JP2004113384A - Tile carpet and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide pieces of tile carpet produced by recycling recovered pieces of the tile carpet and finely-pulverized resin products in which a fiber component forming a surface pile layer is separated from scraps produced at manufacturing by a paste-sol-coat method and a method for efficiently manufacturing the same. <P>SOLUTION: In the pieces of the tile carpet, a backing resin layer or a sealing layer and the backing resin layer are formed on a back side of a backing consisting of a backing cloth tufted with pile by the sol-coat method. The recovered pieces of the tile carpet and the scraps produced at the manufacturing are pulverized and air-separated by a dust separation device to recover pulverized products of the backing resin layer in which the fiber component consisting of the surface pile layer is separated. The recovered resin component is finely pulverized, sieved out, mixed with vinyl chloride resin paste sol and applied onto a predetermined surface to form the backing resin layer on the back side of the tile carpet backing by laminating the backing consisting of the backing cloth tufted with the pile and to produce the pieces of the tile carpet using the recycled material. <P>COPYRIGHT: (C)2004,JPO

Description

【０１１２】
（ ＩＩ ）分離樹脂の微粉砕
実施例１−２
ターボ工業社製ターボミルＴ−４００型に吸引ダクトとブロワー、サイクロンセパレーター、集塵機からなる微粉砕物回収装置を設置し、実施例１−１で回収した樹脂粉砕物３０ｋｇを３０００回転にて微粉砕した。つぎに、回収した該微粉砕物を、目開き０．８５ｍｍの篩で選別した結果、２５．５ｋｇの樹脂微粉砕物が回収され、該微粉砕物中の繊維含有量は０．９％であった。
【０１１３】
実施例２−２
実施例１−２で回収した樹脂粉砕物３０ｋｇを、尾上機械社製の横型スイングハンマクラッシャＧＸ−２型に開口径２ｍｍのスクリーンを設置して３６００回転にて微粉砕し、バグフィルターを設置した粉砕物回収装置により微粉砕物を回収した。回収した微粉砕物を実施例２−１と同様に、目開き０．８５ｍｍの篩で選別した結果、２８．５ｋｇの樹脂微粉砕物が回収され、該微粉砕物中の繊維含有量は２．１％であった。
【０１１４】
実施例３−２
実施例３−１で回収した樹脂粉砕物３０ｋｇを、尾上機械社製の横型スイングハンマクラッシャＧＸ−２型に開口径２ｍｍのスクリーンを設置して３６００回転にて微粉砕し、バグフィルターを設置した粉砕物回収装置により微粉砕物を回収した。回収した微粉砕物を実施例２−１と同様に、目開き０．８５ｍｍの篩で選別した結果、２５．７ｋｇの樹脂微粉砕物が回収され、該微粉砕物中の繊維含有量は２．８％であった。
【０１１５】
比較例１−２
比較例１−１で回収した樹脂粉砕物３０ｋｇを、実施例１−２と同様にして微粉砕した結果、粉砕効率が悪く、実施例１−２の３倍以上の時間を要した。目開き０．８５ｍｍの篩で選別した結果、樹脂微粉砕物が１６．０ｋｇ回収され、該微粉砕物中の繊維含有量は１１．５％であった。
【０１１６】
比較例２−２
比較例２−１で回収した樹脂粉砕物３０ｋｇを、実施例１−２と同様にして微粉砕した結果、粉砕効率が悪く、実施例１−２の約２倍の時間を要した。目開き０．８５ｍｍの篩で選別した結果、樹脂微粉砕物は１９．５ｋｇ回収され、該微粉砕物中の繊維含有量は９．８％であった。
【０１１７】
（樹脂微粉砕物中の繊維成分含有量）
回収された樹脂微粉砕物中の繊維含有量は、以下の手順で求めた。
【０１１８】
回収した樹脂粉砕物を精秤後、３０重量倍のテトラヒドロフラン（ＴＨＦ）に溶解後、不溶分を沈降させ、濾別した。つぎに、１２％塩酸にＴＨＦ不溶分を溶解し、さらに、不溶分を沈降させて濾別、乾燥して重量を精秤した。濾別した不溶分を６００℃で燒結して残留量を秤量し、その差を繊維成分の含有量とした。
【０１１９】
微粉砕物の回収率と該樹脂微粉砕物中に含まれる繊維含有量の結果を表２に示す。
【０１２０】
【表２】

【０１２１】
（ ＩＩＩ ）ペーストゾルコート方式でのタイルカーペット製造
（塩化ビニル系樹脂ペーストゾルの調製）
塩化ビニル系ペースト樹脂１００重量部に、可塑剤（ＤＯＰ）１００重量部、ステアリン酸カルシウム１重量部、カーボンブラック１部を配合したペーストゾルに、充填剤として重質炭酸カルシウムを１００〜４００重量部添加して混合、均質化し、塩化ビニル系樹脂ペーストゾルを調製した。
【０１２２】
実施例１−２−１
前記配合において、充填剤４００重量部使用した塩化ビニル系樹脂ペーストゾルに、実施例１−２で調製した微粉砕物５重量％を混合した結果、粘度６１Ｐａ・ｓであった。このゾル混合物を鉄板にコーティングした結果、外観性、表面状態ともに良好であった。
【０１２３】
実施例１−２−２
前記配合において、充填剤３００重量部使用した塩化ビニル系樹脂ペーストゾルに、実施例１−２で調製した微粉砕物８重量％を混合した結果、粘度６０Ｐａ・ｓであった。このゾル混合物を鉄板にコーティングして、シートにした結果、外観性、表面状態ともに良好であった。
【０１２４】
実施例１−２−３
前記配合において、充填剤を１００重量部に減量した塩化ビニル系樹脂ペーストゾルに、実施例１−２で調製した微粉砕物１６重量％を混合した結果、粘度５４Ｐａ・ｓであった。このゾル混合物を鉄板にコーティングしてシートにした結果、外観性、表面状態ともに良好であった。
【０１２５】
実施例２−２−１
前記配合において、充填剤３００重量部使用した塩化ビニル系樹脂ペーストゾルに、実施例２−２で調製した微粉砕物５重量％を混合した結果、粘度４６Ｐａ・ｓであった。このゾル混合物を鉄板にコーティングしてシートにした結果、外観性、表面状態ともに良好であった。
【０１２６】
実施例３−２−１
前記配合において、充填剤３００重量部使用した塩化ビニル系樹脂ペーストゾルに、実施例３−２で調製した微粉砕物４重量％を混合した結果、粘度５５Ｐａ・ｓであった。このゾル混合物を鉄板にコーティングしてシートとした結果、外観性、表面状態ともに良好であった。
【０１２７】
比較例１−２−１
前記配合において、充填剤３００重量部使用した塩化ビニル系樹脂ペーストゾルに、比較例１−２で調製した微粉砕物５重量％を混合した結果、粘度は１００Ｐａ・ｓを超え、高粘度となった。このゾル混合物を鉄板にコーティングしたが、シート表面が凹凸となって平滑なシートとすることができなかった。
【０１２８】
比較例２−２−１
前記配合において、充填剤３００重量部使用した塩化ビニル系樹脂ペーストゾルに、比較例２−２で調製した微粉砕物５重量％を混合した結果、粘度は１００Ｐａ・ｓを超え、高粘度となった。このゾル混合物を鉄板にコーティングしたが、シート表面が凹凸となって平滑なシートとすることができなかった。
【０１２９】
（ゾル混合物の粘度）
塩化ビニル系樹脂ペーストゾルに樹脂微粉砕物を混合したゾル混合物の粘度は、塩化ビニル系樹脂ペーストゾルに樹脂微粉砕物を混合したゾル混合物を調製した後、３０℃にて、ＴＯＫＩＭＥＣ社製ＢＨ型粘度計でローター５を使用し、１０回転にて測定した。
【０１３０】
（ゾル混合物の性能評価）
１５０ｍｍ×６０ｍｍの鉄板の上に、ゾル混合物をコーターで５０ｍｍ×１００ｍｍで厚み３ｍｍにコーティングし、１４０℃×１０分間加熱して、シートを形成した。そのシートにおいて、外観性、表面状態を評価した。その結果を表３に示す。
【０１３１】
外観性：形成したシートの表面性を目視評価した。
【０１３２】

【０１３３】
【表３】

【０１３４】
【発明の効果】
以上述べたように、本発明によれば、タイルカーペットの、表面パイル層を形成する繊維成分と樹脂裏打ち層からなる樹脂成分を、容易にかつ精度良く分離することができる。さらに、回収した該樹脂成分を微粉砕、篩選別して塩化ビニル系樹脂ペーストゾルに混合、分散したゾル混合物は、ゾルコート法でタイルカーペット基材裏側に積層して樹脂裏打ち層を形成し、リサイクル素材を利用したタイルカーペットとすることができる。また、本発明のタイルカーペットの製造方法によれば、従来、廃棄されていたカーペット廃材、特に、タイルカーペットの製造工程で発生する端材や廃材を再生して、容易に有効利用することができる。
【図面の簡単な説明】
【図１】図１は、タイルカーペットを粉砕、風力分離し、タイルカーペットを構成する表面パイル層を形成する繊維成分を分離して樹脂粉砕物を回収し、該樹脂粉砕物を微粉砕した後に、塩化ビニル系樹脂ペーストゾルに混合分散してタイルカーペットをゾルコート法によりリサイクルする方法の基本的実施態様の１例を模式的に示す系統図である。
【図２】図２は、一軸剪断式粉砕機の回転刃および固定刃の構成の１例を示す拡大概略説明図である。
【図３】図３は、タイルカーペットを粉砕し、横型スイングハンマクラッシャで粉砕する系統図であり、かつ、横型スイングハンマクラッシャの拡大概略の１例を示す説明図である。
【図４】図４は、ダスト分離装置２９（Ａ）の分離塔の１例を示す拡大縦断面図である。
【図５】図５は、タイルカーペットを一軸剪断式粉砕機で粉砕する第１粉砕工程と、ついで、風力分離する第１風力分離工程を行って、樹脂粉砕物を回収する分離方法の１例を示す系統図である。
【図６】図６は、タイルカーペットを横型スイングハンマクラッシャで粉砕する第２粉砕工程と繊維成分からなる綿状ゴミを風力分離する第２風力分離工程を行って、樹脂粉砕物を回収する分離方法の１例を示す系統図である。
【図７】図７は、タイルカーペットの樹脂粉砕物を横型スイングハンマクラッシャで粉砕後、ダスト分離装置２９（Ａ）と該ダスト分離装置２９（Ａ）の分離塔下部にダスト分離装置２９（Ｂ）を設置したダスト分離装置（Ｃ）で風力分離して樹脂粉砕物を回収する分離装置の構成の１例を示す系統図である。
【図８】図８は、比重分離機の１例を示す概略原理図である。
【図９】図９は、タイルカーペットの表面パイル層からなる繊維成分を分離除去した樹脂微粉砕物をタイルカーペットの樹脂裏打ち層にペーストゾルコート法によりリサイクルするための工程の一例を示すリサイクル工程図である。
【符号の説明】
１　　横型スイングハンマクラッシャ
１ａ　衝撃粉砕部
１ｂ　粉砕物回収部
２　　投入口
３ａ　タイルカーペット粗切断品または端材
３ｂ　タイルカーペット粉砕品
４　　吸引用エアダクト
５ａ　タイルカーペット樹脂粉砕物
５ｂ　タイルカーペット樹脂粉砕物
５ｃ　タイルカーペット樹脂粉砕物
５ｄ　タイルカーペット樹脂粉砕物
６　　粉砕機内部
７　　回転体
８　　衝撃ハンマ
９　　スクリーン
１０　　回転軸
１１　　輸送ブロワー
１２　　衝撃ハンマ懸架部
１３　　タイルカーペット繊維層の粉砕物（綿状ゴミ）
１４　　固定刃
１５　　回転刃
１６ａ　回転刃刃先
１６ｂ　固定刃刃先
１７　　一軸剪断式粉砕機
１８　　投入口
１９　　粉砕物回収皿
２０　　空気輸送管
２１　　輸送用ファンモーター
２２　　風力分離塔
２６　　粉砕物回収箱
２８　　サイクロンセパレーター
２９　　ダスト分離装置
２９（Ａ）　ダスト分離装置（Ａ）
２９（Ｂ）　ダスト分離装置（Ｂ）
２９（Ｃ）　ダスト分離装置（Ｃ）
３１　　真空吸引口（ａ）
３３　　円形板
３５　　通気間隙
３６　　ハンドル
３７　　吊下チェーン
３８　　先端開口
４０　　囲枠
４１　　揺動皿
４４　　開口
４５　　ネット
４７　　吸引ブロワー
４８　　吸引ダクト
４９　　真空吸引口（ｂ）
Ｅ　　出口側
１０１　　送風機
１０２　　整流格子
１０３　　マルチ通風機構
１０４　　特殊スクリーン
１０５　　軽比重物（○）
１０６　　重比重物（●）
１０７　　振動方向
２０１　　塩化ビニル系樹脂ペーストゾルタンク
２０２　　移送ポンプ
２０３　　リサイクル樹脂微粉砕物ホッパー
２０４　　混合槽
２０５　　ゾルコーター
２０６　　移送ポンプ
２０７　　ＰＴＦＥベルト
２０８　　基材
２０９　　ガラス繊維基布
２１０　　ゾルコーター[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a tile carpet using a recycled material, which is effective for recycling and utilizing used collected products or scraps at the time of manufacture in a tile carpet lined with a vinyl chloride resin on the back side of a base material, and a method for manufacturing the same. About. More specifically, a finely ground resin backing layer of a tile carpet having a surface pile layer and a resin backing layer, in which a fiber layer composed of the surface pile layer is separated and removed to 7% by weight or less, is used as a vinyl chloride resin paste sol. After mixing the paste sol mixture on a predetermined surface, a base material in which a pile is tufted is laminated on a base fabric, and a resin backing layer is formed on the back surface of the base material. And a method of manufacturing the same.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, cut scraps have been generated during the production of tile carpets, and used carpets, particularly tile carpets, have been disposed of without being recycled as construction waste. However, in recent years, from the viewpoint of protection of the global environment and effective use of resources, there has been an issue of treating waste materials and waste materials of waste tile carpets and waste materials accompanying renewal. At present, 90% or more of the backing material of tile carpets depends on vinyl chloride resin, and development of appropriate treatment and recycling methods is desired.
