JPS6021859B2 - Method for manufacturing sheet-like products using scraps of thermoplastic synthetic resin products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing high-grade sheet-like interior materials such as floor coverings and wall coverings using waste products and scraps of thermoplastic synthetic resin products.

Conventionally, scraps of thermoplastic synthetic resin products have been processed such as pulverization and recycled, and the amount that has been incinerated as industrial waste or municipal waste or sent to landfills has not been very large. However, among the scraps of these thermoplastic synthetic resin products, there are those that are composited with other foreign materials such as cloth and paper, old materials and scraps that are used as floor teaching materials and wall coverings, and that generate gruel when reupholstered, and those that have been used for many years. If the quality deteriorated or became dirty during the period, it was impossible to put it back on the Li cycle line, and it had to be disposed of as industrial waste. Among products made of laminated fabrics made of natural fibers, especially cotton, those with a relatively thick resin layer are removed by burning the cotton layer with sulfuric acid, and after washing the remaining resin tank with water,
If pulverized, it can be used as an extender for the surface layer of synthetic resin floor teaching materials, but currently, most thin materials are disposed of in landfills or incinerated. The present invention was made in view of the current situation, and to explain one example of its implementation, it is possible to use waste products and scraps of thermoplastic synthetic resin products, especially thermoplastic synthetic resin products laminated with paper, cloth, etc., to manufacture automobiles. This is a method for producing high-grade sheet-like products such as trunk room rugs and power mats, anti-slip rugs for poolside and shower rooms, surface materials for bulletin boards, and even wall coverings with foam textured patterns. The product scraps are pulverized using a pulverizer and processed into fine particles with a size of about 10 mesh or less.

Therefore, the easier it is to crush, that is, the more filler there is, the harder it is due to deterioration, the more advantageous it is.Particles larger than this are divided and passed through a crusher many times, so the yield is almost 100%. The particles are refined with a recovery rate close to . Items with laminated materials such as asbestos paper or kraft paper are easier to crush than items without laminations, and during the crushing process, the paper is separated from the resin layer, and at the dividing stage, the paper is separated based on the difference in specific gravity from the resin particles. removed.

For example, if the cloth is laminated, such as a vinyl leather type cloth, it is relatively easy to crush it if it is a plain weave cloth, and the coarse particles due to the cloth attached are repeatedly passed through the crusher, so the cloth will gradually separate and become fine particles. do. The fine particles thus obtained are divided into 10-mesh nodes to form particles with 1 to 2 ribs.

There will be no problem even if these particles include paper or cloth that is still attached or crushed particles of paper or cloth. Examples of thermoplastic synthetic resin products include non-foaming vinyl wallpaper and low-foaming vinyl wallpaper.

This wallpaper has a vinyl layer with a thickness of 0.15 to 0.2 ribs, and in the past, it was rarely recycled and was disposed of in landfills or incinerated. An example of a cloth-backed product is long vinyl flooring.The scraps generated during the manufacturing process are used for re-kneading by peeling off the linen cloth on the back, but the scraps generated during the manufacturing process are used for re-kneading. Used floor coverings have not been reprocessed in this way and have been treated as industrial waste, but with the present invention, these used floor coverings can be easily reduced to fine particles by pulverization, and most of the cloth is It turns out that it can be separated. A powdered hot-melt adhesive is added to the fine particles thus obtained, mixed uniformly, and the fine particles are coated with the powdered adhesive.

This powdery hot-melt adhesive has particles of about 100 microns, and suitably has grains of 150 to 160 mesh. Examples of this type of powdered hot-melt adhesive include polyester resin-based PES-110P "1120P, 1140P,
These powder hot melt adhesives are smooth and fluid powders at room temperature and do not exhibit any adhesive effect, but when heated to a temperature appropriate for the grade, they melt and become liquid. This flows between substances as an adhesive film, and when cooled to room temperature again, it solidifies and exhibits an excellent adhesive effect.

Therefore, when a powder with such performance is mixed with scrap fine particles and uniformly sprinkled thereon, and the fine particles are heated, the above phenomenon occurs, and after cooling, the fine particles become firmly bonded. The amount of powdered hot melt adhesive added to the scrap fine particles depends on the grain size of the fine particles, but is approximately 3 to 8.
Good in the weight department. In this case, if the particle size of the powdered hot melt adhesive is coarse, the binding effect of the scrap particles will be reduced, so it will be necessary to increase the amount added. Bonding of scrap particles by adding a powdered hot-melt adhesive is extremely simple, and it is sufficient to heat the scrap particles in a 170 to 200 oo heating furnace for 1 to 2 minutes, and then cool the scrap particles.

