WO2003054324A1

WO2003054324A1 - Floor structure using reclaimed pet material

Info

Publication number: WO2003054324A1
Application number: PCT/JP2002/013237
Authority: WO
Inventors: Minoru Yoshida; Hiroshi Yoshida; Takahiko Hirose; Ryoji Miyadera
Original assignee: Kyodo Ky-Tec Corp.
Priority date: 2001-12-21
Filing date: 2002-12-18
Publication date: 2003-07-03
Also published as: JP2007131998A; TW200302310A

Abstract

In a floor structure, such as underfloor backing structure or double floor structure member, with a frame body (30) received in a basic structure (10) made of hardenable material, the frame body (30) is made of reclaimed PET material. Interposed between the reclaimed PET material frame body (30) and the basic structure (10) is a corrosion preventive layer that is a corrosion preventive material resistant to alkali so as to prevent the basic structure (10) and the reclaimed PET material frame body (30) from contacting each other. Thereby, the frame body (30) is protected from alkali components by the corrosion preventive layer, thereby preventing the occurrence of cracking or cleaving. Since the reclaimed material is effectively used, recycling is improved and so is the strength and reliability of the structure using the reclaimed material.

Description

Description Floor structure using recycled PET

The present invention relates to a floor structure formed of a composite material with a resin molding material and a method for manufacturing the same, and in particular, a floor structure used as a paving stone for buildings, roads, sidewalks, and the like using recycled PET (polyethylene terephthalate) material. The present invention relates to a floor structure such as a base material, a support structure for a double floor, and a method for producing the same.

Background art

BACKGROUND ART Flooring materials formed by filling a curable filler inside a frame formed by a resin molding method are widely used as finishes for building rooftops, roads, sidewalks, paving stones, and the like. Such an underfloor material structure can be installed while permitting the undulation of the laying surface, can obtain a good finish state, and has excellent walking properties after installation. On the other hand, the double-floor structure (free access floor) has been widely used in general offices and the like due to the introduction of so-called OA equipment. Such a double-floor structure makes it possible to process wiring under the floor due to the installation of various types of OA equipment, thus improving wiring management. In recent years, for this kind of free access floor, products of various materials such as resin and concrete have been proposed.

For example, in Japanese Patent Publication No. 7-99043, for example, pages 3 to 4 and FIGS. 1 to 5, a curable filler is filled inside a frame formed of resin. A double-floor structure that is formed and installed so that the resin frame is positioned on the outer surface, that is, so as to cover the cured filler from the top surface, that is, the double-floor support The legs are shown.

In the field of various floor structures, demands for environmental protection, effective use of resources, reduction of waste, and recycling have led to movements to effectively use recycled materials. Against this background, for example, so-called PET bottles, which are widely used as beverage containers, are not being recycled after use. Attention has been drawn to the remarkable development of products such as new containers using recycled PET (polyethylene terephthalate). For example, Japanese Patent Application Laid-Open Publication No. 11-116742, "Molded article using recycled resin", for example, from page 3 to page 6, FIG. 1 and JP-A-2000-281040, "Recycled multilayer resin bottle" For example, see pages 2 to 3, FIG. 1, FIG. 2, and the like.

Also, in the general construction industry, a technology that uses recycled resin in heat insulating materials, sound absorbing materials, formwork materials for concrete casting, and the like is known. For example, Japanese Patent Publication, JP-A-2000-314191, "Improved Building Materials Using Plastic Materials", for example, pages 5 to 6, FIG. 1, FIG. 2, and Japanese Utility Model Publication, See FIG. 1 of Kaihei 6-79953, “Plastic Formwork”, for example, pages 5-9. This tendency extends to the above-mentioned free access floor field, and studies are being conducted on the effective use of recycled PET materials as typical recycled materials. In particular, for structures composed of PP (polypropylene) resin, ABS (acrylonitrile butadiene styrene) resin, etc. as a single material, convert them to recycled PET or partially mix recycled PET. Is being considered.

By the way, for example, on page 3, page 4, FIG. 1, and FIG. 2 of conventional technology, for example, Japanese Patent Laid-Open Publication No. 4-221162, “Non-flammable natural wood decorative interior material and its production method”. Concrete, mortar, and cement materials as hardening fillers are known to have alkaline properties, whereas recycled PET is known to be weak in alkalinity.