[0003]
Various methods have been proposed for recycling tile carpets. For example, Patent Literature 1 discloses a method in which, after pulverization, as a resin backing layer of a carpet, a pulverized material of the tile carpet is sprayed on a sol of virgin raw material, sandwiched and laminated to regenerate as a resin backing layer. Patent Document 3 discloses a method of forming a sheet using carpet waste material, in which a crushed material of the carpet waste material is used as a part of a material for a resin backing layer of a tile carpet, kneaded with a Banbury mixer, and calendered to produce a carpet tile. Suggest a way to do it.
[0004]
On the other hand, as a method of crushing and separating a carpet, Patent Document 4 proposes a method of crushing a carpet by applying an impact force at a low temperature, separating a surface pile layer and recycling the carpet. Also, in Patent Document 5, in order to recycle waste carpet material, a resin backing layer is separated from at least two pulverization stages and three separation stages including a vibrating sieving process, and is used as a backing material by a melt extrusion method. We propose a recycling method. When recycling the resin backing layer of a tile carpet, it is necessary to accurately separate the surface pile layer. As an efficient method, a method of pulverizing and separating the carpet with an impeller or the like is known. It is.
[0005]
By the way, most of the tile carpets currently used are roughly divided into an upper layer and a lower layer. In terms of production in 1998, nylon and polypropylene occupy 96% of the upper fiber material, and 97% of the lower resin material is made of PVC. In the tile carpet manufactured by the paste sol coating method, the surface pile layer is planted on the resin backing layer, so the surface pile layer and the resin backing layer are hard to peel off, and it is easy to separate and recycle both layers Was not.
[0006]
Further, in order to recycle the resin backing layer as a resin material as a raw material by crushing the tile carpet, it was necessary to accurately separate the fiber component comprising the surface pile layer. For example, when crushed by an impact crusher in a form of hitting and crushing a carpet tile with the above-described impeller or the like, the fiber component composed of the surface pile layer is unwound and swells, and a part of the resin component is separated from the fiber component. However, there has been a problem that the flocculent fiber component and the resin component are entangled with each other and cannot be separated, so that the efficiency is not improved.
[0007]
Further, in the method of pulverizing the carpet of Patent Document 4 by applying an impact force at a low temperature and separating and recycling the surface pile layer, a method of pulverizing and separating by performing impact crushing at a low temperature of −30 ° C. However, in order to pulverize and separate at a low temperature, dedicated equipment is required, and there has been a problem in that processing costs related to the cooling and pulverization increase.
[0008]
On the other hand, as a method for recycling tile carpet waste material, a method in which after grinding to 3 mm or less in Patent Document 1 and spraying it on a sol of virgin material as a resin backing layer of the carpet, sandwiching and laminating to regenerate, is disclosed in Patent Document 2. A method of producing a sheet by using carpet waste material, a method of manufacturing a carpet tile by kneading and calender rolling with a Banbury mixer using a crushed material of the carpet waste material of Patent Document 3 as a part of a resin backing layer material of a tile carpet However, in these methods, a tiled carpet on a paste sol is sprayed on the applied powder, or a resin backing layer of the tile carpet is formed and recycled as an extruded sheet after melt-kneading.
[0009]
By the way, the carpet regeneration method of Patent Document 5 is a method of collecting backing material from used carpet using a vibrating sieve after repeating pulverization and air-flow separation using a cyclone provided with a stirring means. According to this method, it is described that the proportion of impurities contained in the heavy material consisting of the backing material can be set to 2% by weight or less, but the recovered backing material is melt-kneaded to form a sheet. It has not been attempted to recycle it into a tile carpet by refining, pulverizing and then using a paste sol coating method.
[0010]
When recycling and recycling the backing resin of a tile carpet, the vinyl chloride resin used as the backing resin has a different melting temperature from the fiber components constituting the surface pile layer, for example, nylon and polyester. When forming a resin backing layer of a tile carpet, if a large amount of fiber is mixed in, the air will be drawn in and the surface of the backing resin layer will have irregularities, impairing the surface properties, or the viscosity of the paste sol tends to increase, and molding There is a problem that the processability is reduced and the quality of the finished product is impaired. In addition, when a resin containing a large amount of fiber is mixed and recycled in the paste sol, the resin backing layer cannot be uniformly applied from the above-described problem, the surface property of the resin backing layer is impaired, and when forming the resin backing layer, However, there is a problem that the viscosity of the sol mixture tends to be high and it is not possible to add a sufficient amount of resin to recycle. Therefore, in order to recycle the backing resin of the waste tile carpet, it is necessary to accurately separate the fiber component consisting of the surface pile layer and reduce the amount of the fiber component mixed in. It was necessary to uniformly disperse the resin in the paste sol, and it was necessary to establish an efficient manufacturing method for forming a resin backing layer made of the paste sol mixture on the back surface of the substrate and recycling the resin.
[0011]
[Patent Document 1]
Japanese Patent Publication No. 7-110530
[Patent Document 2]
JP-A-11-105096
[Patent Document 3]
JP-A-7-32520
[Patent Document 4]
JP-A-9-173197
[Patent Document 5]
JP 2002-509036 A
[0012]
[Problems to be solved by the invention]
Accordingly, the present invention provides a resin in which the fiber component of the surface pile layer is accurately separated to reduce the amount of the fiber component mixed into the resin, and the fiber component is accurately separated in order to recycle the backing resin of the tile carpet waste. Efficient production method for uniformly dispersing the pulverized material in the paste sol, forming a resin backing layer composed of the paste sol mixture on the back surface of the substrate and recycling, and the high quality obtained by the production method Provide recycled tile carpets.
[0013]
[Means for Solving the Problems]
The present invention separates a fiber component consisting of a surface pile layer of a tile carpet lined with a vinyl chloride resin and separates and removes the finely pulverized resin backing layer having a fiber component content of 7% by weight or less. A mixture of 0.5% by weight or more and 20% by weight or less is mixed with a vinyl resin paste sol, the paste sol mixture is applied on a predetermined surface, and a base material obtained by tufting a pile on a base fabric is laminated. And a method of manufacturing a tile carpet having a resin backing layer formed on the back surface of the tile carpet.
[0014]
More preferably, the content of the fiber component is 4% by weight or less.
[0015]
In the separation of the fiber component comprising the surface pile layer of the tile carpet,
A first crushing step of crushing the tile carpet with a shear crusher, a first wind separation step of separating the fiber components in the crushed material by a wind force using a wind separation device, and crushing the resin component collected by the wind separation with a swing hammer crusher The second pulverization step of performing, and the second wind separation step of separating the fiber component in the pulverized matter by wind force using a wind separation device, collects the pulverized matter of the resin backing layer,
By a separation method comprising a fine pulverizing step of finely pulverizing the collected resin pulverized product with a fine pulverizer and a sieve selecting step of selecting with a sieve after the fine pulverization, a fiber component comprising a surface pile layer of a tile carpet is separated. Is preferred.
[0016]
The wind separation device used in the first wind separation step and the second wind separation step,
(A) A circular plate is horizontally supported in a vertical cylindrical separation tower provided with a vacuum suction port (a) at an upper part and an air supply port at a lower part so that a ventilation gap exists around the circular plate. The pulverized material of the tile carpet pulverized by the pulverizer is carried into the center of the pulverized by a pulverizer. A dust separating device (A) in which the air is sucked into a vacuum suction port (a) by being put on an air flow rising in the separation tower, or
After the dust separating device (A), (a) a flat plate-shaped swinging plate which is disposed horizontally and has an enclosing frame set up on the periphery except for the outlet side, and an opening is provided on the bottom surface on the outlet side. A swinging plate that covers the opening in the opening and has a mesh having a predetermined mesh, and sequentially sends the pulverized material supplied by being moved back and forth to the outlet side to the outlet side, and above the net, A suction duct provided with vacuum suction ports (b) opposed to each other while being separated from each other by a predetermined distance. The fiber component in the mixture discharged through the upper surface of the net as the swinging plate moves back and forth is subjected to vacuum. It is preferable that the dust separating device (C) is combined with the dust separating device (B) that is configured to be sucked by suction.
[0017]
The dust separating device (A) has a substantially lower half portion of the separation tower formed in a funnel shape, and a circular plate is suspended and supported in the separation tower in a vertically movable manner so that the ventilation gap can be adjusted. Preferably it is a dust separation device.
[0018]
In the dust separating device (B), it is preferable that the vacuum suction port (b) can be moved up and down so that the space between the dust separating device (B) and the net can be freely changed.
[0019]
It is preferable that a particle size of the pulverized material is set to 3 mm or more and 30 mm or less by installing a screen made of a punching metal for regulating the size of the pulverized material pulverized by the shearing type pulverizer.
[0020]
It is preferable to adjust the distance between the cutting edge of the rotary blade and the fixed blade of the shearing crusher to be 0.4 mm or more and 3 mm or less.
[0021]
It is preferable to adjust the clearance between the rotary blade and the fixed blade of the shearing crusher by cutting off the rotary blade and / or the fixed blade.
[0022]
The swing hammer crusher is a horizontal swing hammer crusher, and is further provided with a screen made of a punching metal or a grid for regulating the size of the crushed crushed material, and crushing the crushed material to a size of 2 mm or more and 20 mm or less. Is preferred.
[0023]
The fine pulverizer used in the fine pulverization step is a vortex impact type pulverizer or a horizontal swing hammer crusher provided with a screen made of a punching metal for controlling the size of the pulverized pulverized material. It is preferable to grind the diameter to 1.5 mm or less.
