JPH11291248A - Building floor material using composite plastic waste material as raw material and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To effectively reutilize a plastic waste material and a rubber waste material. SOLUTION: A PP waste material is ground by a grinder 6 to obtain fine pieces having a size of about 1 cm<2> and a PP laminate waste material is also ground in the same way and a rubber waste material such as an old tire or the like is ground to be formed into a powder form. A material weighing and mixing supply apparatus 7 weighs these ground materials so that the rubber material becomes 80 wt.% and these materials are supplied to a mixer 8. The materials in a chamber are stirred and mixed by the high speed rotation of the stirring blades of the mixer 8 to melt a resin by internal frictional heat to form a gel-like mixed material. This material is formed into a panel shape by a press molding device 10 to obtain a building floor material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a polypropylene,
TECHNICAL FIELD The present invention relates to a flooring material for building and a method of manufacturing the same using a composite waste plastic material as a raw material for effectively utilizing a waste plastic material such as polyethylene and a waste rubber material such as an old tire of an automobile.

[0002]

[0005] A large amount of various types of plastic products are provided on the market. With this, a large amount of plastic waste material is discharged as industrial waste and general waste, thereby protecting the environment and securing resources. From the viewpoint of the above, the treatment is becoming a big social problem. It has been recommended that such plastic waste materials be separately collected for each type, and some of them are reused (recycled) as recycled materials. However, only about 10% of plastic waste is recycled.
At present, the remaining 90% (more than 7 million tons of industrial waste per year) is landfilled or incinerated.

As a method of regenerating plastic waste materials (thermoplastic resins such as PP and PE), for example, a predetermined kind of collected plastic waste material is fragmented, and the fragmented material is put into an extruder. Heating a heater to a predetermined melting temperature to dissolve it, extruding the melted plastic into a thin string shape, cooling it, and chopping (pelletizing) it to obtain a pellet-shaped plastic recycled material. ing.

At this time, the melting temperature (melting point) differs for each type of plastic, and there is a problem of thermal deterioration, so that it is generally impossible to mix a plurality of types of plastics into a recycled material or a recycled product. . Therefore, in order to regenerate the plastic material, it is necessary not to mix different kinds of plastics or foreign substances, which has been a major factor that hinders the recycling of the plastic material.

[0005] Among plastic waste materials, particularly, a laminated product obtained by laminating plastic with paper, aluminum foil, different kinds of plastics, fibers, etc., is subjected to the above-mentioned melting and pelletizing in order to make it a recycled material. In the previous stage, extra troublesome intermediate steps such as separation, sorting, sorting, etc. are required extraly, so the cost for regeneration becomes extremely high, economically unprofitable, and it is actually recycled. It is rarely possible.

On the other hand, at present, it is difficult to treat rubber waste materials such as old tires of automobiles. Such plastic waste and rubber waste are expected to increase more and more in the future, and there is an urgent need to solve their disposal problems.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a flooring material for building using composite plastic waste as a raw material and a method for manufacturing the same, which can effectively reuse plastic waste and rubber waste. To offer.

[0008]

The inventor of the present invention has disclosed a device for melting plastic waste, which has a plurality of stirring blades in a chamber, and rotates the stirring blades at a very high speed (when the tip speed of the blades is 15). ~ 40 m / sec) by using a different mixing machine (different melting points).
Even if the material is a mixture of plastics (thermoplastic resins), it can be stirred vigorously to generate frictional heat and be melted, and gel-like molding material without thermal degradation or shearing action Was obtained. In this case, not only a mixture of dissimilar plastics,
Even if a foreign material such as rubber or a laminate material is mixed with plastic, a mixed material thereof can be obtained.

Based on this finding, a gel-like mixed material is obtained from a material in which different types of plastic waste materials are mixed or further mixed with different types of waste materials, and the mixed material is formed into a desired shape to be recycled. The present invention has been accomplished by confirming that a floor material for construction can be obtained by making the regenerated molded product into a plate shape at this time.

