JP2957953B2 - Insulation board for tatami floor and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to an insulation board for tatami floors and a method for producing the same. More particularly, the present invention relates to a high quality insulation board for tatami floors, which is useful for treating industrial wastes, and a method for producing the same.

[0002]

2. Description of the Related Art FIG. 3 is a cross-sectional view of a conventional tatami floor. An insulation board 51 has a polystyrene foam 52 sandwiched between two insulation boards 51. 53 is a tatami table. The insulation board 51 is a T-class insulation board specified in JIS, and is made of wood made into chips. The polystyrene foam 52 is formed by foaming a polystyrene resin into a board.

[0003]

However, the insulation board 51 in the above-mentioned conventional example maintains the restoring force (cushion) by reducing the pressure when it is formed into a board. In addition, there is a problem in that when the house is cut into a floor plan, even if the blade is cut even a little, it is chipped or loses its shape. In addition, there is also a problem that the re-use cannot be performed since the edge of the board is broken and the edge of the board is broken when the table is replaced. In spite of the above-mentioned problems, the current situation is that there is no straw or no sticky board so that it is constantly used today.

[0004] On the other hand, there are the following problems of industrial waste treatment. 2. Description of the Related Art In recent years, the production of disposable diapers and sanitary articles has been increasing, and these use polyethylene films as exterior materials, nonwoven fabrics and paper pulp as interior and absorbent materials, and use rubber cords and the like in some of them. Normally, these are mass-produced by an automatic production line, but sometimes scraps that cannot be sold as a product occur due to line failure or the like.
These sanitary products are now in substantial quantities,
Some factories produce a few tons of waste per month. However, waste products such as garbage and polyethylene emit black smoke when incinerated and cause pollution, so they are stored in warehouses, but there is no proper treatment method, so the storage space is in short supply.

[0005] Further, polystyrene foam 52 used for tatami floors may be incinerated when it is old, but generates high heat during incineration and damages the incinerator or emits black smoke and pollutes the environment. . In addition, there is also a problem in terms of location when discarded as waste, which is inconvenient in terms of social environment.

SUMMARY OF THE INVENTION In view of the above circumstances, an object of the present invention is to provide an easy-to-use and reusable insulation board for tatami floors while solving the problems of waste disposal and social environment.

[0007]

According to a first aspect of the present invention, there is provided an insulation board for a tatami floor, comprising a foam of polyethylene foam and wood sludge as main components , and a shrinkage of the board on an outer surface of the board mixed with an adhesive. Enough strength to prevent
Characterized in that the non-woven fabric is bonded by The insulation board for a tatami floor according to claim 2, wherein the outer surface of the board is mainly composed of a powder of garbage waste and a paper-made wood sludge, which are mainly made of polyethylene, nonwoven fabric and paper pulp, and is mixed with an adhesive for a tatami floor. Strong enough to prevent shrinkage of the board
It is characterized in that the non-woven fabric is bonded by the degree . The method for producing an insulation board for a tatami floor according to claim 3 is a first step of pulverizing a polystyrene foam, or a waste product of a physiological product mainly composed of polyethylene, nonwoven fabric, and paper pipe, mixing an adhesive with the pulverized product, and defibrating. And a second step in which the papermaking wood sludge is defibrated and the primary raw material obtained in the first step is kneaded with the second raw material, and the secondary raw material obtained in the second step is formed and dried to form a board. A third step of producing a semi-finished product, and pressing the board-like semi-finished product obtained in the third step and applying the board
And a fourth step of bonding the nonwoven fabric with sufficient strength to prevent shrinkage of the nonwoven fabric.

[0008]

Next, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a block diagram of a manufacturing method according to the present invention. As a raw material of the insulation board of the present invention, a polystyrene foam is used in the invention of claim 1, and a waste product of a physiological product is used in the invention of claim 2.

When using polystyrene foam as a raw material,
In a first step I, the polystyrene foam waste is pulverized in water with a beater to a powder of about 2 mm or less. In addition, it is good to use what was used for the tatami which discards polystyrene foam waste. By doing so, the problem of waste disposal can also be solved. Further, the waste of the poly-based resin may be ground together with the polystyrene foam and used as a raw material.