[0024]
A plurality of impact hammers whose one ends are rotatably fixed around an axis parallel to the axial direction of the rotating body of the horizontal swing hammer crusher are each formed in a plate shape, and these impact hammers are combined into one sheet. Alternatively, it is preferable that two or more sheets constitute one set, and that the plane directions of the respective plate-shaped impact hammers are perpendicular to the axial direction of the rotating body and are arranged at a predetermined interval from each other.
[0025]
The sieve used in the sieve sorting step preferably has an opening of 0.1 mm or more and 1.5 mm or less.
[0026]
It is preferable that the resin component recovered in the second wind separation step is finely pulverized after being subjected to specific gravity separation by a specific gravity separator.
[0027]
Further, the present invention relates to a tile carpet obtained by the manufacturing method.
[0028]
Further, the present invention is a tile carpet comprising a base material in which a pile of tufted base fabric and a resin backing layer on the back surface of the base material,
The resin backing layer is used to remove the finely pulverized material having a fiber component content of 7% by weight or less in the finely pulverized material of the resinous backing layer separated and recovered from the waste tile carpet from 0.5% by weight to 20% by weight. For a tile carpet comprising.
[0029]
BEST MODE FOR CARRYING OUT THE INVENTION
In the present invention, the product shape of the tile carpet to be treated is, for example, 50 cm × 50 cm and a thickness of about 6 mm, and the thickness of the surface pile layer and the thickness of the resin backing layer are substantially the same.
[0030]
The tile carpet used in the present invention includes cut scraps generated during the production of carpet and materials discarded at the time of renewal, etc., particularly those lined with a backing material made of a thermoplastic resin such as a vinyl chloride resin. It is. Nylon filaments, polypropylene filaments, wool, acryl, and polyester filaments are used as the fiber material of the surface pile layer. Of these, nylon filaments account for 75% or more. Materials constituting the resin backing layer include vinyl chloride resin, bitumen, polyurethane resin, polyolefin resin, and the like. In tile carpets manufactured in Japan, vinyl chloride resin accounts for 97% (1998). . In a tile carpet in which the resin backing layer is made of a vinyl chloride resin, if the fiber components forming the surface pile layer are accurately separated, the recovered resin is a vinyl chloride resin, so workability is high. It is easy to recycle.
[0031]
The gist of the tile carpet and the method for producing the same of the present invention is to separate and remove the fiber component comprising the surface pile layer from the resin component, then pulverize the finely pulverized material, and sieve and sort the finely pulverized material to obtain the fiber component comprising the surface pile layer. Carpet pet produced by mixing the finely pulverized resin having a content of 7% by weight or less with a vinyl chloride resin paste sol at 0.5% by weight or more and 20% by weight or less by a paste sol coating method and the production thereof After separating and removing the fiber component comprising the surface pile layer from the resin component, the resin component is finely pulverized, and the finely pulverized material is sieved and screened to reduce the content of the fiber component comprising the surface pile layer to 4% by weight or less. Tile carpet produced by mixing the pulverized material with a vinyl chloride resin paste sol in an amount of 0.5% by weight or more and 20% by weight or less by a paste sol coating method Tsu in the door and a method of manufacturing the same.
[0032]
(I) Separation of surface pile layer and resin backing layer constituting tile carpet
The tile carpet is first easily crushed using a shear crusher in the first crushing step. The shear-type crusher used in the present invention is, for example, shown in FIG. 2 and described below. When the tile-type carpet is crushed by the shear-type crusher, the fiber layer composed of the surface pile layer is also cut, and the tile is crushed. The crushed carpet is collected. When crushing a tile carpet with a shearing crusher, the shearing crusher is usually provided with a screen made of punched metal, and by selecting an opening diameter of the screen, a crushed material having a desired particle size is obtained. Can be recovered.
[0033]
Further, by adjusting the blade edge spacing of the rotary blade and the fixed blade of the shearing crusher used in the first crushing step to be 0.4 mm or more and 3 mm or less, preferably 0.7 mm or more and 2 mm or less, As a result, the separability of the fiber component in the first wind separation step is improved, and as a result, the separation level of the fiber component in the finally recovered resin is improved. This is because the surface pile layer of the tile carpet is planted in the resin backing layer, so when the tile carpet is crushed with a normal shearing crusher, the fiber component planted on the resin surface is cut and the crushed material is cut. Collected. On the other hand, when crushing is performed using a shear crusher in which the clearance between the rotary blade and the fixed blade of the shear crusher is adjusted, the cutting action of the fiber component between the crushing blades is reduced, and the resin component and the fiber component rotate. Before the fiber component is cut by being caught by the blade, the resin component is rubbed off from the fiber component, or the fiber component is pulled out from the resin component, whereby the fiber component is separated and the separation accuracy is improved.
[0034]
As a method of adjusting the interval between the rotating blade and the fixed blade of the shearing crusher, the cutting edge of the rotating blade and / or the fixed blade can be adjusted by shaving off the cutting edge with a file or the like. In this case, the level at which the cutting edge of the rotary blade and / or the fixed blade is shaved off is preferably a level at which the fiber is difficult to cut and the resin component can be crushed. The distance between the rotary blade and the fixed blade is 0.4 mm or more and 3 mm or more. Hereafter, preferably, the clearance is adjusted by grinding with a file or the like so as to be 0.7 mm or more and 2.3 mm or less, or achieved by changing the edge distance between the fixed blade and the rotary blade in a normal shearing-type crusher. Is done. When grinding off the crushing blade with a file, it is possible to remove both the fixed blade and the rotating blade, or only one of them, but usually the clearance between the fixed blade and the rotating blade is about 0.3 mm, When both cutting edges are shaved off, the shaving allowance is 0.05 mm or more and 1.35 mm or less. However, in terms of separability of fiber components contained in the finally collected resin pulverized material and efficiency of pulverizing tile carpet. For this reason, the thickness is preferably 0.2 mm or more and 1 mm or less. Instead of cutting the edge of the rotary blade and / or the fixed blade, it is also possible to use a rotary blade and a fixed blade without a blade for cutting.
[0035]
When the tile carpet is pulverized using a shearing type pulverizer in which the rotating blades and the fixed blades are sharpened, it is preferable to pulverize the tile carpet after rough cutting in advance. The size of the rough cutting is preferably 1 cm square or more and 20 cm square or less, and is preferably set to a size that can be put into a shearing type pulverizer used in the first pulverizing step. In addition, a screen made of punching metal that regulates the size of the pulverized material is installed in the shearing type pulverizer, and the particle size of the pulverized material is 3 mm or more and 30 mm or less, preferably 5 mm or more and 10 mm or less. Pulverization is preferred from the viewpoint of the separation efficiency of the fiber component.
[0036]
The crusher used in the second crushing step of the method for separating resin material of a tile carpet according to the present invention is a swing hammer crusher that rotates and rotates a rotary blade made of a hammer as described later. In this swing hammer crusher, a plurality of hammers installed around the circumference of a rotary shaft are driven to rotate by the rotation of the rotary shaft to apply an impact to a workpiece and to pulverize by the impact force. One.
[0037]
According to the "Waste Management and Recycling Technology Handbook", edited by the Construction Industry Research Council and the Waste Management and Recycling Technology Handbook Editing Committee, the hammer crusher includes a horizontal ring hammer crusher, a horizontal swing hammer crusher, and a vertical ring. Four types of hammer crushers, a hammer crusher and a vertical swing hammer crusher, are described. Among them, the swing hammer crusher used in the present invention is described. Further, among the swing hammer crushers, a horizontal swing hammer crusher is most preferable. In the ring hammer crusher, the tile carpet, which is the object to be processed in the present invention, is compared with the swing hammer crusher used in the present invention because the ring hammer pushes and crushes the object to be processed by the pushing action of the object to the screen. In the case of pulverization, the effect of beating the fiber component implanted in the resin backing material and separating it from the resin backing material is reduced. As described above, among the swing hammer crushers, a horizontal swing hammer crusher is most preferable, and a plurality of hammers, which are fixed at one end on the circumference of the rotation shaft and are freely rotatable, rotate the rotation shaft by centrifugal force generated by rotation of the rotation shaft. Is opened in the vertical direction and is driven to rotate to apply an impact to the object to be processed and to pulverize by the impact force.
[0038]
The impact hammer of the horizontal swing hammer crusher has a plurality of impact hammers each having a plate shape, one end of which is rotatably fixed around an axis parallel to an axial direction of a rotating body driven and rotated by a motor. In addition, one of the plurality of impact hammers, or two or more impact hammers, as a set, each having a surface direction perpendicular to the axial direction of the rotating body and arranged at a predetermined interval from each other. It is preferred to use. In the case of using a pair of impact hammers, if one impact hammer is provided with a projection so as not to be intimately joined to each other and spaced apart from each other, a cross-sectional area for giving an impact is 2 It is possible to increase the frequency of impact applied to the crushed material of the tile carpet, compared to using a single plate-shaped impact hammer having a cross-sectional area equivalent to the number of sheets. The interval between the two impact hammers is preferably selected according to the size of the workpiece to be supplied and the capacity of the crusher. For example, when a horizontal swing hammer crusher having a power of 11 kW is used, 5 mm or more and 10 mm or more are used. It is preferable to set to about the following.
[0039]
By setting a screen made of perforated metal or a lattice at the lower part of the main body in this horizontal swing hammer crusher, the object to be processed is repeatedly pulverized until it reaches a particle size passing through the opening, and is discharged through the opening. The rotating blade of the swing hammer crusher has one end suspended from the rotating pole and is not fixed. Therefore, when the material (crushed material of tile carpet) is thrown in, the cotton blade made of the crushed material of tile carpet or fiber component is used. When dust is caught on the rotary blade and a load is applied, the rotary blade escapes, and it is characterized in that it is difficult to apply a load exceeding an allowable load. When the tile carpet is crushed to separate the fiber components as described above, the horizontal swing hammer crusher of the four types of hammer crushers is most effective. Among the horizontal swing hammer crushers, the Baltz-type crusher is one of the models that implements the present invention because of the reasons that the blade shape can be easily changed to the optimum one and changed easily, and the blade rotation speed is high. It is suitable for.
[0040]
In particular, a horizontal swing hammer crusher is usually characterized by the fact that a screen is installed and a rotary blade made of a hammer is rotated at a high speed to pulverize the hammer crusher. is there. When the number of revolutions is 1000 rpm or more and 1800 rpm or less, the pulverization efficiency is high, which is a desirable mode. When a horizontal swing hammer crusher is used, the size of the crushed material can be controlled by the opening diameter of the screen, and the residence time of the object to be processed can be controlled.
[0041]
In other words, when the tile carpet is crushed with a horizontal swing hammer crusher, the object to be processed is impacted by a rotary blade made of a hammer, so that the resin backing material in which the fiber component is planted is beaten and crushed. It is characterized in that the resin component of the backing layer can be efficiently separated.
[0042]
In the horizontal swing hammer crusher of the present invention, a suction air duct is provided in a predetermined portion thereof, for example, inside the crusher 6 where the crushed crushed material falls through the opening of the screen 9 as shown in FIG. By sucking the inside of this horizontal swing hammer crusher from the suction air duct connected to the blower, the crushed material of the tile carpet generated by the crushing can be collected by suction, and further passed through a screen made of a lattice or punching metal. By improving the passing speed of the crushed material by suction by the suction duct, the processing speed can be improved, and an effect of preventing clogging and adhesion of the processed material inside the crusher can be provided.
[0043]
By the way, in the present invention, the tile carpet is crushed using a combination of a shear crusher and a swing hammer crusher, such as a shear crusher in the first crushing step and a swing hammer crusher in the second crushing step. On the other hand, using only a shear-type crusher, the opening diameter of the screen is increased in the first crushing step, and the opening diameter of the screen is reduced in the second crushing step. When performed, as described above, along with the pulverization of the resin component of the resin backing layer of the tile carpet, the fiber component forming the surface pile layer is cut, and as a pulverized product in which the fiber component is planted in the resin backing layer. Therefore, it is difficult to accurately separate the fiber component from the resin component, regardless of how the pulverized material is treated with any combination of a wind separator, a sieve separator, and a specific gravity separator.
