JP4540816B2 - Tile and manufacturing method thereof - Google Patents

Description

＊１ポリ塩化ビニル（重合度７００〜１０００）
＊２塩化ビニル−酢酸ビニル共重合体（重合度７００、酢酸ビニル含有量１０％）
＊３模様チップに使用する炭酸カルシウムは平均粒径７０μｍ、ベースシートに使用する炭酸カルシウムは１０〜５０μｍの粒径を有する重質炭酸カルシウム

【表２】

＊比較例１のサンプルはマチコＶ（当社コンポジションタイル）
＊比較例２のサンプルはメルストーン（当社ホモジニアスタイル）
＊上記物性値の試験方法については、反りは３０３ｍｍ角の試料を室温２０±２℃、湿度６５±１０％に調整された恒温室内にて１２時間養生した後、磨き板ガラスの上に載せ、試料の四隅と前記ガラス板との間隙を、１／１０ｍｍスケール付ルーペを用いて２０℃の反りを測定した。次に８０±２℃に調整された空気乾燥器中に６時間放置し、さらに、上記恒温室内にて１時間養生した後、上記と同様、前記ガラス板との間隙を、１／１０ｍｍスケール付ルーペを用いて８０℃の反りを測定した。また、３０３ｍｍ角の試料を前記恒温室内で１２時間養生した後、５℃に設定された可変室中に前記試料とともに磨き板ガラスを１時間放置し、試料の四隅と前記ガラス板との間隙を、１／１０ｍｍスケール付ルーペを用いて５℃の反りを測定した。また、加熱長さ変化率、及び吸水長さ変化率はＪＩＳＡ５７０５に準じて行った。