[0010] At this time, a gel-like mixed material obtained by mixing a plastic material obtained by slicing the plastic waste material and a rubber material obtained by converting the rubber waste material into particles is formed into a plate-like shape.
In particular, it is possible to obtain a recycled molded product suitable as a building floor material. In this case, the rubber material itself does not melt,
The surface of the particles is in a molten state, and the melted thermoplastic resin fuses with the surface of the rubber particles and plays a role as a whole binder.

[0011] The building flooring made of the composite plastic waste material according to the first aspect of the present invention is a plate-like material obtained by mixing the fragmented composite plastic waste material and melting it by internal frictional heat. It has the characteristic of being formed.
According to this, a flooring material for building can be obtained by using the composite plastic waste material, so that the cost can be reduced, and even if different types of plastic materials are mixed as described above, there is no problem. In addition, since foreign materials are allowed to be mixed, there is no need to separate, sort, etc. for each type, and the process can be simplified.

At this time, the composite plastic waste material is
It is possible to include a plastic material obtained by slicing a plastic waste mainly composed of a thermoplastic resin such as polypropylene or polyethylene, and a rubber material made of a particulate rubber waste such as a tire (the invention of claim 2). ). According to this, a floor material for building is composed of a mixed material obtained by mixing and melting a plastic material mainly composed of a thermoplastic resin and a rubber material by internal frictional heat, which is a characteristic inherent to rubber. However, it is possible to provide a flooring material having a function of being excellent in sound insulation and vibration absorption and also excellent in heat retention.

In this case, it is preferable that the mixing ratio of the rubber material is 50 to 80% by weight of the whole mixed material (the invention of claim 3), whereby good properties as a floor material for building are obtained. be able to. If the mixing ratio of the rubber material exceeds 80% by weight, the amount of the plastic as a connecting material becomes too small, so that the fluidity of the mixed material is reduced and the strength of the molded product is reduced. On the other hand, if the mixing ratio of the rubber material is less than 50% by weight, the plastic material becomes too large, the molded product becomes hard, and the inherent characteristics of the rubber cannot be fully utilized.

The plastic waste materials include polypropylene or polyethylene, paper, aluminum foil,
A laminate material in which different kinds of plastics, fibers, and the like are bonded can be included (the invention of claim 4). According to this, it is possible to easily recycle a laminate material which was difficult to recycle in the past, and not only that,
Rather, advantages such as reinforcement, weight reduction, and improvement in thermal conductivity can also be obtained.

[0015] The construction flooring made of the composite plastic waste material according to claim 5 of the present invention is characterized in that a gel-like mixed material obtained by mixing fragmented composite plastic waste material and melting by internal frictional heat is used as a plate. It is characterized in that it is formed into a shape and a rubber material in the form of particles is adhered to its surface. According to this, it is possible to obtain a two-layered building flooring material of rubber and plastic, and at this time the cost can be reduced and the process can be simplified.

[0016] The construction flooring made of composite plastic waste material according to claim 6 of the present invention is characterized in that a gel-like mixed material obtained by mixing fragmented composite plastic waste material and melting by internal frictional heat is produced from rubber material. It is characterized in that it is formed into a plate while being bonded to a sheet. According to this, it is possible to obtain a two-layered building flooring material of rubber and plastic, so that the cost at this time can be reduced and the process can be simplified.

[0017] The method for producing a flooring material for building using the waste composite plastic material of the present invention as a raw material comprises polypropylene,
A plastic material obtained by slicing waste plastic material mainly composed of thermoplastic resin such as polyethylene and a rubber material made of rubber waste material such as tires are accommodated in a chamber having stirring blades rotating at high speed and stirred. Mixing and melting by internal friction heat to obtain a gel-like mixed material,
And a molding step of molding the gel-like mixed material into a plate shape by a molding device (the invention of claim 7).

According to this, in the melting step, a gel-like mixed material obtained by mixing and melting a rubber material and a plastic material mainly composed of a thermoplastic resin by internal frictional heat is obtained,
In the forming step, the mixed material is formed into a plate to obtain a building flooring. At this time, as described above, it is possible to easily and inexpensively obtain a flooring material which is excellent in sound insulation and vibration absorption as well as excellent in heat retention, and is formed by a molding device, so that it has a desired size and shape. Architectural flooring can be obtained.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described below with reference to FIGS. First,
FIG. 1 shows an appearance of a building flooring 1 according to the present embodiment. As will be described later, the floor material 1 is made of a rubber material made of rubber waste material, and a plastic waste material (mainly a thermoplastic resin such as polypropylene (hereinafter abbreviated as “PP”) or polyethylene (hereinafter abbreviated as “PE”)). Mixed material with plastic material (laminated material) (composite plastic waste material)
, And is formed into a rectangular plate shape.