[0044]
In addition, if the tile carpet is not crushed in advance with a shearing crusher but crushed with a swing hammer crusher, the fiber components are entangled with the rotating blades and are stored inside the crusher, and a load is applied during operation of the swing hammer crusher, and the grinding efficiency is reduced. There was a problem of not going up. In addition, even when a crusher is used in which a carpet tile is hit and crushed with the above-described impeller or the like, the fiber component forming the surface pile layer is unraveled and swells, and a part of the resin component is separated from the fiber component. However, there has been a problem that the flocculent fiber component is not cut, the resin and the fiber component are entangled and difficult to separate, and the efficiency is not improved.
[0045]
On the other hand, after the pulverized material obtained by pulverizing the tile carpet with a shearing pulverizer in advance and then pulverizing with a swing hammer crusher, the fiber component is finely cut with a shearing pulverizer. The problem that the load is entangled and the fiber component is accumulated inside the swing hammer crusher and not discharged is less likely to occur.
[0046]
The pulverization of the tile carpet can be performed by using a shearing pulverizer equipped with a screen made of a punching metal that regulates the size of the pulverized material. Is preferably 3 mm or more and 30 mm or less, preferably 5 mm or more and 10 mm or less. When the particle size of the pulverized material is 30 mm or more, as described above, in the second pulverization step, the fiber component of the tile carpet is likely to be stored at the upper portion of the screen, and the load on the pulverizer increases, and the pulverization efficiency decreases. The problem arises. On the other hand, if it is less than 3 mm, the crushing efficiency and the accuracy of separating the fiber components are reduced. Furthermore, if the particle size of the pulverized material is selected to be 5 mm or more and 10 mm or less, the tile carpet can be efficiently pulverized, and the fiber component is sufficiently separated from the resin component in the process of being pulverized by the horizontal swing hammer crusher. Therefore, it is more preferable.
[0047]
Further, when the pulverized material pulverized by the shearing type pulverizer is separated by wind force, and then pulverized by a horizontal swing hammer crusher, a screen made of a punching metal or a grid for regulating the size of the pulverized material is installed, and the pulverized material is pulverized. It is desirable to pulverize the particles to a size of 2 mm or more and 20 mm or less, preferably 3 mm or more and 7 mm or less. This is because if the particle size of the pulverized material is less than 2 mm, the fiber component is difficult to pass through the screen, so that the pulverization efficiency is significantly reduced. This is because the separability is impaired. Among them, pulverization to 3 mm or more and 7 mm or less is more preferable because the pulverized resin and the flocculent dust composed of fiber components are easily separated and the pulverization efficiency is high. Preparation of the particle size of the pulverized product is achieved by selecting the size of the opening of the screen installed in the pulverizer.
[0048]
Further, the rough cutting of the tile carpet, the first pulverizing step with the shearing type pulverizer, and the pulverization in the second pulverizing step with the horizontal swing hammer crusher sequentially perform the screen so that the particle size of the pulverized material of the tile carpet becomes small. It is preferable to selectively grind, since the separability of the cotton-like dust composed of the fiber component is improved.
[0049]
As a wind separation device used in the first wind separation step and the second wind separation step of the method for separating a resin material of a tile carpet of the present invention, a dust separation apparatus disclosed in JP-A-2000-37663 (hereinafter referred to as a dust separation apparatus) 29 (A)) or a dust separation device 29 (A) and a dust separation device disclosed in JP-A-2002-219449 (hereinafter referred to as a dust separation device 29 (B), the details of which will be described later). The disposed dust separation device (hereinafter, referred to as a dust separation device (C)) is preferable because the separation accuracy of the fiber component is high.
[0050]
As a generally used known wind separation device, a dry type device having a mechanism of a classification device is applied, and most of them are used. According to the “Powder Equipment / Equipment Handbook” published by Nikkan Kogyo Co., Ltd., the classifiers are classified into three groups, gravity classification, inertial classification, and centrifugal classification, according to the mechanism. Models are shown. Horizontal gravity type, vertical flow type, zigzag type as gravity classification, linear type, curved type, louver type as inertial classification, cyclone, Phanton Gelen, Kuracyclon, dispersion, separator, microplex as centrifugal classification, A centrifugal classifier with rotating blades is also shown as a centrifugal classifier.
[0051]
The above-mentioned dust separation device is a wind separation device developed for the purpose of separating a mixture of crushed chips formed by crushing waste such as automobile interior materials and flocculent dust. The dust separator 29 (A) supports a circular plate horizontally in a vertical cylindrical separation tower having a vacuum suction port (a) at the top and an air supply port at the bottom so that there is a ventilation gap around it. Then, a pulverized product of a tile carpet made of a mixture of a fiber component forming a surface pile layer and a resin component formed of a resin backing layer is carried into a center portion of the circular plate by an air transport pipe, and the pulverized product of the resin component is introduced. Is dropped from the peripheral edge of the circular plate, and the fiber component forming the pulverized surface pile layer enters through the air supply port, is put on the airflow rising in the separation tower, and is sucked into the vacuum suction port (a). It is characterized.
[0052]
Further, the dust separation device 29 (A) is capable of adjusting the ventilation gap by forming a substantially lower half of the separation tower in a funnel shape and suspending and supporting a circular plate in the separation tower in a vertically movable manner. It is characterized by having done. In addition, the present invention is a wind power separation apparatus suitable for separating the cotton-like dusts at a separation level at which the cotton-like dusts slightly containing the fiber components are mixed into the resin pulverized material, and for continuously and efficiently separating the cotton-like dusts.
[0053]
After the coarsely cut material or scraps of the tile carpet is pulverized by a shearing pulverizer, the dust separator 29 (A) or the dust separator 29 (A) and the dust separator (B) are used in the first wind separation step. By performing the wind separation of the fiber component forming the surface pile layer by the dust separator 29 (C) connected in series, troubles at the time of pulverization by the swing hammer crusher which is subsequently pulverized in the second pulverization step, namely, By reducing the problem of fiber components accumulating inside the swing hammer crusher and preventing the load from being entangled with the rotating blade, the resin collected material from which the cotton-like garbage composed of the fiber components is separated is impact-crushed, This improves the separation efficiency. The resin pulverized product introduced into the swing hammer crusher having a suction air duct connected therein and subjected to impact pulverization is further subjected to wind separation in the second wind separation step, in which the fiber component made of the surface pile layer has become cotton-like. .
[0054]
In the case where the dust separation device 29 (C) is used in the first wind separation step and / or the second wind separation step, the pulverized material including the resin backing layer recovered from the dust separation device 29 (A) is separated from the dust separation device. The crushed material is sequentially sent to the outlet side by receiving and swinging in the swinging plate of 29 (B). During this time, the cotton-like material that adheres to the outer surface of the pulverized material and cannot be removed by the separation tower is dropped by the pulverized materials adjacent to each other being rubbed. In this way, when reaching the upper surface of the net, the light cotton-like dust is sucked from the upper side and pushed by the rising air flow, so that the light cotton-like dust rises and is sucked into the vacuum suction port (b), while the crushed material is discharged without rising because it is heavy. You. This operation further increases the purity of the pulverized resin material comprising the resin backing layer of the tile carpet.
[0055]
The distance between the vacuum suction port (b) and the net or the mesh size of the net is appropriately set to a predetermined amount so that the pulverized material of the tile carpet can efficiently separate the resin pulverized material and the fiber component, respectively. Is set. The dust separation device 29 (B) is generally used in combination with a separation tower (dust separation device 29 (A)) in series as a dust separation device (C). It is also possible to use the device 29 (B) alone.
[0056]
Furthermore, in order to improve the separation accuracy of the fiber component forming the surface pile layer of the tile carpet and the resin component consisting of the resin backing layer, the specific gravity of the resin pulverized material collected from the dust separator is separated by a specific gravity separator. You may. The use of a specific gravity separator in addition to the dust separator is effective in further improving the separation accuracy between the fiber component and the resin component.
[0057]
FIG. 8 shows a principle diagram of the specific gravity separator used in the present invention. According to the "Handbook for Waste Management and Recycling Technology" published by the Japan Construction Industry Research Council, research and development are being carried out as a specific gravity sorting method using air instead of water as a fluid. . In this apparatus, when substances of different specific gravities are introduced into an air stream near their terminal velocity, light specific gravities form layers in the upper layer and heavy substances in the lower layer. Vibration is applied to the lowermost screen so that these layers are not disturbed, and the screen is separated and classified based on the difference between the floating state due to the specific gravity difference and the interaction due to the vibration. The specific gravity material is moved to the inclined upper portion 106, and the light specific gravity material is moved to the inclined lower portion 105 to extract and separate each substance.
[0058]
When the crushed material of the tile carpet collected from the dust separation device is treated with a specific gravity separator, the resin component comprising the resin backing layer is moved to the inclined upper portion 106 as a specific gravity material and collected, and the fibers forming the surface pile layer are formed. A part of the component is separated into the slanted lower part 105 as a light specific gravity substance by being blown up by an air stream and separated into a floc. Since most of the fiber components are blown up by an air stream, a suction air duct connected to a dust collector is installed above the inclined screen and suctioned, so that the fiber components can be separated and collected, and the working environment can be cleaned. Is preferable.
[0059]
Furthermore, in order to improve the separation accuracy of the fiber component forming the surface pile layer of the tile carpet and the resin component consisting of the resin backing layer, after shearing and pulverizing and separating by wind power, pulverization by a swing hammer crusher and a dust separation device. It is also effective to repeat the wind separation. When the resin component of the tile carpet is repeatedly pulverized by the swing hammer crusher, the resin component can be retained on the screen of the swing hammer crusher by changing the opening diameter of the screen installed in the crusher to a small one. It is possible to improve the separation accuracy by giving the impact to the resin pulverized product again by the rotary blade to separate the attached fiber component.
[0060]
By the way, a glass fiber base fabric is used for a tile carpet in order to secure dimensional stability as a product. Therefore, in order to prevent contamination of the work environment, each process is connected with an air duct for suction, and the crushed material of the tile carpet is transported by a transport blower so that the dust generated during crushing and the fiber component dust contain glass fiber. It is preferable that the processing is performed by a closed system. Further, it is more preferable that the exhausted air be provided with a dust collector and collect the dust through the dust collector. In addition, coarse processing of the tile carpet or the pulverized product of the tile carpet pulverized by the shearing pulverizer can be continuously processed if the next step is carried out using a conveyor belt or pneumatic transportation. Become. Of the two transportation methods, the method using a belt conveyor is advantageous in terms of equipment costs.
[0061]
( II ) Pulverization of separated resin
The surface pile layer and the resin backing layer that constitute the tile carpet are separated, and the collected pulverized resin backing layer is easily pulverized with a pulverizer so as to be easily mixed and dispersed uniformly in the paste sol. . In the paste sol coating method, if a finely pulverized material having a large particle size is mixed, unevenness is generated on the surface of the resin backing layer and the surface property is impaired, and the appearance of the tile carpet may be deteriorated. The size is preferably 1.5 mm or less. Further, when forming the backing layer of the tile carpet, when applying the paste sol to the back side of the substrate with a coater, usually, the clearance of the coater may be set to about 1 mm, so the finely pulverized material Is more preferably adjusted to 1 mm or less.
[0062]
Further, the fiber component composed of the surface pile layer is separated from the waste material or offcuts of the tile carpet by the above-mentioned pulverization and separation method so that the content of the fiber component contained in the fine resin pulverization is 7% by weight or less. Is preferred. If the fiber content exceeds 7% by weight, the viscosity of the vinyl chloride-based resin paste sol mixture increases, and it becomes difficult to process the resin backing layer by coating. Further, when the fiber component is accurately separated so that the content of the fiber component contained in the finely pulverized resin becomes 4% by weight or less, the viscosity of the vinyl chloride-based resin paste sol mixture can be controlled to be low. It becomes easy, and it is possible to increase the compounding amount of the finely pulverized resin material from which the fiber component is separated and the filling material. That is, the lower the fiber content in the finely pulverized resin, the lower the viscosity of the paste sol mixture, as a result, it becomes possible to form a resin backing layer of the tile carpet by blending a large amount of finely pulverized resin, In order to recycle the waste material or scrap wood of the tile carpet, it is preferable to prepare a finely pulverized resin having a low fiber content.