【００４７】
この結果、５℃の反り、加熱長さ変化率、吸水長さ変化率にいずれも本発明品は、従来のコンポジションタイル、ホモジニアスタイルよりも優れているか、もしくは遜色がないことが示された。
【００４８】
【発明の効果】
接着剤が付着したままの使用済み床材等の建築廃材等のリサイクル粉砕物が含まれていても、基材表面は平滑であった。
【００４９】
建築廃材リサイクル粉砕品を使用しても、美しい化粧層のリサイクルタイルを得た。リサイクルタイルの物性は通常の既存のタイルと何ら遜色はなかった。
【００５０】
リサイクル粉砕品を改めて練り返したり、あるいはプレス機等により加熱、加圧することなく、当該リサイクル粉砕品を撒布しながら連続的にタイルを製造することができた。
【００５１】
現場回収品を含むペレットを練り返してシートにするのではなく、そのままペレットを熱圧成型するので、練り返しに伴う異物除去の工程が省かれ、より簡単にタイルのリサイクルを行うことも可能となった。
【００５２】
また、コンポジションタイルのリサイクル粉砕品を再混練することなく基材を形成することができたので不純物の除去が必要なく効率的にタイルが得られた。
【００５３】
特に、リサイクルすることが困難あったため、大量に産業廃棄物として処分されていたコンポジションタイル等の廃棄処分品等も本発明によりかなりの量をリサイクルすることができ、コンポジションタイル等から発生する産業廃棄物を顕著に減少させることができ、環境負荷の低減、及び資源の有効活用を図ることができる。
【図面の簡単な説明】
【図１】 参考例の製造工程図である。
【図２】 本発明の床タイルの一例の製造工程図である。
【図３】 参考例の断面図である。
【図４】 化粧層を一部剥がしたタイル斜視図である。
【図５】 本発明の床タイルの一例の断面図である。
１、１１ ベースシート
２、１２、１４ ホッパー
３ リサイクル粉砕品
４、１６ 加熱ゾーン
５、５’、１７、１７’ プレスロール
６ 化粧層シート
７ 透明層シート
９ 冷却ゾーン
１５ 模様チップ
１９、１９’ 面出しロール
２２、３０ 本発明タイル
２４、２８ 基材層
２５ 化粧層
２９ 模様チップからなる化粧層[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a tile that can be effectively used as a recycled product of the tile and a manufacturing method thereof.
[0002]
[Prior art]
Japanese Patent Application Laid-Open No. 6-339940 discloses a method in which a resin powder having a high porosity made from carpet waste is filled in a mold and laminated with a decorative layer. In this method, a composition floor is disclosed. No recycling of tile grinds is disclosed.
[0003]
[Problems to be solved by the invention]
Construction waste materials such as floor tiles that have been disposed of after construction, especially tiles made of polyvinyl chloride resin, can generate substances that seriously affect the living environment, such as hydrogen chloride and dioxin, when burned. In addition, from the viewpoint of effective use of resources, there has been a demand for a method for effectively recycling industrial waste such as tile scraps and wastes in a factory without burning.
[0004]
On the other hand, a composition tile generally refers to a tile having a binder amount of less than 30% by weight (hereinafter, “% by weight” is referred to as “%”), but most of the composition tiles that are commercialized have a binder amount. It is comprised from 10 to 15% and the amount of fillers is 70 to 80%. In order to recycle such composition tiles, pulverization with a pulverizer, etc. is necessary, and the pulverization blades of the pulverizer are extremely worn. Can only be used as a partial substitute for fillers, and since pigments are included in addition to resins and fillers, it cannot be used for the surface layer from the standpoint of preventing color blurring, etc. It was only recycled while being re-kneaded in small portions on a back layer of a homogeneous style or the like. Moreover, most of the waste materials such as tiles adhered from the construction site and the like were not recycled.
[0005]
Under such circumstances, the amount of composition tile waste generated and the amount recycled cannot be balanced, and a large amount of composition tile waste is not recycled but is discarded in large quantities as industrial waste. Early improvement was desired.
[0006]
[Means for Solving the Problems]
The present invention relates to interior materials such as floor and wall tiles, tiles characterized by laminating a decorative layer on a smooth surface of a non-foamed plastic pellet aggregate base material (hereinafter referred to as a base material), and Non-foamed plastic pellets (hereinafter referred to as pellets) are stacked on a base sheet, heated and pressed without kneading to form a sheet, the surface is smoothed, and a decorative layer is laminated. A method for producing tiles and a plastic chip (hereinafter referred to as a pattern chip) for forming a surface pattern on the stacked pellets are sprayed, and this is heated and pressed without kneading to form a sheet and the surface is coated. The gist of the tile manufacturing method is to provide a decorative layer on the pellet layer by smoothing, and then prepare the surface with a finishing roll. In the present specification, non-foamed plastic pellets are made of resin such as polyvinyl chloride resin, or tiles made by heating and kneading tiles made of resin such as polyvinyl chloride resin, as well as polyvinyl chloride resin and the like. It refers to a pulverized product such as a tile made of resin, and the base sheet refers to a sheet made of resin such as polyvinyl chloride resin, or a woven or non-woven fabric made of organic or inorganic fibers. Recycled pulverized products are tiles made of thermoplastic resin (not limited to polyvinyl chloride resin), and residual materials generated when punching continuous sheets into tiles (hereinafter referred to as frame). In addition, it refers to a crushed product of tile waste material to which an adhesive or the like is attached.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail.