Further, a step portion 1a is provided on the left side of the flooring material 1 in the figure so as to be concave by half the thickness dimension on the lower surface side. Symmetrically, a stepped portion 1b that is concave on the upper surface side is provided. The floor material 1 has a length L of, for example, 920 m.
m, the actual width W excluding one step portion 1b is 920 m
m, thickness H is formed to 20mm, weight is about 17kg
It has been. In this case, in this embodiment, the mixing ratio of the rubber material in the mixed material is set to 80% by weight (the plastic material is 20% by weight). The method of manufacturing the flooring 1 will be described later.

FIG. 2 shows an example of a use form of the floor material 1. In this method, the floor material 1 is used for a floor portion of a living room of an apartment or a condominium, and a hot water pipe 3 for floor heating is provided on an upper surface of a concrete floor panel 2. The floor material 1 is laid. At this time, the steps 1a, 1b are wrapped so as to mesh with each other between the adjacent flooring materials 1 so that the flooring materials 1 can be densely spread without gaps. The flooring material 4 is provided on the upper surface of the flooring material 1 to form a floor.

Now, a method of manufacturing the building flooring material 1 will be described in detail below. First, an apparatus configuration used for manufacturing the flooring 1 will be described. FIG. 4 shows a schematic layout of the manufacturing equipment 5 for the flooring material 1.
Is a pulverizing device 6 for pulverizing a plastic material, a material metering / mixing / supplying device 7 for accommodating and measuring and supplying the material, and a gel-like mixed material obtained by melting the supplied material by internal friction heat. Mixing machine 8, a gel conveying robot 9 for conveying the mixed material discharged from the mixing machine 8, a press forming apparatus 10 for press-forming the mixed material into a plate, and a product (floor material) formed by the press forming apparatus 10. The apparatus includes a product unloading device 11 for unloading 1), a control panel 12 for controlling the above devices, and the like.

The crushing device 6 comprises, for example, a general-purpose crusher, and crushes plastic waste material into small pieces of, for example, about 1 cm square. Here, the collected PP waste material and the laminate material of PP and paper, aluminum, PE, etc. are crushed. In this case, the material metering / mixing / supplying device 7 includes three hoppers 7a, and is configured to measure the materials in the hoppers 7a by predetermined amounts and supply the materials to the mixing machine 8 through the supply paths 7b. .

In this case, each of the three hoppers 7a contains a material obtained by shredding PP waste material, a material obtained by shredding PP laminate waste material, and a rubber material obtained by converting rubber waste material into particles (powder). It is supposed to be. As the rubber material, for example, a material obtained by treating a collected used old tire of an automobile to form a particle is used. In the present embodiment, the rubber material is 80% by weight, the PP material and the laminate pulverized material are 20% in total, and 1%.
A total of about 17 kg of material is supplied to the mixing machine 8 in each operation.

The mixing machine 8 is configured as shown in FIG. That is, a motor 14 is provided on the right side of the mixing machine 8 in the figure on the base 13, and the chamber 15 is provided on the left side of the mixing machine 8 in the figure on the base 13.
Is provided. A material supply chamber 16 is provided adjacent to the right side of the chamber 15, and they are connected to a communication port 16a.
Is communicated with. Further, a drive shaft 17 is provided which extends through both the chamber 15 and the material supply chamber 16 in the left-right direction through the communication port 16a.

The drive shaft 17 has bearings 18, 1 at both ends.
8 and is rotatably supported, and the right end in FIG.
4a. The drive shaft 17 is provided with a screw 20 located in the material supply chamber 16 for feeding the material into the chamber 15 through the communication port 16a. Are provided, and a plurality of stirring blades 21 are provided for mixing and melting by internal frictional heat. Although not shown,
The drive shaft 17 is formed in a hollow shape, so that cold water for preventing overheating is circulated therein through a cold water circulation pipe 22 provided at the left end in the figure.

