JP4499236B2 - Composite sheet - Google Patents

Description

[Industrial application fields]
The present invention relates to an effective use of an olefin-based resin waste material containing at least a crosslinked ethylene / propylene / diene terpolymer and polypropylene.
[Prior art]
[0001]
Olefin made of cross-linked ethylene / propylene / diene terpolymer (EPDM), cross-linked ethylene / propylene rubber (EPR), polypropylene, polyethylene, etc. A so-called olefin-based leather reinforced by backing with a crosslinked polypropylene foam or a crosslinked polyethylene foam is used for the sheet.
[0002]
When manufacturing the above-mentioned upholstery or panel using the above-mentioned olefin-based leather, the part corresponding to the window or instrument is punched out or cut into a size with a margin than the size to be manufactured, so by so-called trimming Loss is equivalent to about 50% of the entire leather actually used.
[0003]
Conventionally, waste materials discharged by such trimming have been incinerated or reused as injection molding materials.
[0004]
However, the waste material is bulky, and it is expensive to transport it for incineration, resulting in high cost and poor economic efficiency.
[0005]
On the other hand, when used as an injection molding material, it is usually mixed with polypropylene, but the waste material contains a cross-linked product, so if the mixing ratio increases, the fluidity will drop and it will not be suitable for injection. However, only 20 to 30% of the whole injection material can be mixed, and the processing efficiency is poor.
[0006]
In addition, it can be reused by being mixed into the material for extrusion molding, and the amount of mixing can be relatively larger than that for injection molding, but the fluidity tends to be poor and the slippage at the base becomes worse. The so-called “eye and eye” phenomenon (see FIG. 3) consisting of a light and dark stripe pattern occurs in the extruded product (B), and a good extruded product cannot be produced.
[0007]
[Problems to be solved by the invention]
An object of the present invention is to provide a composite sheet having a good quality in which the waste material of olefin-based leather as described above is efficiently reused.
[0008]
[Means for Solving the Problems]
Thus, according to the invention of claim 1 of the present application, “at least 50 to 90% by weight of a recycled material from a material containing a crosslinked ethylene / propylene / diene polymer and polypropylene, and an ethylene / vinyl acetate copolymer” The upper material (2) is laminated on the surface of the sheet body (1) comprising a composition of 50 to 10% by weight of a mixture and metal soap added at a ratio of 0.1 to 1 part with respect to 100 parts of the mixture. A composite sheet (A1) ”is provided.
[0009]
In the present invention, the regenerated material is a material regenerated using at least a crosslinked ethylene / propylene / diene terpolymer (hereinafter abbreviated as EPDM) and polypropylene. Therefore, a so-called olefin-based material reinforced with a polypropylene foam, polyethylene foam, or the like, on a olefin-based sheet made of crosslinked EPDM, crosslinked ethylene / propylene rubber (hereinafter abbreviated as EPR), polypropylene, polyethylene or the like. Leather waste is preferably used.
[0010]
The regenerated product is mixed with an ethylene / vinyl acetate copolymer (hereinafter abbreviated as EVA). The EVA is used as one that can impart fluidity advantageous for molding or the like to the regenerated product.
[0011]
In the mixture of the regenerated material and the EVA, if the regenerated material is less than 50% by weight, it is not preferable in that the processing efficiency of the material is lowered, and if it exceeds 90% by weight, the fluidity of the mixture is insufficient. It is not preferable.
[0012]
In the present invention, the regenerated product is most preferably used in the form of regenerated pellets. In general, such a regenerated pellet is preferably produced by passing crushed particles obtained by crushing the waste material to about 4 mm or less through a die twice. At this time, since the regenerated raw material is subjected to heating again, it is preferable to add an antioxidant or the like as appropriate.