"Figure 1" reference An example manufacturing process diagram is shown, and FIG. 2 shows the present invention. Floor tile Of manufacturing method The manufacturing process figure of another example is shown. 1 and 2, pellets constituting the base material layer are filled in the hoppers 2 and 12, and the pattern chips constituting the decorative layer are filled from the hoppers 14, and the pellets or pattern chips are formed from the lower openings of the hoppers. It is distributed by dropping. In addition to the above-described method of distributing using a hopper, it is only necessary to distribute the pellets or pattern chips almost uniformly, and a known distributing device or the like may be used. When distributing pattern chips, from the viewpoint of design diversity, use pattern chips of two or more colors, and from the viewpoint of pattern stability, stir in advance with a stirrer such as a blender, then use a distribution apparatus. It is preferable to distribute.
[0008]
Especially in the present invention, recycled pulverized products as pellets to be distributed, that is, pulverized composition tiles that have been difficult to recycle, and so-called when punching continuous sheets into tiles when manufacturing tiles at the factory, etc. A crushed product of scrap material such as a frame, and a crushed product of tile attached with adhesive that has been disposed of after landfilling or incineration, which has been unavoidable, can be used.
[0009]
Such recycled pulverized products can be used as pellets. The thermoplastic resin constituting the recycled pulverized product is one of polyvinyl chloride resin, vinyl chloride-vinyl acetate copolymer, ethylene-vinyl acetate copolymer (EVA), PP, PE, polyester, acrylic, polyurethane. Or a mixture of two or more of the resins.
[0010]
The recycled pulverized product is distributed on a base sheet or an endless belt. As described above, the base sheet may be made of a thermoplastic resin or the like. On the other hand, the pattern chip further distributed on the distributed recycled pulverized product is also made of a thermoplastic resin. Moreover, about the said pattern chip | tip, you may add a plasticizer, a stabilizer, a pigment, a light stabilizer, an antistatic agent etc. as needed.
[0011]
Hereinafter, the case where the base sheet is made of a thermoplastic resin and the pattern chip will be described in more detail. As a thermoplastic resin usable for the base sheet and the pattern chip, one of polyvinyl chloride resin, vinyl chloride-vinyl acetate copolymer, EVA, PP, PE, polyester, acrylic, polyurethane, or the resin A mixture of two or more of these is exemplified.
[0012]
When a polyvinyl chloride resin is used as the resin used for the base sheet and the pattern chip, a plasticizer is required, but any plasticizer that can be used may be used as a usable plasticizer. For example, phthalate plastics such as dioctyl phthalate (hereinafter referred to as DOP), dihexyl phthalate, dimethyl phthalate, diethyl phthalate, dibutyl phthalate, diisobutyl phthalate, octyl capryl phthalate, butyl benzyl phthalate, dibenzyl phthalate, dimethyl glycol phthalate Agents, phosphate plasticizers such as tributyl phosphate, tricresyl phosphate, trichloroethyl phosphate, fatty acid ester plasticizers such as methyl acetyl lysylate, dioctyl adipate, dioctyl azelate, and trimet acids such as trioctyl trimet acid And plasticizers, epoxy plasticizers such as epoxidized soybean oil, and polyester polymer plasticizers. These plasticizers can be used alone or in admixture of two or more. From the viewpoint of processability and appropriate flexibility of the product, the addition amount is preferably 20 to 40 PHR for the base sheet and 20 to 40 PHR for the pattern chip.
[0013]
As the filler used for the base sheet and pattern chip, any substance can be used as long as it does not cause chemical or physical changes such as melting and decomposition at the processing temperature. Examples thereof include inorganic fillers such as silicon dioxide, clay, magnesium carbonate, aluminum hydroxide, and aluminum sulfate. The addition amount is preferably from 50 to 200 PHR for the base sheet and from 400 to 800 PHR depending on the pattern to be applied to the pattern chip.
[0014]
Examples of stabilizers include metal stabilizers made of metal compounds including, for example, zinc, barium, tin, calcium, cadmium, strontium, aluminum, magnesium, sodium, lead, etc., organic phosphate compounds, polyhydric alcohols, epoxy compounds Etc. may be used alone or in admixture of two or more. The addition amount is preferably 15 to 30 PHR for the base sheet and 5 to 15 PHR for the pattern chip. If the added amount of the additive is less than the above added amount, the effect as a stabilizer may not be sufficiently exhibited. If the added amount is more than the above added amount, an extra blending cost is required, or bleeding of the added stabilizer, etc. Problems may arise, which is undesirable from an economic or quality perspective.
[0015]