A hopper 23 is provided above the material supply chamber 16 for receiving the material supplied from the material measuring and mixing supply device 7. A discharge port 24 for discharging the melted and gelled mixed material is provided below the chamber 15, and the discharge port 24 is opened and closed by an opening and closing mechanism 25. Outlet 2
A gutter-shaped discharge path 26 is provided outside of 4. Further, a temperature detector 27 such as an infrared temperature sensor for detecting the internal temperature in a non-contact manner is provided in an upper portion of the chamber 15. The opening of the outlet 24 is controlled by the temperature detector 27 detecting a predetermined temperature (for example, 220 ° C.).

As described later in the operation, the mixing machine 8 sends the material supplied to the material supply chamber 16 into the chamber 15 by rotating the drive shaft 17 by the motor 14. The material is strongly stirred by the high-speed rotation of the stirring blade 21 (tip speed is 15 to 45 m / sec), melted in a very short time (for example, several seconds to several tens of seconds) due to the generation of frictional heat, and becomes gel-like. It is a mixed material. Then, based on the temperature detected by the temperature detector 27, the opening / closing mechanism 25 opens the discharge port 24, and the gel-like mixed material is discharged to the discharge path 26. In this case, the material is kept for a very short time (eg, 28
Seconds).

As shown in FIG. 4, the gel transfer robot 9 receives the gel-like molten mixed material discharged into the discharge path 26 of the mixing machine 8 by a tray 9a or the like, and transfers it to the press molding apparatus 10. Then, it is put into the mold 28. The press molding apparatus 10 has a mold 28 corresponding to the floor material 1.
Press molding is performed at a pressure of about 50 kg / cm @ 2. The molded product (floor material 1) is taken out of the mold 28 and transported by the product transport device 11. In addition, the press molding device 10 and the product transfer device 1
1 may be provided in two or more systems as needed.

Next, a procedure for manufacturing the building flooring 1 using the manufacturing equipment 5 will be described. As described above, the rubber waste material serving as the raw material of the flooring material 1 is converted into a particulate (powder-like) rubber material and stored in one hopper 7 a of the material mixing and feeding device 7. In addition, the PP waste material is
Into a piece of about 1 cm square and accommodated in another hopper 7a.
Is cut into pieces of about 1 cm square and further hopper 7a
Is housed in

Then, the material is supplied from the material metering / mixing / supplying device 7 to the hopper 23 of the mixing machine 8 at a predetermined ratio, and the mixing machine 8 executes a melting process. In the melting step, the material supplied from the material supply chamber 16 into the chamber 15 is strongly stirred and mixed at a high speed by the stirring blades 21 to generate frictional heat. At this time, of course, all the materials are uniformly mixed. In this embodiment, specifically, the drive shaft 17 is rotated at a high speed of, for example, 5000 rpm, and the tip speed of the stirring blade 21 is set to, for example, 36 m / sec.

Due to the internal frictional heat generated by the stirring and mixing, the temperature of the chip-shaped PP material, which is a thermoplastic resin in the material, and the PP resin in the laminate material rise rapidly, and the temperature rises for a very short time (several seconds to several tens of seconds). Seconds). At the same time, since the rubber particles are thermosetting and do not melt as a whole at 220 ° C., the surface becomes molten by the high temperature, and the melted PP resin fuses with the surface of the rubber particles. It plays a role as a whole tether. Further, foreign materials (paper, aluminum, fibers, etc.) in the laminate material are also sufficiently mixed and dispersed in the mixed material.

In this way, a gel-melted mixed material is obtained, and after a lapse of a predetermined time (in this case, 28 seconds), a gel-like (hardness like freshly-polished rice cake) molten mixed material is obtained. Is discharged from the discharge port 24. At this time, since the time until the PP material is melted by stirring and mixing is extremely short, there is no thermal deterioration and no shearing action occurs. At this time, even if different kinds of plastics (PE or the like) having different melting points are contained in the laminate material (or in the PP material), they are similarly melted without thermal deterioration and mixed.