For example, in Japanese Patent Laid-Open Publication No. 2001-90318, “Building Board and its Manufacturing Apparatus”, for example, from page 3 to page 6 and FIG. 1, the waterproof function of the back surface used for the outer wall of the building is described. In the field of building exterior walls and exterior wall boards, a backing material made by laminating a PE foam layer and recycled PET into a sheet is known.

The structure of the support of the free access floor as the floor structure is made of a fluid and hardening filler such as mortar, and the frame covering this material is PP (polypropylene) resin, PVC (polyvinyl chloride) resin, etc. Is used. When recycled PET material is mixed into these resin bodies, the recycling efficiency is poor depending on the mixing ratio. There is a problem that the use of recycled materials is not effective.

In addition, when all such resin materials are replaced with recycled PET materials, concrete, mortar, and cement materials to be filled in such frames are alkaline (for example, see Japanese Patent Publication No. And Japanese Patent Application Laid-Open No. 4-221162) had the following problems.

That is, as described above, the curable filler is alkaline, whereas the recycled PET has the property of being weak in alkalinity. This is because the ester bond portion of the recycled PET material is cut by the alkali component and the PET is decomposed, and the two are incompatible, and it is not preferable to use them together. For this reason, in the related art, particularly in the technical field relating to a floor structure and a double floor structure, it has generally been avoided to construct and use the two together.

Therefore, when a support such as a free access floor is composed of recycled PET and curable filler, the curable filler contacts the recycled PET material, causing alkali components to adhere to the contact surface of the recycled PET and eroding. As a result, the support frame made of recycled PET material was cracked or cracked.

In addition, stress was added due to a difference in shrinkage due to a temperature change or the like between the recycled PET material and the curable filler, and cracks and cracks might occur in the support frame of the recycled PET material. Furthermore, in the case of recycled PET, it is desired to improve the strength and reliability against the stress caused by external factors such as temperature change and the state of close contact with the curable filler, as well as the load applied when moving or walking the furniture. Was rare.

The technology disclosed in the above-mentioned Japanese Patent Publication and JP-A-4-221162 is to form a resin film for preventing the discoloration of the decorative thin veneer on the surface of the decorative interior material due to the force of the inorganic board. It is not a technology for floor structures such as underfloor materials or double-floor components, and it does not use recycled PET materials. Accordingly, the prior art this is the purpose and issues at specific aspect called effective use of recycled materials in the art of floor structure according to the present invention, main components, not disclosed operations and effects _c Also, In the above-mentioned Japanese Patent Publication and JP-A-2001-90318, in the technology of the outer wall of a building and the outer wall plate, a backing material formed by laminating a PE foam layer and a recycled PET into a sheet shape is used. Although it has improved waterproofing on the back, It is not a technical field or a technical content of the floor structure as in the present invention, nor does it suggest a technique for preventing an adverse effect of a hardening filler such as cement due to an alkali component. Therefore, this prior art also does not disclose the purpose, the problem, the configuration, the operation, and the effect of the floor structure according to the present invention.

Purpose of the invention

SUMMARY OF THE INVENTION An object of the present invention is to provide a floor structure using a recycled PET material capable of effectively using a recycled material, improving its recyclability, and improving strength and reliability of a structure using the recycled material. The body is to provide its manufacturing method-that is.

Disclosure of the invention

A floor structure using a recycled PET material according to the present invention is a floor structure in which a basic structure including a curable material is stored in a frame, wherein the frame includes a recycled PET material, and the frame and the basic structure An erosion preventive layer for preventing alkali erosion is interposed between the base structure and the base structure, so that the basic structure and the frame do not come into contact with each other. The floor structure includes a floor base material structure and a double floor structural member.

According to the present invention, further, in the floor structure using the recycled PET material, a basic structure including a curable material having an alkali component is housed in a molded body, and the molded body includes at least a recycled PET material and an alkali. By molding an erosion-preventing material that prevents erosion, the recycled PET material is formed on the outer surface and the erosion-preventing material is formed on the inner surface, and inside the molded body on which the erosion-preventing material is formed. The storage of the basic structure prevents contact between the basic structure and the recycled PET material and prevents the components of the basic structure from eroding the recycled PET material. Note that the molded body includes those formed by molding methods such as pressure forming, injection molding, co-extrusion molding as well as molding necessary for forming the floor structure, for example, laminate molding and vacuum molding.