However, in reality, in order to obtain a sheet-like product from scrap particles, it is necessary to combine them with a backing material such as paper or cloth, so a binder is required to bond these hair batting materials and the scrap particle layer. Become. This binder is not particularly specified as long as it is the same as the thermoplastic synthetic resin constituting the scrap particles or has excellent adhesive affinity with the resin. If the scrap particles are obtained from solid or hard to semi-hard pinyl chloride products, then pinyl chloride base can be used as the binder of choice. In addition, when the scrap particles are obtained from ABS resin, the above-mentioned vinyl chloride base may be used. In the case of a sheet material in which the backing material is used in a state where it is combined with a scrap particle layer, a binder layer is first provided on the upper surface of ordinary paper, a plain woven cloth that has been subjected to sealing treatment, a knitted cloth, etc. A mixture of scrap particles and powdered hot melt adhesive is applied in a predetermined amount by a scattering method or a blade method.
After turning it over to remove excess scrap particles that are not attached to the binder layer, it is passed through a heating furnace at 17 to 200°C, heated for 2 to 3 minutes, and then cooled to make paper or cloth. A lined sheet is obtained.

In addition to the above-mentioned inversion method, a suction method using a suction device is effective for removing excess scrap particles. For applications where there is only a scrap particle layer and no hair batting material such as paper or cloth is required, use template paper in the same way as the backing material, perform the above processing, heat and cool it, and then remove the release paper as the backing material. , a sheet of very flexible scrap particles is obtained, in which case the pattern paper can be considered as a bag material, even if it is later peeled off.

Both composite sheets made by combining paper and cloth and single sheets made using the release paper method can be used as surface materials for public health bulletin boards and boar-proofing sheets by poolsides, but if necessary, vinyl chloride resin leather or sheets are usually used. Various post-processing methods used during processing can be performed at will.

For example, the above-mentioned composite sheets and single sheets have rough irregularities and a very rough surface because the scrap particles have a rounded shape or are slightly melted and have a rounded shape. It has become.

Although the boar-proof sheet is preferable because of its rough texture, it is somewhat unsuitable for applications such as wall coverings, interior lining materials for automobile trunks, and car mats for driver's cabins.
Therefore, for such uses, it is possible to apply embossing to make the surface smooth and crush it, or to apply other squeeze patterns at the same time as with ordinary leather or sheets, so the range of its applications is significantly widened. .

Furthermore, if the embossing method is used, valley beam embossing is added to the granite-like ground pattern of the scrap particle layer, so it can be used as a wall covering material to provide a more decorative effect than conventional wall coverings. When a nonwoven fabric is used as the backing material, it is not necessary to use a binder such as vinyl chloride base.

This is thought to be because the fluff on the surface of the nonwoven fabric promotes the formation of fine particles. In this case, the fine particles are applied using the blade method, and the mixed layer of scrap particles and powdered hot melt adhesive on the nonwoven fabric is heated in a heating furnace to bond the fine particles. By cooling, a sheet-like product having an appearance similar to the above-mentioned paper, cloth, or single sheet can be obtained. However, in this case, since the bonding layers made of powdered adhesive are stacked in multiple layers, the strength between the bonding layers is weaker than the bonding between the binders, so in order to increase the strength and improve the surface condition, It may be necessary to apply embossing. An interesting example of the invention is the use of scrap particles based on scrap of low foam vinyl wallpaper.

Low-foaming vinyl wallpaper uses a chemical foaming agent as one of its ingredients, and is heated and foamed in the embossing process to form a relatively deep drawing pattern. In the case of this type, the rate of decomposition of the foaming agent is lower than that of foaming in a full-scale foaming furnace, resulting in incomplete foaming.
In particular, the concave parts of the shibori pattern have the potential to expand because the vinyl sheet that has already expanded is forcibly compressed and becomes concave, and the convex parts are also foamed during the embossing process, so they foam even more. , retains the ability to expand. Therefore, scrap particles made from scraps of low-foam vinyl wallpaper have potential foaming and expansion power, and therefore, such particles can be used to make sheet-like products using the method described above. In this case, reheating at 170 to 2000 C for 2 to 3 minutes causes foaming and expansion of the particles themselves, and each particle increases in volume, exhibiting a rounded appearance, and a foamed sheet-like product is obtained. This foamed sheet-like material can be used as a wall covering material as it is, but by using the foamed hot properties to dye and emboss, it creates a rich three-dimensional effect.
In addition, vinyl wallpaper with excellent decorative properties can be obtained. The use of scraps of thermoplastic synthetic resin products by the method of the present invention is unprecedented and unique, and in addition to the above-mentioned European quality products, hard to semi-hard products such as Amo resin can also be used, and fine particles can be used. By using powdered hot-melt adhesive, the action of the powdered adhesive can provide bonding between fine particles even if there is no fusion between the particles, so it can be used even if it is hard or semi-hard. This is something that can be done.

Claims (1)

[Scope of Claims] 1 Waste products or scraps of thermoplastic synthetic resin products are pulverized into fine particles, powdered hot melt adhesive is added to the particles, mixed uniformly, and then applied onto a backing material to a predetermined thickness. 1. A method for producing a sheet-like product using scrap of a thermoplastic synthetic resin product, which comprises spraying the scrap on a thermoplastic synthetic resin product and then heating it in a heating furnace to bond the fine particles. 2. The method for producing a sheet-like article according to item 1, wherein the thermoplastic synthetic resin product is paper-backed vinyl wallpaper. 3. The method for producing a sheet-like article according to item 1, wherein the fine particles are particles with a mesh size of under 10. 4. The method for producing a sheet-like article according to item 2, wherein the vinyl wallpaper is a low-foaming wallpaper with a low expansion ratio.