RU2624645C2 - Method for manufacturing rubber tiles - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: method for manufacturing rubber tiles comprises preparing the mixture by mixing the filler from the rubber crumb and the polyurethane-based binder, while simultaneously and separately preparing the mixtures for the base layer and the upper coloured layer. In the mixture for the base layer, the filler of rubber crumb with the fraction of 1-2 mm is used; in the mixture for the top coloured layer, the filler of rubber crumb with the fraction of 0.5-1 mm and a pigmentary dye are used. While preparing the mixture for the top coloured layer, with the exception of the red and the grey colour, the mixture bleaching process is first carried out by means of adding titanium dioxide and then mixing the bleached mixture with the pigment dye; thereinafter, the mixture for the top coloured layer and the mixture for the base layer are subsequently loaded into the mould. The moulds with the mixtures are installed in vertical rows, pressed under pressure, then the resulting mixture is maintained until completely cured.

EFFECT: invention allows to improve the quality of rubber tiles due to obtaining a smoother and more dense surface, to reduce the consumption of mounting glue, to eliminate the formation of lumps when mixing, to simplify the production line.

6 cl, 5 ex

Description

The invention relates to methods for manufacturing rubber tiles, rubber pavers used at various construction sites for the construction of paths, sidewalks, coatings in children’s, sports and other venues.

A known method of manufacturing a rubber tile, which consists in preparing mixtures for the lower and upper layers of the tile, the mixtures including a filler in the form of rubber crumb and a binder based on polyurethane, pigment dye is added to the mixture for the upper layer of the tile, these components are mixed in mixer, the resulting mixture is unloaded and pressed into molds (utility model patent RU No. 137752 U1, IPC B30B 13/02, 05/10/1995). In the manufacture of rubber tiles, heating the molds to a temperature of 100-160 ° C is required.

The disadvantage of this method is the relatively low quality of the rubber tile, since it does not have the optimal combination of plastic and elastic deformations. This is due to the fact that hot pressing is required to obtain the finished product, because of which the rubber tile obtained in this way may not provide the necessary strength and flexibility, especially under conditions of low temperatures and dynamic alternating loads. As a result, during operation, such tiles can quickly collapse. In addition, due to exposure to high temperatures, the tile may have the smell of burnt rubber.

The prototype is a method of manufacturing a rubber tile, comprising preparing a mixture by mixing a filler from rubber crumb and a binder based on polyurethane, then unloading the resulting mixture, while simultaneously and separately from each other, mixes for the base and top layers are made, the filler is used in the mixture for the base layer from crumb rubber fraction 2-12 mm, in the mixture for the upper layer using filler from crumb rubber fraction 1-3 mm and pigment dye, and in the process of mixing the mixture for the top it its compacted layer, then into the mold successively discharged mixture for the top layer, then the mixture for the base layer and compressed under a pressure using a press, and then allowed to stand until full cure and produce discharge from the mold the resulting tiles. The mixture is aged until completely hardened in the mold is carried out at a temperature of 70 ÷ 90 ° C. The mixture for the top layer is mixed in the first mixer, wherein the compaction of said mixture is carried out by means of a piston, which moves under pressure in said mixer. Molds with mixtures are installed in holding devices located one below the other, forming vertical rows of molds for their subsequent pressing. To prepare the mixture for the upper layer, the mass ratio of the binder to the filler is 1 ÷ 3 parts of the binder to 15 parts of the filler. To prepare the mixture for the base layer, the mass ratio of the binder to the filler is 1 ÷ 2 parts of the binder to 20 parts of the filler (patent RU No. 2465294, IPC C09D 175/04, 10.27.2012).

The technical result is the possibility, due to cold pressing, of high-performance manufacturing of two-layer rubber tiles with damping properties, which is reliable and durable in use, as well as the possibility of expanding the range of rubber tiles of various forms and color combinations of layers.

