JP2010208118A - Recycling sheet, floor material including the recycle sheet as constitutive material, and method of manufacturing the recycling sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reuse a carpet with a disposal backing, without separating the backing from a textile product. <P>SOLUTION: Thermoplastic synthetic resin films and the backings of ground matters, and the backings of ground matters, are mainly fused thermally to be molded into a prescribed shape, by filling the ground matters prepared by cutting the carpet with the disposal backing into a prescribed size without separating the backing from the textile product, between two sheets of the upper and lower thermoplastic synthetic resin films, through a first and second heating processes for conducting heating at about 190°C of surface temperature for 15-30 sec, and a first and second pressing processes for conducting press at 2-5 kg/cm<SP>2</SP>of pressure for 5-10 sec. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a recycled sheet, a floor material including the recycled sheet as a constituent material, and a method for manufacturing the recycled sheet. More specifically, the present invention relates to a backing carpet comprising a backing made of unvulcanized rubber or thermoplastic resin and a textile product made of woven fabric, knitted fabric or nonwoven fabric bonded and integrated with the backing. Recycled without using excessive energy in addition to the amount of heat sufficient to melt the backing, using the pulverized product crushed to a predetermined size as raw material without separating it into a backing and textile products. The present invention relates to a sheet, a flooring material containing the recycled sheet as a constituent material, and a method for producing the recycled sheet.

  As for carpets, JIS L 4404 defines the details for “woven carpet”, JIS L 4405 for “tufted carpet”, and JIS L 1904 for “tile carpet”. Description is omitted.

  In the present invention, a rug composed of a backing made of unvulcanized rubber or thermoplastic resin and a textile product made of woven fabric, knitted fabric or nonwoven fabric bonded and integrated with the backing is referred to as "carpet with backing". To do. The backing carpet to which the present invention is directed is not limited by the backing material, appearance shape, physical properties, and the material, appearance shape, physical properties, etc. of the textile product joined and integrated with the backing. From the shape surface of the carpet with backing which is the subject of the present invention, it is manufactured by cutting in advance to a predetermined standard size at the production site, so-called tile carpet, and is manufactured as a long type at the production site and at the construction site. It includes a so-called long type that is cut into a predetermined shape.

  The term “recycle sheet” used in the present invention is defined in advance. The recycled sheet of the present invention is used as a carpet with a backing as a main raw material, and collects defective products, cut pieces or used ones produced in the manufacturing process of the carpet with a backing, and recycles it, that is, recycles it. Since it is used and formed into a sheet, it is called a “recycle sheet”. In addition, although it is a special case, it may occur when a carpet with a backing that has been properly manufactured and has commercial value but has been disposed of without being used is used as a raw material in the present invention. The term “recycle sheet” used in the present invention is included.

  In the process of manufacturing a carpet with a backing, unvulcanized rubber or thermoplastic resin used as a backing is blended with various additives for unvulcanized rubber or thermoplastic resin in order to achieve the desired effect. However, this is a known technical matter, and the present invention that uses a properly manufactured backing carpet as a starting material includes them, and thus detailed description thereof is omitted. Furthermore, textile products made of woven fabric, knitted fabric or non-woven fabric that are bonded and integrated with the backing in the process of manufacturing the carpet with backing have a wide variety of technologies regarding fiber types, manufacturing methods, textures, properties, etc. However, these points are known technical matters, and the present invention that uses a properly manufactured backing carpet as a starting material includes them, and thus detailed description thereof is omitted. That is, since the recycled sheet of the present invention uses a properly manufactured carpet with a backing as a raw material, an unvulcanized rubber used as a backing or an unvulcanized rubber added to a thermoplastic resin or The effects of various additives for thermoplastic resins, or the texture, characteristics, etc. of the textile product made of woven fabric, knitted fabric or nonwoven fabric bonded and integrated with the backing are maintained as they are.

  The term “recycle sheet” used in the present invention is not particularly limited by thickness, and should be interpreted broadly as a flat plate. Thus, as used herein, the term “recycled sheet” includes so-called sheets, thicker plates, and films thinner than sheets.

  The method for producing the recycled sheet of the present invention includes a pressing method in which a recycle sheet is formed in advance using a mold and a rolling method in which the recycle sheet is formed in an endless manner.

  Moreover, the recycling sheet of this invention can be used as a self-contained floor material as a single item by selecting a shape and physical property, and can be used as a constituent material for manufacturing a new floor material. In the latter case, for example, the recycled sheet of the present invention is formed as a new tile carpet as a structure comprising a lower layer sheet + recycled sheet of the present invention + paste + textile product made of woven fabric, knitted fabric or non-woven fabric, or a lower layer sheet + book. A novel resin tile, for example, a vinyl chloride tile, can be formed as a structure comprising the surface layer of the thermoplastic synthetic resin such as the recycled sheet + intermediate layer + vinyl chloride of the invention. Accordingly, in the present invention, the “floor material including the recycled sheet of the present invention as a constituent material” includes the two types of configurations described above.