According to such a floor structure, for example, an olefin resin such as PP resin or PE resin is formed between a frame as a molded body and a basic structure formed of a hardening material such as concrete. Since the erosion prevention material intervenes to form a layer, the frame is protected from alkali components by the erosion prevention layer and is not affected by it, so that cracks and cracks are prevented from occurring, and durability is improved. Improves performance and reliability. The erosion prevention layer is not limited to the olefin resin. Alternatively, a metal such as titanium may be used.

In the floor structure using the recycled PET material according to the present invention, the molded body formed at least in contact with the basic structure including the curable material has at least three layers including a contact prevention material, an olefin adhesive, and a recycled PET material. It has a structure, and the contact prevention material is placed on the upper surface of the basic structure to form the lowermost layer of the molded body so that the recycled PET material does not touch the basic structure. The olefin adhesive is a contact prevention material. The contact-preventing material is placed on the upper surface of the recycled PET material to form an adhesive intermediate layer, and the recycled PET material is placed on the upper surface of the olefin-based adhesive material to form The upper layer is formed.

In other words, a contact prevention material is in contact with the basic structure to form a layer, an olefin adhesive is laminated on the upper surface thereof, and a recycled PET material is further laminated to form a three-layer structure. With this three-layer configuration, it is possible to reliably prevent the alkali component of the basic structure from coming into contact with the recycled PET and being eroded, thereby improving the stability of molding quality and the quality of the entire product.

In such a floor structure, the contact-preventing material or the erosion-preventing material may be made of a PE or PP olefin resin. The thickness may be at least substantially in the range of 30 μπι to 200 / zm before thermoforming. The contact preventive or erosion preventive is not limited to PE or PP, but may be a sheet or film of another resin. The thickness should theoretically be such that the recycled PET material does not contact the basic structure, that is, in the range of more than Ομιη and not more than approximately 200μηι. Further, the thickness of the recycled PET material before the thermoforming may be at least substantially in the range of 450 μπι to 800 μιη. Furthermore, the olefin-based bonding portion of the erosion-preventing material or the contact-preventing material is made of an olefin-based bonding material that bonds the recycled PET material to the basic structure. What is necessary is to substantially satisfy the range of 20 μηι to 30 / xm (25 μηι ± 5 μιη).

By setting these thicknesses, in a molded body using recycled PET material, the formability in thermoforming is stabilized, and the quality level of the product is improved.

Such a floor structure may also be a two-layer structure of a molded body including recycled PET material and an erosion prevention layer, the total thickness of which is substantially 480 μιη before thermoforming. Or 1,000 μιη. In addition, the total thickness of the three-layer structure of the molded body including the recycled PET layer, the olefin-based adhesive layer, and the contact prevention layer is substantially 500 111 to 1,030 111 (the Including the case where the thickness of the system adhesive layer is 0 μm.) Just add it. By setting these thicknesses, it is possible to stabilize the formability, improve the quality level, and maintain stability in a molded body that makes effective use of recycled PET material. According to the present invention, the method for producing a floor structure using recycled PET also includes forming a two-layer structure of a recycled PET layer containing recycled PET material and an erosion preventing layer containing Al erosion preventing material. A two-layer structure forming step, and a molded body which is formed by molding the two-layer structure to form a molded body having a storage portion for the basic structure such that the erosion prevention layer is on the inner side and the recycled PET layer is on the outer side. A forming step and a filling step of filling the storage section with a curable material are included.

According to the present invention, a method for manufacturing a floor structure using a recycled PET material includes a recycled PET sheet forming step of forming a sheet-shaped member from the recycled PET material, and a recycled PET material formed by molding the sheet member. A molded body forming step of forming a molded body for accommodating the basic structure so as to be on the outer surface side, and forming an erosion preventing layer as an alkali erosion preventing material on the inner surface of the housing of the molded body basic structure. And a filling step of filling a curable material into a housing portion of the molded body.