Examples of pigments include inorganic pigments such as titanium oxide, zinc white, carbon black, petal, titanium yellow, ultramarine blue, cobalt blue, and yellow lead, azo pigments such as disazo red and disazo yellow, and organic materials such as phthalocyanine blue and phthalocyanine green. A pigment can be used. Moreover, it is preferable to add in the range of 5-30PHR to a pattern chip | tip. On the other hand, since the base sheet does not contribute much to the appearance, it is sufficient to add a colorable degree. Specifically, it is preferable to add in the range of 0.5 to 10 PHR.
[0016]
Examples of the light stabilizer include organic ultraviolet absorbers such as benzotriazole, benzophenone, and salicylic acid ester, inorganic ultraviolet absorbers such as particulate zinc oxide and cerium oxide, or bis- (2,2,6,6-tetra Hindered amine radical scavengers such as methyl-4-piperidinyl) sebacate, piperidine radical scavengers, and the like can be used. In order to exhibit the effect sufficiently, it is preferable to use the ultraviolet absorber and the radical scavenger in combination as conventionally performed. The addition amount is preferably in the range of 3 to 6 PHR with respect to the pattern chip. If the addition amount of the additive is less than the above addition amount, the effect as a light stabilizer may not be sufficiently exhibited. If the addition amount is more than the above addition amount, an extra blending cost is required, which is not preferable from an economical viewpoint. In addition, about the base sheet which comprises the back surface of this invention tile, since it takes the structure by which surface layers, such as a decorative layer, are provided through a base material layer, it is not necessary to add a light stabilizer especially.
[0017]
Further, a quaternary ammonium salt surfactant is used as the antistatic agent, and the addition amount is preferably in the range of 2.5 to 5.5 PHR for the pattern chip. Note that it is not necessary to add an antistatic agent to the base sheet for the same reason as the antistatic agent.
[0018]
When the base sheet used for the tile of the present invention is made of a thermoplastic resin, a conventional method for manufacturing a sheet or the like can be used as a method for manufacturing the base sheet. For example, raw materials such as resin, filler, etc. of a predetermined composition are mixed and kneaded with a Banbury mixer, kneaded with a mixing roll, molded into a 5-30 mm pad, and then with a calendar roll, 0.4-1.5 mm By rolling to a thickness, it is turned into a sheet, cooled by a water cooling device, an air cooling device, a cooling roll or the like, and more specifically, cooled to 40 ° C. or less, trimmed to a predetermined width, and then taken up by a winder Wind up the sheet.
[0019]
In addition, the base sheet may be formed only from a thermoplastic resin or the like as described above, but at least one kind of inorganic fibers such as glass, carbon, and metal (including alloys), pulp, cotton, rayon, polyester, nylon In addition, a woven fabric or a nonwoven fabric made of at least one organic fiber among urethane, acrylic, and polypropylene, or a sheet formed of a thermoplastic resin and the woven fabric or the nonwoven fabric may be appropriately bonded. Thus, the mechanical strength of the base sheet can be enhanced by bonding the sheet and the woven fabric or the like.
[0020]
On the other hand, as a method for producing a pattern chip used for the tile of the present invention, a conventional method for producing a chip or the like can be used. For example, raw materials such as resins and fillers of a predetermined composition are mixed and kneaded with a Banbury mixer, and the raw materials kneaded with a mixing roll are molded into a pad of 5 to 40 mm, and then a thickness of 1.0 to 3.3 with a calendar roll. By rolling to 0 mm, it is made into a sheet, sufficiently cooled by a water cooling or air cooling device, more specifically cooled to 40 ° C. or less, pulverized by a pulverizer, and using a shaker with a predetermined opening. By classifying, a pattern chip having a diameter of 1.0 to 10.0 mm is obtained.
[0021]
"Figure 1" reference An example manufacturing process diagram is shown, and FIG. 2 shows the present invention. Floor tile Manufacturing method The manufacturing process figure of another example is shown. 1 and 2, pellets constituting the base material layer are filled in the hoppers 2 and 12, and the pattern chips constituting the decorative layer are filled from the hoppers 14, and the pellets or pattern chips are formed from the lower openings of the hoppers. It is distributed by dropping. In addition to the above-mentioned method of distributing using a hopper, it is only necessary to distribute the pellets or pattern chips almost uniformly, and a known distributing machine or the like may be used. When distributing pattern chips, from the viewpoint of design diversity, use pattern chips of two or more colors, and from the viewpoint of pattern stability, stir in advance with a stirrer such as a blender, It is preferable to distribute.

