JP3707022B2 - Method for producing molded article made of floor covering waste material and molded article thereof - Google Patents
Method for producing molded article made of floor covering waste material and molded article thereof Download PDFInfo
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- JP3707022B2 JP3707022B2 JP31227796A JP31227796A JP3707022B2 JP 3707022 B2 JP3707022 B2 JP 3707022B2 JP 31227796 A JP31227796 A JP 31227796A JP 31227796 A JP31227796 A JP 31227796A JP 3707022 B2 JP3707022 B2 JP 3707022B2
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- molded body
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/62—Plastics recycling; Rubber recycling
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- Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
- Processing Of Solid Wastes (AREA)
Description
【０００１】
【発明の利用分野】
この発明は、種々のカーペットなどの床敷物廃材を原料として有効利用して形成する成形体の製造方法及びその成形体に関する。
【０００２】
【従来の技術】
周知のように、コンクリートや板材などのボード等からなる床の上に敷く床敷物は、一般に表面の繊維質部分と、床面上に接する補強層部分とからなる面材である。このような床敷物としては、ＪＩＳにも規定されているように、織じゅうたん、タフテッドカーペット、タイルカーペットなどの種類が存在する。この床敷物は使用用途によって、長尺に成形したものを巻いておいて使用時に必要な長さに切断して用いたり、タイルカーペットなどのように最初から比較的小形の方形に切断してあるものなどがあるが、とくに、最近は、その利便性から、組み合わせて床に敷いて使用するタイルカーペットが、業務用市場を中心に近年その需要が大幅に増大している。このような床敷物を構成する成分は種類によって異なるが、例えば、タイルカーペットの場合には、繊維部分である上面の毛羽部分と、これを結合する基布、下面の強固な２〜４mmの補強層から構成され、通常、繊維部分としてのナイロンやポリエステルなどが全体の１４重量％以上の割合を占め、基布としてのガラス繊維が１％以上、補強層はバインダー樹脂分として塩化ビニール樹脂、ポリエステル、合成ゴム、オレフィンなどの軟質合成樹脂成分と、炭カルと、そして、フタル酸エステル、アジビン酸エステル、セバシン酸エステルなどの可塑剤とからなり、これが８０重量％以上の割合からなっており、製品の種類によって適宜割合が選択される。補強層の内訳は、バインダー樹脂分が１４〜２３重量％、炭カルが６３〜７０重量％、可塑剤が１４〜１６重量％となっている。
【０００３】
上記のようなタイルカーペットを始めとする床敷物は年々需要が増大しているのであるが、その製造工程において所定の大きさに裁断した時に発生する耳などの床敷物廃材も増加している。又、床敷物の張り替え時に使用済みの床敷物廃材が発生している。このような、製造工程や張り替え時に発生した床敷物廃材の有用な利用方法としては、これらを細かく粉砕して、床敷物の補強層の一部として少量混入する程度の極僅かの利用に留まり、大部分は産業廃棄物として焼却処分、埋め立てしているのが現状である。
【０００４】
【発明が解決しようとする課題】
上記した床敷物廃材を産業廃棄物として焼却処分するにしても、その量が大量であるために、運搬費や、焼却場所に困るという問題点がある。また、焼却に伴う大気汚染が発生するという問題点もある。更に、埋め立て場所がなくなりつつあるという問題点もある。
この発明はこのような事情に鑑みてなされたものであって、従来産業廃棄物として処分に困っていた床敷物廃材を再資源として有効利用することを目的として、床敷物廃材を原料とする成形体の製造方法とその成形体を提案するに至ったものである。
【０００５】
【課題を解決するための手段】
この発明は上記目的を達成する手段として、請求項１乃至１２においては床敷物廃材を原料とする成形体の製造方法を、また、請求項１３乃至２４においてはその成形体を提案するものである。
【０００６】
請求項１は、繊維素材より構成される表面素材と、塩化ビニール樹脂を含有する補強層とで構成される床敷物廃材を粉砕機にかけて、補強層の大きさが平均径１０mm以下となる粉砕片とし、次に、１５５乃至２４０℃の加熱及び５乃至５０Kg／cm2の加圧操作のみによって融着一体化させ、次いで冷却して成形体とする、床敷物廃材を原料とする成形体の製造方法であって、前記加圧操作における加圧力を加減することによって、前記成形体の密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整する、床敷物廃材を原料とする成形体の製造方法である。
請求項２は、前記成形体の熱伝導率が０．１１乃至０．２６ｋｃａｌ／ｍｈｒ℃であるところにある。
請求項３は、繊維素材より構成される表面素材と、塩化ビニール樹脂を含有する補強層とで構成される床敷物廃材を粉砕機にかけて、補強層の大きさが平均径１０ mm 以下となる粉砕片とし、次に、１７５乃至２２０℃の加熱及び１０乃至３０ Kg ／ cm 2 の加圧操作のみによって融着一体化させ、次いで冷却して成形体とする、床敷物廃材を原料とする成形体の製造方法であって、前記加圧操作における加圧力を加減することによって、前記成形体の密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整する、床敷物廃材を原料とする成形体の製造方法である。
請求項４は、繊維素材より構成される表面素材と、塩化ビニール樹脂を含有する補強層とで構成される床敷物廃材を粉砕機にかけて、補強層の大きさが平均径１０ mm 以下となる粉砕片とし、次に、２０５乃至２２０℃の加熱及び１７乃至３０ Kg ／ cm 2 の加圧操作のみによって融着一体化させ、次いで冷却して成形体とする、床敷物廃材を原料とする成形体の製造方法であって、前記加圧操作における加圧力を加減することによって、前記成形体の密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整する、床敷物廃材を原料とする成形体の製造方法である。
請求項５は、前記成形体の熱伝導率が０．１１乃至０．２５ｋｃａｌ／ｍｈｒ℃であるところにある。
請求項６は、前記加圧操作における加圧時間が５乃至２０分であるところにある。
【０００７】
請求項７は、前記粉砕片を、予備圧縮部を通過させた後、加熱及び加圧するところにある。
【０００８】
請求項８は、前記粉砕片に、熱可塑性合成樹脂の粉砕片を混ぜてなるところにある。
【００１１】
請求項９は、エンドレスベルトの上面に粉砕片を載せて上下方向から断続的に加熱と加圧を行うようにして連続生産する製造方法としたところにある。
【００１３】
請求項１０は、前記加熱と加圧が、バッチ式に行われる製造方法としたところにある。
【００１４】
請求項１１は、前記粉砕片が、粉砕機に設けられた直径が１０mmのパンチングメタルを通過して得られるところにある。
【００１５】
請求項１２は、前記粉砕片が、裁断又は打ち抜きによって得られるところにある。
【００１６】
