KR20130036101A - Manufacturing process of a porous elastic mat - Google Patents

Abstract

PURPOSE: A manufacturing method for a porous elastic mat is provided to include absorptiveness to moisture with excellent permeability and reasonable manufacturing costs, and to improve insulation performance on radiant heat. CONSTITUTION: A manufacturing method for a porous elastic mat comprises: a first step of grinding foam, which is comprised of a mixture of polyethylene and polypropylene, of 0.002-0.500 g/cm^3 of apparent density to a size of 3-100 mm; a second step of molding a porous sheet with a molding roller having a heater or with hot air at 150-200 deg. C, or pressurizing the foam with a heat press at 120-150 deg. C; and a third step of laminating an elastic synthetic resin chip composition on the upper surface of the porous sheet after manufacturing the elastic synthetic resin chip composition by mixing 90-95 wt% of a chip comprised of one of urethane rubber, EDPM, and EVA, and 5-10 wt% of an urethane resin adhesive. [Reference numerals] (AA) First step of grinding and sorting foam(PE, PP) with an apparent density of 0.002-0.500 g/cm^3 to a size of 3-100 mm; (BB) Second step of molding a porous sheet by using a molding roller with a heater or pressurizing with a heat press at 120-150 deg. C; (CC) Third step of manufacturing an elastic synthetic resin chip composition(Urethane rubber, EDPM, EVA) and laminating and bonding the elastic synthetic resin chip composition on the upper surface of the porous sheet;

Description

MANUFACTURING PROCESS OF A POROUS ELASTIC MAT}

The present invention relates to a method for producing a porous elastic mat, and more particularly, a foam formed by mixing and foaming any one or two materials of polyethylene (PE) and polypropylene (PP) into a specific size and molding By bonding the elastic synthetic resin sheet to the upper surface of the porous sheet, the elastic sheet is sufficiently elastic and absorbed against impact, and in particular, the mat is not damaged from high heels, walking sticks and sharp metals, and has good durability. It relates to a method of manufacturing an environmentally friendly porous elastic mat that can be applied to various indoor and outdoor flooring materials, such as tracks and fields, pedestrian and bicycle roads, kindergarten indoors.

In general, indoor and outdoor flooring materials such as tracks and fields of children's playgrounds, playgrounds or parks, pedestrian and bicycle roads, indoors of kindergartens, etc., while minimizing the impact of gravity, exercise effects are sufficiently exhibited by using a constant repulsive force. There is a tendency to be packed with elastic mat to prevent the joints from overdoing.

As described above, the elastic mat is mainly obtained by stirring a pulverized product such as polyurethane, epoxy, recycled urethane, ethylene-propylene-diene termonomer (EPDM), PVC, waste tire, waste rubber, etc. together with a curing agent or an adhesive at a constant ratio. It is packaged by a method of curing it after application to a necessary place in the state or by extrusion molding the stirred pulverized product into a panel size of a predetermined size and directly attaching it in the field.

However, when laying the waste rubber sheet on the floor or using the elastic mat of the waste rubber crushing, a large amount of heavy metal contained in the waste rubber is not only eluted, but also scattered as dust, especially in summer, the bad smell of rubber There is an extremely unsanitary side, and the application of the mixed pulverized powder in the field after curing directly has the advantage that can be seamlessly packaged continuously, while the packaging elasticity is difficult to pack in a uniform thickness The problem is that the shock absorbing or repelling force of the mat is not uniform.

In addition, in order to construct elastic pavement on roads and parks, urethane resins and rubber chips are mixed and compacted using heating rollers or trowels. However, the above construction methods require long working hours and high working conditions. In addition, there is a disadvantage in using harmful ingredients such as primers or diluents in the processing operation.

In general, since only urethane resin is used as a binder, the elasticity is excellent, but it exhibits a weakness against horizontal and vertical tensile stress.In order to overcome this problem, in some cases, an elastic mat may be used by mixing rubber chips with resin or There is a method of manufacturing an elastic mat with improved durability and elasticity by mixing the waste tire rubber chip and the waste epoxy powder, but this elastic mat has a disadvantage that the strength of the coating film is not sufficient, and in order to reinforce it, Although non-woven fabric or fiber reinforcement may be attached to it, the non-woven fabric or fiber reinforcement used at the bottom does not have a reinforcing effect on the tensile stress applied to the mat itself, and the use of such fiber material only shows an effect of enhancing adhesion to the substrate. .