[0010] In the case where physiological wastes are used as raw materials, in the first step I, wastes of physiological products mainly composed of polyethylene, nonwoven fabric and paper pulp are ground. As mentioned above, sanitary products such as disposable diapers and sanitary products are stored in large quantities near a sanitary product factory today, and they are roughly cut and sieved. Thereby, the absorbing polymer which is a chemical substance mixed as the absorbing agent is removed. Since the waste of the physiological product after removing the polymer is mainly composed of polyethylene film, non-woven fabric and paper pulp, these are pulverized in water by a beater to obtain powder of about 2 mm or less.

Next, in both cases where the raw material is a polystyrene foam or a physiological product,
Fibers such as polypropylene, rayon, ester, cotton, and hemp are mixed and defibrated until the length is about 10 to 20 mm. In this way, in the first step I, a primary raw material in which powder of polystyrene foam waste or powder of physiological product waste and rectangular fiber of the adhesive are mixed is produced.

The second step II is carried out simultaneously with the first step I by using another pulper. First, papermaking sludge or woody sludge is defibrated with a pulper, and when the defibration is appropriately performed, the primary raw material is charged and mixed. At the same time, a suitable amount of a water-resistant agent such as a wax emulsion is added. When the fibers are sufficiently defibrated in this manner, a semi-fluid secondary material is produced in which the powder of polystyrene foam waste or the powder of physiological product waste, the rectangular fiber of the adhesive and the sludge fiber are mixed and entangled with each other. .

Next, in a third step III, the secondary raw material is made into a paper and dried with a drier to reduce the water content to 10% or less to produce a board-shaped semi-finished product.

Next, in a fourth step, a nonwoven fabric is bonded to the outer surface (for example, on both front and back surfaces) of the board-shaped semifinished product. As the nonwoven fabric used here, there is a nonwoven fabric made of polypropylene, polyester, nylon, vinylon, acrylic, polyethylene, rayon, cupra, or the like, and is used without any particular limitation. There is an advantage that press bonding is easy underneath. As a method of joining nonwoven fabric,
Arbitrary methods such as bonding with an adhesive, heat sealing by heating and pressing, and fusion by heating with hot air can be appropriately adopted. As described above, the nonwoven fabric may be bonded not only to the front and back surfaces but also to either the front surface or the back surface. However, bonding to the front and back surfaces increases the bending strength of the board and increases the shrinkage prevention effect described later.

In the fourth step, the pressure-sensitive adhesive is dissolved by applying pressure under heating. As a result, the adhesive is well bonded between the powder and the fiber of the board material, and the adhesiveness is improved. The heating and pressurizing may be performed also as the fusion work of the nonwoven fabric, or may be performed as a separate step in the former stage or the latter stage.

At the time of cooling after the heat molding in the above process, a shrinkage phenomenon in which the board shrinks occurs and the dimensions are out of order. Therefore, conventionally, cutting had to be performed in advance in anticipation of this. Since the nonwoven fabric previously attached to the board surface resists the shrinking action, there is an advantage that the shrinkage phenomenon hardly occurs. Further, there is an advantage that the difference in the thickness of the board caused by the heating in the manufacturing process can be eliminated.

When the above operations are completed, the pieces are cut into prescribed dimensions of 1 m × 2 m. As a result, an insulation board according to the present invention is completed. in this case,
For the reasons mentioned above, the finished dimensions of the insulation board are accurate and the thickness is uniform.

Among the components of the insulation board manufactured by the above-described method, sludge has a function of solidifying the powder of the physiological product waste. Polystyrene foam debris and sanitary debris serve as a bulking agent, reduce the excessive solidification properties inherent in sludge, and provide cushioning properties due to the inherent restoring force of nonwovens and paper pulp. This has the effect of improving the touch of the tatami mat. The adhesive imparts to the board, which is a combination of sludge, which is the main component, and garbage powder, physiological properties, a strong tenacity against impact and bending, a sharp cutting edge, a stiffness of the board, and a high bending restoring force. 20-80% of polystyrene foam waste and garbage products
Particularly, it is preferably around 50%. If it is less than 20%, a large amount of sludge must be used and the problem of industrial waste disposal cannot be solved. If it exceeds 80%, it becomes difficult to maintain the shape as a board.