請求項１３は、繊維質素材により構成される表面素材と、塩化ビニール樹脂を含有する補強層とで構成される床敷物廃材の粉砕片を、１５５乃至２４０℃の加熱及び５乃至５０Kg／cm2の加圧操作のみによって融着及び一体化させてなる成形体であって、前記加圧操作における加圧力を加減することによって、密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整した成形体である。
請求項１４は、熱伝導率が０．１１乃至０．２６ｋｃａｌ／ｍｈｒ℃であるところにある。
請求項１５は、繊維質素材により構成される表面素材と、塩化ビニール樹脂を含有する補強層とで構成される床敷物廃材の粉砕片を、１７５乃至２２０℃の加熱及び１０乃至３０ Kg ／ cm 2 の加圧操作のみによって融着及び一体化させてなる成形体であって、前記加圧操作における加圧力を加減することによって、密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整した成形体である。
請求項１６は、繊維質素材により構成される表面素材と、塩化ビニール樹脂を含有する補強層とで構成される床敷物廃材の粉砕片を、２０５乃至２２０℃の加熱及び１７乃至３０ Kg ／ cm 2 の加圧操作のみによって融着及び一体化させてなる成形体であって、前記加圧操作における加圧力を加減することによって、密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整した成形体である。
請求項１７は、熱伝導率が０．１１乃至０．２５ｋｃａｌ／ｍｈｒ℃であるところにある。
【００１７】
請求項１８は、前記粉砕片が、補強層の大きさが、平均径で１０mm以下であるところにある。
【００１８】
請求項１９は、前記粉砕片が、補強層の大きさが、平均径で８mm以下であるところにある。
【００１９】
請求項２０は、前記粉砕片が、補強層の大きさが、平均径で５mm以下であるところにある。
【００２０】
請求項２１は、前記床敷物がタイルカーペットであるところにある。
【００２１】
請求項２２は、前記表面素材が、ガラス繊維不織布を基布とし、パイル布がポリエステル及び／又はナイロン、ポリプロピレンであるところにある。
【００２３】
請求項２３は、前記粉砕片に熱可塑性合成樹脂の粉砕片を混ぜたところにある。
【００２４】
請求項２４は、前記成形体が、板状物であるところにある。
【００２５】
【発明の実施の形態】
この発明の実施形態について、以下説明する。この発明の床敷物廃材を原料とする成形体の製造方法は、繊維素材より構成される表面素材と、補強層とで構成される床敷物廃材を、粉砕機にかけて、補強層の大きさが平均径１０mm以下となる粉砕片とし、次に、加熱及び加圧操作のみによって融着一体化させ、次いで冷却して成形体とするものである。
【００２６】
前記床敷物は、従来の技術の欄でも触れたように、JIS L 4404 に示される織りじゅうたん、JIS L 4405 に示されるタフテッドカーペット、JIS L 1904 に示されるタイルカーペットなどがある。これらは、使用目的にあった種々の用途に利用されているが、ナイロンやポリエステル、ポリプロピレンなどからなる繊維素材より構成される表面素材と、バインダー樹脂分として塩化ビニール樹脂、軟質ポリオレフィン樹脂、合成ゴムなどの軟質合成樹脂成分からなる補強層とで構成される点において共通している。とくに、タイルカーペットの場合には、繊維部分である上面の毛羽部分と、これを結合する基布、下面の強固な２〜４mmの補強層から構成され、通常、繊維部分としてのナイロンやポリエステルなどが全体の１４重量％以上の割合を占め、基布としてのガラス繊維が１％以上、補強層はバインダー樹脂分として塩化ビニール樹脂などの軟質合成樹脂成分と、炭カルと、そして、フタル酸エステル、アジビン酸エステル、セバシン酸エステルなどの可塑剤とからなり、これが８０重量％以上の割合からなっており、製品の種類によって適宜割合が選択される。補強層の内訳は、バインダー樹脂分が１４〜２３重量％、炭カルが６３〜７０重量％、可塑剤が１４〜１６重量％となっている。
【００２７】
このような床敷物の製造工程で生じた廃材や、床敷物として長年の使用後の床敷物廃材を原料として用いる。製造工程の裁断時の耳などの粉砕片の場合には前記した成分の割合をそのまま維持しているが、不良品の場合にはその内容いかんによっては前記した成分の割合を維持しない場合があるが、この場合にも極端な場合を除いてそのままあるいは前記耳などの粉砕片と混合するなどして原料として使用できる。又、使用済の床敷物廃材の場合には、使用時の場所や状態あるいは使用期間によって汚れや破損が生じている場合があるが、洗浄等の前処理をすることなくそのまま原料として使用できる。又、表面素材や補強層の部分が長年の使用によって磨耗している場合であっても、この発明の成立自体には何らの影響を与えるものではない。
【００２８】
このような原料としての床敷物廃材をまず粉砕するが、粉砕手段は特に限定されるものではなく、既存の粉砕機、裁断機、打ち抜き機などを使用して行うことができるが、粉砕機による場合には、大量の床敷物廃材を短時間で処理できる。又、粉砕片を所定径の孔の開いたパンチングメタルを通過させることも容易であり、所定の平均径をもつ粉砕片を得やすい。いずれの手段によって粉砕された粉砕片も、表面素材と補強層が一体となっているものが殆どであるが、分離しているものが混ざっていても差し障りはない。表面素材は、繊維状であるので、その長さを正確に測定しにくいが、補強層の部分は固形状であるので大きさの測定は容易である。
【００２９】
この補強層の部分の平均の大きさが、１０mm以下であれば、表面素材の大きさに係わらず加熱時に短時間で中心部まで熱がよく伝導され、又、圧力をかけた場合にも全体に平均して圧力が伝えられ密度が均一化されると共に、床敷物廃材を構成する各々の成分が全体としてよく分布しているのであえて攪拌する必要がなくなるからである。１０mm以上では、厚みの均一化が難しく、加熱時間がかかり、また、加圧しても圧力が均一に分布しにくく、その結果、密度や物理的機械的性質のバラツキが生じ、成形体の表面も粗となり、外観不良となるから好ましくなくなるからである。粉砕片の補強層の部分を小さくするには、それだけ粉砕に要する手間がかかるものの、平均の大きさが８mm以下であればより好ましく、５mm以下であればなお一層好ましい。このような補強層の部分の均一な大きさの粉砕片を得る一方法として、例えば、粉砕機に直径が１０mmのパンチングメタルを設ければ、ここを通過した粉砕片の平均径が１０mm以下のものを容易に得ることができる。
【００３０】
上記した粉砕片を所定形状の型枠や連続成形の場合にはホッパー等に入れてから、予備圧縮部で密度むらを少なくするように、巾全体にわたっての供給量をほぼ均一になるように調整し、次いで除々に圧縮しながら板状に形を整形した後、本体に入れて加熱しつつ圧縮して融着一体化させるが、この時の温度は床敷物廃材の補強層に含まれるバインダー樹脂分が溶融する１５５℃乃至２４０℃が適当で、より好ましくは１７５℃乃至２２０℃の範囲である。１５５℃より低い場合にはバインダー樹脂分の溶融が十分生じないために各粉砕片の結合が弱くなり成形体が得られ難くなり、２４０℃を越えると表面素材のナイロンやポリエステルが溶融して繊維部分がなくなり、成形体の腰が弱く脆いものとなり、又、補強層の成分である塩化ビニール樹脂などの軟質合成樹脂分が熱分解により有毒ガスを発生し始めることにもなるからである。これらの温度の範囲からどの温度を選択するかは、どの位の時間高温状態を維持しつつ加圧するかによって変化するが、一般的には低温度の方が長時間となる。また、バインダー樹脂分の成分によっても温度の選択がなされる。
【００３１】