In addition, in the case of directly attaching the elastic mat produced in the form of a panel of a predetermined size in the field, it is easy to work on the other hand. Easily occurs deformation due to pressure, etc. In addition, in the case of the elastic mat mass produced in the form of a panel of a predetermined size according to the prior art there is a problem that the durability is lowered because it is weak to ultraviolet rays.

In order to solve the above problems, the applicant of the present invention has developed and used elastic flooring material and its construction method using expanded olefin as Patent Application No. 10-2009-0082640 (filed date 2009. 09. 02), In addition, Patent No. 10-0596192 (registration date 2006. 06. 26) is to prepare a porous sheet for construction made from foamed polyethylene (PE) and expanded polypropylene (PP), or a foam prepared by mixing the two materials Its strength is much higher than that of the conventional sheet, and it is very excellent in noise prevention, sound insulation, insulation, and vibration damping effect. Also, it has developed a porous sheet for building that is very simple to manufacture. Doing.

The present invention utilizes the technical features of the patent developed by the applicant, by producing a porous elastic mat bonded to the elastic synthetic resin sheet as a reinforcing material on the upper surface of the porous sheet to tracks and fields, pedestrians of children's playgrounds, playgrounds or parks By using it as an indoor or outdoor flooring material such as a bicycle road, a kindergarten indoor, etc., it has sufficient elasticity and shock absorbing power. The invention is completed.

Patent Application No. 10-2009-0082640 Patent Registration No. 10-0596192

An object of the present invention is to use a foamed polyethylene (PE), a foamed polypropylene (PP), or a mixture of the two materials formed of a specific particle size distribution, or a porous sheet molded by pure heat without using an organic solvent as a substrate. As a result, the air permeability is good, the water discharged into the soil is good, the water evaporation is good, and the heat insulation and impact resistance against radiant heat are excellent. To provide a manufacturing method.

Another object of the present invention is to bond the artificial turf sheet, cork sheet, TPE sheet or elastic synthetic resin chip composition as a reinforcing material on the upper surface of the porous sheet to be used as a base material without damaging the mat from high heels, walking sticks, or sharp metal parts. The impact resistance is excellent, and even if it is used for a long time, the deformation of the porous sheet hardly occurs, and thus the durability is very good. have.

Method for producing a porous elastic mat of the present invention for solving the above problems, the foam of the foam density of 0.002 ~ 0.500g / cm3 of any one or a mixture of polyethylene (PE) and polypropylene (PP) 3 First step of grinding to a size of ~ 100mm; A second step of forming the porous sheet by press-molding the crushed foam at a temperature of 120 to 150 ° C. in a hot press or a forming roller equipped with a hot air or a heater having a temperature of 150 to 200 ° C .; Instead of the third step of bonding the elastic synthetic resin sheet to the upper surface of the porous sheet, 90 to 95% by weight of the chip (chip) consisting of any one or more of urethane rubber, EDPM, EVA and urethane resin adhesive 5 to 10 weight A third step of preparing an elastic synthetic resin chip composition by mixing the%, then laminating on the upper surface of the porous sheet and pressing by pressing at 100 to 120 ° C. for 10 to 15 minutes using a press mold or directly laying it in the field. It characterized in that it is molded.

In the method of manufacturing the porous elastic mat of the present invention, a porous polyethylene molded by pure heat without using an organic solvent by mixing the polyethylene foam (PE) or the expanded polypropylene (PP) formed with a specific particle size distribution, and the above two materials Since the sheet is used as a base material, it is excellent in air permeability, good water pumping and evaporation against moisture, excellent heat insulation and impact resistance against radiant heat, environmentally friendly and low manufacturing cost. Do.

The porous elastic mat manufactured by the manufacturing method of the present invention is formed by bonding artificial turf sheet, cork sheet, TPE sheet or elastic synthetic resin chip composition with a reinforcing material on the porous sheet used as a substrate, and forming a mat from high heels, a cane or a sharp metal fitting. Is not damaged, the absorption of shock is good, the skin or clothes are not contaminated from the soil even in rainy weather, and the deformation of the porous sheet hardly occurs due to long-term use, so that the durability of the mat is good, It is easy to form various patterns, patterns, and decorations.