  Carpets with backing are used for general homes, offices, hotels, stores and other business buildings, aircraft, ships, railway vehicles, automobile floors such as automobile floors, water mats, entrance mats, corridor mats (runners) ), Business mats (dust control mats), and automobile option mats. Along with this, the amount of used backing carpets, especially tile carpets, has also increased, and its treatment or reuse has become a national project. A method for reusing used tile carpets or tile carpets as scraps generated during production is being developed as a kind of national policy project.

  As one of the methods, there is a method in which a tile carpet is pulverized without being separated into a textile product and a backing material and reused as a backing material for the tile carpet. This prior art includes a step of applying heat to the tile carpet to once melt the backing and fibers to form chips.

  Furthermore, it consists of equipment such as a pulverizer, fine pulverizer, extruder, granulator, and separator. The tile carpet is roughly pulverized to a size of about 5 to 10 cm square by a pulverizer, and further finely pulverized. The pulverized product is melt-kneaded at a fixed ratio by a special extruder to obtain a recycled pellet that can be added to a thermoplastic resin. In the case of commercial carpets, carpet waste is roughly pulverized to a size of about 5 to 10 cm square, then pulverized by an impact pulverizer, pulverized, and separated into fiber and resin, each as a recycled product. It is what you use.

  All of the above-described conventional techniques require a large amount of energy because they include a step of applying heat to the tile carpet to once melt the backing and fibers to form chips. In order to establish reuse of used tile carpet as an industry, it is essential to avoid unnecessary costs as much as possible. From this point of view, the prior art has a point to be improved.

  For example, Patent Document 1 describes a recycled sheet for flooring, in which tile carpet waste is reused as a raw material without separating the fiber and resin components, and a tile carpet using the same. In the invention described in Patent Document 1, waste floor material including tile carpet waste material is pulverized to about 10 to 50 mm square by a pulverizer, and put into a heating and melting means equipped with a volume reduction cylinder and a rotating member to reduce the volume. (Patent Document 1, paragraphs 0010, 0025, etc.). This prior art is one of the requirements for fixing reuse of waste materials as an industry in that used tile carpets are reused as raw materials without being separated into fiber and resin components. However, there is a point to be improved in that a large amount of heat is required for volume reduction.

  In Patent Document 2, a so-called tile carpet is pulverized as it is with a pulverizer having a screen diameter of 80 mm without separating the backing layer and the carpet, and is flocked to an average fiber length of 8 mm and a maximum resin lump diameter of 8 mm. Discloses a technique in which a recycled resin kneaded with a Banbury mixer and melt-mixed is rolled with a calender, cooled and reused as a recycled backing (paragraph 0014 et al.). The viewpoint that this prior art makes it necessary to use 50% by weight of a virgin compound with respect to 50% by weight of the raw material recycled from the used backing material, and that it is preferable to avoid unnecessary costs as much as possible. There is a point that should be improved.

  In Patent Document 3, the used vinyl chloride resin foam used for floors around water such as kitchens, bathrooms, and washrooms is crushed or volume-reduced, and a shearing force is applied at a temperature higher than its melting temperature. It discloses a resin composition obtained by melt-kneading and thermoplasticizing, and then crushing or cutting the recovered thermoplastic resin product to form coarse particles or pellets (paragraph 0009 and others). This prior art is characterized by requiring a large amount of heat for volume reduction and finally pelletizing. Therefore, it can be applied to products that can absorb the cost, but it should be improved from the viewpoint of reusing the so-called used tile carpet as raw material without separating it into fiber and resin and fixing it as an industry. There is a point.

  In Patent Document 3, the used vinyl chloride resin foam used for floors around water such as kitchens, bathrooms, and washrooms is crushed or volume-reduced, and a shearing force is applied at a temperature higher than its melting temperature. It discloses a resin composition obtained by melt-kneading and thermoplasticizing, and then crushing or cutting the recovered thermoplastic resin product to form coarse particles or pellets (paragraph 0009 and others). This prior art is characterized by requiring a large amount of heat for volume reduction and finally pelletizing. Therefore, it can be applied to products that can absorb the cost, but it should be improved from the viewpoint of reusing the so-called used tile carpet as raw material without separating it into fiber and resin and fixing it as an industry. There is a point.

In Patent Document 4, a surface material composed of a fiber material and a floor covering waste material composed of a reinforcing layer containing a vinyl chloride resin are applied to a pulverizer, and the size of the reinforcing layer becomes an average diameter of 10 mm or less. Molded body made from floor covering waste material as a pulverized piece, then fused and integrated only by heating at 155 to 240 ° C. and pressure operation at 5 to 50 kg / cm ² , and then cooled to form a molded body The manufacturing method of the molded object which uses the floor covering waste material which adjusts the density of the said molded object by adjusting the pressurizing force in the said pressurization operation as a raw material is described.