[0013]
In the present invention, a metal soap is further added to the mixture of the regenerated material and EVA to prepare a composition for forming a sheet body. In this case, the metal soap is added in order to give slipperiness to the above mixture so that it can be easily subjected to, for example, extrusion molding. The metal soap is added at a ratio of 0.1 to 1 part with respect to 100 parts of the mixture. When the amount is less than 0.1 part, it is not preferable in that sufficient slipperiness is not imparted to the mixture, and when it is more than 1 part, it is not preferable in terms of surface contamination due to bleeding.
[0014]
Examples of the metal soap include calcium stearate and zinc stearate. Calcium stearate is preferable in terms of lubricity with a metal surface.
[0015]
In addition, although the said metal soap may be added to the said mixture, it may be added when pelletizing the said recycled material. In this case, it is more preferable at the point from which the slip property in the die die which extrudes a pellet becomes favorable.
[0016]
In the present invention, the composition obtained by adding the above metal soap to the mixture is produced into a sheet body (1), and the upholstery material (2) is laminated on the surface side thereof.
Examples of the upper material (2) include non-woven fabrics, woven fabrics, planted base fabrics, pile fabrics, decorative sheets, PP films printed on the back surface, and non-woven fabrics are suitable, but not limited thereto. .
[0017]
When manufacturing the said sheet body (1), as shown in this-application "Claim 2", "The said sheet body (1) is formed by extrusion molding, and the said upper material (2) is bonded at the time of extrusion. It is preferable from the viewpoint of the process.
[0018]
Further, as shown in “Claim 3” of the present application, a flame retardant may be applied to the upper material (2).
[0019]
In the present invention, the sheet body (1) has a conical shape having a diameter of 0.5 to 2.5 mm and a height of 0.5 to 2.5 mm on the back surface of the sheet body (1) as shown in “Claim 4” of the present application. If embossing is performed so that the protrusions (3) are scattered, ”an anti-slip effect is imparted, which is a preferable mode.
[0020]
According to the invention of claim 1 of the present application, a reclaimed material from a material containing at least a crosslinked ethylene-propylene-diene terpolymer and polypropylene has a predetermined amount of ethylene / vinyl acetate copolymer with respect to the predetermined amount. Are mixed to give fluidity, and a predetermined amount of metal soap is added to give slipperiness. As a result, a composition suitable for molding is obtained, which is molded into a sheet body (1). The upholstery material (2) is laminated on the surface side to obtain the composite sheet (A1).
[0021]
According to the invention relating to “Claim 2” of the present application, the composition according to Claim 1 is formed into a sheet body (1) and extruded, and at this time, the upper material (2) is bonded to the surface side. The composite sheet (A1) in which the upholstery is integrated can be easily obtained.
[0022]
According to the invention of claim 3 of the present application, since the flame retardant is applied to the upper material (2), a composite sheet having a flame retardant surface is obtained.
[0023]
According to the invention of claim 4 of the present application, embossing is performed so that conical protrusions (3) having a diameter of 0.5 to 2.5 mm and a height of 0.5 to 2.5 mm are scattered on the back surface of the sheet body (1). As a result, the composite sheet (A2) having a non-slip formed on the back surface is obtained.
[0024]
【Example】
EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited by this.
[0025]
[Example 1]
Manufacture of reclaimed pellets On the back of an olefin-based leather with the following composition, the waste material of the sheet laminated with a cross-linked PP foam with a gel fraction of 53%, a foaming ratio of 15 times, and a thickness of 2.5 mm The mixture was pulverized with a crusher equipped with a screen having a diameter of 5 mm to obtain a granular material having a particle diameter of 4 mm or less.
[0026]
[Composition of olefin leather]
Crosslinked EPDM 50%
Homo PP 25%
Random PP 25%
[0027]
Add 10g of calcium stearate, 50g of lrg.1010 as an antioxidant (phenolic) and 50g of pigment carbon to 10kg of the above powder and mix, and at a temperature of 210 ° C, 40mmφ · L / D = 28 After being kneaded by an extruder equipped with a vacuum vent, it was extruded linearly through a die having a diameter of 6 mm, and this extrusion was repeated twice to obtain 9 kg of regenerated pellets.