このような高温状態で粉砕片に圧力を加えると、表面素材のナイロンやポリエステルが溶融した補強層を構成する塩化ビニール樹脂等のバインダー樹脂の中に分散される。この分散は攪拌や他の手段による混合などの作業は一切不要で、加圧のみで十分である。その理由は、粉砕片を前記したように適度な大きさに粉砕しているので、攪拌、混合することなく十分に各成分が均一に分布しているからである。そして加圧によってこれらの成分が溶融している補強層のバインダー樹脂分に分散されるのである。この場合に加える圧力は、５乃至５０kg／cm2の範囲、より好ましくは、１０乃至３０kg／cm2の範囲が適当である。５kg／cm2以下であると、加熱温度が高くても表面素材や補強層の成分に十分に熱が伝導されなく、又、各成分の融着の度合いも緩くなり、従って、密度の高い引張りに強い成形体ができず、逆に５０kg／cm2以上では圧縮限度に達して、同じ密度で留まり、加圧に要するエネルギーが無駄となるからである。又、連続プレスの場合には、漏れ出ることも生じるからである。これらの圧力の範囲からどの位の圧力を選択するかは、温度との関係によって変化する。一般的には低圧力の方が高温で、高圧力程低温である。
【００３２】
上記した高温状態で加圧して成形体を製造する場合には、所定形状をなし、前記した温度範囲のいずれかの高温状態にある型枠の中に床敷物廃材の粉砕片の原料を入れて、既存のプレス装置を用いその押力面も高温状態にして押圧する、いわゆるバッチ式で行う。この場合、型枠に投入する前に原料自体をある程度高温状態にしておくと成形する時間が短縮できるので尚好ましい。更に又、粉砕片を型枠内等で予め予備圧縮しておくと、圧縮時間が短縮され、能率良く製造できる。このようにして所定時間の間加圧状態を維持してから、型枠から取り出して冷却させて成形体ができる。高温状態で加圧する時間は、成形体の形状等によって異なるが、一般的には５分乃至２０分程度の範囲である。又、加圧力を加減することによって、成形体の密度を自在に調整できることが可能となる。なお、密度の調節は、原料の投入量によっても可能である。
【００３３】
長尺な成形体を連続的に製造する場合には、一般にカレンダー成形機と呼ばれるロール式連続加圧機を使用して賦形し、これをエンドレスベルト上に載せて搬送と冷却を行うようにしてもよいし、あるいは又、エンドレスベルトの上面に粉砕片を載せて上下方向から断続的に加熱と加圧を行うようにして連続的に製造しても良いし、その他の手段によって成形体を得てもよい。このような連続成形の製造方法を採用するか、バッチ式の製造方法を採用するかは、求める成形体の形状によって決定される。板状物の場合には、連続的な製造方法の方が大量に且つ安価に製造できるし、又、利用の範囲も広範である。
【００３４】
なお、前記した床敷物廃材の粉砕片の原料に別途熱可塑性合成樹脂をあらかじめ加えて混合させて加熱加圧によって成形した場合には、強度がより強くなる。この場合の熱可塑性合成樹脂は、粉砕片の補強層に含まれているバインダー樹脂分と同じか、又は、それらと同じ温度で溶融するポリエチレン、ポリプロピレン、ポリスチレン等が好ましい。この場合の熱可塑性合成樹脂の大きさはとくに限定されないが、粉砕片と同じ位の大きさに粉砕した廃材としてのフィルム、ボトルなどの再使用できる前記熱可塑性合成樹脂が好適に使用できるが、粉末状であってもよい。混入量は多くなる程成形品の硬度が硬く且つ強くなるだけであるのでとくに限定されるものではない。また、ここで使用される熱可塑性合成樹脂は、接着剤としての性質を有するものであってもよい。例えば、ホットメルト接着剤として使われるエチレン−酢ビ共重合体等の粉末を使用すれば、粉砕片の融着を助け、低温側低圧側で成形体を得ることができる。
【００３５】
床敷物廃材がタイルカーペットの場合には、前記したように、補強層にバインダー樹脂分が１４〜２３重量％、炭カルが６３〜７０重量％、可塑剤が１４〜１６重量％含まれているので、これらが相互に作用して、熱可塑性合成樹脂などの他の調整部材を加えることなく、応用範囲の広い適宜な製品密度、曲げ強さ、熱伝導率等を有する成形体が得られる利点がある。
【００３６】
また、表面素材が、ガラス繊維不織布を基布とし、パイル布がポリエステル及び／又はナイロンであれば、これらが成形体の内部で分布して強い結合力が得られて、柔軟性と曲げの強い成形体となる。また、補強層が塩化ビニール樹脂成分である場合には、比較的低温で溶融するので、発熱経費が少なくて済むという利点があると共に、成形体の難燃性が得られるという利点がある。
【００３７】
又、成形体に合成樹脂シートを積層して固着した場合には、表面が美しく仕上がるので、利用用途が拡大される。更に、プレス装置の型枠から取り出した成形体が熱い状態において他の形状に変形させたり、連続成形の場合にはライン上で他方向から力を加えて他の形状に変形させるいわゆるインライン２次加工が可能であるので、この点からも利用用途が拡大される。
【００３８】
【実施例】
（実施例１）
製造工程で発生したタイルカーペット屑である床敷物廃材を粉砕機で粉砕してパンチングメタルの孔の直径が１０mmを通過した粉砕片を原料として、表１の条件で加熱加圧し成形体を得た。尚、成形体の厚さを１０mmにするため周囲に１０mmのスペーサーを置いて成形したので、製品密度は粉砕片の量で調節した。上記条件で成形した成形体の特性を同じ表１に示す。
【００３９】
【表１】
表１から判るように、処理温度が１５０℃では、温度が低すぎて軟質合成樹脂分のバインダー樹脂分が融解しないために固まらず、製品とならなかった。また、圧力が４kg／cm 2 では、温度が２０５℃であっても内部まで熱が均一に伝達されず、その結果、フワフワの状態となり製品とならなかった。
【００４１】
（実施例２）
使用済の補強層のある廃織じゅうたん屑を裁断機によって裁断して得られた補強層の平均径が５mm以下となった粉砕片と、使用済みポリプロピレンフィルムの粉砕片（ＰＰと記す）を表２の条件で混合し加熱加圧し成形品を得た。
尚、成形品の厚さを１０mmにするため周囲に１０mmのスペーサを置き厚さ調整した。
粉砕片の総量は９９０ｇとしてＰＰの割合を変えた。
上記条件で成形した成形体の特性を同じ表２に示す。
【００４２】
【表２】
（実施例３）
連続加熱加圧機を使用し、使用済みのタイルカーペットを粉砕機によって平均径が１０mm以下となった粉砕片を原料として用いて、幅１２００mm、厚さ１０mmのボードを連続し製造した。製品密度はラインスピードで変更可能である。
尚、粉砕片の平均径が１０mm以上とした比較例を、比較例３ー１として表３に挿入した。
製造条件及び製品密度及び成形体の特性を表３に示す。
【００４４】
【表３】
上記表３から明らかなように、粉砕片の大きさが２０mmでは、製品密度のバラツキが大きく、且つ、表面も凹凸が発生し、良質な製品が得られなかった。
【００４６】
上記の３つの実施例の製造方法及び当該製造方法で得た成形体の特性からも明らかなように、この製造方法で得た成形体は、実施例１と３のタイルカーペットの場合の難燃性は防災２級、３級であって防燃性に優れ、熱伝導率は０．１５前後とＡＬＣ板にほぼ等しく断熱性にも優れている。更に、吸水率も少なく、最大の１３．４％の場合であっても成形体に水膨れなどによる変形は全く生じなかった。これらのことから、床、壁、天井などの建築材料としての利用用途が特に好適である。尚、上記製造方法においては、成形体がボードである場合について述べたが、これに限定されることなく凹凸のある立体形状の成形品を同様に得ることもできる。
【００４７】
【発明の効果】
以上の説明からも明らかなように、この発明の床敷物廃材を原料とする成形体の製造方法は、繊維素材より構成される表面素材と、補強層とで構成される床敷物廃材をその平均長さが１０mm以下の粉砕片となるように粉砕し、これを加熱して高温状態で加圧するだけでよいので、製造工程が極めて簡単である利点がある。さらに、必要に応じて、使用済みの熱可塑性合成樹脂の粉砕片を適当量混合して製造することもできるので、製造できる成形体の難燃性などの特性が種々得られる利点がある。また、床敷物廃材の製造工程で発生する裁断時の耳などの破片や不良品や使用済の床敷物からなる廃材を有効利用するものであるから、廃棄に要する手間が省け、且つ、有効利用できるので、環境問題、再資源化などの点からより有用なものである。利用用途は今後の研究開発によって種々展開されるものであるが、現状においては、とくに建材用、土木用への展開が特に有用であると思慮される。そして、加熱温度が１５５乃至２４０℃、加圧力が５乃至５０Kg／cm2の広範囲で製造できる利点がある。また、加熱温度が１７５乃至２２０℃、加圧力が１０乃至３０Kg／cm2 であるか、又は、加熱温度が２０５乃至２２０℃、加圧力が１７乃至３０ Kg ／ cm 2 であれば、密度が一層均一に分布したより好ましい成形体ができる。さらに、補強層が、塩化ビニール樹脂を含有する塩化ビニール樹脂組成物であり、製品原価の安い、しかも、比較的低温加熱で成形体が得られるので、光熱費の節減をも図ることができる。また、難燃性であるので、防火上好ましいものとなる。
