-26 1995-06-26 Manufacture of molded carpet

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP7183599A JPH092128A (en) 1995-06-26 1995-06-26 Manufacture of molded carpet

Publications (1)

Publication Number Publication Date
JPH092128A true JPH092128A (en) 1997-01-07

Family

ID=16138637

Family Applications (1)

Application Number Title Priority Date Filing Date
JP7183599A Pending JPH092128A (en) 1995-06-26 1995-06-26 Manufacture of molded carpet

Country Status (1)

Country Link
JP (1) JPH092128A (en)

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