Furthermore, according to the present invention, a method of manufacturing a floor structure using recycled PET includes a recycled PET material, a contact preventing material for preventing the recycled PET material from contacting the basic structure, a contact preventing material, and a recycled material. By co-extrusion molding with the olefin adhesive to enable close contact with the PET material, the uppermost layer and the olefin adhesive are recycled so that the recycled PET material does not contact the basic structure. A sheet-like forming step of forming at least three layers of sheet-like members by forming an intermediate layer that enables the PET material to adhere to the contact-preventing material and a lowermost layer so that the contact-preventing material contacts the basic structure. A thermoforming step of thermoforming the three-layer sheet-like member to form a molded body such that a contact prevention material is formed on the inner surface thereof; Filling process for filling conductive materials Characterized in that it comprises a.

According to the present invention, the method for manufacturing a floor structure using recycled PET further includes a first sheet forming step of forming the recycled PET material into a substantially sheet-shaped recycled PET member, and a method of adhering to the recycled PET member. A second sheet forming step of forming a contact-preventing material on the substantially sheet-shaped contact-preventing member, the contact-preventing member being provided with an olefin adhesive for preventing the recycled PET member from contacting the basic structure. The top layer so that it does not touch the basic structure, and the intermediate layer that allows the olefin-based adhesive to adhere the recycled PET member to the contact prevention member. And a third sheet-like forming step of forming at least three substantially sheet-like layer members so that the lowermost layer is formed so that the contact prevention member contacts the basic structure. Thermoforming step of forming a molded body such that a contact-preventing member is formed on the inner surface thereof, and a filling step of filling a curable material into a housing portion of the basic structure inside the molded body. And

As described above, in the manufacturing method in which the contact-preventive sheet containing the olefin adhesive and the recycled PET sheet are formed into three layers by sheet-like molding, the sheet structure is laminated and formed to form a floor structure using recycled PET. The body can be easily manufactured. In addition, in the example of application to a support having a double-floor structure, the upper surface means the upper surface in a state where the molded body is installed so as to cover from above the basic structure. In an application example in which the base structure is installed upside down, the base structure is installed with the molded body covering the lower surface side, and the upper surface means the bottom surface. With such a configuration, an erosion prevention layer is formed on the top and bottom parts, which are most important as a floor structure, in other words, on the part that receives the most load and impact, so that cracks and cracks in that part can be prevented. Generation can be prevented and sufficient strength can be secured.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is an explanatory partial cross-sectional view showing a basic structure of a floor structure formed by laminate molding according to an embodiment of the present invention,

FIG. 2 is an explanatory partial cross-sectional view showing a basic structure of a floor structure by two-type resin co-extrusion molding according to an embodiment of the present invention,

FIG. 3 is an explanatory partial cross-sectional view showing a basic structure of a floor structure by a painting / coating process according to an embodiment of the present invention,

FIG. 4 is a schematic partial cross-sectional view showing a specific configuration example of a support as a floor structure according to an embodiment of the present invention;

FIG. 5 is a schematic partial sectional view showing a configuration example in which an erosion prevention layer according to an embodiment of the present invention is partially formed,

FIG. 6 is a schematic partial cross-sectional view showing a configuration example of a support formed by coating and coating according to an embodiment of the present invention.

FIG. 7 and FIG. 8 are diagrams showing an example of a manufacturing process of a floor structure by laminate molding, FIG. 9 is a partial cross-sectional view showing an example of a manufacturing process of a floor structure by laminate molding. FIG. 10 is a diagram showing an example of a manufacturing process of a floor structure by laminate molding.

11 and 12 are schematic partial cross-sectional views showing an example of a completed floor structure. FIG. 13 is a drawing showing a manufacturing process of a floor structure by a coating process. FIG. 14 is a coating process. FIG. 15A and FIG. 15B show an example of a manufacturing process of a floor structure by a coating process.

FIG. 16 is a schematic partial cross-sectional view showing an example in which the floor structure according to the embodiment is applied to a double floor structure.