[0063]
According to the "Powder Engineering Handbook" edited by the Society of Powder Engineering, fine mills include roller mills, atomizers that are impact-type pulverizers, pin disk mills, supermicron mills, ball mills, stirring mills, jet mills, etc. Although described, as a pulverizer used for preparing a finely pulverized product of the resin backing layer, when using an impact type pulverizer having a mechanism for rotating the wings or a hammer at a high speed to perform fine pulverization, continuous This is preferable because the desired finely pulverized material can be efficiently recovered. Among them, a vortex impact type crusher (turbo mill) or a crusher in which a screen having an opening diameter of 2 mm or less is installed in the horizontal swing hammer crusher is used. It is more preferable to finely pulverize the resin from which the resin has been separated from the viewpoints of workability and productivity.
[0064]
In addition, the recovered resin finely pulverized material can be sieved and screened to adjust the particle size of the finely pulverized material, and the fragments of the fiber components are also separated and removed, so that the separation accuracy can be improved. The opening of the sieve is from 0.1 mm to 1.5 mm, preferably from 0.5 mm to 1 mm. When the sieve opening is larger than 1.5 mm, the particle size distribution of the finely pulverized resin fines is widened, and the uniformity of the collected finely pulverized products is reduced. This is because the efficiency of the operation is reduced. Further, when the content of the finely pulverized material smaller than 0.1 mm increases, the total surface area of the fine powder increases, and as a result, the sol viscosity when mixed and dispersed in the paste sol is easily increased. In addition, since the resin pulverized material and the fiber fragments that have not been finely pulverized by being screened with a sieve remain on the sieve, the recovery rate can be improved by repeatedly pulverizing with a fine pulverizer.
[0065]
( III ) Tile carpet production by paste sol coat method
In the paste sol coating method, after a vinyl chloride resin paste is applied on a predetermined surface such as a belt or a plate, a base material obtained by tufting a pile on a base cloth is laminated, so that the back surface of the base material is made of a vinyl chloride resin. A resin backing layer is formed to make a tile carpet.
[0066]
For example, a vinyl chloride resin paste sol is applied by a coater on a releasable belt such as a PTFE belt whose surface is coated with polytetrafluoroethylene (PTFE), and a base material obtained by tufting a pile on a base fabric is laminated. Then, the resin is heated and gelled to a temperature lower than the softening temperature of the surface pile layer, for example, 120 to 150 ° C., to form a resin backing layer.
[0067]
In addition, the vinyl chloride resin paste sol for forming the resin backing layer in the tile carpet of the present invention is preferably blended and used in the following ratio, and further comprises (a) to (e). Additives such as a hygroscopic agent, an antioxidant, a lubricant, a processability improver, an ultraviolet absorber, and an antifoaming agent (antifoaming agent) can also be selected and added to the obtained vinyl chloride resin paste sol.
(A) 100 parts by weight of vinyl chloride paste resin
(B) Plasticizer: 50 to 150 parts by weight
(C) filler: 100 to 500 parts by weight
(D) Stabilizer # 1 to 10 parts by weight
(E) Pigment # 1 to 10 parts by weight
[0068]
The vinyl chloride-based paste resin used in the present invention includes a vinyl chloride-based copolymer such as a polyvinyl chloride resin, a vinyl chloride-vinyl acetate copolymer, and a vinyl chloride-ethylene-vinyl acetate copolymer.
[0069]
Examples of the plasticizer used in the present invention include dibutyl phthalate, dihexyl phthalate, di-2-ethylhexyl phthalate (DOP), di-isononyl phthalate, phosphate, chlorinated paraffin, trimellitate, and epoxidized Although soybean oil or the like is used alone or as a mixture, it is preferable to use di-2-ethylhexyl phthalate (DOP) from the viewpoint of processability.
[0070]
The filler used in the present invention is an inorganic filler such as calcium carbonate, calcium oxide, barium carbonate, barium sulfate, magnesium hydroxide, aluminum hydroxide, clay, and talc. Among them, heavy calcium carbonate is preferably used. The hardness of the resin backing layer is adjusted by the amount of the filler, and the use of a filler having a high specific gravity can improve the sound insulation.
[0071]
Further, as the stabilizer, calcium stearate, Ca-Zn stearate, Ba-Zn stearate, Pb-based metal soap, and organotin-based stabilizer are known, but it is preferable to use calcium stearate. Examples of the pigment include carbon black and titanium dioxide.
[0072]
The finely pulverized resin material obtained by separating and removing the fiber component composed of the surface pile layer is mixed and dispersed in an amount of 0.5% by weight or more and 20% by weight or less with respect to the vinyl chloride-based resin paste sol prepared by the above-described blending. It is preferable to manufacture a tile carpet by forming a resin backing layer by laminating a pile on the back side of a tufted base material. If the resin finely pulverized material is mixed in more than 20% by weight, the amount of plasticizer absorbed in the finely pulverized material increases, and the resin finely pulverized material from which the fiber content is completely removed is used, and the amount of the filler is reduced. This is because, even in this case, the viscosity of the sol mixture increases, and the coating cannot be performed with a coater. When the mixing amount of the finely pulverized resin is less than 0.5% by weight, the recycling efficiency is too low.
[0073]
Further, it is more preferable that the finely pulverized resin material from which the fiber component comprising the surface pile layer is separated and removed is blended in an amount of 0.5% by weight or more and 10% by weight or less. By blending, even when the amount of the filler is, for example, 300 parts or more, the stability of the sol mixture is increased, and the resin backing layer can be easily formed. Further, it is more preferable that the finely pulverized resin material from which the fiber component comprising the surface pile layer is separated and removed is 0.5% by weight or more and 5% by weight or less, because the processing width at the time of producing the tile carpet is widened.
[0074]
FIG. 9 shows that a finely pulverized resin obtained by separating and removing a fiber component comprising a surface pile layer is mixed and dispersed in a vinyl chloride resin paste sol, and the paste sol mixture is applied to a PTFE belt 207 by a sol coater 205. FIG. 9 is a system diagram showing an example of a method for manufacturing a tile carpet in which a base material 208 having a tufted pile is laminated on a base fabric to form a resin backing layer of the tile carpet. The vinyl chloride resin paste sol of the present invention is prepared by mixing a vinyl chloride resin paste sol tank 201 with a vinyl chloride paste resin, a plasticizer, a filler, a stabilizer, a pigment and various additives. Then, after transferring the vinyl chloride resin paste sol to a mixing tank 204 equipped with a stirrer by a transfer pump 202, a finely pulverized resin material obtained by separating and removing a fiber component composed of a surface pile layer is provided at a top of the mixing tank. The crushed material is put into the hopper 203, mixed and dispersed by a stirrer, and homogenized. The homogenized vinyl chloride-based resin paste sol mixture is transferred to a line for forming a resin backing layer by a transfer pump 206, and is applied onto a PTFE belt 207 by a sol coater 205. 209 are superimposed. Further, after the above-mentioned vinyl chloride resin paste sol mixture is applied thereon by a sol coater 210, a base material 208 in which a pile is tufted is laminated on a base fabric to form a resin backing layer of a tile carpet. The tile carpet on which the resin backing layer is laminated in this manner is heated to a temperature lower than the softening temperature of the surface pile layer, gelled, peeled off the PTFE belt, and cut into a product.
[0075]
Hereinafter, the present invention will be described in more detail.
[0076]
An object of the tile carpet of the present invention is to effectively use waste waste materials of tile carpets and scrap materials generated during manufacturing as recycled materials.
[0077]
A tile carpet and a method of manufacturing the same in one embodiment of the present invention will be described with reference to the system diagram of FIG.
[0078]
First, the waste material of the tile carpet can be pulverized into a shear-type pulverizer used in the first pulverization step to make it pulverizable and pulverized into a 1 cm square to 20 cm square pulverized resin molded product made of vinyl chloride. Was roughly cut with a general purpose crusher. Next, using a uniaxial shearing-type pulverizer manufactured by Sanriku Seisakusho equipped with a screen made of perforated metal, the rough cut material or the scrap 3a of the tile carpet is sized to 3 mm or more and 30 mm or less, preferably 5 mm or more and 10 mm or less. And the resin pulverized product 3b was collected (first pulverization step). The pulverized material 3b is pneumatically transported to the dust separation device 29 (A) or the dust separation device 29 (C) to separate the fiber component and the resin component (first wind separation step), and then is made of a punched metal or a lattice. Using a horizontal swing hammer crusher 1 equipped with a screen, the particles were pulverized to a particle size of 2 mm to 20 mm, preferably 3 mm to 7 mm (second pulverizing step). Further, the pulverized material is subjected to fiber separation by a dust separator 29 (A) or a dust separator 29 (C) in which a dust separator 29 (B) is installed below the separation tower 22 of the dust separator 29 (A). Separated from the crushed material, the crushed material 5c of the tile carpet was collected (second wind separation step).
[0079]
The single-shaft shearing crusher 17 is known to have three blades and four blades, but FIG. 2 shows an example of three blades. A screen 9 made of perforated metal for regulating the size of the pulverized material is installed at the lower part. Further, the fiber 16 is hardly cut at the tip 16a of the rotary blade and / or the tip 16b of the fixed blade in the uniaxial shearing type pulverizer. The resin is cut down to a crushable level, and the interval between the blades of the rotary blade 15 and the fixed blade 14 is set to 0.4 mm or more and 3 mm or less, preferably 0.7 mm or more and 2.3 mm or less. It grind | pulverized with the set single-shaft shearing grinder. When the cutting edge of the rotary blade 15 and / or the fixed blade 14 is scraped off, the fiber component forming the surface pile layer planted in the resin backing layer of the tile carpet has a small cutting action between the crushing blades, and Before the component or fiber component is caught by the rotary blade and the fiber component is cut, the resin component is rubbed off from the fiber component or the fiber component is pulled out from the resin component, resulting in separation and separation accuracy. It is.
[0080]
FIG. 5 shows a tile carpet obtained by crushing a rough cut or scrap of a tile carpet to be treated according to the present invention with a uniaxial shear crusher and wind-separating the dust carpet with a dust separator 29 (A). FIG. 2 is a system diagram showing a separation method of separating a constituent fiber component and collecting a resin pulverized material 5a (that is, a first pulverization step and a first wind separation step). The rough cut material or scrap 3a of the tile carpet is fed from the inlet 18 of the single-shaft crusher 17, and has a size smaller than or equal to the opening of the screen 9 installed in the single-shaft crusher 17. And is discharged to the tray 19 through the opening of the screen. The crushed material 3b is introduced into the separation tower 22 of the dust separating device 29 (A) by the transport fan motor 21 through the suction air duct 4, and is separated by wind.
[0081]
As shown in the vertical sectional view of the dust separation device 29 (A) in FIG. 4, the separation tower 22 has a vertical cylindrical shape in which the lower half portion has a funnel shape, and a vacuum suction port (a) 31 is provided at the upper part thereof. The air supply port 32 is provided at the lower part. Reference numeral 30 denotes a handle shaft rotatably supported by the bearing 30a in the separation tower 22, reference numeral 36 denotes a handle formed at the outer end of the handle shaft, and reference numeral 37 denotes a suspension chain having one end wound around the handle shaft 30. It is. Reference numeral 33 denotes a circular plate suspended and supported by the suspension chain, whereby the circular plate 33 is horizontally supported at the center in the separation tower 22 so that a passing gap 35 exists around the circular plate. Then, the tip opening 38 of the air transport pipe 20 faces downward in the separation tower 22 so as to face the center of the circular plate 33. Reference numeral 26 denotes a box for collecting a pulverized resin material disposed below the air supply port 32.
[0082]
In FIG. 5, reference numeral 25 denotes a fan having the suction side duct 24 connected to the vacuum suction port (a) 31 at the upper part of the separation tower 22, reference numeral 28 denotes a cyclone separator provided on the outlet side of the fan 25, and reference numeral 27 denotes a cyclone separator 28. It is a fiber content recovery device provided at the lower part.