1 is a flow chart sequentially showing a first manufacturing method of a highly porous elastic mat according to the present invention.
2 is a flow chart sequentially showing a second manufacturing method of a highly porous elastic mat according to the present invention.

The method for producing a porous elastic mat of the present invention is a first method of pulverizing a foam having an apparent density of 0.002 to 0.500 g / cm3 by mixing any one or a mixture of polyethylene (PE) and polypropylene (PP) to a size of 3 to 100 mm. step; A second step of forming the porous sheet by press-molding the crushed foam at a temperature of 120 to 150 ° C. in a hot press or a forming roller equipped with a hot air or a heater having a temperature of 150 to 200 ° C .; Bonding an elastic synthetic resin sheet composed of any one of artificial grass sheets, cork sheets, and TPE sheets to an upper surface of the porous sheet; Alternatively, an elastic synthetic resin chip composition is prepared by mixing 90 to 95% by weight of a chip composed of any one or more of urethane rubber, EDPM, and EVA and 5 to 10% by weight of a urethane resin adhesive, and then forming an upper portion of the porous sheet. The molding is performed including a third step of laminating and bonding the surface.

Hereinafter, a method for manufacturing a porous elastic mat according to the present invention will be described with reference to the drawings, which is intended to exemplify the self invention having ordinary skill in the art to which the present invention pertains. This does not mean that the technical spirit and scope of the present invention are limited.

As shown in Figure 1, the method for producing a porous elastic mat according to the present invention comprises a first step to a third step.

The first step is to crush the foam having an apparent density of 0.002 to 0.500 g / cm3 to 3 to 100 mm in size by mixing any one or a mixture of polyethylene (PE) and polypropylene (PP), and the foam is crosslinked and A non-crosslinked polyethylene, polypropylene, or a conventional foam obtained by mixing and foaming the two materials, and a material having an apparent density of 0.002 to 0.500 g / cm 3 to a size of 3 to 100 mm is used as a porous sheet even after long-term use. It is possible to maintain the original shape for a long time without reducing the elasticity of the finished flooring, and at the same time, its appearance shrinks or expands with climate change.

Here, since the foam does not use the fine powder of less than 3mm particle size, the foam is excellent air permeability and good water evaporation and moisture evaporation is discharged to the soil, which evaporates the moisture through the permeable pores to take the heat of vaporization By reducing the temperature of the mat surface to alleviate the heat island phenomenon, and also excellent thermal insulation performance does not generate radiant heat due to geothermal heat and excellent usability and durability. In addition, since the foam does not use coarse foam particles having a particle size of more than 100 mm, properties such as hardness, bending strength, and tensile strength of the porous sheet are maintained uniformly over the entire area of the elastic mat.

In addition, the foam particles made of polyethylene (PE) and polypropylene (PP) may use some or all of the waste materials as long as the apparent density does not deviate from the range suggested by the present invention.

The second step process is to form a porous sheet by pressing the crushed foam in a hot press at a temperature of 120 ~ 150 ℃ or by molding roller equipped with a hot air or heater of 150 ~ 200 ℃, wherein the sheet In order to impart flame retardancy or fire resistance, flame retardants such as magnesium hydroxide and sodium silicate are added to the foam particles based on the total weight of the foam, 5 to 15%, and then molded into a hot press or a forming roller to impart flame retardance to the sheet. The flame retardant may be vacuum impregnated or applied to the surface of the molded sheet.

As described above, the second step process of the present invention is press-molded the crushed foam particles at a temperature of 120 ~ 150 ℃ using a hot press or at a temperature of 150 ~ 200 ℃ using a forming roller equipped with a hot air blower or heater Molding is desirable to maintain inherent physical and chemical properties such as porosity, density and elasticity of the foam, by preventing melting and pore closure within the foam particles forming the porous sheet, particularly where high strength is required. In the above, the foam particles may be molded by adding a thermoplastic resin such as hot-melt to about 20 to 30% based on the total weight of the particles.

