JPH05272042A - Production of felt and carpet - Google Patents

Abstract

PURPOSE:To effectively reuse a waste material for carpet having been mainly used as floorclothes for automobile beds. CONSTITUTION:Since ground material or recovered material from waste of carpet comprises ground thermoplastic synthetic resin such as a thermoplastic or a thermoplastic synthetic resin binder, the ground thermoplastic synthetic resin is used as a binder, blended with fibers and needle-punched to give an interlaced material or softened by heating to bond fibers, and then formed into felt having high rigidity.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing felt by recycling waste carpet material and a carpet lined with felt obtained by the manufacturing method.

[0002]

2. Description of the Related Art Conventionally, for example, a carpet used as an automobile floor covering is molded into an automobile floor shape. Therefore, a rigid resin felt using a polyethylene film or a synthetic resin binder for the purpose of imparting moldability and shape stability. Is further lined, and a resin felt using an ordinary phenol resin binder is lined through a hot melt layer.

Conventionally, the waste material of this kind of carpet has been reused by incineration treatment or by mixing with polyurethane foam waste to carry out urethane chip molding to produce a pad material and the like.

[0004]

However, since the waste material of the carpet is not reused in the incineration process, the resources are wasted, and the labor and energy of the incineration are wasted.

On the other hand, even when it is reused as a raw material for urethane chip molding, a large amount of carpet waste cannot be added in terms of cushioning property, and the remainder of the carpet waste has to rely on incineration.

[0006]

According to the present invention, a felt (6) is produced from a waste material of a carpet (1) lined with the above-mentioned polyethylene film (2) or resin felt (3), and the felt (6) is used as a carpet. It is intended to be used as a backing material for (1).

The waste material of the carpet (1) used in the present invention is mainly used for automobile floor coverings.
As shown in Fig. 2, the carpet (1) is lined with a thermoplastic film (2) such as a polyethylene film, a polypropylene film, a polyamide film, an ethylene-vinyl acetate copolymer film, and the thermoplastic film (2). Resin felt (5) using a normal phenol resin binder is adhered via the resin, or synthetic resin is applied via the thermoplastic film (2) lined with the carpet (1) as shown in FIG. A rigid resin felt (3) using a binder is lined, and further a resin felt (5) is bonded via a hot melt layer (4).

The synthetic resin binder used in the rigid resin felt (3) is mainly polyethylene,
There are thermoplastic synthetic resin binders such as polypropylene, polyamide, ethylene-vinyl acetate copolymer, and the thermoplastic synthetic resin binders are usually the above-mentioned rigid resin felts.
About 30 to 50% by weight is added to (3).

With the above-mentioned thermoplastic synthetic resin binder,
Alternatively, instead of the thermoplastic synthetic resin binder, a thermosetting synthetic resin binder such as phenol resin, melamine resin, urea resin or epoxy resin may be used.

The waste material of the carpet (1) is crushed by a crusher to an average diameter of about 5 mm or fluffed by a fluffing machine to a fluffy material having a length of about 1 to 10 cm. , Acrylic fibers, polyamide fibers, polyethylene fibers, polypropylene fibers, or recycled fibers thereof. The mixing amount may be arbitrary, but normally the carpet (1) waste material pulverized product is 30 to 4
0% by weight.

The mixture of the fibers and the crushed material of the carpet (1) is entangled by needling to form a felt, or a thermoplastic film and a rigid resin felt ((1) lining the carpet (1)) By heating to a temperature above the softening point of the thermoplastic synthetic resin binder of 3), the fibers are bound together to form a felt. The heating softens the thermoplastic film and the thermoplastic synthetic resin binder and functions as a binder for the entangled body. Further, the entangled body obtained by the needling may be heated as described above to bind the fibers to each other to form a felt.

Thus, the felts (6), (16) of the present invention
The felts (6) and (16) of the present invention are used, for example, as a backing material for an automobile flooring carpet (7).

[0013]

The carpet (1) waste material pulverized product to be reused in the present invention contains the thermoplastic synthetic resin pulverized product derived from the thermoplastic film or the thermoplastic synthetic resin binder as described above. The crushed plastic synthetic resin is softened by the above heating and binds the mixed entangled body of the carpet (1) waste material and fiber, and the resultant felt (6)
It gives high rigidity to and also functions as an adhesive.