[0022]
In FIG. 1, pellets 3 are spread on the base sheet 1 with a thickness of 2 to 15 mm from the hopper 2. The distribution and the thickness of the deposited pellets can be in the range of 2-15 mm. However, the pellet 3 has a thickness of 0.5 to 5.0 mm in the processing step, more preferably 1.0 to 4.0 mm, and a diameter of 1.0 to 10.0 mm. preferable. As the pellet 3, a recycled pulverized product, for example, a comminuted product of a composition tile (with a binder amount of less than 30%) or a homogeneous style (with a binder amount of 30% or more) can be used.
[0023]
Next, the pellets 3 spread and deposited on the base sheet 1 are heated in a heating zone 4 in the chamber by a heating device (heat platen) at 180 to 250 ° C. so as to keep the pellets flat.
[0024]
Further, pressing is performed by press rolls 5 and 5 ′ provided in the heating zone 4. The decorative layer sheet 6 or the decorative layer sheet 6 and the transparent resin layer sheet 7 are laminated on the obtained sheet. The decorative layer sheet thickness is preferably 0.5 to 1.0 mm, and is prepared in advance, such as a plain sheet, wood grain pattern or marble pattern, transfer printing, direct printing by rotary screen or gravure, or sheet formation. What was laminated | stacked afterwards is suitable. On the other hand, as the transparent resin layer sheet 7, a film or sheet of polyvinyl chloride resin, EVA, acrylic, nylon, polyurethane resin having a thickness of 0.1 to 1.0 mm is laminated via rolls 8 and 8 ′. .
[0025]
Subsequently, the sheet was pressurized by a cooling device (cold platen) containing cooling water at about 30 ° C. in the cooling zone 9 in the chamber, and a sheet 16 having a total thickness of 2.0 to 5.0 mm and having a smooth sheet surface was obtained. The upper and lower endless belts in the heating zone 4 and the cooling zone 9 are Teflon-coated or silicon-coated belts, which are pressed against the sheet with a platen from the inside to obtain a smooth surface sheet.
[0026]
As the transparent resin layer, a paste resin or UV resin may be coated instead of the thermoplastic resin film. The rolling apparatus may be a method other than “FIG. 1”, for example, an apparatus disclosed in Japanese Patent Publication No. 51-2947.
[0027]
Furthermore, the obtained laminated body 10 is appropriately punched into a desired shape and size by a punching press and molded as a tile. Usually, the tile of the present invention is obtained by cutting into 20 to 50 cm square or rectangle. Rather than kneading pellets containing on-site collected products into sheets, the pellets are directly hot-press molded, so tiles can be recycled more easily.
[0028]
FIG. 2 is a manufacturing process diagram of another example of the tile of the present invention, more specifically, a manufacturing process diagram of the tile of the present invention in which a decorative layer is provided by a pattern chip.
[0029]
Pellets 13 are spread on the base sheet 11 at a thickness of 2 to 15 mm from the hopper 12 or directly on the endless belt, and then spread on the base sheet at a thickness of 2 to 15 mm from the hopper 14 into which the pattern chips are put. Pattern chips 15 are spread on the pellets so that the spread, deposited pellets, and pattern chips are kept flat at 180 to 250 ° C. with a heating device (heat platen) in the heating zone 16 in the chamber. It is heated and rolled by press rolls 17, 17 '. When rolling the said pellet and a pattern chip | tip, it is not restricted to the said rolling apparatus, For example, the apparatus disclosed by Japanese Patent Publication No.51-2947 may be used.
[0030]
Next, the surface of the obtained sheet is passed through the facing rolls 19 and 19 ′ to bring the surface into a desired surface state. Here, the chamfering rolls 19 and 19 ′ are rolls used for adjusting the surface to a desired shape, such as an embossing roll, a mirror roll, and a matting roll. After the surface state is adjusted by the surface rolls 19 and 19 ′, the sheet surface is cooled to 20 to 60 ° C. by natural cooling in a cooling zone.
[0031]
Furthermore, the obtained laminate 20 is appropriately punched into a desired shape and size by a punching press and molded as a tile. Usually, it is punched into a square or rectangle of 20 to 50 cm, and the tile of the present invention is obtained.
[0032]
Moreover, you may provide a transparent resin layer on the surface of the decorative layer which consists of a pattern chip | tip before passing through the chamfering rolls 19 and 19 'after passing a heating apparatus. The transparent resin layer has a thickness of 0.1 to 1.0 mm made of a thermoplastic resin such as polyvinyl chloride resin, vinyl chloride-vinyl acetate copolymer, EVA, acrylic, nylon, polyurethane resin, or a mixture of these thermoplastic resins. The film or sheet may be formed by laminating via a press roll in the same manner as in the above embodiment, or may be provided by coating a paste-like resin or UV resin other than the film. good.
[0033]
Also according to this embodiment, as in the above embodiment, the pellets containing the on-site collected product are not kneaded into a sheet, but the pellets are hot-press molded as they are, so the step of removing foreign matter accompanying the kneading is omitted, Tile can be recycled more easily.
[0034]
FIG. 3 shows a cross-sectional view of an example of the tile of the present invention. Reference numeral 23 denotes a base sheet on which a base material layer 24 is formed. The base material layer 24 is composed of the recycled pulverized product, has a thickness of 0.6 to 3.0 mm, and has a smooth surface. The base material layer may be an aggregate of relatively large pellets having a diameter of 5.0 to 10.0 mm, but in the case of a crimped sheet of relatively small pellets of 1.0 to 5.0 mm, the surface becomes smoother. preferable. On this smooth surface, the pattern layer 25 is formed. Examples of the pattern layer include a colored film such as a plain pattern, a wood grain pattern, and a marble pattern, a sheet having a pattern printed on a rotary screen, a portion printed directly on a base material, and the like, and a transparent resin is further laminated. In this way, the tile of the present invention is obtained.
[0035]
"FIG. 4" is a perspective view of an example of the tile of the present invention shown in "FIG. 3" with a part of the decorative layer peeled off, wherein 24 is a base material layer and 25 is a decorative layer.
[0036]
FIG. 5 shows a cross-sectional view of another example of the tile of the present invention. A decorative layer 29 made of a pattern chip is formed on the base material layer 28. As in the above embodiment, the base material layer is composed of the recycled pulverized product. The base material layer 28 has a thickness of 0.5 to 5.0 mm, preferably 1.0 to 3.0 mm, and does not necessarily need to be smooth because the decorative layer 29 made of a pattern chip is provided. However, it is necessary to make the base material invisible between the pattern chips constituting the decorative layer.
[0037]
When the decorative layer is provided by a pattern chip, the thickness of the decorative layer 29 is 1.0 to 5.0 mm, and preferably 1.0 to 3.0 mm. Further, the pattern chip constituting the decorative layer 29 has a thickness of 1.0 to 5.0 mm, preferably 1.0 to 3.0 mm. Moreover, about a diameter, it is 1.0-15.0 mm, Preferably it is 1.0-10.0 mm. The thickness or diameter of the pattern chip is limited to the above range. If the thickness or diameter is smaller than the above, the chips may be kneaded with each other in the heating and rolling stages, and the pattern may not appear. Yes, if the thickness or diameter is larger than the above, the pattern chip on the upper side covers the pattern chip on the lower side in the heating and rolling stages, so the pattern chip is not heated sufficiently, and the pattern chip It is because there exists a possibility that it may become a fusion | melting insufficient.
[0038]
Moreover, 1.0-7.0 mm is preferable and, as for the total thickness of this invention tile which consists of the base material layer 28 and the decorative layer 29 of a pattern chip | tip, More preferably, it is 2.0-5.0 mm. If the total thickness is less than 1.0 mm, there may be a problem in strength such as cracking. On the other hand, if it is thicker than 7.0 mm, the tile will be heavy and the handling will be hindered. Because there is a fear.
[0039]
【Example】
( Reference example The base sheet used in this example was made of a thermoplastic resin. That is, the blend of “(Table 1)” was kneaded with a Banbury mixer, rolled to a 10 mm thick pad with a mixing roll with a front roll set to 195 ° C. and a back roll set to 185 ° C., and set to 160 ° C. After being rolled with a calender roll to a thickness of 0.5 mm, it was cooled with a cooling roll and trimmed to a width of 980 mm.