[0083]
In this apparatus, by operating the fan 25 and sucking air in the separation tower 22 from the vacuum suction port (a) 31, the air enters the separation tower from the air supply port as indicated by the arrow in FIG. A stream of air rising in the tower is formed. Then, the resin pulverized material 3b transported by the pneumatic transport pipe 20 is carried into the center of the circular plate 33. Then, the cotton-like dust 13 composed of a light fiber component is sowed in the air flow and sucked up by the vacuum suction port (a) 31 to be sent to the cyclone separator 28. Also, the resin pulverized material 5a in the pulverized material 3b is heavy and falls from the peripheral edge of the circular plate 33 without soaring, slides down the inner wall surface of the separation tower, and falls into the resin pulverized material collection box 26.
[0084]
Further, in the cyclone separator 28, the cotton-like dust 13 composed of the fiber component sent together with the air is separated by the centrifugal action, and the cotton-like dust 13 composed of the fiber component is accumulated in the fiber collecting device 27, and the collected fiber is collected. Packed as 23.
[0085]
In the separation tower 22, the circular plate 33 suspended and supported by the suspension chain 37 can be moved up and down by operating the handle 36 and rotating the handle shaft 30, and the size of the ventilation gap 35 can be adjusted. Separation is easily performed according to the size and specific gravity of the resin pulverized material 5a in the pulverized material 3b formed by pulverizing the roughly cut carpet or the scrap material, or the properties of the cotton-like dust 13 composed of fiber components. The optimum ventilation gap 35 can be set so as to obtain. That is, by appropriately setting the ventilation gap 35, the speed of the airflow rising in the separation tower can be easily adjusted, and the circular plate 33 is checked while observing the situation of the resin pulverized material 5a dropped into the resin pulverized material collection box 26. By adjusting the height of, a favorable separation state is always obtained.
[0086]
FIG. 6 shows that the collected resin pulverized material 5a is further pulverized by a swing hammer crusher, separated by wind power using a dust separator 29 (C) in the same manner as described above, and the fibers in the pulverized material are separated. It is a system diagram showing the separation method (namely, 2nd pulverization process and 2nd wind separation process) which separates a component and collect | recovers the resin pulverized material 5c.
[0087]
The rough cut material or the scrap 3a of the tile carpet is turned into a crushed material 3b by a uniaxial shearing crusher, and is wind-separated by a dust separating device 29 (A) into a crushed tile carpet resin material 5a. Is ground by the horizontal swing hammer crusher 1 (second grinding step). As shown in FIG. 6, after the resin crushed material 5a of the tile carpet is thrown in from the inlet 2 of the horizontal swing hammer crusher 1, it is attached to the rotating body 7 which rotates at high speed, and is impacted by an impact hammer 8 composed of a hammer suspended. Shocked, cut and beaten. The resin crushed material 5a of the tile carpet is given an impact force until the size is smaller than or equal to the size of the opening of the screen 9 installed in the horizontal swing hammer crusher 1, and passes through the opening of the screen to be crushed. It is discharged into the machine interior 6. The pulverized material that has been subjected to the pulverization process passes through the suction air duct 4 and is transported by the transport blower 11 to the dust separating device 29 (A) through the air transport pipe 20. In the dust separation device 29 (A), the cotton-like dust 13 composed of the fiber component is separated from the crushed resin, and the crushed resin 5b is collected from the lower part of the dust separation device 29 (A).
[0088]
As shown in FIG. 3, the horizontal swing hammer crusher 1 is provided with a rotating body 7 that rotates at a high speed by a motor or the like on the input side 1a, and at the same time, the discharge side 1b is formed in a case shape. An inlet 2 for feeding a raw material is provided above the rotating body 7, and a semi-circular screen made of a lattice or punched metal is provided below the rotating body 7.
[0089]
A plurality of fixing poles 12 are attached to the rotating body 7 substantially in parallel with the rotating shaft 10, and one end of the impact hammer 8 is rotatably fixed and suspended on these fixing poles 12. In the example of FIG. 3, the impact hammer 8 has a plate-like shape, and is arranged at a plurality of positions, for example, four positions at right angles to the rotation axis 10 of the rotating body 7, that is, parallel to the rotating body 7. ing. Further, two or more impact hammers 8 may be combined into one set and attached to each fixing pole 12 at a plurality of locations at intervals.
[0090]
When the rotating body 7 is rotated at high speed, the impact hammer opens in a direction perpendicular to the rotation axis (radial direction of the rotating body) due to the centrifugal force, and the impact hammer 8 It gives a shock like shaking off an ax blade, cuts and crushes it. By using an ammeter as a detector for detecting the load applied to the horizontal swing hammer crusher 1, it is easy to operate within the allowable load. At the same time, the rotation speed of the impact hammer 8 can be controlled by installing an inverter in the motor that drives the rotating body 7 to rotate.
[0091]
The horizontal swing hammer crusher 1 is usually provided with a screen 9 made of a grid or punched metal, and the diameter of the collected crushed material is regulated by the opening diameter. As described above, the particle size of the pulverized product is preferably 2 mm or more and 20 mm or less, and more preferably 3 mm or more and 7 mm or less. Therefore, it is desirable that the horizontal swing hammer crusher 1 be provided with a screen made of a lattice or punching metal having an opening diameter of 2 mm or more and 20 mm or less, preferably 3 mm or more and 7 mm or less. The shape of each opening is most commonly circular, but is not particularly limited, and may be elliptical, rectangular, or any other shape.
[0092]
The crushed material of the tile carpet treated by the horizontal swing hammer crusher 1 is a dust separating device 29 (A) or a dust separating device 29 (B) connected in series with the dust separating device 29 (A). In (C), wind separation is performed.
[0093]
The details of the dust separation device 29 (B) will be described by way of an example of a method in which the dust separation device 29 (B) is connected in series with the dust separation device 29 (A) to perform wind separation using the dust separation device (C).
[0094]
As shown in FIGS. 6 and 7, the dust separating device 29 (B) has side frames erected on both sides of a vertically long base plate 39, and between the side frames, below the air supply port 32 of the separation tower 22, The swinging plate 41 that is located at the opposite position is disposed horizontally. The oscillating plate 41 is for storing the resin pulverized material 5b separated and discharged by the separation tower 22. The rocking plate 41 is a rectangular plate-shaped plate body having a surrounding frame 40 erected on the periphery except for the outlet side E. Become. The left and right sides of the dish main body are also at the front and rear positions, and the upper ends are respectively supported by the side frames and are supported so as to freely rotate in the vertical plane, so that they can swing freely in the front and rear direction. . Further, the dish main body is provided with a horizontally long opening 44 on the bottom surface of the outlet side E, and a net 45 covering the opening 44 and having a mesh of a predetermined size is provided.
[0095]
The net 45 is stretched over a frame-shaped frame plate 43 larger than the opening 44 and has a mesh of a predetermined size (for example, 50 mesh). Several kinds of nets 45 having different mesh sizes according to the size of the crushed resin are prepared. For this reason, an opening 44 is provided in the bottom surface of the dish main body, and a net 45 is provided in the opening 44 in a replaceable manner.
[0096]
A driving device 46 for swinging the swinging plate 41 substantially horizontally is provided outside the swinging plate 41. That is, the support plate 42 disposed between the both side frames is connected to the driving device 46 through the crankshaft, and the swinging plate 41 is configured to swing back and forth, and is stored in the swinging plate 41. The resin pulverized materials 5b are sequentially sent to the front side.
[0097]
Reference numeral 49 denotes a blower for sucking air, and a suction duct 48 is a vacuum suction device for a lower end opening surface which is disposed so as to be spaced apart from and opposed to a predetermined distance so as to cover the upper surface of the opening 44, that is, the net 45. Port (b) 49 is connected. Reference numeral 50 denotes a suction port portion attached to the tip of a suction duct 48 above the net 45, which is formed of a hollow box body having a wide lower portion, and a vacuum suction port (b) 49 at a lower end opening surface is formed from the opening 44. Formed one size larger. The suction pressure of the air is variously set depending on the weight of the resin pulverized material 5b. The suction port 50 moves up and down so that the distance between the vacuum suction port (b) 49 and the net 45 can be changed freely, so that the resin crushed material 5c and the cotton-like dust 13 composed of fiber components can be changed. Is set at a predetermined position so that the separation from the normal operation is performed.
[0098]
The dust separating apparatus 29 (B) according to the present invention has the above-described configuration. Next, a method of using the dust separating apparatus 29 (B) to separate cotton-like dust composed of fiber components from pulverized tile carpet will be described. Since the resin pulverized material 5b collected from the dust separation device 29 (A) is mixed with the cotton-like dust 13 composed of a fiber component at a level of several percent or less due to adhesion to the surface, etc. It is preferable to perform the treatment in (B). In FIG. 7, the resin pulverized material 5 b from which the cotton-like dust composed of the fiber component has been separated in the separation tower 22 falls onto the rocking plate 41 and is stored on the rocking plate 41. The stored resin pulverized material 5b is sequentially sent to the outlet side E by the longitudinal movement of the swinging plate 41 by the driving device 46. During this time, the pulverized resin products 5b rub against each other to dislodge and drop the cotton-like dust 13 composed of the fiber component attached to the surface. When the upper surface of the net 45 of the opening 44 on the outlet side E is reached in this manner, the air is sucked from below by the suction blower 47 and pushed by the rising airflow, so that the cotton-like dust 13 composed of a light fiber component rises and rises. (B) Suctioned by 49. On the other hand, the heavy resin crushed material 5 c in the swinging plate 41 is discharged without rising, and is stored in the resin crushed material collection box 26 via the discharge chute 51.
[0099]
The purity of the pulverized resin material 5c thus obtained is nearly 100%, which is higher than that of the pulverized resin material 5b separated by the separation tower 22. When sucking through the suction port 50, the fine and light resin pulverized material 5d is also sucked together with the cotton-like dust 13 made of the fiber component, but these are sent to the mesh-like separation box 52 via the suction blower 47, where they are sent. It is separated into the cotton-like trash 13 made of the fiber component scooped by the net-like separation box 52 and the pulverized resin material 5 d that passes through and is stored in the storage dish 53. The ground resin material 5d is returned to the ground resin collection box 26.
[0100]
In addition, the pulverized material pulverized by the horizontal swing hammer crusher is subjected to wind separation by the dust separator 29 (A) and the collected resin pulverized material 5b is subjected to specific gravity separation to separate the resin pulverized material from the cotton-like dust 13 composed of a fiber component. Can be performed with high accuracy. When the specific gravity of the resin pulverized material 5b is separated, a specific gravity separator manufactured by Nippon Senki Co., Ltd. is used as the dry specific gravity separator shown in FIG. 8, and the air fluid and the vibration are applied to the resin pulverized material 5b of the tile carpet by inverter control. The pulverized resin material can be separated as the heavy specific gravity 106, the cotton-like dust 13 composed of the fiber component can be separated as the light specific gravity 105, or blown off from the special screen 104 as a separation surface by being put in an air stream.
[0101]
Next, the resin pulverized material obtained by separating the collected resin pulverized material 5c or the resin pulverized material 5b with specific gravity can be efficiently pulverized by a pulverizer described below (pulverization step). As the fine pulverizer, for example, it is preferable to use an impact type pulverizer including a pulverizer in which a punching metal having an opening diameter of 2 mm is installed in a turbo mill manufactured by Turbo Kogyo Co., Ltd. or the above-mentioned horizontal swing hammer crusher manufactured by Onoe Kikai Co., Ltd. Using these pulverizers, the resin pulverized material obtained by separating the collected resin pulverized material 5c or the resin pulverized material 5b with a specific gravity is operated at a high speed of 2,000 or more and 5,000 or less to obtain a high yield. Finely pulverized material of 1 mm or less is collected.
[0102]
The collected finely pulverized material can be separated and removed by sieving and separating the finely crushed material having a desired particle size or more (sieving and sorting step). By repeatedly pulverizing with a fine pulverizer, the recovery rate of the finely pulverized material can be improved.