The main disadvantage of the prototype is the insufficiently high quality of the obtained rubber tile due to the fact that for the top layer, filler is used from relatively large rubber crumbs of a fraction of 1-3 mm, obtaining not enough high surface smoothness and density of the tile into which pores dirt can penetrate. The disadvantage is the increased consumption of mounting adhesive when laying the resulting rubber tiles on a solid base due to the highly porous lower surface, since a filler of relatively large crumb rubber of a fraction of 2-12 mm is used for the base layer. In addition, in the process of mixing a filler of rubber crumb and a binder based on polyurethane, a mixer is used that performs unidirectional mixing of the upper and lower volumes of the base and top layers, and in order to obtain a uniform mass and avoid the formation of lumps, the mixture is mixed for the top layer the coating is accompanied by its compaction by introducing into the first mixer a piston that moves smoothly under pressure in the range from 5 to 100 bar, which greatly complicates the design of the mixer . The disadvantage is that the exposure of the mixture to its complete hardening in the mold is carried out at a temperature of 70 ÷ 90 ° C in a heat chamber (hot hardening), which complicates the production line for the manufacture of rubber tiles.

The objective of the invention is to remedy these disadvantages of the analogue and prototype.

The technical result is to improve the quality of the obtained rubber tiles by obtaining a smoother and denser surface, which provides better dirt protection and a more aesthetic appearance, reducing the consumption of mounting glue, eliminating the formation of lumps by a simpler design of mixers, simplifying the production line due to the implementation of the cold hardening process, eliminating the need to use a heat chamber.

The technical result is achieved by the fact that in a method for manufacturing a rubber tile, comprising preparing a mixture by mixing a filler of rubber crumb and a binder based on polyurethane, while simultaneously and separately from each other, mixtures for the base and upper color layers are made, in the mixture for the base layer use rubber crumb filler; in the mixture for the upper color layer, rubber crumb filler and pigment dye are used in the manufacture of the mixture for the upper color layer, for the suit By adjusting the red and gray colors, first the process of bleaching the specified mixture is carried out by adding titanium dioxide to it and then mixing the bleached mixture with a pigment dye, then the mixture for the upper color layer is subsequently unloaded into the mold, then the mixture for the base layer, then press molds with mixtures are installed in holding devices located one below the other, forming vertical rows of molds, and then pressed under pressure using a press, then the resulting mixture is kept until complete hardening and unloading of the obtained tile from the mold, according to the present invention, when mixing the mixture for the base and upper color layers, mixers made in the form of multidirectional mixing devices for the upper and lower volumes of the base and upper color layers are used, in the manufacture of the mixture for the base layer filler from rubber crumbs of a fraction of 1-2 mm, in the manufacture of the mixture for the upper color layer using filler from rubber crumbs of a fraction of 0.5-1 mm, and the shutter speed PhD mixture of base and upper layers of the color, to complete its curing in the mold is carried out for at least 24 hours at a temperature of not less than 20 ° C and humidity not less than 65%.

To prepare the mixture of the base layer using the following ratio of components, wt. %:

1-2 mm rubber crumb filler 93,507-94,143 polyurethane binder 5,857-6,493

To prepare the mixture of the upper color layer, with the exception of red and gray colors, use the following ratio of components, wt. %:

0.5-1 mm rubber crumb filler 87-88 pigment dye 2.5-3.1 titanium dioxide 0.9-1.0 polyurethane binder 8.6-9.1

To prepare the mixture of the upper layer of red, use the following ratio of components, wt. %:

0.5-1 mm rubber crumb filler 86.99-87.99 pigment dye red 3.43-4.14 polyurethane binder 8.57-9.11

To prepare the mixture of the upper gray layer using the following ratio of components, wt. %:

0.5-1 mm rubber crumb filler 88.72-89.52 titanium dioxide 1.7-2.1 polyurethane binder 8.73-9.29

The mixture for the base layer is mixed alternately in the first and third mixers, and the mixture for the upper color layer is mixed alternately in the second and fourth mixers.