The porous sheet formed by the above method is bonded by the surface melting between the foam particles at low temperature without using any organic solvent, so that the fine pores remain as they were when foamed, so that bending strength, tensile strength and shock absorption are achieved. Of course, to form a porous sheet excellent in heat insulation and durability and environmentally friendly, the thickness of the sheet to be formed can be set in a variety of about 20 ~ 100㎜ to manufacture the appropriate thickness according to the use and required properties of the flooring can do.

The third step process is to bond the elastic synthetic resin sheet consisting of any one of artificial grass sheet, cork sheet, TPE sheet on the upper surface of the porous sheet, the elastic synthetic resin sheet is the upper portion of the porous sheet used as a substrate Artificial grass sheet, cork sheet, TPE sheet or elastomeric resin chip composition is bonded to the surface and used as reinforcing material, so that the mat is not damaged from high heels, walking sticks and sharp metal, and durability is good. The elastic synthetic resin sheet is laminated on the upper surface of the porous sheet is pressed by a press mold or bonded by applying an adhesive to form a variety of patterns, patterns, decorations, etc. separately on the surface of the elastic mat, the elastic synthetic resin chip composition Silver is laminated on the upper surface of the porous sheet by pressing with a press die or bonded directly in the field to prepare a porous elastic mat of the present invention by bonding.

Artificial turf sheet used as a reinforcing material as described above is preferably to use a product planted with a hair length of 6 ~ 45㎜ made of a material such as nylon, PE, PP in latex, by forming a variety of colors and patterns depending on the purpose Compared to the elastic mat using waste tires, it is effective to prevent odor and discoloration, thereby creating a clean and pleasant road surface environment. In addition, Cork-sheet is manufactured by crushing and drying natural cork bark and mixed with synthetic resin adhesive, and it is compressed and dried. Excellent appearance

The TPE (Thermoplastic elastomer) used in the TPE sheet can be molded and processed in the same manner as the thermosetting plastic during processing, has the elasticity of the thermosetting rubber at room temperature, and can obtain various physical properties by the phase separation structure. The TPE industry has been developed since the early 1960s, and is now easily recycled. Therefore, TPE has taken an important position as a polymer material, and it is not necessary to vulcanize it compared to conventional rubber, and it is possible to simplify the processing process. In addition, once used scrap has the economic advantages that can be used for regeneration, as well as excellent bending strength and shock absorption.

As described above, the present invention may be molded by pressing a reinforcing material such as artificial turf sheet, cork sheet, TPE sheet, or by applying an adhesive to the upper surface of the porous sheet to a thickness of 10 to 50mm, the adhesive The type of is not particularly limited as long as it is not harmful to the environment, but in the present invention, it is preferable to use a spray type as a urethane resin or a synthetic resin that is harmless to the human body and a porous sheet composed of polyethylene and polypropylene foam. It is preferable in terms of adhesiveness, workability and environment, and in the present invention, when bonding the porous sheet base material and the elastic synthetic resin sheet reinforcement by using an adhesive, the upper surface of the porous sheet is about 100 ~ 150g per square meter (m 2) The porous sheet and the elastic synthetic resin sheet by applying and curing at room temperature for about 6 to 12 hours It is joined integrally with the molding of the environment friendly porous resilient mat is to be completed.

In addition, as shown in Figure 2, the third step process according to another embodiment of the present invention, 90 to 95% by weight of the chip (chip) consisting of any one or more of urethane rubber, EDPM, EVA and urethane resin 5 to 10 wt% of the adhesive is mixed to prepare an elastic resin chip composition, and then bonded to the upper surface of the porous sheet, wherein the elastic synthetic resin chip composition is put in various colors and patterns on the upper surface of the porous sheet 10 to 50 It can be variously carried out by the process of press-molding with a press mold to a thickness of ㎜ or by directly installing on the upper surface of the porous sheet in the field.

In other words, the porous elastic mat according to the present invention laminates the elastic synthetic resin chip composition on the surface of the porous sheet and press-molded for 10 to 15 minutes at a temperature of about 100 ~ 120 ℃ in the molding machine, thereby forming the foam particles of the porous sheet Pore shrinkage is prevented, and the molding pressure is preferably performed at a low pressure within a range where deformation of the porous sheet does not occur. In addition, even when the elastic synthetic resin chip composition is installed on the porous sheet and installed directly in the field, the urethane resin contained in the chip composition is naturally dried for about 6 to 12 hours at room temperature by laying the chip composition on the upper surface of the porous sheet. The adhesive is hardened to firmly bond the reinforcement composed of the elastic synthetic resin chip composition to the upper surface of the substrate, and it is preferable to pressurize using a conventional roller after installing the chip composition. If it is not, it is studied that there is no problem in use as long as the surface is evenly ground to the extent that the reinforcement is molded.