[0028]
Production of composite sheet 2 kg of EVA was added to the total amount of the recycled pellets and mixed well to obtain an extrusion molding composition. The above composition is extruded from a 40 mmφ · L / D = 24 extruder equipped with a die having a diameter of 2 mm × width 220 mm, and a long sheet body having a width (a) of 180 mm and a thickness (b) of 1.5 mm. At the same time as molding (1), at the exit of the extruder, the upper material (2) made of a PP spunbonded nonwoven fabric of 200 g / m ² on the surface side of the sheet body (1), the sheet body (1 The composite sheet (A1) shown in FIG. 1 was obtained.
[0029]
In addition, when extruding to the sheet body (1), due to the influence of the metal soap (calcium stearate) mixed in the composition, the slip at the base part is good, None of the so-called “eyes” phenomenon occurred.
In addition, since 80% by weight of recycled pellets could be mixed into the extrusion molding composition, the amount of recycled pellets was greatly increased.
[0030]
The obtained composite sheet (A1) can be used as an automobile mat, for example, by molding by hot pressing in a shallow tray shape.
In addition, if a flame retardant is applied to the above-mentioned upper material (2), it becomes a composite sheet with flame retardancy and can be used more effectively.
[0031]
[Example 2]
The composite sheet obtained in the same manner as in Example 1 was further embossed with dotted conical protrusions (3) having a diameter of 4 mm and a height of 1 mm as shown in FIG. A sheet (A2) was produced.
[0032]
The composite sheet (A2) obtained in this example was heat-aged for 500 hours in an aging test at 110 ° C., and the dimensional change was measured. No change was observed.
[0033]
The composite sheet (A2) obtained in this example was suitable for use as a mat because the embossing applied to the back surface exhibited an anti-slip action.
[0034]
[Example 3]
Manufacture of recycled pellets The waste material of a sheet in which a cross-linked PE foam with a gel fraction of 49%, a foaming ratio of 15 times, and a thickness of 5 mm was laminated on the back of an olefin-based leather with the following composition, The mixture was pulverized with a crusher equipped with a 5 mm screen to obtain a granular material having a particle size of 4 mm or less.
[0035]
[Composition of olefin leather]
Crosslinked EPDM 40%
Homo PP 40%
Metallocene PE 20%
[0036]
Add 10g of lrg.1010 as antioxidant (phenolic) and 50g of pigment carbon to 10kg of the above powder and mix, and with a vacuum vent of 40mmφ · L / D = 28 at 210 ° C. After kneading with an extruder, it was extruded linearly through a die having a diameter of 6 mm, and this extrusion was repeated twice to obtain 9 kg of recycled pellets.
[0037]
Preparation of calcium stearate master batch 0.3kg of calcium stearate was added to 2.7kg of EVA with acetic acid concentration of 10% and melt mixed for 20 minutes at a jacket temperature of 110 ° C in a 3 liter pressure kneader. . After this mixture was cooled to room temperature, a granular material having a particle diameter of 4 mm was obtained with a crusher equipped with a screen having a hole diameter of 5 mm.
The above powder fluid was melt-mixed with an extruder of 40 mmφ · L / D = 28 at 140 ° C., and then extruded linearly through a die having a diameter of 6 mm to obtain a 1.5 kg master batch.
[0038]
Production of composite sheet To 8 kg of the above regenerated pellets, 1 kg of EVA having an acetic acid concentration of 15% and 1 kg of a master batch of calcium stearate were added and mixed well to obtain an extrusion molding composition. The above composition is extruded from a 40 mmφ · L / D = 24 extruder equipped with a die having a diameter of 2 mm × width 220 mm to form a long sheet body having a width of 180 mm and a thickness of 1.5 mm. At the exit of the extruder, an overcoat made of a 200 g / m ² polyester spunbond nonwoven fabric was bonded to the surface side of the sheet body with the heat of the sheet body to obtain a composite sheet (not shown).