Then, the discharged gel-like mixed material is
The gel is transferred to the press forming apparatus 10 by the gel transfer robot 9, and the forming step is performed. By this forming step, the mixed material is press-formed into a plate shape, and the building flooring material 1 is obtained. One product (floor material 1) is completed in about 1 to 1.5 minutes.

The architectural flooring material 1 obtained as described above
Since the rubber contains 80% by weight of a rubber material, it has a function of being excellent in sound insulation and vibration absorption, and also excellent in heat insulation, which are inherent characteristics of rubber. Further, since the rubber waste material and the plastic waste material are used as raw materials, the raw material cost can be significantly reduced.

Here, according to the study of the present inventor, it is preferable that the mixing ratio of the rubber material is 50 to 80% by weight of the whole mixed material. Can be obtained. The mixing ratio of rubber material is 8
If the content is more than 0% by weight, the amount of plastic as a connecting material becomes too small, so that the fluidity of the mixed material is reduced and the strength of the molded product is reduced. on the other hand,
If the mixing ratio of the rubber material is less than 50% by weight, the plastic material becomes too large, the molded product becomes hard, and the original characteristics of the rubber cannot be fully utilized.

In this embodiment, since PP is used as the plastic material, it is possible to use the building flooring material 1 which is relatively resistant to high temperatures. It becomes suitable. In this case, if the floor is used in a cold region or the like and does not use floor heating or the like, it is preferable that the plastic material is mainly composed of PE, thereby obtaining a merit that the floor material 1 can withstand a low temperature. it can. Furthermore, if you include a laminate material in the material,
By mixing paper or fiber, it is possible to achieve weight reduction and reinforcement, and when an aluminum laminate is used, advantages such as improved thermal conductivity and flame retardancy can be obtained.

According to the method of manufacturing the building flooring material 1 of this embodiment, the plastic waste material is not formed into pellets at one end, and the steps of separating, sorting, and sorting the laminate material are not required. Waste materials can be directly recycled into products, and intermediate processes can be largely omitted to enable recycling (recycling) with simple processes.
In this case, the recycling of the laminated material, which has been difficult in the past, is also facilitated. The manufacturing equipment 5 is also simple,
Since the manufacturing process is relatively simple and the product can be manufactured in a short time, the manufacturing cost (the cost required for recycling) is low, and the economical advantage is extremely large.

As a result, according to the present embodiment, it is possible to obtain an excellent effect that plastic waste and rubber waste, which had been difficult to treat in the past, can be easily and effectively reused. As a result, it can greatly contribute to solving the problem of treating plastic waste and rubber waste.

FIG. 5 shows a building flooring material 31 according to a second embodiment of the present invention. The floor material 31 has a rubber layer 33 made of a rubber waste material on a surface of a plastic layer 32 formed into a rectangular plate from a material (a composite plastic waste material) obtained by mixing a plastic waste material mainly composed of a thermoplastic resin. It is configured. At this time, the rubber layer 33 can have a thickness of 1 to 10 mm according to the intended use.

In manufacturing the floor material 31, first, the crushed composite plastic waste material is stirred and mixed at a high speed by the above-mentioned mixing machine 8, and then mixed in a gel state by internal frictional heat as in the above embodiment. Get the material. And
The gel-like mixed material is formed into a plate shape by a press molding device 9 to perform a primary molding to obtain a plastic layer 32. Once the mold 28 is opened, a rubber material in the form of particles is formed on the surface of the plastic layer 32. Place it so that it covers the predetermined thickness,
Press molding is performed again. With this, the plastic layer 32
Thus, the floor material 31 having the rubber layer 33 adhered to the surface thereof is obtained.

FIG. 6 shows a third embodiment of the present invention. As shown in FIG. 6B, a building floor material 41 according to this embodiment is made of a plastic material formed by mixing a plastic waste material mainly composed of a thermoplastic resin (composite plastic waste material) into a rectangular plate. A rubber layer 43 made of a rubber sheet is attached to the surface (the lower surface in the figure) of the layer 42 in a bonded state. In this case, the rubber layer 43 (rubber sheet) can also have a thickness of 1 to 10 mm according to the intended use.