  In the method described in Patent Document 4, a backing of a so-called backing carpet and a textile product made of a woven fabric, a knitted fabric, or a nonwoven fabric bonded and integrated with the backing are directly placed in a predetermined manner without separating the backing and the textile product. The pulverized product cut into a size is heated and pressurized as it is, heat-fused and solidified to be formed into a board. Accordingly, since the heat-sealed backing and the fiber product remain exposed on the surface of the manufactured board, the impression as a product is lowered and the application is extremely limited.

JP 2006-37274 A Japanese Patent Laid-Open No. 7-32520 JP 2008-196213 A Japanese Patent No. 3707022

  In recent years, with the improvement of living conditions, carpets with backing have been used on floors for automobile floor mats, various buildings, hotels, hospitals, collective / detached houses, various public facilities, etc. . At the same time, the amount of used backing carpet has increased, and its disposal or reuse has become a national project.

  As described in the above-mentioned patent document, as a method for reprocessing a used backing carpet, if the cost of the end use can be sufficiently absorbed, the used backing carpet is bonded to the backing and the backing. There is a method of separating into a textile product made of woven fabric, knitted fabric, or non-woven fabric, and pulverizing or further heating and melting into pellets. However, depending on the use of the final product, the cost may not be absorbed by the method described in the aforementioned patent document. For example, the case may be a case where a used carpet with a backing is reused and a floor surface unevenness adjusting material, or a product that does not require a so severe finished state, a so-called product image.

  Therefore, the main problem to be solved by the invention is to use a crushed product obtained by pulverizing a used backing carpet with a predetermined size as a raw material without separating it into a backing and a textile product. It can be used as a self-contained product by adhering a part of the pulverized product without requiring excessive energy in addition to the amount of heat sufficient to melt polyvinyl chloride, such as polyvinyl chloride. It is to be molded into a recycled sheet.

The above problems are solved by the means described in the following items.
1. Backed carpets made of unvulcanized rubber or thermoplastic synthetic backings and textiles made of woven, knitted or non-woven fabric bonded and integrated with the backing, without separating the backing and textiles A recycled sheet in which a pulverized product cut into a predetermined size as it is is randomly disposed between two upper and lower thermoplastic synthetic resin films to maintain a predetermined shape,
That the backing of the pulverized product and the thermoplastic synthetic resin film are thermally fused together,
The fibers of the textile product are embedded in a thermoplastic synthetic resin film without melting,
Adjacently, the backings of the adjacent pulverized material interposed between the two upper and lower thermoplastic synthetic resin films are thermally fused together, and the upper and lower two thermoplastic synthetic resin films are disordered. Recycled sheets in which the fibers of the pulverized carpet intervening in each other are entangled with each other to maintain the overall shape.

2. In the above item 1, the backing carpet is a defective product, a cut piece, or a used one generated in the manufacturing process of the backing carpet.

3. A flooring material comprising the recycled sheet according to item 1 or 2 as a constituent material.

4). Backed carpets made of unvulcanized rubber or thermoplastic synthetic backings and textiles made of woven, knitted or non-woven fabric bonded and integrated with the backing, without separating the backing and textiles A process of producing a pulverized product by cutting into a predetermined size as it is,
Sprinkling a predetermined amount of the pulverized product on a lower mold comprising two upper and lower parts;
Placing a thermoplastic synthetic resin film on the surface of the dispersed pulverized product,
A first heating step of heating from above the thermoplastic synthetic resin film,
A first pressurizing step of forming a preform by pressing with a mold on cooling;
Reversing the preform,
Placing a thermoplastic synthetic resin film on the inverted preform;
A second heating step of heating from above the thermoplastic synthetic resin film,
And a second pressurizing step of forming a recycled sheet by pressing with a cooling upper mold.

5. In the above item 4, it is assumed that the backing carpet is a defective product, a cut piece, or a used one that has been generated in the manufacturing process of the backing carpet.

6). 6. In the above 4 or 5, the first heating step and the second heating step are carried out at a surface temperature of about 190 ° C. for 15 to 30 seconds, and the first pressurizing step and the second pressurizing step at 2 to 5 kg / cm ² . Perform for 5-10 seconds.

7). A backing carpet composed of a backing made of rubber or thermoplastic synthetic resin and a textile product made of woven fabric, knitted fabric, or nonwoven fabric bonded and integrated to the backing, and without being separated from the backing and the textile product. Cutting the size into a pulverized product,
Extending the thermoplastic synthetic resin film on the endless belt;
Spraying a predetermined amount of the pulverized product on a thermoplastic synthetic resin film;
A step of placing a thermoplastic synthetic resin film on the crushed material,
And a step of intermittently heating and pressing the thermoplastic synthetic resin film placed above from the top and bottom.

8). In the item 7, the backing carpet is a defective product, a cut piece, or a used one generated in the manufacturing process of the backing carpet.