【００４８】
また、前記粉砕片の予備圧縮部を備えれば、更に製造時間の短縮を行える利点にくわえて、密度、物性の均一化に役立つ利点がある。
【００４９】
前記粉砕片に、熱可塑性合成樹脂の粉砕片を混ぜれば、一層引っ張り強度が強く、しかも、耐久性のあるものを製造することができる利点がある。
【００５２】
エンドレスベルトの上面に粉砕片を載せて上下方向から断続的に加熱と加圧を行うようにして連続生産することができるので、大量の成形体を連続して製造できると共に、加熱加圧機械の選択の余地が拡大する。
【００５４】
前記加熱と加圧が、バッチ式に行うことができるので製造方法の選択の余地が拡大する。
【００５５】
前記粉砕片が、粉砕機に設けられた直径が１０mmのパンチングメタルを通過して得られるようにすれば、平均径が１０mm以下の粉砕片が容易に得られる。
【００５６】
前記粉砕片が、裁断、打ち抜きによっても得られるので、粉砕片を製造する工程の選択の余地が拡大する。
【００５７】
更に、この発明の成形体は、繊維質素材により構成される表面素材と、補強層とで構成される床敷物廃材の粉砕片を、加熱及び加圧操作のみによって、融着及び一体化させてなる成形体であるので、製造が簡単であると共に、その製品特性も、前記のように、建材を始め、種々の用途に利用できるものを持ち合わせているので、応用範囲が広いという利点がある。また、加熱温度が１５５乃至２４０℃、加圧力が５乃至５０Kg／cm2であるか、加熱温度が１７５乃至２２０℃、加圧力が１０乃至３０ Kg ／ cm 2 であるか、又は、加熱温度が２０５乃至２２０℃、加圧力が１７乃至３０ Kg ／ cm 2 であると共に、補強層が、塩化ビニール樹脂を含有する塩化ビニール樹脂組成物であるので、上記と同様の利点がある。
【００５８】
前記粉砕片が、その補強層の大きさが平均径で１０mm以下であれば、密度の均一した成形体が得られる。
【００５９】
前記粉砕片は、その補強層の大きさがが平均径で８mm以下であれば、一層密度の均一した成形体が得られる。
【００６０】
前記粉砕片が、その補強層の大きさが、平均径で５mm以下であるば、更により一層密度の均一した成形体が得られる。
【００６１】
前記床敷物がタイルカーペットである場合には、そのもの自体が有している成分によって、応用範囲の広い成形体が得られる。
【００６２】
前記表面素材が、ガラス繊維不織布を基布とし、パイル布がポリエステル及び／又はナイロン等であれば、これらガラス繊維不織布及びポリエステル及び／又はナイロン等が成形体の内部において相互の結合材としての役割を果たすので、引っ張り強度の高い成形体が得られる。
【００６４】
前記粉砕片に熱可塑性合成樹脂の粉砕片を混ぜれれば、引っ張り強度が一層強くなり、且つ、耐久性のある成形体となる。
【００６５】
前記成形体が、板状物であれば、種々の用途に応用できるので、応用範囲の広いものとなる。しかも、連続大量生産できるので、安価に製造できる。[0001]
[Field of the Invention]
The present invention relates to a method for producing a molded body that is formed by effectively using floor covering waste materials such as various carpets as a raw material, and the molded body.
[0002]
[Prior art]
As is well known, a floor covering laid on a floor made of a board such as concrete or a plate is generally a surface material composed of a fibrous portion on the surface and a reinforcing layer portion in contact with the floor surface. As such floor coverings, there are various types such as woven carpets, tufted carpets and tile carpets as defined in JIS. Depending on the intended use, this floor covering is rolled into a long shape and cut to the required length when used, or cut into a relatively small square from the beginning, such as a tile carpet. In recent years, in particular, because of its convenience, the demand for tile carpets that are combined and laid on the floor has increased significantly in recent years, particularly in the commercial market. The components that make up such a floor covering differ depending on the type. For example, in the case of tile carpet, the fluff portion on the upper surface, which is a fiber portion, the base fabric that binds the fluff portion, and the strong 2-4 mm reinforcement on the lower surface Nylon or polyester as the fiber part accounts for more than 14% by weight, glass fiber as the base fabric is 1% or more, and the reinforcing layer is made of vinyl chloride resin or polyester as the binder resin. , Composed of soft synthetic resin components such as synthetic rubber and olefin, charcoal cal, and plasticizers such as phthalic acid ester, adibic acid ester and sebacic acid ester, which consist of 80% by weight or more, A ratio is appropriately selected depending on the type of product. The breakdown of the reinforcing layer is that the binder resin content is 14 to 23% by weight, charcoal cal is 63 to 70% by weight, and the plasticizer is 14 to 16% by weight.
