JPH11105098A - Production of backing resin for carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To achieve the strike-through of a needle carpet unnecessary material for a car to an extruder along with a virgin material in order to recycle the unnecessary material to a carpet backing material for a car and to line the rear surface of a carpet with a uniformly kneaded sheet article. SOLUTION: In this resin producing method, a needle carpet unnecessary material having a backing resin wherein a filler is compounded with an ethylene/vinyl acetate resin is kneaded at temp. melting only the resin by a pressure kneader to form a lumpy material which is, in turn, cut or ground through a feeder loader or a sheet preforming machine to be cut or ground and a virgin material is mixed with the cut or ground material to be supplied to an extruder and this mixture is extruded into a sheet shape at temp. melting only the resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the recycling of unnecessary materials from car needle carpets into car carpet backings.

[0002]

2. Description of the Related Art Japanese Unexamined Patent Publication (Kokai) No. 58-1 discloses recycling of carpet-free materials to carpet backing materials.
39828 / 61-390. Japanese Patent Application Laid-Open No. 58-139828 pulverizes or cuts trimming waste from an automobile carpet, melt-extrudes the ground or cut trimming waste to form a block-shaped mass, cools and solidifies the mass, and cools and solidifies the mass. The lumps thus obtained are pulverized, and at any stage of the above process, a mixture of virgin resin materials is melt-extruded into pellets, and the pelletized material is used for backing.

Japanese Patent Publication No. Sho 61-390 discloses a carpet lined with a backing material made of a thermoplastic synthetic resin having a low compatibility with a material resin of the carpet material and having a low melting point. Unnecessary material such as the cut off material is crushed, and the crushed small pieces are mixed with a thermoplastic synthetic resin having compatibility with the backing material and adhesive with the material resin of the backing material. This is a method for producing a carpet backing resin which is heated and melted at a temperature lower than the melting point of the carpet material and higher than the melting point of the backing material and the added resin.

[0003]

As described above, Japanese Unexamined Patent Publication No.
In 8-139828, crushing or cutting off the waste,
In 390, the unnecessary material is pulverized and then extruded by an extruder at a temperature at which only the resin component is melted. The problem is that the cut and crushed material has a lower specific gravity than the virgin resin, so classification occurs in the hopper that is supplied to the extruder, resulting in non-uniform compounding. There is a problem that it is difficult to mix. An object of the present invention is to smoothly penetrate an extruder and form a uniformly kneaded sheet on the back of a carton greige machine.

[0004]

Means for Solving the Problems The present invention relates to a method of kneading a material unnecessary for a needle carpet having a backing resin in which an inorganic filler is mixed with an ethylene vinyl acetate resin at a temperature at which only the resin is melted by a pressure kneader. Immediately after forming a sheet through a sheet preforming machine and cutting or pulverizing it into a pellet, or immediately after forming a sheet through a sheet preforming machine and cutting or pulverizing it into a pellet, cut or pulverized material A method for producing a carpet backing resin in which a virgin material is mixed and supplied to an extruder and extruded into a sheet at a temperature at which only the resin is melted. " A backing carpet containing an inorganic filler in an ethylene vinyl acetate resin is commonly called a mass back carpet and is a carpet provided with sound insulation, and the backing amount is also one.
Ethylene vinyl acetate resin is used as a resin having a Kg of −4 Kg / m ^{2, which} is higher than other carpets, so that it is not extremely hard and can contain a large amount of filler. The vinyl acetate content of the ethylene vinyl acetate resin is 14-33%, preferably 19-28%. If the vinyl acetate content is less than 14%, the limit compounding amount of the filler becomes low and the sheet becomes too hard, which is not preferable. If the vinyl acetate content is 33% or more, the softening temperature is too low, and there is a problem in heat-resistant shape retention after carpet molding, which is not preferable.