The rubber tile production line according to the proposed method includes:

electronic scales for weighing rubber crumb filler, a binder based on polyurethane, pigment dye and titanium dioxide,

a mixing system consisting of two mixers for alternately preparing a mixture of the base mixture and two mixers for alternately preparing the upper color layer, and a platform for placing the mixers,

molding table,

complete sets of polymer molds for the manufacture of various types of rubber tiles,

holding devices (lodgement frames) in which the molds are placed,

fixing stands (carts) for placement of holding devices with molds and their movement to the hydraulic press,

hydraulic press with pump station,

a conductor for manufacturing technological holes in a rubber tile, used when the resulting tile must be equipped with docking sleeves.

The proposed method is implemented as follows.

To determine the exact ratio of components on an electronic balance, rubber crumb filler, a polyurethane-based binder, pigment dye and titanium dioxide are weighed in accordance with the formulation of the base and top color layers.

After weighing and determining the exact amount of raw material in each dosage composition, the starting components are loaded into mixers that carry out multidirectional mixing of the upper and lower volumes of the base and upper color layers.

The mixture for the base layer is mixed alternately in the first and third mixers, and the mixture for the upper color layer is mixed alternately in the second and fourth mixers.

As a binder, one-component polyurethane glue of the STOKMAYER company (Germany) is used, which does not exclude the use of a binder from other manufacturers that have the same properties and characteristics as the above binder.

As pigment dyes use organic, inorganic iron oxide pigments, as well as titanium dioxide. Pigment dyes can have the following colors: green, blue, red, sand, orange, etc.

Mixtures for the base and upper color layers are prepared simultaneously and separately from each other in different mixers.

The preparation of the mixture for the base layer is carried out by alternately mixing to a homogeneous mass in the first and third mixers of the filler from the crumb rubber fraction 1-2 mm with a binder, while the following ratio of components is used to prepare the mixture of the base layer, wt. %:

1-2 mm rubber crumb filler 93,507-94,143 polyurethane binder 5,857-6,493

In the manufacture of the mixture for the upper color layer, with the exception of red and gray colors, the process of bleaching the mixture is first carried out by adding titanium dioxide to it and then mixing the bleached mixture with pigment dye, which allows to obtain a more saturated bright color of the upper decorative layer of the rubber tile.

The mixture for the upper color layer is prepared by alternately mixing in the second and fourth mixers a filler of rubber crumb of a fraction of 0.5-1 mm with a pigment dye and then introducing a binder, while the following ratio of components is used to prepare the mixture of the upper color layer, wt. %:

0.5-1 mm rubber crumb filler 87-88 pigment dye 2.5-3.1 titanium dioxide 0.9-1.0 polyurethane binder 8.6-9.1

To prepare the mixture of the upper layer of red, use the following ratio of components, wt. %:

0.5-1 mm rubber crumb filler 86.99-87.99 pigment dye red 3.43-4.14 polyurethane binder 8.57-9.11

To prepare the mixture of the upper gray layer using the following ratio of components, wt. %:

0.5-1 mm rubber crumb filler 88.72-89.52 titanium dioxide 1.7-2.1 polyurethane binder 8.73-9.29

The process of mixing the mixture is accompanied by multidirectional mixing of the upper and lower volumes of the base and upper color layers. The total duration of the mixing process of the mixture is at least 8 minutes.

Simultaneously with the preparation of the above mixtures, the molds are prepared, namely, their inner surface is lubricated with PMS-200 polymethylsiloxane grease or another similar grease.

Preferably, the mold was made of plastics, which avoids adhesion of the mixtures to the mold and facilitates the removal of the manufactured rubber tiles from the mold.

After preparing the above mixtures into the prepared mold, the mixture is unloaded from the second mixer for the upper layer of rubber tile with its subsequent alignment, for example, using a spatula and / or trowel. Then, the prepared mixture for the base layer of the tile is unloaded from the first mixer into the same mold, followed by leveling the mixture, for example, using a spatula and / or trowel. The mold is placed in a holding device, which is located in the fixing stand.

The holding devices are made in the form of lodgment frames, and the fixing stands are trolleys equipped with special jacks (screw clamps). The mold placed in the holding device is covered with a plastic film, after which a punch is placed on it.

To increase productivity, ten rows of holding devices with molds can be installed in the fixing stand, and these holding devices are located one under the other, forming horizontal and vertical rows of molds. After that, pressing is carried out with a pressure of 9 tons (9 kg / cm ² ) of molds filled with the molding mixture on a hydraulic press.