[0003]
The demand for floor coverings such as the above-mentioned tile carpets is increasing year by year, but the waste of floor coverings such as ears generated when cutting into a predetermined size in the manufacturing process is also increasing. In addition, used floor covering waste material is generated when the floor covering is replaced. As a useful method of using such floor covering waste materials generated during the manufacturing process and re-covering, these are finely pulverized and used only in a very small amount so that they are mixed in a small amount as a part of the reinforcing layer of the floor covering, Most of the waste is incinerated and landfilled as industrial waste.
[0004]
[Problems to be solved by the invention]
Even if the above-mentioned floor covering waste material is incinerated as industrial waste, there is a problem that the amount of transportation is large and the incineration place is troubled because the amount is large. There is also a problem that air pollution accompanying incineration occurs. Furthermore, there is a problem that the landfill site is disappearing.
This invention was made in view of such circumstances, and for the purpose of effectively using as a resource a floor covering waste material that has been difficult to dispose of as an industrial waste conventionally, molding using a floor covering waste material as a raw material It came to propose the manufacturing method of a body, and its molded object.
[0005]
[Means for Solving the Problems]
As a means for achieving the above object, the present invention provides claims 1 to12In the method of manufacturing a molded body made from floor covering waste material,13Thru24Proposes the molded body.
[0006]
Claim 1 is a crushed piece in which a floor covering waste material composed of a surface material composed of a fiber material and a reinforcing layer containing a vinyl chloride resin is applied to a pulverizer, and the size of the reinforcing layer becomes an average diameter of 10 mm or less. And then heating at 155 to 240 ° C. and 5 to 50 kg / cm2A method of manufacturing a molded body made of floor covering waste material, which is fused and integrated only by the pressure operation of the sheet, and then cooled to form a molded bodyThe density of the compact is 1.10 to 1.56 g / cm by adjusting the pressure in the pressurizing operation. Three To produce a molded body made of floor covering waste materialIt is.
Claim 2The molded body has a thermal conductivity of 0.11 to 0.26 kcal / mhr ° C.
According to the third aspect of the present invention, a floor covering waste material composed of a surface material composed of a fiber material and a reinforcing layer containing a vinyl chloride resin is applied to a pulverizer, so that the size of the reinforcing layer has an average diameter of 10 mm The crushed pieces are as follows, and then heated at 175 to 220 ° C. and 10 to 30 Kg / cm 2 It is a method for producing a molded body using floor covering waste material as a raw material, which is fused and integrated only by the pressure operation, and then cooled to form a molded body, by adjusting the pressure in the pressure operation, The density of the molded body is 1.10 to 1.56 g / cm. Three It is the manufacturing method of the molded object which uses a floor covering waste material as a raw material to adjust to.
According to a fourth aspect of the present invention, a floor covering waste material composed of a surface material composed of a fiber material and a reinforcing layer containing a vinyl chloride resin is applied to a pulverizer, and the size of the reinforcing layer has an average diameter of 10 mm The resulting crushed pieces are then heated at 205-220 ° C. and 17-30 Kg / cm 2 It is a method for producing a molded body using floor covering waste material as a raw material, which is fused and integrated only by the pressure operation, and then cooled to form a molded body, by adjusting the pressure in the pressure operation, The density of the molded body is 1.10 to 1.56 g / cm. Three It is the manufacturing method of the molded object which uses a floor covering waste material as a raw material to adjust to.
A fifth aspect of the present invention is that the thermal conductivity of the molded body is 0.11 to 0.25 kcal / mhr ° C.
According to a sixth aspect of the present invention, the pressurizing time in the pressurizing operation is 5 to 20 minutes.
[0007]
Claim7Is in the place where the crushed pieces are heated and pressurized after passing through the pre-compression section.
[0008]
Claim8Is in a state where a pulverized piece of thermoplastic synthetic resin is mixed with the pulverized piece.
[0011]
Claim9The endless beltPlace the crushed pieces on the top surface of the slab and heat and press intermittently from above and below.There is a manufacturing method for continuous production.
[0013]
Claim10Is a manufacturing method in which the heating and pressurization are carried out batchwise.
[0014]
Claim11Is that the crushed pieces are obtained by passing through a punching metal having a diameter of 10 mm provided in the pulverizer.
[0015]
Claim12Is where the crushed pieces are obtained by cutting or punching.
[0016]
Claim13Is a crushed piece of floor covering waste material composed of a surface material composed of a fibrous material and a reinforcing layer containing a vinyl chloride resin, heated at 155 to 240 ° C. and 5 to 50 kg / cm2Formed by fusing and integrating only by the pressure operation ofThe density is 1.10 to 1.56 g / cm by adjusting the pressure in the pressurizing operation. Three It is a molded article adjusted to.
Claim14IsThe thermal conductivity is 0.11 to 0.26 kcal / mhr ° C.
Claim 15 is the heating of 175 to 220 ° C. and 10 to 30 of crushed pieces of floor covering waste material composed of a surface material composed of a fibrous material and a reinforcing layer containing a vinyl chloride resin. Kg / cm 2 The molded body is formed by fusing and integrating only by the pressurizing operation, and the density is 1.10 to 1.56 g / cm by adjusting the pressurizing force in the pressurizing operation. Three It is a molded article adjusted to.
Claim 16 is the heating of 205 to 220 ° C. and 17 to 30 of the floor covering waste material composed of a surface material composed of a fibrous material and a reinforcing layer containing a vinyl chloride resin. Kg / cm 2 The molded body is formed by fusing and integrating only by the pressurizing operation, and the density is 1.10 to 1.56 g / cm by adjusting the pressurizing force in the pressurizing operation. Three It is a molded article adjusted to.
The seventeenth aspect is that the thermal conductivity is 0.11 to 0.25 kcal / mhr ° C.
[0017]
Claim18The crushed pieces are such that the size of the reinforcing layer is 10 mm or less in average diameter.
[0018]
Claim19The crushed pieces are such that the size of the reinforcing layer is 8 mm or less in average diameter.
[0019]
Claim20The crushed pieces are such that the size of the reinforcing layer is 5 mm or less in average diameter.
[0020]
Claim21Is where the floor covering is a tile carpet.
[0021]
Claim22The surface material is based on a glass fiber nonwoven fabric and the pile fabric is polyester and / or nylon or polypropylene.
[0023]
Claim23Is a mixture of the crushed pieces of thermoplastic synthetic resin with the crushed pieces.
[0024]
Claim24Is where the molded body is a plate-like material.
[0025]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below. The method for producing a molded body using the floor covering waste material of the present invention as a raw material is obtained by applying a floor covering waste material composed of a surface material composed of a fiber material and a reinforcing layer to a pulverizer, and the size of the reinforcing layer being average. Make crushed pieces with a diameter of 10 mm or less, then heatas well asIt is fused and integrated only by the pressurizing operation, and then cooled to form a molded body.