17 is a schematic plan view showing a configuration example of a double floor structure to which the floor structure of the present invention is applied, FIG. 18 is a partial cross-sectional view showing a configuration example of the double floor structure shown in FIG. 17,

19A and 19B are a perspective view and a partial cross-sectional view showing a configuration example of the back surface of the frame of the floor structure according to the embodiment of the present invention,

20A, 20B and 20C are flow charts showing an example of the manufacturing process of the floor structure according to the embodiment,

FIG. 21 is a characteristic diagram showing an example of the thickness of the erosion prevention layer in the floor structure according to the example at an optimum formability level.

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiments of the present invention will first be briefly described with reference to the accompanying drawings. In FIG. 1, a basic structure 10 is formed of a curable material such as mortar. As a material other than mortar, various cements and concretes are suitable materials. Between the recycled PET layer 30 on the upper surface of the basic structure 10 and the resin layer 20 such as a olefin-based resin, preferably PP or PE, or even PVC (polyvinyl chloride), etc. An erosion protection layer 20 is formed.

The erosion prevention layer 20 has a role as a contact prevention material for preventing the recycled PET material 30 from contacting the basic structure 10. Therefore, the erosion preventing layer 20 may be any material that can prevent erosion of the basic structure 10 by an alkali component, and may be, for example, a specific resin material, particularly preferably the above-mentioned olefin resin material. The olefin resin material is compatible with each of recycled PET and hardened fillers such as concrete. The resin material is also suitable in terms of adhesiveness and adhesiveness, and is also suitable as a binder. Further, the material is not limited to a resin material, and a metal material such as a titanium material may be used. The same applies to a coating material and a coating material described later.

In this embodiment, an adhesive / adhesive resin layer 21 such as a modified olefin is provided as an olefin adhesive between the uppermost recycled PET layer 30 and the erosion prevention layer 20. The resin layer 21 is formed as a layer having an intermediate property for further improving the adhesion between the recycled PET layer 30 and the erosion preventing layer 20. Therefore, in the present invention, it is not always necessary to provide such a layer for improving the adhesiveness. However, as shown in FIG. 1, a contact preventing material 20 of a specific material, an olefin-based adhesive 21 and It is preferable to form a molded body 50 made of a recycled PET material 30 and having a structure of at least three types and three layers.

The contact prevention material 20 is on the upper surface of the basic structure 10 and forms the lowermost layer of the molded body 50 in which the recycled PET material 30 does not contact the basic structure 10. The olefin adhesive 21 is provided on the upper surface of the contact preventing material 20 and has an adhesive property for securely holding the recycled PET material 30 on the contact preventing material 20 to form an intermediate layer. Further, the recycled PET material 30 is located on the upper surface of the orientation adhesive 21 and forms the uppermost layer of the molded body 50. As a result, the overall molding strength of the molded body 50 can be ensured as a three-layer three-layer structure, and the adverse effect of the component can be reliably prevented by the interposition of the olefin-based adhesive 21.

As shown in FIG. 2, the above-described function is basically achieved even with a configuration in which the erosion prevention layer 20 is merely interposed between the basic structure 10 and the uppermost recycled PET layer 30.

FIG. 3 shows an example in which the erosion prevention layer 20 is formed between the basic structure 10 and the uppermost layer of the recycled PET layer 30 by painting or coating, and its operation is described in FIGS. 1 and 2. It is no different from the composition. That is, the configuration according to the present invention is not limited to the method of forming each layer alone and then laminating each layer as in the configuration shown in FIGS. It can also be achieved by forming a thin resin film or metal film by painting and coating. FIG. 4 shows an example in which the present invention is applied to an actual floor structure. In this figure and the following figures, the thickness of each layer is shown at a different ratio from the actual thickness for easy understanding. That is, the illustrated erosion prevention layer 20 and the recycled PET layer 30 are exaggerated from their actual thickness. In FIG. 4, the support 1 has a basic structure 10 having a desired height as its basic structure, and is formed of a hardening filler such as concrete, cement, mortar, or the like. The support 1 is to be laid under the figure, for example, placed on the floor (not shown) of the building, and the height of the basic structure 10 is set as the support foot of the double floor. In the application example where the function is to work, the height is to secure the wiring space of the double floor.

The basic structure 10 is covered with a recycled PET layer 30 that forms a frame that is a molded body that covers the entire structure from above in FIG. Between the recycled PET layer 30 and the basic structure 10, an erosion-preventing layer 20 of an olefin resin, for example, PP or PE resin is interposed as the alkali erosion-preventing material.