[0040]
Place the above 0.5mm thick base sheet on the conveyor belt, and then recycle the composition tile recycled product containing used composition tiles of 2.0mm thickness and 3mm diameter (7 mesh under) as pellets on it. 3300g / m ² And heated and pressurized at 220 ° C. to form a 1.7 mm substrate sheet. This backing layer is formed by crimping a non-foamed thermoplastic resin. Even if the adhesive of the used flooring material appears on the surface, the surface is completely smooth, and the thickness printed on the rotary screen is 0.5 mm. A 0.3 mm polyvinyl chloride resin layer was further laminated thereon as a transparent resin layer.
[0041]
The obtained surface-patterned continuous sheet was cut at 30.3 cm to obtain a new recycled tile with a printed pattern. In this way, it was possible to form the base material layer without kneading the composition tile recycled pulverized pellets, so there is no need to remove impurities and there is no problem even if different colors are included, and tiles can be obtained efficiently. It was.
[0042]
(Implementation Example) The base sheet is Reference example The thing similar to what was used in "was used. For the pattern chips, the blend of “(Table 1)” was kneaded with a Banbury mixer, rolled to a 35 mm thick pad with a mixing roll with a front roll set at 160 ° C. and a back roll set at 160 ° C. The sheet temperature was adjusted to 30 ° C. or less by rolling the sheet with a calender roll set to 2.0 mm to a thickness of 2.0 mm and immersing it in a water tank. Furthermore, the said sheet | seat was grind | pulverized with the grinder, and the pattern chip | tip with a diameter of 4 mm was obtained by using a 5 mesh shaker.