  According to the first aspect of the present invention, the carpet with backing is not separated into the backing and the textile product, but only the pulverized product is crushed to a predetermined size as it is between the two upper and lower thermoplastic synthetic resin films. The crushed material backing and the thermoplastic synthetic resin film are heat-sealed, and the pulverized product fibers are not melted and are embedded in the thermoplastic synthetic resin film, The backings of the adjacent pulverized products interspersed randomly between the plastic synthetic resin films are thermally fused together, and the pulverized products interspersed randomly between the upper and lower thermoplastic synthetic resin films The carpet fibers can be entangled with each other to produce a recycled sheet that retains its overall shape. Accordingly, since no raw materials are required other than the pulverized product obtained by pulverizing the backing carpet as it is and the thermoplastic synthetic resin film, the raw material costs are reduced. Moreover, since the pulverized product obtained by pulverizing the carpet with backing is used as it is, the amount of energy to be dropped is reduced as compared with the conventional technique in which the backing and the fiber product are separated and heated and melted to form pellets. . This recycled sheet can be used as a constituent material when manufacturing a self-contained floor material as it is, for example, a non-land surface adjusting material or a new floor material.

  According to the invention described in claim 2, in the invention described in claim 1, a carpet with a backing, a defective product, a cut piece, or a used product generated in the manufacturing process of a textile product with a backing is used as an unnecessary cost as much as possible. Therefore, in combination with the effect of the invention described in claim 1, the possibility of fixing reuse (recycling) of the carpet with the used backing as an industry is expanded.

  According to the invention described in claim 3, a floor material including the recycled sheet described in claim 1 or 2 as a constituent material is manufactured. That is, for example, a new tile carpet as a structure comprising a lower layer sheet + recycled sheet + paste + fabric, knitted fabric, or nonwoven fabric described in claim 1 or 2, or a lower sheet + claim 1 or 2 A new resin tile, for example, a vinyl chloride tile, can be used as the structure comprising the surface layer of the thermoplastic synthetic resin such as the recycled sheet + intermediate layer + vinyl chloride described in 1). In this case, by appropriately selecting the thickness of the recycled sheet according to claim 1 or 2, it becomes possible to freely set the total thickness as the flooring material, and the range of reuse of the recycled sheet is expanded. Is done.

  According to the invention described in claim 4, a backing carpet comprising a backing made of unvulcanized rubber or thermoplastic synthetic resin and a textile product made of woven fabric, knitted fabric or nonwoven fabric bonded and integrated with the backing, Only the pulverized material cut into a predetermined size without separating the backing and the textile product is interposed in the upper and lower thermoplastic synthetic resin films, and the backing and the thermoplastic synthetic resin film are merely fused. A backing carpet can be formed into a recycled sheet of a predetermined shape in a simple manner and with a minimum amount of energy.

  According to the invention described in claim 5, in the invention described in claim 4, the carpet with the backing is a defective product, a cut piece, or a used one generated in the manufacturing process of the carpet with the backing, and the unnecessary cost is reduced as much as possible. Since it is used as it is without being applied, in combination with the effect of the invention described in claim 4, the possibility of fixing reuse (recycling) of the carpet with the used backing as an industry is expanded.

According to the invention described in claim 6, in the invention described in claim 4 or 5, the first heating process and the second heating process are performed at a surface temperature of about 190 ° C. for 15 to 30 seconds, the first pressurizing process and the first heating process. since the 2 pressing step carried out in 2~5kg / cm ² 5~10 seconds, either be a refurbished maintaining the texture without melting the fibers of the carpet.

  According to the method described in claim 7, since the recycled sheet can be produced endlessly, mass production is possible as compared with a method of producing a recycled sheet of a predetermined shape by a press die one by one, It can be cut into an arbitrary shape, and the use of the manufactured recycled sheet is expected to be expanded.

  According to the invention described in claim 8, in the invention described in claim 7, the carpet with the backing is made defective, cut, or used in the manufacturing process of the carpet with the backing, and the unnecessary cost is reduced as much as possible. Since it is used as it is without being applied, in combination with the effect of the invention described in claim 7, the possibility of fixing reuse (recycling) of used backing carpet as an industry is expanded.

It is an enlarged pictorial diagram for demonstrating the internal structure of the recycling sheet by Example 1 and 2 of this invention. 6 is a sectional view showing an internal structure of Example 3. FIG. 7 is a cross-sectional view showing an internal structure of Example 4. FIG.

  Embodiments will be described below with reference to the accompanying drawings.

  FIG. 1 is an enlarged pictorial diagram for explaining the state of the recycled sheet manufactured in Example 1. FIG. Defective items, cut pieces, and used recovered items generated during the manufacturing process are covered with a backing made of polyvinyl chloride (tile carpet) joined to a polyester fiber pile. Without separation, a side was roughly cut into 1 to 10 cm to produce a pulverized product.