[0026]
Examples of the floor covering include a woven carpet shown in JIS L 4404, a tufted carpet shown in JIS L 4405, and a tile carpet shown in JIS L 1904, as mentioned in the prior art section. These are used for various purposes according to the purpose of use, but surface materials composed of fiber materials such as nylon, polyester and polypropylene, and vinyl chloride resin, soft polyolefin resin, synthetic rubber as binder resin components This is common in that it is composed of a reinforcing layer made of a soft synthetic resin component. In particular, in the case of tile carpet, it is composed of a fluff portion on the upper surface, which is a fiber portion, a base fabric that binds the fluff portion, and a strong 2-4 mm reinforcing layer on the lower surface. Usually, nylon or polyester as the fiber portion, etc. Occupies 14% by weight or more of the total, glass fiber as the base fabric is 1% or more, the reinforcing layer is a soft resin component such as vinyl chloride resin as a binder resin, carbon char, and phthalate And a plasticizer such as adibic acid ester and sebacic acid ester, and the ratio is 80% by weight or more, and the ratio is appropriately selected depending on the type of product. The breakdown of the reinforcing layer is that the binder resin content is 14 to 23% by weight, charcoal cal is 63 to 70% by weight, and the plasticizer is 14 to 16% by weight.
[0027]
Waste materials generated in such a floor covering manufacturing process and floor covering waste materials after many years of use are used as raw materials. In the case of crushed pieces such as ears at the time of cutting in the manufacturing process, the ratio of the components described above is maintained as it is, but in the case of a defective product, the ratio of the components described above may not be maintained depending on the contents. However, in this case as well, except for extreme cases, it can be used as a raw material as it is or by mixing with crushed pieces such as the ears. Moreover, in the case of used floor covering waste material, it may be soiled or damaged depending on the place, state or period of use, but it can be used as it is without any pretreatment such as washing. Even if the surface material or the reinforcing layer portion is worn out over many years of use, it does not affect the establishment of the present invention.
[0028]
The floor covering waste material as such a raw material is first pulverized, but the pulverizing means is not particularly limited and can be performed using an existing pulverizer, cutting machine, punching machine, etc. In some cases, a large amount of floor covering waste can be processed in a short time. It is also easy to pass the crushed piece through a punching metal having a hole with a predetermined diameter, and it is easy to obtain a crushed piece having a predetermined average diameter. Most of the pulverized pieces pulverized by any means are those in which the surface material and the reinforcing layer are integrated, but there is no problem even if separated ones are mixed. Since the surface material is fibrous, it is difficult to accurately measure its length, but the size of the reinforcing layer is easy because the portion of the reinforcing layer is solid.
[0029]
If the average size of the reinforcing layer portion is 10 mm or less, the heat is well conducted to the central portion in a short time during heating regardless of the size of the surface material, and even when pressure is applied This is because, on average, the pressure is transmitted and the density is made uniform, and each component constituting the floor covering waste material is well distributed as a whole, so that it is not necessary to stir. If it is 10 mm or more, it is difficult to make the thickness uniform, it takes a long time to heat, and even if pressure is applied, it is difficult to uniformly distribute the pressure, resulting in variations in density and physical and mechanical properties, and the surface of the molded body is also This is because it becomes rough and unfavorable due to poor appearance. In order to reduce the size of the reinforcing layer portion of the crushed pieces, it takes much time and effort to pulverize, but the average size is more preferably 8 mm or less, and even more preferably 5 mm or less. As one method for obtaining a pulverized piece having a uniform size in such a reinforcing layer portion, for example, if a pulverizer is provided with a punching metal having a diameter of 10 mm, the average diameter of the crushed pieces that have passed therethrough is 10 mm or less. Things can be easily obtained.
[0030]
Adjust the supply amount over the entire width so that the density unevenness is reduced in the pre-compression section after putting the above-mentioned crushed pieces into a hopper or the like in the case of a mold with a predetermined shape or continuous molding. Then, after gradually shaping into a plate shape while gradually compressing, it is put into the main body and heated and compressed and fused and integrated, but the temperature at this time is the binder resin contained in the reinforcing layer of the floor covering waste material A temperature of 155 ° C. to 240 ° C. at which the fraction melts is suitable, and a range of 175 ° C. to 220 ° C. is more preferable. When the temperature is lower than 155 ° C., the binder resin content is not sufficiently melted, so that the crushed pieces are weakly bonded and it becomes difficult to obtain a molded product. This is because the portion disappears, the molded body becomes weak and brittle, and a soft synthetic resin component such as vinyl chloride resin, which is a component of the reinforcing layer, starts to generate toxic gas due to thermal decomposition. Which temperature to select from these temperature ranges varies depending on how long the pressure is applied while maintaining the high temperature state.RuHowever, in general, the temperature is longer at a lower temperature. The temperature is also selected depending on the component of the binder resin.
[0031]
When pressure is applied to the crushed pieces in such a high temperature state, the surface material nylon or polyester is dispersed in a binder resin such as a vinyl chloride resin constituting a reinforcing layer in which the surface material is melted. This dispersion does not require any work such as stirring or mixing by other means, and only pressurization is sufficient. This is because the crushed pieces are pulverized to an appropriate size as described above, so that the components are sufficiently uniformly distributed without stirring and mixing. And these components are disperse | distributed to the binder resin part of the reinforcement layer which has melted by pressurization. The pressure applied in this case is 5 to 50 kg / cm2Range, more preferably 10 to 30 kg / cm2The range of is appropriate. 5kg / cm2If it is below, heat is not sufficiently transferred to the surface material and the components of the reinforcing layer even if the heating temperature is high, and the degree of fusion of each component is also loosened. On the contrary, 50kg / cm2This is because the compression limit is reached, stays at the same density, and energy required for pressurization is wasted. Further, in the case of continuous press, leakage may occur. How much pressure is selected from these pressure ranges varies depending on the relationship with temperature. Generally, the lower pressure is higher and the higher pressure is lower.
[0032]
In the case of producing a molded body by pressurizing in the above-described high temperature state, a predetermined shape is formed, and the raw material of the crushed pieces of the floor covering waste material is put into a mold in any one of the above-described temperature ranges. A so-called batch method is used in which an existing pressing device is used to press the pressing surface with a high temperature. In this case, if the raw material itself is kept at a certain high temperature before being put into the mold,formIt is still preferable because it can shorten the time to do. Furthermore, if the crushed pieces are pre-compressed in a mold or the like in advance, the compression time is shortened and production can be performed efficiently. Thus, after maintaining a pressurized state for a predetermined time, it is taken out from the mold and cooled to form a molded body. The time for pressurization in a high temperature state varies depending on the shape of the molded body and the like, but is generally in the range of about 5 to 20 minutes. Further, by adjusting the applied pressure, the density of the molded body can be freely adjusted. It should be noted that the density can be adjusted by the amount of raw material input.
[0033]
When continuously manufacturing a long molded body, it is shaped using a roll type continuous press machine generally called a calendering machine, and this is placed on an endless belt for transport and cooling. Alternatively, it may be continuously manufactured by placing a crushed piece on the upper surface of the endless belt and intermittently heating and pressing from above and below, or obtaining a molded body by other means. May be. Whether such a continuous molding manufacturing method or a batch type manufacturing method is employed is determined by the shape of the molded body to be obtained. In the case of a plate-like product, the continuous production method can be produced in a large amount and at a low cost, and the range of use is wide.