[0005] The inorganic filler is used alone or as a master batch with calcium carbonate, barium sulfate, talc and the like. Needle carpet is used as the carpet material, and these materials are polyester and polypropylene. The batch-type pressure kneading device mixes virgin materials as needed and kneads them at a temperature at which only the resin component is melted to form a lump mass, without the necessity of shredding and grinding the scrap carpet. In addition, environmental problems caused by scattering of fiber fragments can be eliminated. The sheet preforming machine used in the following claim 1 and the feeder ruder processing used in the claim 2 are performed in order to increase the specific gravity and to facilitate subsequent cutting or grinding. The cutting or grinding is to cut or grind to facilitate the subsequent mixing and feeding of the inorganic filler and virgin material such as ethylene vinyl acetate resin to the extruder and to cut the fibers to a suitable length. The cut or crushed material has a specific gravity close to that of the virgin material, so that it is mixed and supplied to the extruder, the classification in the hopper is very small, uniform mixing is performed smoothly, and the sheet-like backing resin is extruded from the die. .

[0006] The feeder ruder is a device for feeding a melt to a single-screw extruder by, for example, a twin-screw feeder and extruding the melt into a strand or a sheet. The sheet preforming machine is a device that includes a heating roll pair and a cooling roll pair and forms a sheet through a massive melt to form a cooling sheet.

[0007]

EXAMPLE 1 Polyester raw Chakuwata 320 g / m ² of the needle back surface to 25 parts vinyl acetate content of 28% ethylene vinyl acetate resin of the carpet, Karupetto A (manufactured by Nitto Funka Kogyo calcium carbonate master batch, calcium carbonate content 80% ) 75 parts of a cut ² piece of carpet backed by ² kg / m ² was put into a pressure kneader and the temperature was 110 °-
The mixture is melt-kneaded at 120 ° C for 5 minutes, formed into a 4 mm sheet at an inlet roll temperature of 98 ° C, then passed through a 5 ° C cooling press roll to form a 3.8 mm thick sheet, and then crushed by a 6 mm mesh. Crushed. Carpet A 45 parts Evaflex 250 (Mitsui DuPont ethylene vinyl acetate resin, vinyl acetate content 28%)
25 parts were mixed and put into a hopper of a single screw extruder equipped with a T die, kneaded and extruded at a die temperature of 130 ° C., and then welded to the back of the carpet greige.

A backing sheet having good penetration into the extruder and good dispersion uniformity could be produced, and a backing carpet having no problem in quality was obtained.

[0009]

Example 2 The backing material of Example 1 was lined with the back surface of a greige machine coated with 80 g / m ² of styrene-butadiene latex on the back surface of a brushed needle 410 g / m ² composed of 51 mm of 6-denier polyester raw cotton. The carpet cuttings for automobiles were kneaded with a pressure kneader in the same manner as in Example 1, followed by a 110 mm-120 mm die having a diameter of 5 mm.
The granules were cut and granulated through a #c feeder ruder, air-cooled with a cyclone to obtain chips, and virgin raw materials were blended into the chips as in Example 1, and the chips were welded to a needle carpet greige machine.

A backing material sheet having good penetration into the extruder and good dispersion uniformity could be produced, and a backing carpet having no problem in quality was obtained.

[0011]

According to the present invention, the unnecessary waste of the needle carpet is melted and kneaded, then cut and ground through a feeder ruder or a sheet preforming machine, the specific gravity approaches the virgin material, mixed with the virgin material, and supplied to the extruder. Since the extruded sheet was formed, the carpet with good uniformity was continuously obtained into the extruder, and as a result, a carpet having good productivity and physical properties could be obtained.

Claims (2)

[Claims] 1. A needle carpet unnecessary material having a backing resin in which an inorganic filler is blended with an ethylene vinyl acetate resin is kneaded at a temperature at which only the resin is melted by a pressure kneader to form a lump, which is immediately passed through a sheet preforming machine. Forming a sheet and cutting or pulverizing it into pellets, mixing a virgin material with the cut or pulverized material, supplying the mixture to an extruder, and extruding into a sheet at a temperature at which only the resin is melted. Production method. 2. A needle carpet unnecessary material having a backing resin in which an inorganic filler is blended with an ethylene vinyl acetate resin is kneaded at a temperature at which only the resin is melted by a pressure kneader to form a lump, which is immediately extruded through a feeder ruder. A method for producing a carpet backing resin in which a virgin material is mixed with the cut or crushed material and the mixture is supplied to an extruder and extruded into a sheet at a temperature at which only the resin is melted.