[0019]

EXAMPLE Insulation manufactured by the above method
An example of a board (one using waste products) is shown.
It is shown in FIG. In addition, the raw material ratio shown in Table 1 is width 1m, length
2m, 15mm thick board, total weight
Approximately 12.5-13 kg. Table 1 Raw material weight (kg) Weight ratio (%)  Sludge (paper, wood, etc.) 1.014 8 Refuse powder for physiological products 11.000 87 Adhesive 0.486 3.9 Non-woven fabric 0.120 1.1Suitable amount of waterproofing agent −

Next, the following performance tests were performed on the insulation boards of the present embodiment described in Table 1 above. (a) Local compression test A press-fit rod having a diameter of 25 mm was placed on an insulation board as a test piece, a load of 20 kgf was applied, and a displacement after 30 seconds of loading was measured. The measured value is the maximum value at any three locations.
The smaller the measured value, the better the strength. (b) Bending strength test A bending test was performed according to the test method (6.4) specified in JIS A5905. The distance between the fulcrums is 150 mm. The larger the measured value, the better the strength. (c) Moisture content test A moisture content test was performed according to the test method (6.3) specified in JIS A5905. It is preferable that the measured value is lower because it gives a dry feeling. (d) Density test A density test was performed according to the test method (6.2) specified in JIS A5905.

Table 2 shows the results of the above tests. * 1 in the comparative example is the conventional insulation board 51.
* 2-4 are JIS A5905 (5.
This is the quality condition of the Class B insulation board specified in 3).

Table 2 This example Comparative example  Local compression test 0.54mm 4mm * 1 Flexural strength test 17.3kgf / cm^Two 6kgf / cm^Two * 2 Moisture content test 5.6% 6-10% * 3Density test 0.44 g / cm ^Two 0.40 g / cm ^Two * 4

As shown in Table 2 above, the insulation board of this embodiment has a good result of the local compression test, and has a bending strength several times that of the JIS standard.
Further, the water content and the density are better than the JIS standard values. Therefore, it can be judged that the insulation board of the present invention has higher quality than the conventional insulation board when viewed comprehensively. The degree of the cushioning property and the tenacity varies depending on the mixing ratio of the main component. Therefore, the mixing ratio may be changed as appropriate to obtain a board that emphasizes the cushioning property or a board that emphasizes the tenacity.

FIG. 2 shows a sectional structure of a tatami mat using the above-mentioned insulation board. 1 is an insulation board of this embodiment, 2 is a polystyrene foam, 3
Is a tatami table. If the tatami mat has such a structure, the discarded physiological product scraps and polystyrene foam can be regenerated as the insulation board 1, which contributes to resource saving and pollution prevention. In addition, an insulation board having an accurate finish size and a uniform thickness can be obtained.

[0025]

According to the present invention, it is possible to provide an insulation board having a uniform thickness without causing any shrinkage in size while preventing environmental pollution while preventing pollution. .

[Brief description of the drawings]

FIG. 1 is a block diagram showing a method for manufacturing an insulation board according to the present invention.

FIG. 2 is a sectional view of a tatami mat using an insulation board according to one embodiment of the present invention.

FIG. 3 is a sectional view of a conventional tatami mat.

[Explanation of symbols]

 1 Insulation board 2 Polystyrene foam 3 Tatami table

Claims (3)

(57) [Claims] 1. A nonwoven fabric comprising a polyethylene foam powder and a papermaking wood sludge as main components, and a nonwoven fabric bonded to an outer surface of a board mixed with an adhesive with sufficient strength to prevent shrinkage of the board. Insulation board for tatami floor. 2. The outer surface of a board mainly containing polyethylene, nonwoven fabric and paper pulp, a powder of a sanitary product waste and papermaking wood sludge, and containing an adhesive for a tatami floor .
An insulation board for a tatami floor , wherein a nonwoven fabric is joined with sufficient strength to prevent shrinkage of the board. 3. A first step of pulverizing a polystyrene foam or a waste product of a physiological product mainly composed of polyethylene, non-woven fabric, and paper pipe, mixing it with an adhesive, and defibrating the pulp; A second step in which the primary material obtained in the first step is kneaded, a second step in which the secondary material obtained in the second step is formed and dried to produce a board-shaped semi-finished product; Strength sufficient to press the board-like semi-finished product obtained in the third step and prevent the board from shrinking on its outer surface.
In the manufacture of a tatami floor insulation board, characterized by comprising a fourth step of bonding the nonwoven fabric.