Then the molds are fixed in the fixing stand in a fixed position using special jacks. The jacks allow you to maintain a constant compression ratio on the molds filled with the mixture after removing them from the hydraulic press. After that, the molds located on the fixing stand are kept in a sealed state under a fixed pressure for at least 24 hours at a temperature of at least 20 ° C and a humidity of at least 65% until the mixtures completely harden.

Next, rubber tiles are unloaded from the molds, if necessary, the assembly (docking) holes are drilled using a jig and the tiles are completed with plastic connecting bushings, quality control of the rubber tiles obtained and packaging of the rubber tiles are carried out.

Examples of specific performance.

The inventive method is made of a two-layer rubber tile, rubber pavers, with virtually no hidden defects that could occur during operation.

Example 1

A rubber tile 500 × 500 × 40 mm in size is made as described above.

Prepare a molding mixture of 5 square meters. m of rubber tiles (10 rows of restraints in a fixing stand).

The base layer in the manufacture of rubber tiles with a size of 500 × 500 × 40 mm in all colors has the following prescription composition (wt.%):

1-2 mm rubber crumb filler 93.79 polyurethane binder 6.21

In the manufacture of rubber tiles of all colors, with the exception of red and gray colors, the molding mixture for the upper color layer has the following formulation (wt.%):

0.5-1 mm rubber crumb filler 88 pigment dye 2.5 titanium dioxide 0.9 polyurethane binder 8.6

In the manufacture of red rubber tiles 500 × 500 × 40 mm in size, the molding mixture for the upper color layer has the following formulation (wt.%):

0.5-1 mm rubber crumb filler 87,983 pigment dye red 3,433 polyurethane binder 8,584

In the manufacture of rubber tiles with a size of 500 × 500 × 40 mm in gray, the molding mixture has the following recipe composition (wt.%):

0.5-1 mm rubber crumb filler 89.5 titanium dioxide 1.75 polyurethane binder 8.73

The total duration of the mixing process of the mixture is at least 8 minutes.

Exposure of the resulting mixture, consisting of the base and upper color layers, to its complete hardening in the mold is carried out for at least 24 hours at a temperature of at least 20 ° C and a humidity of at least 65%.

Example 2

A rubber tile of 350 × 350 × 20 mm in size is made ("mesh" and "spider line") as described above.

Prepare a molding mixture of 3.75 square meters. m of rubber tiles (10 rows of restraints in a fixing stand).

The base layer in the manufacture of rubber tiles measuring 350 × 350 × 30 mm in all colors has the following prescription composition (wt.%):

1-2 mm rubber crumb filler 94.14 polyurethane binder 5.86

In the manufacture of rubber tiles measuring 350 × 350 × 20 mm in all colors, with the exception of red and gray, the molding mixture for the upper color layer has the following formulation (wt.%):

0.5-1 mm rubber crumb filler 87,439 pigment dye 2,936 titanium dioxide 0.979 polyurethane binder 8,646

In the manufacture of rubber tiles measuring 350 × 350 × 30 mm in red, the molding mixture for the upper color layer has the following formulation (wt.%):

0.5-1 mm rubber crumb filler 87,439 pigment dye red 3,915 polyurethane binder 8,646

In the manufacture of rubber tiles with a size of 350 × 350 × 20 mm gray, the molding mixture has the following recipe composition (wt.%):

0.5-1 mm rubber crumb filler 89.18 titanium dioxide 2.0 polyurethane binder 8.82

The total duration of the mixing process of the mixture is at least 8 minutes.

Exposure of the resulting mixture, consisting of the base and upper color layers, to its complete hardening in the mold is carried out for at least 24 hours at a temperature of at least 20 ° C and a humidity of at least 65%.

Example 3

Paving stones are made of “brick” 40 mm (50 pcs. In 1 sq. M) as described above.

Prepare a molding mixture of 4 square meters. m of rubber tiles (10 rows of restraints in a fixing stand).