[0014]

EXAMPLES The present invention will be described with reference to one example shown in FIGS. 1 and 2. As shown in FIG. 5, a polyethylene film (2) having a weight of 350 g / m ² is lined, and the polyethylene film (2) is further lined. Carpet lined with a rigid resin felt (3) of 3 mm thickness and 700 g / m ² weight through a resin, and a resin felt (5) using a normal phenol resin binder through a hot melt layer (4)
The waste material of (1) is crushed to an average diameter of 5 mm. The rigid resin felt (3) is obtained by adding 40% by weight of a fibrous binder of polypropylene to recycled fibers, needle punching and heating to 180 ° C. to soften the binder to bind the recycled fibers. produced.

35% by weight of the crushed material of the above-mentioned carpet (1) is added to and mixed with recycled fibers, the mixture is entangled by needle punching, and the entangled body is heated at 180 ° C. for 40 seconds. The polyethylene film by the above heating
(2) The ground product and the rigid resin felt (3) The polypropylene fibrous binder in the ground product softens and becomes a binder to bind the fibers to each other and the high rigidity felt (6) (thickness 3 m
m, 700 g / m ² weight).

The felt (6) is heated at 140 ° C. for 40 seconds to soften the crushed synthetic resin, and the polyethylene film (8) is applied to the carpet (7) as shown in FIG.
Is crimped and lined through. And while the synthetic resin pulverized product is maintained in a heated state, it is molded into a predetermined shape by a molding die (11). At this time, the molding layer (11) has an insulation layer formed in a predetermined shape ( 9) is set. The insulation layer (9) is obtained by tying the mixture of the crushed material of the carpet (1), recycled fiber and fibrous binder of polypropylene into an entangled body by needle punching, and heating the entangled body at 180 ° C. for 40 seconds to bind the entangled body. And the thickness is 15 mm and the weight is 600 g / m ² . At this time, since the crushed synthetic resin contained in the felt (6) functions as an adhesive, the felt (6) is bonded to the insulation layer (9) without requiring an adhesive layer such as a hot melt adhesive.

Thus, as shown in FIG. 2, an automobile floor covering (10) comprising a carpet (7), a polyethylene film (8), a felt (6) and an insulation layer (9) is manufactured. In the floor covering (10), the felt (6) imparts moldability and shape stability, and the insulation layer
(9) provides sound insulation.

FIG. 3 shows another embodiment. In this example, the same waste material as the carpet (1) used in the previous example was fluffed to obtain fluff (16A) having a length of 1 to 10 cm, and the fluff (16A) was heated to 200 ° C. The polyethylene film (2) and the fibrous binder of polypropylene are softened by passing them through a heated conveyor press (11) so that the fibers are bound to each other to form a highly rigid felt (16) (thickness 3 mm, 700 g / m 2).
² weight). The felt 16 is lined on the carpet as in the previous embodiment.

[0019]

Therefore, according to the present invention, almost all the waste material of the carpet can be effectively reused, resources and energy are saved, and the labor such as incineration is eliminated, and a useful high-rigidity felt can be obtained.

[Brief description of drawings]

 1 and 2 show an embodiment of the present invention.

FIG. 1 Explanatory drawing of molding process

[Fig. 2] Cross section of automobile floor covering

FIG. 3 is a felt manufacturing process chart of another embodiment.

[Fig. 4] Sectional view of carpet for automobile flooring

[Fig. 5] Cross-section of another carpet for automobile bedding

[Explanation of symbols]

 1 Carpet (waste material) 2 Polyethylene film 3 Rigid resin felt 4 Hot melt adhesive layer 5 Resin felt 6,16 Felt 16A Anti-hairy material 7 Carpet

Claims (4)

[Claims] 1. A crushed product of a waste material of a carpet lined with a thermoplastic film or a mixture of fluff and a fiber is kneaded to form an entangled body, or is heated to a temperature above the softening point of the thermoplastic film. A method for producing a felt, characterized in that fibers are bound together by 2. A crushed product of a waste material of a carpet lined with a thermoplastic film or a mixture of fibers and a fiber is made into an entangled body by needling, and the entangled body is further heated to a softening point or more of the thermoplastic film. A method for producing a felt, characterized in that the fibers are heated to bind each other. 3. The method for producing a felt according to claim 1, wherein the carpet is lined with a resin felt using a synthetic resin binder through a thermoplastic film. 4. A carpet lined with felt obtained by the method according to claim 1, 2 or 3.