  The present invention is not limited to polyvinyl chloride in terms of backing, but can be applied to various thermoplastic resins such as polyester, various synthetic rubbers, ethylene-vinyl acetate copolymer, and olefin. In order to increase the strength of the backing, various reinforcing materials such as glass fiber, carbon fiber, and glass net are mixed in various thermoplastic resins such as polyvinyl chloride, polyester, various synthetic rubbers, ethylene-vinyl acetate copolymer, and olefin. Of course, the present invention is also applicable to such a reinforcing backing.

  Further, the present invention is not limited to nylon with respect to the fibers constituting the pile, and is also applicable to polyester, polypropylene, and the like. Pile textures include cut (plush, velor, saxony, hard twist, shaggy, hair), leap (level loop, multi-level loop / ripple, high-low loop), cut and loop (high-cut low loop, level cut) & Loop), flat (felt type, weave type) and the like. However, in order to achieve the effect of confounding fibers, not only a loop but also a cut, cut & loop type is preferable. The present invention can also be applied to carpets without piles, such as woven carpets, sewn carpets, and compressed carpets.

  The present invention has an essential requirement to produce a pulverized product by roughly cutting a carpet with a backing (tile carpet) into a side of 1 to 10 cm without separating the backing and the pile. However, when practicing the present invention, it is not essential to use a uniform pulverized product having a side of 1 to 10 cm as the pulverized product of the backing carpet. It is not excluded to mix and use the pulverized product. Rather, by using a mixture of a pulverized product having a large size or particle size and a pulverized product having a smaller size, a pulverized product having a small size or particle size is formed in the space formed by the pulverized products having a large size or particle size. Is preferable because it improves the overall strength. In this embodiment, the mixing ratio of the pulverized product having a large size or particle size and one or more pulverized products having a smaller size or particle size is determined by the strength and smoothness of the recycled sheet as the final product. It should be arbitrarily determined in consideration of various physical properties such as fixing strength.

  In addition, in the present invention, when mixing one or two or more kinds of carpets with backings cut into a predetermined size and shape, it is excluded to select and mix appropriately from various additives for plastic and rubber. do not do.

  Further, in the present invention, when mixing one or more kinds of pulverized carpets with backings cut into a predetermined size and shape, spraying a hot melt adhesive improves the overall adhesive strength. This is preferable because the strength of the recycled sheet as the final product is improved.

  A press mold composed of upper and lower molds having a predetermined shape (depth, length, width) that forms a predetermined cavity was prepared. The pulverized material was weighed in advance on the basis of the physical properties of the mold volume and the use of the recycled sheet to be produced, and was uniformly dispersed in the lower mold. In the case of this invention, the kind of metal mold | die is not restrict | limited, Steel or aluminum may be sufficient.

  Next, a film made of polyvinyl chloride was placed on the surface of the pulverized material that was spread. Then, in the first heating step, the film was heated for 15 seconds with a heater set so that the surface temperature of the film was 190 ° C. In the case of the present invention, the heating temperature and time in the primary heating step are not limited to 190 ° C. and 15 seconds. That is, the heating temperature can be arbitrarily set in the range of 190 ° C. ± 10 ° C. and the heating time in the range of 15 to 30 seconds. However, if the heating temperature and the heating time are exceeded, the texture of the pile fibers is broken, which is not preferable.

Next, in the first pressurizing step, a molded product was manufactured by pressurizing with a mold on cooling at a unit pressure of 2 kg / cm ² for 5 seconds. In the case of the present invention, the unit pressure and pressurization time in the first pressurization step are not limited to ² kg / cm ² and 5 seconds. That is, the unit pressure can be arbitrarily set in the range of ^{2 to} 5 kg / cm ² and the pressurization time in the range of 5 to 10 seconds. However, if the unit pressure and pressurization time range are exceeded, the texture of the pile fibers is broken, which is not preferable.

  The manufactured molded article was inverted, and a film made of polyvinyl chloride was placed on the surface. Then, in the secondary heating step, the film was heated for 15 seconds with a heater set so that the surface temperature of the film was 190 ° C. In the case of the present invention, the heating temperature and time in the secondary heating step are not limited to 190 ° C. and 15 seconds. That is, the heating temperature can be arbitrarily set in the range of 190 ° C. ± 10 ° C. and the heating time in the range of 15 to 30 seconds. However, if the heating temperature and the heating time are exceeded, the texture of the pile fibers is broken, which is not preferable.

Next, in the second pressurizing step, a molded product was produced by pressurizing with a mold on cooling at a unit pressure of 2 kg / cm ² for 5 seconds. In the case of the present invention, the unit pressure and pressurization time in the second pressurization step are not limited to ² kg / cm ² and 5 seconds. That is, the unit pressure can be arbitrarily set in the range of ^{2 to} 5 kg / cm ² and the pressurization time in the range of 5 to 10 seconds. However, if the unit pressure and pressurization time range are exceeded, the texture of the pile fibers is broken, which is not preferable.