With such a configuration, it is possible to prevent the alkaline basic structure 10 from adversely affecting the recycled PET layer 30, that is, to prevent decomposition of the recycled PET due to the alkali component. Therefore, the possibility of using recycled PET material in the field of various floor structures including the double floor structure, which is an issue, can be improved.

FIG. 5 shows another configuration example of the floor structure. As shown, the erosion prevention layer 20 interposed between the basic structure 10 and the recycled PET layer 30 is partially provided. In a double-floor support leg or floor base structure, the frame is subjected to a load or impact, such as when moving furniture or walking, on the upper surface of the frame. Durability of 30 is most important. Therefore, in this configuration example, the erosion prevention layer 20 is formed only on the upper surface of each support 1. Of course, in an application example in which the basic structure 10 is installed upside down so that the basic structure 10 is exposed on the upper surface, the erosion prevention layer 20 is formed on the bottom surface.

As a result, cracks and cracks in the recycled PET layer 30 in the upper surface region of the support 1 can be efficiently prevented, and the durability and strength of the upper surface portion of the recycled PET layer 30 can be improved. it can. Further, the Rukoto to form the erosion layer ² 0 only on the upper surface area as this, by effectively utilizing the resin material for forming the erosion layer 20, savings can be achieved.

FIG. 6 shows an application example in which the erosion prevention layer 20 is formed by painting or coating. As shown, the layer formed by painting or coating has a small thickness. However, the effect of preventing erosion due to alkalinity is shown in Figs. 4 and 5. Has no inferiority.

Hereinafter, an example of a manufacturing process of the support 1 applied to the floor structure as described above will be described. 7 to 9 show a manufacturing process of a frame housing the basic structure 10 formed of a curable material. First, as shown in FIG. 7, a recycled PET layer 30 and an erosion prevention layer 20 of, for example, PE resin are formed, and then the both are passed through a laminator 100 and compressed to form a laminate. Form body 40. That is, the recycled PET layer 30 and the erosion prevention layer 20 are in close contact with each other.

Next, as shown in FIG. 8, the laminate molding 40 is passed between a pair of molds 200-1 and 200-2 to perform vacuum molding. More specifically, the laminated molded body 40 is arranged such that the erosion preventing layer 20 is on the inner surface side of the frame, and the recycled PET layer 30 is on the outer surface side, and a vacuum molding process is performed using a mold.

FIG. 9 shows a frame body 50 as a compact formed by vacuum forming in this manner. As shown in the figure, both side surfaces 50b and the connecting portion 50c of the frame body 50 are extended by a pressing operation using the mold 200 and formed in a thin-walled shape as compared with the upper surface region 50a.

Thus, these molded bodies, that is, the frame body 50, can function as the support 1 of the floor structure. The frame body 50 serving as such a support is composed of the upper surface region 50a and the side surface 50b as described above, and has a substantially square shape capable of housing the basic structure 10 of the curable filler inside. However, it goes without saying that the present invention is not limited to such a square block shape, but may be another polyhedral shape, in other words, a cylindrical shape or a conical shape. Here, the thickness of each layer of the vacuum molded frame, that is, the laminated molded body 40 will be exemplified. Before the thermoforming, the total thickness is set, for example, to about 0.5 sq. To 1 sword. For example, when the total thickness is 0.725 mm, the recycled PET layer 30 is formed with 650 m, the adhesive / adhesive resin layer (modified olefin) is formed with 25 μηι, and the erosion prevention layer 20 is formed with 50 πι.

One preferred embodiment will be described with reference to FIG. As an example, the recycled PET layer 30 is formed with 550 μηι, the modified olefin layer as an adhesive layer is formed with 25 μm, and the PE layer 20 as erosion prevention is formed with 50 μπι to a total thickness of 625 μπι before thermoforming. You have set.

According to the characteristic diagram based on the experimental data by the applicant, the recycled PET layer 30 has 500 μn! ~ 800 μιη range, ΡΕ layer 20 is theoretically 0 μη! It was confirmed that the range of ~ 150 µm was the optimum value. This indicates that the formability level depends on the thickness of the protective layer based on the experimental data in Fig. 21. It is clear from the characteristic diagram showing the bell.