In manufacturing the floor material 41, first, the crushed composite plastic waste material is stirred and mixed at a high speed by the above-mentioned mixing machine 8, and the gel-like mixing is performed by internal frictional heat in the same manner as in the above embodiment. A material 44 is obtained. Then, as shown in FIG. 6A, a rubber sheet (rubber layer 43) is placed in advance in a mold of the press molding device 9, and
The mixed material 44 in the form of a gel is placed on the rubber sheet and pressed. As a result, a floor material 41 in which the rubber layer 43 is integrated with the surface of the plastic layer 42 as shown in FIG. 6B is obtained.

In each of the above embodiments, polypropylene or polyethylene is used as an example of the plastic material. However, ABS, polystyrene, acrylic resin, vinyl chloride, ethylene-vinyl acetate copolymer, polyester resin, polyamide resin It can be applied to thermoplastic resins in general, and it is needless to say that a mixture of a plurality of different types of plastic materials may be used, and a mixture of different materials may be used. Applicable in general. In addition, the present invention is not limited to the above-described embodiments, for example, the shape and size of the flooring material and various forms of use are also possible. It can be implemented.

[0045]

As is apparent from the above description, according to the flooring material for construction using the waste composite plastic as a raw material and the method for producing the same according to the present invention, the waste composite plastic can be used at low cost and in a simple process. It has an excellent effect that it can be effectively reused (recycled) as a flooring material, and thus can greatly contribute to solving the problem of treating plastic waste materials and rubber waste materials.

[Brief description of the drawings]

FIG. 1 shows a first embodiment of the present invention, and is a perspective view of a building flooring material.

FIG. 2 is a longitudinal sectional view showing an example of a usage form of a flooring material.

FIG. 3 is a side view of the mixing device, partly in longitudinal section.

FIG. 4 is a plan view schematically showing a floor material manufacturing facility.

FIG. 5 is a longitudinal sectional view of a floor material showing a second embodiment of the present invention.

FIG. 6 shows a third embodiment of the present invention and is a longitudinal sectional view showing a manufacturing process of a flooring material.

[Explanation of symbols]

In the drawings, 1 is a building floor material, 5 is a manufacturing facility, 8 is a mixing machine, 10 is a press molding device, 15 is a chamber, 21 is a stirring blade, and 28 is a mold.

Claims (7)

[Claims] An architectural material made from a composite plastic waste material, which is obtained by mixing a fragmented composite plastic waste material and melting it by internal frictional heat to form a gel-like mixed material into a plate shape. Flooring. 2. The composite plastic waste material includes a plastic material obtained by slicing a plastic waste material mainly composed of a thermoplastic resin such as polypropylene and polyethylene, and a rubber material made of rubber waste material such as tires in a particulate form. A flooring material for construction, comprising the waste composite plastic material according to claim 1 as a raw material. 3. The building flooring made of composite plastic waste according to claim 2, wherein the mixing ratio of the rubber material is 50 to 80% by weight of the whole mixed material. 4. The composite plastic waste material according to claim 2, wherein the plastic waste material includes a laminate material in which polypropylene or polyethylene is bonded to paper, aluminum foil, different kinds of plastics, fibers, and the like. Flooring for building made from 5. A gel-like mixed material obtained by mixing flaked composite plastic waste materials and melting by internal frictional heat is formed into a plate shape, and a particulate rubber material is adhered to the surface thereof. A flooring material for buildings made from waste composite plastics. 6. A method in which a gel-like mixed material obtained by mixing flaked composite plastic waste materials and melting by internal friction heat is formed into a plate shape while being bonded to a sheet made of a rubber material. Architectural flooring made from the characteristic waste of composite plastic. 7. A stirring blade which rotates a high-speed rotating plastic material obtained by slicing a plastic waste material mainly composed of a thermoplastic resin such as polypropylene or polyethylene, and a rubber material such as a tire into a rubber waste material. A melting step of accommodating in a chamber, stirring and mixing, and melting by internal frictional heat to obtain a gel-like mixed material, and a forming step of forming the gel-like mixed material into a plate by a molding device are performed. A method for producing a flooring material for buildings using composite plastic waste material as a raw material.