[0034]
It should be noted that a separate thermoplastic synthetic resin is added to the raw material of the above-mentioned floor covering waste material crushed pieces, mixed and heated and pressed.formIn this case, the strength becomes stronger. The thermoplastic synthetic resin in this case is preferably polyethylene, polypropylene, polystyrene, or the like that is the same as the binder resin contained in the reinforcing layer of the crushed piece or melts at the same temperature. The size of the thermoplastic synthetic resin in this case is not particularly limited, but the above-mentioned thermoplastic synthetic resin that can be reused such as a film, a bottle as a waste material that has been crushed to the same size as the crushed pieces can be used, It may be in powder form. Increasing the amount of contaminationformSince the hardness of the product is only hard and strong, there is no particular limitation. Moreover, the thermoplastic synthetic resin used here may have a property as an adhesive. For example, hotRuthIf a powder such as an ethylene-vinyl acetate copolymer used as an adhesive is used, it is possible to help fusion of the crushed pieces and obtain a molded body on the low temperature side and low pressure side.
[0035]
When the floor covering waste material is a tile carpet, as described above, the reinforcing layer contains 14 to 23% by weight of binder resin, 63 to 70% by weight of charcoal, and 14 to 16% by weight of plasticizer. Therefore, they can interact with each other, and without adding other adjusting members such as a thermoplastic synthetic resin, an advantage is obtained that a molded product having an appropriate product density, bending strength, thermal conductivity and the like having a wide application range can be obtained. There is.
[0036]
If the surface material is a glass fiber non-woven fabric and the pile fabric is polyester and / or nylon, they are distributed inside the molded body to obtain a strong bonding force, and are flexible and strong in bending. It becomes a molded body. Further, when the reinforcing layer is a vinyl chloride resin component, it melts at a relatively low temperature, so that there is an advantage that the heat generation cost can be reduced and there is an advantage that the flame retardancy of the molded body can be obtained.
[0037]
Further, when the synthetic resin sheet is laminated and fixed to the molded body, the surface is finished beautifully, and the usage application is expanded. Furthermore, the molded body taken out from the mold of the press device is deformed to another shape in a hot state, or in the case of continuous molding, a so-called in-line secondary is deformed to another shape by applying force from other directions on the line. Since processing is possible, the use application is expanded also from this point.
[0038]
【Example】
Example 1
The floor covering waste material, which is tile carpet waste generated in the manufacturing process, was pulverized with a pulverizer, and a pulverized piece having a punched metal hole diameter of 10 mm as a raw material was heated and pressed under the conditions shown in Table 1 to obtain a compact. . In order to make the molded body 10 mm thick, a 10 mm spacer was placed around it.formTherefore, the product density was adjusted by the amount of crushed pieces. Table 1 shows the characteristics of the molded body molded under the above conditions.
[0039]
[Table 1]
As can be seen from Table 1, when the processing temperature was 150 ° C., the temperature was too low and the binder resin content of the soft synthetic resin did not melt, so it did not harden and did not become a product. The pressure is 4kg /cm 2 Then, even if the temperature was 205 ° C., heat was not uniformly transferred to the inside, and as a result, it was fluffy and did not become a product.
[0041]
(Example 2)
Table shows crushed pieces with the average diameter of the reinforcing layer obtained by cutting waste textile waste with used reinforcing layer with a cutting machine to 5 mm or less, and crushed pieces of polypropylene film (denoted as PP). Mix under the conditions of 2 and heat and press.formI got a product.
In addition,formIn order to adjust the thickness of the product to 10 mm, a 10 mm spacer was placed around and the thickness was adjusted.
The total amount of the crushed pieces was 990 g, and the ratio of PP was changed.
The properties of the molded body molded under the above conditions are shown in Table 2.
[0042]
[Table 2]
(Example 3)
Using a continuous heating and pressurizing machine, a board having a width of 1200 mm and a thickness of 10 mm was continuously produced from a used tile carpet using a crushed piece having an average diameter of 10 mm or less by a pulverizer as a raw material. Product density can be changed by line speed.
A comparative example in which the average diameter of the crushed pieces was 10 mm or more was inserted in Table 3 as Comparative Example 3-1.
Table 3 shows production conditions, product density, and characteristics of the molded body.
[0044]
[Table 3]
As apparent from Table 3 above, when the size of the pulverized piece was 20 mm, the product density varied greatly and the surface was uneven, and a high-quality product could not be obtained.
[0046]
As is apparent from the production methods of the above three examples and the characteristics of the molded products obtained by the production methods, the molded products obtained by this production method are flame retardant in the case of the tile carpets of Examples 1 and 3. The properties are disaster prevention grade 2 and grade 3, excellent in fire resistance, and thermal conductivity is about 0.15, almost equal to the ALC plate and excellent in heat insulation. Further, the water absorption rate was small, and even when the maximum was 13.4%, the molded body was not deformed by blistering at all. From these things, the use use as building materials, such as a floor, a wall, and a ceiling, is especially suitable. In the above manufacturing method, the case where the molded body is a board has been described.formGoods can be obtained as well.
[0047]
【The invention's effect】
As is apparent from the above description, the method for producing a molded body using the floor covering waste material of the present invention as a raw material has an average of floor covering waste material composed of a surface material composed of a fiber material and a reinforcing layer. There is an advantage that the manufacturing process is extremely simple because it is only necessary to pulverize the crushed pieces to a length of 10 mm or less, heat them and pressurize them at a high temperature. Furthermore, if necessary, it can be produced by mixing an appropriate amount of used pulverized pieces of thermoplastic synthetic resin, and thus there is an advantage that various properties such as flame retardancy of a molded article that can be produced can be obtained. In addition, because it effectively uses debris such as cutting ears generated during the manufacturing process of floor covering waste material, waste material consisting of defective products and used floor covering, it saves labor and time for disposal. Because it can, it is more useful in terms of environmental issues and recycling. Various uses will be developed by future research and development, but in the present situation, it is considered that the use for building materials and civil engineering is particularly useful. The heating temperature is 155 to 240 ° C., the applied pressure is 5 to 50 kg / cm.2There is an advantage that can be manufactured in a wide range. Also, the heating temperature is 175 to 220 ° C., the applied pressure is 10 to 30 kg / cm.2 Or a heating temperature of 205 to 220 ° C. and a pressing force of 17 to 30 Kg / cm 2 If so, a more preferable molded body having a more evenly distributed density can be obtained. Furthermore, since the reinforcing layer is a vinyl chloride resin composition containing a vinyl chloride resin, the product cost is low, and a molded body can be obtained by heating at a relatively low temperature, so that it is possible to reduce the utility cost. Further, since it is flame retardant, it is preferable for fire prevention.
[0048]
In addition, the provision of the pre-compressed portion for the crushed pieces has the advantage of helping to make the density and physical properties uniform, in addition to the advantage of shortening the production time.
[0049]
If a pulverized piece of thermoplastic synthetic resin is mixed with the pulverized piece, there is an advantage that it is possible to produce a product having higher tensile strength and durability.
[0052]
Endless beltPlace the crushed pieces on the top surface of the slab and heat and press intermittently from above and below.Since it can be produced continuously, a large number of compacts can be produced continuously.At the same time, the scope for selection of heating and pressurizing machines expands..