The base layer in the manufacture of pavers "brick" 40 mm in all colors has the following prescription composition (wt.%):

1-2 mm rubber crumb filler 93.86 polyurethane binder 6.14

In the manufacture of paving stones "brick" 40 mm in all colors, except for red and gray colors, the molding mixture for the upper color layer has the following prescription composition (wt.%):

0.5-1 mm rubber crumb filler 87.6 pigment dye 2.76 titanium dioxide 0.92 polyurethane binder 8.72

In the manufacture of paving stones "brick" 40 mm red, the molding mixture for the upper color layer has the following prescription composition (wt.%):

0.5-1 mm rubber crumb filler 87.6 pigment dye red 3.68 polyurethane binder 8.72

In the manufacture of pavers "brick" 40 mm gray, the molding mixture has the following formulation (wt.%):

0.5-1 mm rubber crumb filler 89.2 titanium dioxide 1.9 polyurethane binder 8.9

The total duration of the mixing process of the mixture is at least 8 minutes.

Exposure of the resulting mixture, consisting of the base and upper color layers, to its complete hardening in the mold is carried out for at least 24 hours at a temperature of at least 20 ° C and a humidity of at least 65%.

Example 4

Paving stones are made of “wave” 40 mm (43 pcs. In 1 sq. M) as described above.

Prepare a molding mixture of 3.5 square meters. m pavers "coil" (10 rows of restraints in the fixing stand).

The base layer in the manufacture of pavers "wave" of 40 mm in all colors has the following prescription composition (wt.%):

1-2 mm rubber crumb filler 93.84 polyurethane binder 6.16

In the manufacture of paving "wave" of 40 mm in all colors, except for red and gray colors, the molding mixture for the upper color layer has the following recipe composition (wt.%):

0.5-1 mm rubber crumb filler 87.62 pigment dye 2.86 titanium dioxide 0.92 polyurethane binder 8.6

In the manufacture of paving stones “wave” of 40 mm red, the molding mixture for the upper color layer has the following recipe composition (wt.%):

0.5-1 mm rubber crumb filler 87.62 pigment dye red 3.81 polyurethane binder 8.57

In the manufacture of pavers "wave" of 40 mm gray, the molding sand has the following recipe composition (wt.%):

0.5-1 mm rubber crumb filler 89.32 titanium dioxide 1.94 polyurethane binder 8.74

The total duration of the mixing process of the mixture is at least 8 minutes.

Exposure of the resulting mixture, consisting of the base and upper color layers, to its complete hardening in the mold is carried out for at least 24 hours at a temperature of at least 20 ° C and a humidity of at least 65%.

Example 5

Paving stones “coil” of 40 mm are made (40 pcs. In 1 sq. M) as described above.

Prepare a molding mixture of 3.5 square meters. m pavers "coil" (10 rows of restraints in the fixing stand).

The base layer in the manufacture of pavers "coil" of 40 mm in all colors has the following prescription composition (wt.%):

1-2 mm rubber crumb filler 94.02 polyurethane binder 5.98

In the manufacture of pavers "coil" of 40 mm in all colors, with the exception of red and gray colors, the molding mixture for the upper color layer has the following prescription composition (wt.%):

0.5-1 mm rubber crumb filler 87.23 pigment dye 3.10 titanium dioxide 1,0 polyurethane binder 8.67

In the manufacture of pavers "coil" of 40 mm red, the molding mixture for the upper color layer has the following recipe composition (wt.%):

0.5-1 mm rubber crumb filler 87.23 pigment dye red 4.14 polyurethane binder 8.63

In the manufacture of pavers "coil" 40 mm gray molding sand has the following formulation (wt.%):

0.5-1 mm rubber crumb filler 89.08 titanium dioxide 2.1 polyurethane binder 8.82

The total duration of the mixing process of the mixture is at least 8 minutes.

Exposure of the resulting mixture, consisting of the base and upper color layers, to its complete hardening in the mold is carried out for at least 24 hours at a temperature of at least 20 ° C and a humidity of at least 65%.