[0103]
The collected resin finely pulverized material is put into the recycled resin finely pulverized material hopper 203 as shown in the recycling process diagram of FIG. The vinyl chloride-based resin paste sol separately prepared and stored in the vinyl chloride-based resin paste sol tank 201 is transferred to the mixing tank 204 by the transfer pump 202 and charged into the mixing tank 204 from the crushed hopper 203 of the recycled resin. After stirring and mixing with the finely pulverized resin to obtain a homogeneous vinyl chloride-based resin paste sol mixture, the mixture is sent to a resin backing layer forming line of a tile carpet by a transfer pump 206. The vinyl chloride resin paste sol mixture is applied and laminated on the PTFE belt 207 by the sol coater 205, and the glass fiber base fabric 209 is overlaid on the applied layer. Further, the above-mentioned vinyl chloride-based resin paste sol mixture is applied thereon by a sol coater 210, and then a substrate 208 is laminated thereon and heated and gelled, whereby a resin backing layer of a tile carpet is formed. After being peeled off, it is cut into tile carpet.
[0104]
【Example】
Hereinafter, the present invention will be described in more detail with reference to Examples, but is not limited to Examples according to the present invention.
[0105]
(I) Separation of surface pile layer and resin backing layer constituting tile carpet
Example 1-1
As a material, 100 kg of tile carpet scrap generated in the manufacturing process was used. This was roughly cut into a square of about 10 cm, and a rotary shaft was ground with a file about 1 mm. A screen made of punching metal with an opening diameter of 8 mm was placed in a uniaxial shearing-type pulverizer manufactured by Sanriki Seisakusho to grind it. And a pulverized product having a particle size of about 8 mm was quantitatively recovered. The pulverized material is supplied to the dust separation device 29 (A) by a pneumatic transportation blower to separate it by wind power, and the resin pulverized material is dropped and collected from the lower part of the separation tower of the dust separation device 29 (A). ) Was dropped directly onto the rocking plate and further separated by wind force, and the cotton-like dust composed of fiber components was separated to collect the crushed resin. Next, the resin pulverized product is pulverized by a horizontal swing hammer crusher (Waltz-15 type manufactured by Onoe Kikai Co., Ltd.) equipped with a screen made of punching metal having an opening diameter of 4 mm, and pulverized through the screen. A suction duct is connected to the lower part of the horizontal swing hammer crusher where the objects fall and accumulates, and the pulverized material is supplied to the dust separator 29 (A) to be separated by wind power, and also dropped from the lower part of the separation tower of the dust separator 29 (A). In order to accumulate, the pulverized resin material was directly dropped and supplied onto a rocking dish of a dust separating device 29 (B) and further separated by wind force, and cotton-like dust composed of fiber components was separated to collect the pulverized resin material. The cotton-like dust composed of the fiber component separated by the dust separator 29 (C) was collected in a dust collector via an exhaust blower. 48 kg of the resin pulverized material comprising the resin backing layer of the tile carpet was recovered.
[0106]
Example 2-1
In the same manner as in Example 1-1, the pulverized material pulverized by the Sanriku Seisakusho single-shaft shear pulverizer is separated by wind power by the dust separator 29 (C), and the resin pulverized material that falls and accumulates from the lower part of the separation tower is collected. did. Next, the pulverized resin material collected by the horizontal swing hammer crusher was treated by a dust separator 29 (A) to separate cotton-like dust composed of fiber components, and the pulverized resin material was recovered. Furthermore, the collected resin pulverized material was separated by a dry type specific gravity separator manufactured by Nippon Senki Co., Ltd. while controlling the air fluid at a normal rotation of 38 Hz by an inverter and vibrating to separate it. As a result, a 45 kg resin backing layer was formed on the heavy specific gravity side. A resin pulverized product was obtained.
[0107]
Example 3-1
In the same manner as in Example 1-1, the pulverized material pulverized by the Sanriku Seisakusho single-shaft shear pulverizer is separated by wind power by the dust separator 29 (C), and the resin pulverized material that falls and accumulates from the lower part of the separation tower is collected. did. Next, the resin pulverized material collected by the horizontal swing hammer crusher was treated by a dust separator 29 (A) to separate cotton-like dust composed of fiber components, and the resin pulverized material was collected. A resin pulverized product was obtained.
[0108]
Comparative Example 1-1
Using 50 kg of the same tile carpet as in Example 1-1, after roughly cutting into a square of about 10 cm, a punched metal having an opening diameter of 8 mm was passed through a uniaxial shearing crusher manufactured by Sanriki Manufacturing Co., Ltd. without rotating blades. A crushed product having a particle size of 8 mm was quantitatively collected by setting a screen. The collected crushed tile carpet is supplied to a dust separator 29 (A) to be separated by wind power, and the resin crushed material that falls and accumulates from the lower part of the separation tower of the dust separator 29 (A) is collected by a dust separator 29 (B). After further wind separation, pulverization is carried out with a uniaxial shear pulverizer manufactured by Sanriki Manufacturing Co., Ltd., which does not have a rotating blade equipped with a screen made of punching metal having an opening diameter of 4 mm. A suction duct is connected to the lower part of the single-shaft shearing crusher that drops and accumulates, and the crushed material is supplied to the dust separator 29 (A) to be separated by wind power, and is also dropped and accumulated from the lower part of the separation tower of the dust separator 29 (A). The resin pulverized material to be supplied is supplied to the dust separator 29 (B) and further subjected to wind separation to separate cotton-like dust composed of a fiber component to recover 41 kg of the resin pulverized material. The resin grind, those fiber components which form a surface pile layer is attached to the resin backing layer were observed many, the pulverized resin product ones fibrous layer is attached to the resin backing layer are mixed was recovered. The cotton-like dust composed of the fiber components separated by the dust separator 29 (A) and the dust separator 29 (B) was collected in a dust collector via an exhaust blower.
[0109]
Comparative Example 2-1
Using 50 kg of the same tile carpet as in Example 1-1, after roughly cutting into about 10 cm square, a screen made of punching metal having an opening diameter of 8 mm was set in a uniaxial shearing type pulverizer manufactured by Sanriki Seisakusho. It was pulverized and a pulverized product having a particle size of 8 mm was quantitatively collected. The pulverized material was sieved and screened with a sieve having an opening of 8 mm, and the resin pulverized material was recovered from the lower part of the sieve. Next, the resin pulverized product is pulverized by a horizontal swing hammer crusher (Balz type crusher manufactured by Onoe Kikai Co., Ltd.) having an opening diameter of 4 mm, and a suction duct is provided at a lower portion of the horizontal swing hammer crusher where the pulverized material drops and accumulates through a screen. , And after collecting the pulverized resin with a cyclone separator, the pulverized material was sieved and screened with a 4 mm sieve, and the pulverized resin was collected from the lower part of the sieve. Among the collected resin pulverized materials, many of the fiber components forming the surface pile layer adhered to the resin backing layer, and 38 kg of the resin pulverized material in which the fiber layer adhered to the resin backing layer was recovered. Was done.
[0110]
Table 1 shows the results of the method for separating the resin material of the tile carpet and the recovered amount of the crushed resin.
[0111]
[Table 1]

[0112]
( II ) Pulverization of separated resin
Example 1-2
A suction duct, a blower, a cyclone separator, and a fine pulverized material recovery device including a dust collector were installed in a turbo mill T-400 manufactured by Turbo Kogyo Co., Ltd., and 30 kg of the resin pulverized material recovered in Example 1-1 was finely pulverized at 3000 rpm. . Next, the collected finely pulverized material was screened with a sieve having an opening of 0.85 mm. As a result, 25.5 kg of finely pulverized resin material was recovered, and the fiber content in the finely pulverized material was 0.9%. there were.
[0113]
Example 2-2
30 kg of the resin pulverized material collected in Example 1-2 was finely pulverized at 3600 rotations on a horizontal swing hammer crusher GX-2 type manufactured by Onoe Kikai Co., Ltd. at 3600 rotations, and a bag filter was installed. The finely pulverized material was collected by the pulverized material collection device. The collected finely pulverized material was screened with a sieve having an opening of 0.85 mm in the same manner as in Example 2-1. As a result, 28.5 kg of finely pulverized resin was recovered, and the fiber content in the finely pulverized material was 2%. 0.1%.
[0114]
Example 3-2
30 kg of the resin pulverized material collected in Example 3-1 was finely pulverized at 3600 rotations on a horizontal swing hammer crusher GX-2 type manufactured by Onoe Kikai Co., Ltd. at 3600 rotations, and a bag filter was installed. The finely pulverized material was collected by the pulverized material collection device. The collected finely pulverized material was screened with a sieve having an opening of 0.85 mm in the same manner as in Example 2-1. As a result, 25.7 kg of finely pulverized resin was recovered, and the fiber content in the finely pulverized material was 2%. 0.8%.
[0115]
Comparative Example 1-2
As a result of finely pulverizing 30 kg of the resin pulverized material collected in Comparative Example 1-1 in the same manner as in Example 1-2, the pulverization efficiency was poor, and it took three times or more the time required in Example 1-2. As a result of screening with a sieve having an opening of 0.85 mm, 16.0 kg of finely pulverized resin was recovered, and the fiber content in the finely pulverized substance was 11.5%.
[0116]
Comparative Example 2-2
As a result of finely pulverizing 30 kg of the resin pulverized material recovered in Comparative Example 2-1 in the same manner as in Example 1-2, the pulverization efficiency was poor, and it took about twice as long as Example 1-2. As a result of screening with a sieve having an opening of 0.85 mm, 19.5 kg of a finely pulverized resin product was recovered, and the fiber content in the finely pulverized product was 9.8%.
[0117]
(Fiber component content in finely pulverized resin)
The fiber content in the recovered finely pulverized resin was determined by the following procedure.
[0118]
The collected resin pulverized product was precisely weighed, dissolved in 30 times by weight of tetrahydrofuran (THF), and the insoluble content was settled out and filtered. Next, the THF-insoluble matter was dissolved in 12% hydrochloric acid, and the insoluble matter was precipitated, separated by filtration, dried and precisely weighed. The insolubles separated by filtration were sintered at 600 ° C. and the residual amount was weighed, and the difference was defined as the content of the fiber component.
[0119]
Table 2 shows the results of the recovery rate of the finely pulverized material and the content of the fiber contained in the finely pulverized resin.
[0120]
[Table 2]

[0121]
( III ) Tile carpet production by paste sol coat method
(Preparation of vinyl chloride resin paste sol)
100 to 400 parts by weight of heavy calcium carbonate is added as a filler to a paste sol obtained by mixing 100 parts by weight of a plasticizer (DOP), 1 part by weight of calcium stearate, and 1 part by weight of carbon black with 100 parts by weight of a vinyl chloride paste resin. The mixture was mixed and homogenized to prepare a vinyl chloride resin paste sol.
[0122]
Example 1-2-1
In the above composition, 5 wt% of the finely pulverized product prepared in Example 1-2 was mixed with a vinyl chloride resin paste sol used in an amount of 400 parts by weight of a filler, and as a result, the viscosity was 61 Pa · s. As a result of coating the sol mixture on an iron plate, both appearance and surface condition were good.
[0123]
Example 1-2-2
In the above blend, 8% by weight of the finely pulverized product prepared in Example 1-2 was mixed with a vinyl chloride resin paste sol using 300 parts by weight of a filler, and as a result, the viscosity was 60 Pa · s. The sol mixture was coated on an iron plate to form a sheet. As a result, both appearance and surface condition were good.
[0124]
Example 1-2-3
In the above composition, 16% by weight of the finely pulverized material prepared in Example 1-2 was mixed with a vinyl chloride resin paste sol in which the filler was reduced to 100 parts by weight, and as a result, the viscosity was 54 Pa · s. The sol mixture was coated on an iron plate to form a sheet. As a result, both appearance and surface condition were good.
[0125]
Example 2-2-1
In the above composition, 5 wt% of the finely pulverized product prepared in Example 2-2 was mixed with a vinyl chloride resin paste sol containing 300 parts by weight of a filler, and as a result, the viscosity was 46 Pa · s. The sol mixture was coated on an iron plate to form a sheet. As a result, both appearance and surface condition were good.