[0054]
Since the heating and pressurization can be performed batchwise, the scope for selecting a manufacturing method is expanded.
[0055]
If the pulverized pieces are obtained by passing through a punching metal having a diameter of 10 mm provided in the pulverizer, pulverized pieces having an average diameter of 10 mm or less can be easily obtained.
[0056]
Since the pulverized pieces can be obtained by cutting and punching, the scope for selecting the process for producing the pulverized pieces is expanded.
[0057]
Further, the molded body of the present invention is obtained by fusing and integrating the ground material of the floor covering waste material composed of the fiber material and the reinforcing layer only by heating and pressing operations. Since the molded article is easy to manufacture and has product characteristics that can be used for various purposes such as building materials as described above, there is an advantage that the application range is wide. The heating temperature is 155 to 240 ° C., the applied pressure is 5 to 50 kg / cm.2IsOr a heating temperature of 175 to 220 ° C. and a pressure of 10 to 30 Kg / cm 2 Or a heating temperature of 205 to 220 ° C. and a pressing force of 17 to 30 Kg / cm 2 In addition, since the reinforcing layer is a vinyl chloride resin composition containing a vinyl chloride resin, there are advantages similar to those described above.
[0058]
If the size of the reinforcing layer of the crushed pieces is 10 mm or less in average diameter, a compact with a uniform density can be obtained.
[0059]
If the size of the reinforcing layer of the crushed pieces is 8 mm or less in average diameter, a molded body having a more uniform density can be obtained.
[0060]
If the size of the reinforcing layer of the crushed pieces is 5 mm or less in average diameter, a molded product having a more uniform density can be obtained.
[0061]
When the floor covering is a tile carpet, a molded product having a wide application range can be obtained by the components of the floor covering itself.
[0062]
If the surface material is a glass fiber nonwoven fabric as a base fabric and the pile fabric is polyester and / or nylon, the glass fiber nonwoven fabric and polyester and / or nylon serve as a binding material inside the molded body. Therefore, a molded article with high tensile strength can be obtained.
[0064]
If the pulverized piece of thermoplastic synthetic resin is mixed with the pulverized piece, the tensile strength is further increased and the molded article is durable.
[0065]
If the molded body is a plate-like material, it can be applied to various uses, and thus has a wide application range. Moreover, since it can be continuously mass-produced, it can be manufactured at low cost.
Claims (24)
前記加圧操作における加圧力を加減することによって、前記成形体の密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整する、床敷物廃材を原料とする成形体の製造方法。A floor covering waste material composed of a surface material composed of a fiber material and a reinforcing layer containing a vinyl chloride resin is applied to a pulverizer to form a pulverized piece having an average diameter of 10 mm or less. A method for producing a molded body using floor covering waste as a raw material, which is fused and integrated only by heating at 155 to 240 ° C. and a pressure operation of 5 to 50 kg / cm 2 , and then cooled to form a molded body ,
A method for producing a molded body using waste floor covering material as a raw material , wherein the density of the molded body is adjusted to 1.10 to 1.56 g / cm 3 by adjusting the pressure applied in the pressurizing operation .
前記加圧操作における加圧力を加減することによって、前記成形体の密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整する、床敷物廃材を原料とする成形体の製造方法。 A floor covering waste material composed of a surface material composed of a fiber material and a reinforcing layer containing a vinyl chloride resin is applied to a pulverizer to form a crushed piece having an average diameter of 10 mm or less. This is a method for producing a molded body using floor covering waste as a raw material, which is fused and integrated only by heating at 175 to 220 ° C. and a pressure operation of 10 to 30 kg / cm 2 and then cooled to form a molded body. hand,
A method for producing a molded body using waste floor covering material as a raw material , wherein the density of the molded body is adjusted to 1.10 to 1.56 g / cm 3 by adjusting the pressure applied in the pressurizing operation .
前記加圧操作における加圧力を加減することによって、前記成形体の密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整する、床敷物廃材を原料とする成形体の製造方法。 A floor covering waste material composed of a surface material composed of a fiber material and a reinforcing layer containing a vinyl chloride resin is applied to a pulverizer to form a crushed piece having an average diameter of 10 mm or less. , Heating at 205 to 220 ° C. and pressure operation at 17 to 30 Kg / cm 2 only, and then cooling and forming the molded body using the floor covering waste material as a raw material. hand,
A method for producing a molded body using waste floor covering material as a raw material , wherein the density of the molded body is adjusted to 1.10 to 1.56 g / cm 3 by adjusting the pressure applied in the pressurizing operation .
前記加圧操作における加圧力を加減することによって、密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整した成形体。 A floor covering waste material composed of a surface material composed of a fibrous material and a reinforcing layer containing a vinyl chloride resin is heated at 155 to 240 ° C. and pressurized at 5 to 50 kg / cm 2. A molded body that is fused and integrated only by
A molded article having a density adjusted to 1.10 to 1.56 g / cm 3 by adjusting the pressure in the pressurizing operation .
前記加圧操作における加圧力を加減することによって、密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整した成形体。 A floor covering waste material composed of a surface material composed of a fibrous material and a reinforcing layer containing a vinyl chloride resin is heated at 175 to 220 ° C. and pressurized at 10 to 30 kg / cm 2. A molded body that is fused and integrated only by
A molded article having a density adjusted to 1.10 to 1.56 g / cm 3 by adjusting the pressure in the pressurizing operation .
前記加圧操作における加圧力を加減することによって、密度を１．１０乃至１．５６ｇ／ｃｍ 3 に調整した成形体。 Heating at 205 to 220 ° C. and pressurizing at 17 to 30 Kg / cm 2 on a floor covering waste material composed of a surface material composed of a fibrous material and a reinforcing layer containing a vinyl chloride resin A molded body that is fused and integrated only by
A molded article having a density adjusted to 1.10 to 1.56 g / cm 3 by adjusting the pressure in the pressurizing operation .
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP31227796A JP3707022B2 (en) | 1996-11-22 | 1996-11-22 | Method for producing molded article made of floor covering waste material and molded article thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP31227796A JP3707022B2 (en) | 1996-11-22 | 1996-11-22 | Method for producing molded article made of floor covering waste material and molded article thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH10151680A JPH10151680A (en) | 1998-06-09 |
| JP3707022B2 true JP3707022B2 (en) | 2005-10-19 |
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| Application Number | Title | Priority Date | Filing Date |
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| JP31227796A Expired - Fee Related JP3707022B2 (en) | 1996-11-22 | 1996-11-22 | Method for producing molded article made of floor covering waste material and molded article thereof |
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| JP (1) | JP3707022B2 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2004330534A (en) * | 2003-05-02 | 2004-11-25 | Kanegafuchi Chem Ind Co Ltd | Molded acoustic material obtained by recycled tile carpet |
| JP5464542B2 (en) * | 2009-03-10 | 2014-04-09 | 広島化成株式会社 | Recycled sheet, flooring containing recycled sheet as a constituent material, and method for manufacturing recycled sheet |
| JP6995911B2 (en) * | 2020-03-19 | 2022-01-17 | 仙台環境開発株式会社 | Protective block used at waste disposal site |
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