  In the final process, it was cut into an arbitrary shape according to the product standard.

A calendar molding machine is prepared as a continuous heating and pressure molding machine, which is placed on an endless belt, and a polyvinyl chloride film is placed on the endless belt, with the same backing as used in Example 1. Based on the physical properties of the recycled sheet to be produced, the pulverized carpet was pre-weighed and uniformly dispersed, and a polyvinyl chloride film was placed thereon. Then, by a roll, the surface temperature of the vertical film was heated for 15 seconds so that the 190 ° C., in the unit pressure 2 kg / cm ^2, pressurized 5 seconds. This heating and pressurizing process was repeated intermittently to produce an endless recycled sheet.

In the method in Example 2, the heating temperature, pressure, and time are not limited to 190 ° C., unit pressure 2 kg / cm ² , and 5 seconds. The heating temperature is 190 ° C. ± 10 ° C., the unit pressure is 2 to 5 kg / cm ² , and the heating time can be arbitrarily set within the range of 15 to 30 seconds. However, if the heating temperature and the heating time are exceeded, the texture of the pile fibers is broken, which is not preferable.

  With reference to FIG. 1, the internal structure of the recycled sheet manufactured in Examples 1 and 2 will be described. FIG. 1 is a partly enlarged and emphasized representation for explaining the internal structure of the recycled sheet produced in Examples 1 and 2, and shows the pulverized products 2, 5, 8, 11, 14, 17 The shape, number and spacing of the backings 3, 6, 9, 12, 15, 18 etc. and the shape, number, spacing, etc. of the pile fibers 4, 7, 10, 13, 16, 19 are not accurate.

  Reference numerals 2, 5, 8, 11, 14, and 17 are pulverized products obtained by cutting a used carpet with a backing (tile carpet) into a cube having a side of 1 to 10 cm. Each pulverized product 2, 5, 8, 11, 14, and 17 is composed of backings 3, 6, 9, 12, 15, and 18, and pile fibers 4, 7, 10, 13, 16, and 19, respectively. . For example, the pulverized product 2 is from the backing 3 and the pile fiber 4, the pulverized product 5 is from the backing 6 and the pile fiber 7, the pulverized product 8 is from the backing 9 and the pile fiber 10, and the pulverized product 11 is from the backing 12 and the pile fiber 13. The pulverized product 14 includes a backing 15 and pile fibers 16, and the pulverized product 17 includes a backing 18 and pile fibers 19. That is, all the pulverized products are provided with a backing and pile fibers.

  The pulverized product 2 is thermally fused with the polyvinyl chloride film 1 whose backing 3 is a thermoplastic synthetic resin. The pile fiber 7 of the pulverized product 5 is entangled with the pile fiber 4 of the pulverized product 2. The backing 6 of the pulverized product 5 is heat-sealed with the backing 9 of the pulverized product 8. A part of the pile fiber 13 of the pulverized material 11 is embedded in the polyvinyl chloride film 1. A part of the pile fiber 16 of the pulverized product 14 is embedded in the backing 12 of the pulverized product 11. The backing 18 of the pulverized material 17 is heat-sealed to the polyvinyl chloride film 1 '.

  Since the actual recycled sheet is filled between the two upper and lower thermoplastic synthetic resin films 1 and 1 ′, the pulverized product is in contact with the two upper and lower thermoplastic synthetic resin films 1 and 1 ′. The backing fiber is heat-sealed with the upper or lower thermoplastic synthetic resin film 1 or 1 ', and the pile fiber of the pulverized material in contact with the upper and lower thermoplastic synthetic resin films 1 and 1' is A part of the film is embedded in the thermoplastic synthetic resin film 1 or 1 ′, and is not in contact with any of the upper and lower thermoplastic synthetic resin films 1 and 1 ′. The adjacent pulverized material backings are heat-sealed, and the adjacent pulverized pile fibers are entangled in any of the left, right, upper and lower positions. In this way, the backing of all the pulverized products, either the upper or lower two thermoplastic synthetic resin films, or the adjacent crushed product backings are heat-sealed, and the pile fibers of the pulverized products are It is embedded in one of the two upper and lower thermoplastic synthetic resin films, or a part of the pile fiber of the adjacent pulverized material is embedded and fixed in the backing, and maintains a predetermined shape as a whole. become.

  The recycled sheets produced in Examples 1 and 2 had a delamination strength of 100 N / 50 mm or more, and it was confirmed that the recycled sheets were sufficiently adhered to the upper and lower thermoplastic resin films.

  FIG. 2 is a cross-sectional view of a tile carpet 20 newly manufactured using the recycled sheet manufactured in Example 1 as a constituent material. In FIG. 2, 21 is a lower layer sheet, 22 is a recycled sheet produced in Example 1, 23 is a vinyl chloride paste, and 24 is a carpet. In addition, since the manufacturing method of the tile carpet 20 of Example 3 is a conventionally well-known method, the detail is omitted.