The urethane rubber used in the elastic synthetic resin chip composition has excellent elasticity despite being of high hardness, and has excellent abrasion resistance, vibration absorption, oil resistance, and excellent resistance to oxidation and aging and adhesive strength, and thus, urethane rubber chips are urethane resin adhesives. When mixed with and bonded to the upper portion of the porous sheet, the separation between the boundary layer does not occur well to form an excellent elastic mat.

In addition, EPDM (Ethylene-propylene-diene ter-monomer) is an amorphous polymer obtained by the hybridization of ethylene and propylene. Chemically stable and vulcanized, its physical properties are natural rubber and SBR (Styrene butadien rubber, styrene-butadiene rubber). ) Shows an intermediate property. Typically, it is classified into EPM (copolymer of ethylene and propylene) composed of ethylene and propylene copolymer and EPDM composed of terpolymer of ethylene, propylene and non-conjugated diene. It has better features than other synthetic rubbers. In addition, excellent weather resistance, heat resistance and cold resistance, chemical resistance, temperature. It is durable against moisture, has excellent elongation, adhesion, and harmful substances such as sodium, mercury, and mercury when in contact with fresh water, and can be recycled as a thermoplastic elastomer.

In addition, ethylene vinyl acetate (Ethylene vinyl acetate, EVA) is a copolymer of ethylene (Ethylene) and vinyl acetate (Vinyl acetate, VA), the properties of which vary greatly depending on the VA content and molecular weight, the lower the VA content Its properties are similar to polyethylene, and the softening point is lowered as much as it increases, and when it is very large, it shows liquid phase at room temperature. Normally, the VA content of 7 ~ 60% is called EVA resin. EVA resin has the same flexibility and rubber elasticity as soft PVC, so it has excellent molding processability, impact resistance and hygienic nontoxicity. In addition, when the EVA resin is crosslinked and foamed, its elasticity and wear resistance are improved, and when blended with other plastic materials, it is effective in improving impact resistance.

And the urethane rubber, EDPM, EVA used in the chip composition may use some or all of the recycled chip.

As described above, it is apparent to those skilled in the art that the porous elastic mat prepared in the first to third step processes may be optionally finished, such as cutting and packaging according to the method applied to the field. Detailed description will be omitted.

The elastic mat produced by the present invention, when the surface to be constructed is sand and then chopped 20 to 30 cm or more from the surface, and in the case of concrete structures, the adhesive is firmly adhered to the bottom surface by applying an adhesive.

Method for producing a porous elastic mat of the present invention, after forming a porous sheet in the field, and then bonded to the upper surface of the elastic synthetic resin sheet consisting of artificial grass sheet, cork sheet, TPE sheet using an adhesive or elastic synthetic resin chip Of course, the composition can be laid and bonded.

As described above, the present invention has been completed through numerous experiments. Hereinafter, the present invention will be described through preferred embodiments to be easily understood and implemented by those skilled in the art.

≪ Example 1 >

A foam having a density of 0.002 g / cm3 made of polyethylene (PE) was crushed into a grinder to sort only a particle size of 3 to 100 mm through a sorting machine, and then the foam particles were subjected to a temperature of 120 ° C. using a heat press. Pressurized in to prepare a porous sheet having a thickness of 70mm, width 2400mm, length 1200mm, and then coated with 300g of adhesive on the top of the porous sheet and bonded to artificial turf sheet having a thickness of 10mm.

<Example 2>

A foam having a apparent density of 0.01 g / cm 3 made of polyethylene (PE) and polypropylene (PP) was put into a grinder to be pulverized to sort only a particle size of 3 to 100 mm through a sorting machine, and then the foam particles were separated using a heat press. Pressurized at a temperature of ℃ ℃ to produce a porous sheet having a thickness of 50mm horizontal 2400mm length 1200mm size, then laminated a cork sheet 10mm thick on the upper portion of the porous sheet and press bonded while heating at high frequency by a press die. .