[0043]
The base sheet having a thickness of 0.5 mm is placed on a conveyor belt with the composition shown in Table 1, and a used composition tile having a diameter of 2.0 mm and a diameter of 4 mm (5 mesh under) is included thereon as pellets. 2900 g / m of recycled composition tiles ² Furthermore, 2900 g / m of pattern chips having a thickness of 2.0 mm and a diameter of 4 mm (5 mesh under) are formed on the pellets. ² After being deposited at a rate of 220 ° C., it is heated and pressed at 220 ° C. to form a continuous sheet, naturally cooled on the conveyor so that the surface temperature of the continuous sheet becomes 140 to 160 ° C., and with a surface roll set to 40 ° C. While adjusting the surface to a mirror surface, the continuous sheet thickness was molded to 3.0 mm. Furthermore, the surface temperature of the continuous sheet was cooled to 40 ° C. or lower with an air cooling device, and the tile of the present invention was punched into 450 mm square by a punching machine.
[0044]
Thus, since the base material layer could be formed without kneading the composition tile recycled pulverized product, the tile was efficiently obtained without the need for removing impurities.
[0045]
“Table 1” shows an example of a base sheet and a pattern chip, and “Table 2” shows physical properties of tiles obtained, existing composition tiles, and homogeneous styles.
[0046]
[Table 1]
(Combination)