  The lower layer sheet 21 includes a thermoplastic resin sheet such as polyvinyl chloride, polyolefin, polyester, and thermoplastic elastomer (TPE) having a thickness of 0.5 to 2 mm, and a nonwoven fabric made of thermoplastic fibers having a thickness of 0.05 to 1.0 mm. Is arbitrarily selected in consideration of the thickness, physical properties, use, etc. of the final product. The thickness of the recycled sheet 22 is arbitrarily selected in the range of 0.5 to 5.0 mm in consideration of the thickness, physical properties, usage, etc. of the final product. When two layers of the vinyl chloride paste 23 are applied, the thickness of the first paste layer is arbitrarily selected within a range of 1 to 3 mm, and the thickness of the second paste layer is arbitrarily selected within a range of 1 to 3 mm. When the vinyl chloride paste 23 is applied as a single layer, it is arbitrarily selected within a range of 1 to 5 mm.

  The carpet 24 is obtained by adhering the above-described backing to a carpet having a pile or a carpet having no pile. Pile carpet textures include cut (plush, velor, saxony, hard twist, shaggy, hair), leap (level loop, multi-level loop / ripple, high-low loop), cut and loop (high cut low loop, level cut & Loop), flat (felt type, weave type) and the like are not particularly limited. Further, examples of the carpet without a pile include a woven carpet, a sewn carpet, and a compressed carpet.

  FIG. 3 is a cross-sectional view of a so-called vinyl chloride tile 23 newly manufactured using the recycled sheet manufactured in Example 1 as a constituent material. In FIG. 3, 26 is a lower layer sheet, 22 is a recycled sheet produced in Example 1, 27 is an intermediate layer, and 28 is a surface layer.

  The lower layer sheet 26 is made of a thermoplastic resin sheet such as polyvinyl chloride, polyolefin, polyester, and thermoplastic elastomer (TPE) having a thickness of 0.5 to 2 mm, and a nonwoven fabric made of thermoplastic fibers having a thickness of 0.05 to 1.0 mm. Is arbitrarily selected in consideration of the thickness, physical properties, use, etc. of the final product. The thickness of the recycled sheet 22 is arbitrarily selected in the range of 0.5 to 5.0 mm in consideration of the thickness, physical properties, usage, etc. of the final product. The thickness of the intermediate layer 27 is arbitrarily selected within the range of 0.5 to 3.0 mm. The surface layer 28 is a thermoplastic resin sheet such as polyvinyl chloride, polyolefin, polyester, and thermoplastic elastomer (TPE) having a thickness of 0.1 to 1.0 mm.

  In addition, between the surface layer 28 and the intermediate | middle layer 27, gravure printing was carried out on thermoplastic resin sheets, such as polyvinyl chloride, polyolefin, polyester, thermoplastic elastomer (TPE) of thickness 0.08-0.3 mm, if desired. It is preferable to interpose a design layer (design film).

  In Example 3, the recycled sheet of the present invention is used as a constituent material for tile carpets, and in Example 4 as a constituent material for vinyl chloride tiles. The advantage of using the recycled sheet of the present invention as a constituent material for tile carpets or vinyl chloride tiles is that the thickness of the recycled sheet, which is relatively low in production cost, is adjusted to increase the cost of the recycled sheet. It is possible to adjust the total thickness of the tile carpet or the vinyl chloride tile by reducing the amount of the constituent material used, thereby reducing the production cost of the tile carpet or the vinyl chloride tile.

The recycled sheet of the present invention has industrial applicability exemplified below.
1. Backing the crushed material and thermoplasticity by interposing between the upper and lower thermoplastic synthetic resin films only the pulverized product that has been pulverized into a predetermined size without separating the carpet with backing into the backing and textile products. The synthetic resin film is heat-sealed, and the fibers of the pulverized product are not melted but are embedded in the thermoplastic synthetic resin film, and the two layers of the thermoplastic synthetic resin film are disordered. Adjacent crushed backings that are interposed between the two are fused together, and the fibers of the crushed carpet that are randomly placed between the two upper and lower thermoplastic synthetic resin films are entangled with each other. Recycled sheets that retain their shape as a whole can be manufactured, and raw materials other than pulverized products and thermoplastic synthetic resin films obtained by pulverizing carpets with backing as they are The cost of raw materials is reduced, and since the pulverized product obtained by pulverizing the backing carpet is used as it is, the backing and the fiber product are separated and heated and melted to form pellets. The amount of energy to be dropped is reduced compared to technology. Therefore, the possibility of fixing as an industry that reuses (recycles) defective products, cut pieces, or used products generated in the manufacturing process of the carpet with backing is expanded.