<Example 3>

A foam having a density of 0.5 g / cm 3 of polypropylene (PP) was put into a grinder, pulverized and sorted only by a particle size of 3 to 100 mm through a sorting machine. The foam particles were then subjected to a temperature of 170 ° C. using a forming roller. After pressurizing in a state to prepare a porous sheet having a thickness of 30mm width 2400mm length 1200mm size, and then laminated a TPE sheet having a thickness of 10mm on top of the porous sheet and pressurized while heating at high frequency by a press die.

<Example 4>

A foam having a apparent density of 0.01 g / cm 3 made of polyethylene (PE) and polypropylene (PP) was put into a grinder to be pulverized to sort only a particle size of 3 to 100 mm through a sorting machine, and then the foam particles were separated using a heat press. Pressurized at a temperature of ℃ to prepare a porous sheet having a thickness of 50mm width 2400mm length 1200mm size, and then 93% by weight chip containing urethane rubber, EDPM, EVA in the same weight on the top of the porous sheet, respectively And the elastic synthetic resin chip composition mixed with 7% by weight of the urethane adhesive was laminated to a thickness of 10mm and bonded by pressing at 100 ℃ for 10 minutes with a press die.

<Example 5>

A foam having a density of 0.5 g / cm 3 of polypropylene (PP) was put into a grinder, pulverized and sorted only by a particle size of 3 to 100 mm through a sorting machine. The foam particles were then subjected to a temperature of 170 ° C. using a forming roller. Pressurized in a state to prepare a porous sheet having a thickness of 30mm width 2400mm length 1200mm size, then the elastic synthetic resin chip composition mixed 93% by weight of the chip (chip) consisting of urethane rubber and 7% by weight of the urethane adhesive on the porous sheet The laminate was laminated to a thickness of 20 mm and pressed by a roller.

The porous elastic mat manufactured as described above is formed by melting the surface of particles by pure heat without using an organic solvent by mixing expanded polyethylene (PE), expanded polypropylene (PP) or the two kinds of materials having a specific particle size. Since the molded porous sheet is used as a base material, it maintains the apparent density before molding, so it is excellent in breathability, has good water absorption and evaporation properties, as well as excellent thermal insulation and impact resistance, and is environmentally friendly. The manufacturing cost is low, and the artificial grass sheet, cork sheet, TPE sheet or elastic synthetic resin chip composition is bonded to the upper surface of the porous sheet to be used as a base material to further improve its functionality and durability, as well as the above. It is also easy to form various patterns, patterns, and decorations on the reinforcement.

Therefore, the porous elastic mat manufactured as described above may be substituted, modified, and changed in various ways without departing from the technical spirit of the present invention, which has a specific gravity of 0.5 or less, and is lighter than ceramic materials. It is used as indoor and outdoor flooring materials for park tracks and fields, pedestrian and bicycle roads, indoors of kindergartens, etc., and has sufficient elasticity and shock absorption. Especially, it is a durable material without damaging the mat from high heels, canes and sharp metals. Can be used in form.

Claims (3)

A first step of pulverizing a foam having an apparent density of 0.002 to 0.500 g / cm 3 to 3 to 100 mm in size by mixing any one or a mixture of polyethylene (PE) and polypropylene (PP);
A second step of forming the porous sheet by molding the pulverized foam by hot pressing at a temperature of 120 to 150 ° C. or by using a forming roller equipped with a hot air or a heater of 150 to 200 ° C .;
An elastic synthetic resin chip composition is prepared by mixing 90 to 95% by weight of a chip composed of any one or more of urethane rubber, EDPM, and EVA and 5 to 10% by weight of a urethane resin adhesive, and then an upper surface of the porous sheet. Method for producing a porous elastic mat, characterized in that formed by including a third step of laminating and bonding to.
The method of claim 1,
The elastic synthetic resin chip composition in the third step is a method of manufacturing a porous elastic mat, characterized in that the bonding by pressing for 10 to 15 minutes at 100 ~ 120 ℃ with a press mold on the upper surface of the porous sheet.
The method of claim 1,
The elastic synthetic resin chip composition of the third step is a method of manufacturing a porous elastic mat, characterized in that directly bonded to the field in the field on the upper surface of the porous sheet.

Images