Distinctive essential features of the claimed invention allow to obtain, in comparison with the prototype, the following technical results:

the use of a finer fraction of 0.5-1 mm for the upper color layer of rubber crumb filler, in combination with increased density, guarantees the durability of the rubber tile, the best aesthetic appearance and dirt protection, since the dirt does not clog into the pores;

the use of a finer fraction of 1-2 mm for the base layer of rubber crumb filler, in combination with increased density, ensures a low consumption of mounting glue when laying the resulting rubber tile on a solid base;

using when mixing the mixture for the base and upper color layers of the mixer, made in the form of a device having fixed blades (static chippers) in the upper part, providing multidirectional mixing of the upper and lower volumes of the base and upper color layers, allows a simpler design to obtain a homogeneous mass, to avoid the formation of lumps in the mixture, thereby improving its quality and, accordingly, the reliability of the rubber tile during its operation;

polymerization of the manufactured rubber tile for at least 24 hours at a temperature of at least 20 ° C and a humidity of at least 65% makes it possible to simplify the production line, since it excludes a heat chamber with an electric heater, temperature sensor, temperature controller, timer that supports temperature and time modes, without compromising the quality of rubber tiles.

Thus, the use of the claimed invention will allow, in comparison with the prototype, to improve the quality of the resulting rubber tiles by obtaining a smoother and denser surface, which provides better dirt protection and a more aesthetic appearance, reduce the consumption of mounting adhesive, eliminate the formation of lumps by a simpler mixer design, simplify production line due to the implementation of the cold hardening process, eliminating the need for a heat chamber.

Claims (10)

1. A method of manufacturing a rubber tile, comprising preparing a mixture by mixing a filler of rubber crumb and a binder based on polyurethane, while simultaneously and separately from each other, mixes for the base and top color layers are made, and rubber crumb filler is used in the mixture for the base layer , in the mixture for the upper color layer, rubber crumb filler and pigment dye are used in the manufacture of the mixture for the upper color layer, with the exception of red and gray, After that, the process of bleaching said mixture is carried out by adding titanium dioxide to it and then mixing the bleached mixture with a pigment dye, then the mixture for the upper color layer is subsequently unloaded into the mold, then the mixture for the base layer, then the molds with mixtures are placed in holding devices located under each other, forming vertical rows of molds, and then pressed under pressure using a press, then stand the resulting mixture until completely hardened and produce a shortcut from the mold of the obtained tile, characterized in that when mixing the mixture for the base and upper color layers, mixers are used made in the form of devices for multidirectional mixing of the upper and lower volumes of the base and upper color layers; in the manufacture of the mixture for the base layer, rubber filler is used crumbs of a fraction of 1-2 mm, in the manufacture of a mixture for the upper color layer, filler is used from rubber crumb of a fraction of 0.5-1 mm, and the exposure of the resulting mixture consisting of a base and top vetnogo layers to complete its curing in the mold is carried out for at least 24 hours at a temperature of not less than 20 ° C and humidity not less than 65%. 2. The method according to p. 1, characterized in that for the preparation of a mixture of the base layer using the following ratio of components, wt. %: 1-2 mm rubber crumb filler 93,507-94,143 polyurethane binder 5,857-6,493 3. The method according to p. 1, characterized in that for the preparation of a mixture of the upper color layer, with the exception of red and gray colors, use the following ratio of components, wt. %: 0.5-1 mm rubber crumb filler 87-88 pigment dye 2.5-3.1 titanium dioxide 0.9-1.0 polyurethane binder 8.6-9.1 4. The method according to p. 1, characterized in that for the preparation of the mixture of the upper red layer using the following ratio of components, wt. %: 0.5-1 mm rubber crumb filler 86.99-87.99 pigment dye red 3.43-4.14 polyurethane binder 8.57-9.11 5. The method according to p. 1, characterized in that for the preparation of the mixture of the upper gray layer using the following ratio of components, wt. %: 0.5-1 mm rubber crumb filler 88.72-89.52 titanium dioxide 1.7-2.1 polyurethane binder 8.73-9.29 6. The method according to p. 1, characterized in that the mixture for the base layer is mixed alternately in the first and third mixers, and the mixture for the upper color layer is mixed alternately in the second and fourth mixers.