2. Only a pulverized product obtained by cutting a carpet with a backing into a predetermined size without separating the backing and the textile product is interposed between two upper and lower thermoplastic synthetic resin films. It can be formed into a recycled sheet having a predetermined shape by the method. Therefore, the possibility of fixing as an industry that reuses (recycles) defective products, cut pieces, or used products generated in the manufacturing process of the carpet with backing is expanded.

3. Since the first heating step and the second heating step are performed at a surface temperature of about 190 ° C. for 15 to 30 seconds, and the first pressing step and the second pressing step are performed at 2 to 5 kg / cm ² for 5 to 10 seconds. However, it is possible to obtain a recycled product that maintains the texture without melting the fibers of the carpet. Therefore, a product having various physical properties can be manufactured by appropriately selecting the conditions of the first heating process, the second heating process, the first pressing process, and the second pressing process in the manufacturing process. Therefore, the possibility of fixing as an industry that reuses (recycles) defective products, cut pieces, or used products generated in the manufacturing process of the carpet with backing is expanded.

  The recycled sheet of the present invention can be used as a self-contained flooring material itself, for example, as a non-land surface adjusting material, or as a constituent material for manufacturing a flooring material. Vinyl chloride tiles can be manufactured. The advantage of using the recycled sheet of the present invention as a constituent material for tile carpets or vinyl chloride tiles is that the thickness of the recycled sheet, which is relatively low in production cost, is adjusted to increase the cost of the recycled sheet. It is possible to adjust the total thickness of tile carpets or vinyl chloride tiles by reducing the amount of constituent materials used, thereby reducing the production cost of tile carpets or vinyl chloride tiles and establishing as a recycling industry The possibility of making it expand.

1, 1 'thermoplastic synthetic resin film 2, 5, 8, 11, 14, 17 ground product 3, 6, 9, 12, 15, 18 backing 4, 7, 10, 13, 16, 19 pile fiber 20 tile Carpet 21 Lower layer sheet 22 Recycled sheet 23 Paste 24 Carpet 25 Vinyl chloride tile 26 Lower layer sheet 27 Intermediate layer 28 Surface layer

Claims (8)

Backed carpets made of unvulcanized rubber or thermoplastic synthetic backings and textiles made of woven, knitted or non-woven fabric bonded and integrated with the backing, without separating the backing and textiles A recycled sheet in which a pulverized product cut into a predetermined size as it is is randomly disposed between two upper and lower thermoplastic synthetic resin films to maintain a predetermined shape,
That the backing of the pulverized product and the thermoplastic synthetic resin film are thermally fused together,
The fibers of the textile product are embedded in a thermoplastic synthetic resin film without melting,
Adjacently, the backings of the adjacent pulverized material interposed between the two upper and lower thermoplastic synthetic resin films are thermally fused together, and the upper and lower two thermoplastic synthetic resin films are disordered. Recycled sheets in which the fibers of the pulverized fiber product intervened in the fabric are entangled with each other to maintain the overall shape. The recycled sheet according to claim 1, wherein the carpet with backing is a defective product, a cut piece, or a used one generated in the manufacturing process of the carpet with backing. A flooring comprising the recycled sheet according to claim 1 or 2 as a constituent material. Backed carpets made of unvulcanized rubber or thermoplastic synthetic backings and textiles made of woven, knitted or non-woven fabric bonded and integrated with the backing, without separating the backing and textiles A process of producing a pulverized product by cutting into a predetermined size as it is,
Sprinkling a predetermined amount of the pulverized product on a lower mold comprising two upper and lower parts;
Placing a thermoplastic synthetic resin film on the surface of the dispersed pulverized product,
A first heating step of heating from above the thermoplastic synthetic resin film,
A first pressurizing step of forming a preform by pressing with a mold on cooling;
Reversing the preform,
Placing a thermoplastic synthetic resin film on the inverted preform;
A second heating step of heating from above the thermoplastic synthetic resin film,
And a second pressurizing step of forming a recycled sheet by pressing with a cooling upper mold. The method according to claim 4, wherein the backing carpet is a defective product, a cut piece, or a used one generated in the manufacturing process of the backing carpet. The first heating step and the second heating step are performed at a surface temperature of about 190 ° C for 15 to 30 seconds, and the first pressurizing step and the second pressurizing step are performed at 2 to 5 kg / cm ² for 5 to 10 seconds. 4. The method described in 4 or 5. Backed carpets made of unvulcanized rubber or thermoplastic synthetic backings and textiles made of woven, knitted or non-woven fabric bonded and integrated with the backing, without separating the backing and textiles A process of producing a pulverized product by cutting into a predetermined size as it is,
Extending the thermoplastic synthetic resin film on the endless belt;
Spraying a predetermined amount of the pulverized product on a thermoplastic synthetic resin film;
A step of placing a thermoplastic synthetic resin film on the crushed material,
And a step of intermittently heating and pressing the thermoplastic synthetic resin film placed above from the top and bottom. The method according to claim 7, wherein the backing carpet is defective, cut or used in the manufacturing process of the backing carpet.

Images