[0126]
Example 3-2-1
In the above composition, 4 wt% of the finely pulverized product prepared in Example 3-2 was mixed with the vinyl chloride resin paste sol used in 300 parts by weight of the filler, and as a result, the viscosity was 55 Pa · s. This sol mixture was coated on an iron plate to form a sheet. As a result, both appearance and surface condition were good.
[0127]
Comparative Example 1-2-1
In the above-mentioned compounding, as a result of mixing 5% by weight of the finely pulverized product prepared in Comparative Example 1-2 with the vinyl chloride-based resin paste sol used in 300 parts by weight of the filler, the viscosity exceeded 100 Pa · s and became high Was. This sol mixture was coated on an iron plate, but the sheet surface became uneven, and a smooth sheet could not be obtained.
[0128]
Comparative Example 2-2-1
In the above formulation, 5 wt% of the finely pulverized material prepared in Comparative Example 2-2 was mixed with the vinyl chloride resin paste sol used in 300 parts by weight of the filler, and as a result, the viscosity exceeded 100 Pa · s, resulting in high viscosity. Was. This sol mixture was coated on an iron plate, but the sheet surface became uneven, and a smooth sheet could not be obtained.
[0129]
(Viscosity of sol mixture)
The viscosity of a sol mixture obtained by mixing a finely pulverized resin with a vinyl chloride resin paste sol is determined by preparing a sol mixture obtained by mixing a finely pulverized resin with a vinyl chloride resin paste sol. The measurement was performed at 10 rotations using a rotor 5 with a mold viscometer.
[0130]
(Evaluation of performance of sol mixture)
The sol mixture was coated on a 150 mm × 60 mm iron plate with a coater to a thickness of 50 mm × 100 mm to a thickness of 3 mm, and heated at 140 ° C. × 10 minutes to form a sheet. The appearance and surface condition of the sheet were evaluated. Table 3 shows the results.
[0131]
Appearance: The surface properties of the formed sheet were visually evaluated.
[0132]

[0133]
[Table 3]

[0134]
【The invention's effect】
As described above, according to the present invention, the fiber component forming the surface pile layer and the resin component forming the resin backing layer of the tile carpet can be easily and accurately separated. Further, the recovered resin component is finely pulverized, screened, mixed with a vinyl chloride-based resin paste sol, and dispersed.The sol mixture is laminated on the back side of a tile carpet base material by a sol coating method to form a resin backing layer, and a recycled material is formed. It can be used as a tile carpet. Further, according to the method for manufacturing a tile carpet of the present invention, conventionally, discarded carpet waste material, in particular, scrap material and waste material generated in the tile carpet manufacturing process can be easily reused. .
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a diagram illustrating a method of pulverizing a tile carpet, separating it by wind, separating a fiber component forming a surface pile layer constituting the tile carpet, collecting a resin pulverized product, and pulverizing the resin pulverized product. FIG. 1 is a system diagram schematically showing an example of a basic embodiment of a method of recycling a tile carpet by mixing and dispersing it in a vinyl chloride resin paste sol by a sol coating method.
FIG. 2 is an enlarged schematic explanatory view showing an example of a configuration of a rotary blade and a fixed blade of a single-shaft shearing crusher.
FIG. 3 is a system diagram of pulverizing a tile carpet and pulverizing it with a horizontal swing hammer crusher, and is an explanatory diagram showing an example of an enlarged schematic of the horizontal swing hammer crusher.
FIG. 4 is an enlarged vertical sectional view showing an example of a separation tower of a dust separation device 29 (A).
FIG. 5 is an example of a separation method for collecting a resin pulverized material by performing a first pulverizing step of pulverizing a tile carpet with a uniaxial shearing pulverizer and then performing a first wind power separation step of wind power separation. FIG.
FIG. 6 is a diagram illustrating a separation for collecting a resin pulverized material by performing a second pulverization step of pulverizing a tile carpet with a horizontal swing hammer crusher and a second pneumatic separation step of wind-separating cotton-like dust composed of fiber components. FIG. 3 is a system diagram illustrating an example of a method.
FIG. 7 is a diagram illustrating a dust separating device 29 (A) and a dust separating device 29 (B) provided at a lower portion of a separating tower of the dust separating device 29 (A) after pulverizing a resin pulverized material of a tile carpet with a horizontal swing hammer crusher. FIG. 1 is a system diagram showing an example of a configuration of a separation device that collects resin pulverized matter by wind separation with a dust separation device (C) provided with ()).
FIG. 8 is a schematic principle diagram showing an example of a specific gravity separator.
FIG. 9 is a recycling process showing an example of a process for recycling a finely pulverized resin material obtained by separating and removing a fiber component from a surface pile layer of a tile carpet to a resin backing layer of the tile carpet by a paste sol coating method. FIG.
[Explanation of symbols]
1 horizontal swing hammer crusher
1a Impact crusher
1b Pulverized material collection section
2 Inlet
3a Tile carpet rough cut products or offcuts
3b tile carpet crushed product
4 Air duct for suction
5a Crushed tile carpet resin
5b Crushed tile carpet resin
5c tile carpet resin crushed material
5d tile carpet resin crushed material
6 Inside the crusher
7 rotating body
8 hammer
9 screen
10 ° rotation axis
11 Transport blower
12 Impact hammer suspension
13 Crushed tile carpet fiber layer (cotton-like garbage)
14 fixed blade
15 rotary blade
16a rotary blade
16b fixed blade
17 single-shaft shearing crusher
18 inlet
19 Pulverized material collection dish
20 air transport pipe
21 Transport fan motor
22 Wind separation tower
26 crushed material collection box
28 cyclone separator
29 dust separator
29 (A) Dust separation device (A)
29 (B) Dust separation device (B)
29 (C) Dust separation device (C)
31 mm vacuum suction port (a)
33 circular plate
35 ° ventilation gap
36mm handle
37mm hanging chain
38 ° tip opening
40 enclosure
41 rocking dish
44 ° opening
45 net
47 ° suction blower
48 suction duct
49 mm vacuum suction port (b)
E Exit side
101 blower
102 rectifying grid
103 multi ventilation system
104 special screen
105 Light specific gravity (○)
106 heavy specific gravity (●)
107 ° vibration direction
201 PVC resin paste sol tank
202 transfer pump
203 Recycled resin crushed material hopper
204 mixing tank
205 sol coater
206 transfer pump
207 PTFE belt
208 substrate
209 glass fiber base cloth
210 sol coater

Claims (16)

The fiber component consisting of the surface pile layer of the tile carpet lined with the vinyl chloride resin is separated, and the finely pulverized resin backing layer separated and removed so that the content of the fiber component is 7% by weight or less is used as the vinyl chloride resin paste. After mixing the paste sol mixture on a predetermined surface, a base material having a tufted pile is laminated on a base cloth, and a resin is formed on the back surface of the base material. A method for producing a tile carpet having a backing layer. The method for producing a tile carpet according to claim 1, wherein the content of the fiber component is 4% by weight or less. In the separation of the fiber component comprising the surface pile layer of the tile carpet,
A first crushing step of crushing the tile carpet with a shear crusher, a first wind separation step of separating the fiber components in the crushed material by a wind force using a wind separation device, and crushing the resin component collected by the wind separation with a swing hammer crusher The second pulverization step of performing, and the second wind separation step of separating the fiber component in the pulverized matter by wind force using a wind separation device, collects the pulverized matter of the resin backing layer,
Claims for separating a fiber component comprising a surface pile layer of a tile carpet by a separation method comprising a fine pulverizing step of finely pulverizing the collected resin pulverized product with a fine pulverizer and a sieve selecting step of selecting with a sieve after the fine pulverization. Item 3. The method for producing a tile carpet according to item 1 or 2. The wind separation device used in the first wind separation step and the second wind separation step,
(A) A circular plate is horizontally supported in a vertical cylindrical separation tower provided with a vacuum suction port (a) at an upper part and an air supply port at a lower part so as to have a ventilation gap around the circular plate. The pulverized material of the tile carpet pulverized by the pulverizer is carried into the center of the pulverized by a pulverizer, the pulverized material is dropped from the peripheral edge of the circular plate, and the fiber component comprising the surface pile layer is introduced from the air supply port. A dust separating device (A) in which air is sucked into a vacuum suction port (a) by being put on an airflow rising in the separation tower, or (a) after the dust separating device (A), It consists of a plate-shaped swinging dish with a surrounding frame erected on the periphery except for the outlet side, an opening is provided on the bottom surface on the outlet side, and a net covering the opening and having a predetermined mesh is provided at the opening. , Which is fed back and forth to the outlet side A swinging tray for sequentially feeding the pulverized material to the outlet side, and a suction duct provided with a vacuum suction port (b) located at a predetermined distance above and opposed to the net, wherein the swinging tray moves back and forth. The tile carpet according to claim 3, wherein the dust carpet is a dust separator (C) combined with a dust separator (B) in which the fiber component in the mixture discharged through the upper surface of the net is sucked by vacuum suction. Manufacturing method. The dust separation device (A) has a funnel-like shape formed in a substantially lower half of the separation tower, and a ventilation gap can be adjusted by suspending and supporting a circular plate in the separation tower so as to be vertically movable. The method for producing a tile carpet according to claim 4, which is a dust separation device. The method for manufacturing a tile carpet according to claim 4 or 5, wherein in the dust separating device (B), the vacuum suction port (b) can be moved up and down so that the distance from the net can be freely changed. The particle size of the pulverized material is set to 3 mm or more and 30 mm or less by installing a screen made of punching metal for regulating the size of the pulverized material pulverized by the shearing type pulverizer. Or the manufacturing method of the tile carpet of 6. 8. The method for producing a tile carpet according to claim 3, wherein the edge distance between the rotary blade and the fixed blade of the shearing crusher is adjusted to be 0.4 mm or more and 3 mm or less. The production of a tile carpet according to claim 3, 4, 5, 6, 6, 7 or 8, wherein the edge distance between the rotary blade and the fixed blade of the shearing crusher is adjusted by shaving off the rotary blade and / or the fixed blade. Method. The swing hammer crusher is a horizontal swing hammer crusher, and is further provided with a screen made of a punching metal or a lattice for regulating the size of the crushed crushed material, and crushing the crushed material to a particle size of 2 mm or more and 20 mm or less. The method for manufacturing a tile carpet according to claim 3, 4, 5, 6, 7, 8, or 9. The fine pulverizer used in the fine pulverization step is a vortex impact type pulverizer or a horizontal swing hammer crusher provided with a screen made of punching metal for regulating the size of the pulverized pulverized material. The method for producing a tile carpet according to claim 3, wherein the diameter is reduced to 1.5 mm or less. A plurality of impact hammers each having one end rotatably fixed around an axis parallel to the axial direction of the rotating body of the horizontal swing hammer crusher are each formed in a plate shape, and these impact hammers are combined into one sheet. Or a set of two or more sheets, wherein the plane directions of the respective plate-shaped impact hammers are perpendicular to the axial direction of the rotating body and are arranged at a predetermined interval from each other. The method for producing a tile carpet according to any one of claims 5, 5, 6, 7, 8, 9, 10 and 11. The tile carpet according to claim 3, 4, 5, 6, 7, 8, 9, 10, 11 or 12, wherein an opening of the sieve used in the sieve sorting step is 0.1 mm or more and 1.5 mm or less. Production method. 14. The tile according to claim 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 or 13, wherein the resin component recovered in the second wind separation step is finely pulverized after being subjected to specific gravity separation by a specific gravity separator. Carpet manufacturing method. A tile carpet obtained by the manufacturing method according to claim 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13 or 14. A tile carpet comprising a base material having a pile of tufted base fabric and a resin backing layer on the back surface of the base material,
The resin backing layer is used to remove the finely pulverized material having a fiber component content of 7% by weight or less in the finely pulverized resinous backing layer separated and recovered from the waste tile carpet from 0.5% by weight to 20% by weight. Tile carpet comprising.

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