* 1 Polyvinyl chloride (degree of polymerization 700-1000)
* 2 Vinyl chloride-vinyl acetate copolymer (degree of polymerization 700, vinyl acetate content 10%)
* 3 Calcium carbonate used for pattern chips has an average particle size of 70 μm, and calcium carbonate used for the base sheet is heavy calcium carbonate having a particle size of 10 to 50 μm.

[Table 2]

* The sample of Comparative Example 1 is Machico V (our composition tile)
* The sample of Comparative Example 2 is Melstone (our Homogene style)
* Regarding the test methods for the above physical property values, a sample of 303 mm square was warped for 12 hours in a temperature-controlled room adjusted to a room temperature of 20 ± 2 ° C. and a humidity of 65 ± 10%, and then placed on a polished plate glass. The warp at 20 ° C. was measured using a 1/10 mm magnifying glass between the four corners of the glass plate and the glass plate. Next, after standing in an air dryer adjusted to 80 ± 2 ° C. for 6 hours and further curing in the temperature-controlled room for 1 hour, the gap with the glass plate is attached with a 1/10 mm scale as above. Warpage at 80 ° C. was measured using a loupe. Further, after a sample of 303 mm square was cured in the temperature-controlled room for 12 hours, the polished plate glass was left with the sample in a variable chamber set at 5 ° C. for 1 hour, and the gap between the four corners of the sample and the glass plate was Warpage at 5 ° C. was measured using a 1/10 mm scale loupe. Moreover, the heating length change rate and the water absorption length change rate were performed according to JISA5705.

[0047]
As a result, it was shown that the product of the present invention is superior to conventional composition tiles and homogenia styles in terms of warpage at 5 ° C, heating length change rate, and water absorption length change rate, or no inferiority. .
[0048]
【The invention's effect】
The surface of the base material was smooth even when recycled pulverized materials such as building waste such as used flooring with the adhesive adhered thereto were included.
[0049]
A beautiful recycled tile with a decorative layer was obtained even when recycled building waste was used. The physical properties of recycled tiles were no different from normal existing tiles.
[0050]
Without recycling the recycled pulverized product again, or heating and pressurizing with a press or the like, it was possible to continuously produce tiles while spreading the recycled pulverized product.
[0051]
Rather than kneading pellets containing on-site collected products into sheets, the pellets are hot-press molded as they are, eliminating the foreign matter removal process associated with kneading and making it easier to recycle tiles. became.
[0052]
Further, since the substrate could be formed without re-kneading the recycled pulverized product of the composition tile, the tile was efficiently obtained without the need for removing impurities.
[0053]
In particular, because it was difficult to recycle, a considerable amount of waste such as composition tiles that were disposed of as industrial waste in large quantities can be recycled according to the present invention. Industrial waste can be significantly reduced, environmental load can be reduced, and resources can be effectively used.
[Brief description of the drawings]
[Figure 1] Reference example FIG.
FIG. 2 Floor tile One It is a manufacturing process figure of an example.
[Fig. 3] reference It is sectional drawing of an example.
FIG. 4 is a perspective view of a tile with a decorative layer partially removed.
FIG. 5 shows the present invention. Floor tile One It is sectional drawing of an example.
1,11 Base sheet
2, 12, 14 hopper
3 recycled ground products
4,16 Heating zone
5, 5 ', 17, 17' press roll
6 Makeup layer sheet
7 Transparent layer sheet
9 Cooling zone
15 Pattern chip
19, 19 'Surface roll
22, 30 tile of the present invention
24, 28 Base material layer
25 makeup layer
29 Cosmetic layer made of patterned chips

Claims (4)

On a base sheet, a step of depositing a non-foamed plastic pellets,
Spraying plastic chips forming a pattern on the non-foamed plastic pellets deposited ;
By smoothing the surface while the sheet of hot pressed without kneading it, and a step of Ru provided a decorative layer on the non-foamed plastic pellet layer,
The non-foamed plastic pellet is a recycled pulverized product,
The plastic chip has a thickness of 1.0 to 5.0 mm and a diameter of 1.0 to 10.0 mm,
The decorative layer is located on the outermost surface
A method for manufacturing a floor tile. Furthermore, the manufacturing method of the floor tile of Claim 1 which has the process of preparing the surface with a finishing roll. The method for producing a floor tile according to claim 1 or 2, wherein the plastic pellet is a recycled pulverized product of floor tile. The floor tile manufactured by the manufacturing method of the floor tile in any one of Claims 1-3.

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