[0039]
Also when extruding into the sheet body, the metal soap (calcium stearate) mixed in the composition has an excellent slip at the base part, and both the front and back surfaces of the sheet body are so-called “eyes”. The phenomenon did not occur.
[0040]
[Comparative example]
Manufacture of reclaimed pellets On the back of an olefin-based leather with the following composition, the waste material of the sheet laminated with a cross-linked PP foam with a gel fraction of 53%, a foaming ratio of 15 times, and a thickness of 2.5 mm The mixture was pulverized with a crusher equipped with a screen having a diameter of 5 mm to obtain a granular material having a particle diameter of 4 mm or less.
[0041]
[Composition of olefin leather]
Crosslinked EPDM 50%
Homo PP 25%
Random PP 25%
[0042]
Add 10g of lrg.1010 as antioxidant (phenolic) and 50g of pigment carbon to 10kg of the above powder and mix, and with a vacuum vent of 40mmφ · L / D = 28 at 210 ° C. After kneading with an extruder, it was extruded linearly through a die having a diameter of 6 mm, and this extrusion was repeated twice to obtain 8 kg of regenerated pellets.
[0043]
Production of composite sheet The above-mentioned recycled pellets are extruded from a 40 mmφ · L / D = 24 extruder equipped with a die having a diameter of 2 mm × width 220 mm, and are 180 mm wide and 1.5 mm thick. At the same time as forming the length sheet body, at the exit of the extruder, a 200 g / m ² PP spunbond nonwoven fabric was bonded to the surface side of the sheet body () with the heat of the sheet body to obtain a composite sheet. .
[0044]
When extruding to the sheet body, so-called “eyes” adhered, and the surface of the sheet body was perforated, and a smooth sheet could not be obtained.
[0045]
【The invention's effect】
According to the invention of claim 1 of the present application, first, a so-called olefin-based leather waste material containing at least a crosslinked ethylene-propylene-diene terpolymer and polypropylene is added to an ethylene vinyl acetate copolymer in a high content. Further, since the obtained sheet material is a non-defective product that does not cause the “eye-eye” phenomenon as in the prior art, the waste material can be used effectively.
[0046]
According to the invention according to the present invention, the composition containing the waste material can be processed by extrusion molding, so that the amount of the waste material processed increases. It becomes very efficient.
[0047]
According to the invention of “Claim 3” of the present application, a composite sheet product that is flame retardant and good can be easily obtained by pasting the laminate with a coating material coated with a flame retardant.
[0048]
According to the invention of claim 4 of the present application, a composite sheet product having an embossed process in which conical protrusions are scattered on the back surface is obtained, and a good sheet product having a higher degree of utilization than that provided with a slip stopper. Can be easily obtained from waste materials.
[Brief description of the drawings]
1 is a schematic perspective view of main parts of a composite sheet of an example of the present invention. FIG. 2 is a schematic perspective view of main parts of a composite sheet of another example of the present invention as viewed from the back side. Schematic perspective view of the main part explaining the explanation
(A1) (A2) ... Composite sheet
(1)… Sheet body
(2)… Upholstery material
(3)… Conical protrusion

Claims (4)

A mixture of 50-90 wt% reclaim from a material comprising at least a cross-linked ethylene-propylene-diene terpolymer and polypropylene, and 50-10 wt% ethylene-vinyl acetate copolymer;
A composite sheet in which an upholstery material is laminated on the surface of a sheet body composed of a composition with metal soap added at a ratio of 0.1 to 1 part with respect to 100 parts of the mixture.   The composite sheet according to claim 1, wherein the sheet body is formed by extrusion and the upper material is bonded at the time of extrusion.   The composite sheet according to claim 1, wherein a flame retardant is applied to the upper material.   The composite sheet according to any one of claims 1 to 3, wherein the back surface of the sheet body is embossed so as to be dotted with conical protrusions having a diameter of 0.5 to 2.5 mm and a height of 0.5 to 2.5 mm.

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