In the example shown in the figure, three types of three-layer structure are mainly used as a measure against alkali in recycled PET, and the protective layer of the laminated sheet before vacuum forming is made of PE. It is the finding of the layer thickness specification. This characteristic diagram is due to the dimensional stability in quality and the bonding of different resins during thermoforming due to the difference in resin molding shrinkage between the recycled PET layer and the PE layer in vacuum molding. Since the thermoformability deteriorates, it shows the essential properties for finding and setting the optimum thickness of both.

For example, the thinner the PE layer, the better. However, if the thickness is extremely thin, appearance defects such as cracks and cracks due to molding occur frequently.On the other hand, if the thickness is extremely thick, the cost will increase due to the use of excessive material, so it is necessary to set the optimum thickness. Become.

More specifically, the horizontal axis shows the protective layer such as a PE layer before vacuum forming, and the vertical axis shows the moldability after vacuum forming. This is a graph plotting the degree of sex. As can be seen from the figure, the thicker the PE layer is, the more the moldability is deteriorated. The moldability shown here is obtained by visually checking the appearance quality of a molded product and classifying the molded product in stages, as described later. For example, check the quality level of the corners by checking the sweetness of the molding at the corners, the uniformity of the thin-walled parts, the absence of sink marks, and the non-elongation. Classified by Here, levels 10 to 9 are indicated by double circles, and levels 9 to 7 are indicated by circles. Although not shown, levels 7 to 4 are ranked in the lower category, and levels 4 to 0 are ranked in the lowest category.

The test conditions in this characteristic diagram are as follows. The thickness of the protective layer (PE) assuming a sheet shape before vacuum forming is Ομπ! Set in multiple steps between ~ 300 / m, recycled PET layer ⁶⁵ 0 / ^{ζ ηι,} also the O-les fin layer as a constant value of 25 μ ιη, total thickness 675 II! Set to ~ 975 / zm. The evaluation criteria are double circles (levels with no problems in thermoformability and appearance quality), circles (levels that require thermoforming time but no problems), and a third rank. The appearance quality was visually checked on the basis of the level at which there was a point that should be partially improved in terms of thermoformability and appearance quality, and the lowest level as a problematic level in terms of thermoformability and appearance quality. However, the appearance quality is that the corner radius is 2 or less, the finished state of the corner, It is based on the sweetness of sex, uniformity of thickness (start-up strength), etc.

From the figure, it can be seen that good formability is obtained in the vicinity of level 7 (circle). At that time, the thickness of the protective layer exceeded Ομιη and was approximately 200μπι or less, and it was found that a thickness not exceeding at least 200 / zm was optimal. except for) .

From the characteristic diagram shown in Fig. 21, it can be seen that when the thickness exceeds about 200 μιη, the moldability sharply deteriorates due to the relationship of the gradient of the characteristic.

(PE) should not exceed around 200 / im. Furthermore, it can be seen that the thickness is less than about 150 μπι, which is more stable and suitable for mass production.

Here, when the thickness of the protective layer is Ομιη, the moldability is the best. However, as described above, the compatibility between the recycled PET layer and the concrete that is the basic structure (prevention of erosion), Since cracks, cracks, wrinkles, deformation, and other problems occur, considering these factors, the thickness of the protective layer must be at least 30 μπι, and preferably 50 μηι or more. is there. This thickness is theoretically in the range of more than Ομπι and approximately 30 m or less as long as it is a resin material capable of forming a uniform ultra-thin protective layer by thermoforming or the like. Good.

Based on the above, in this experimental data, the thickness of the protective layer must be at least 30 μπι to 200 μιη, and the optimal value is preferably 50 μm or more and 150 μm or less. This became clear from the experiment.

Next, with reference to FIG. 10, a process of forming the basic structure 10 using the vacuum formed frame 50 as the completed formed body will be described. In the figure, an operation of filling the curable material 60 before curing is shown. As shown in the figure, the vacuum forming frame 50 is installed with the open portion facing upward, and the curable material 60 is poured into the open portion. By this filling operation, the curable material 60 is completely filled to its open surface and is filled. Curing is carried out for a time until this hardens sufficiently. The flow in FIG. 20A corresponds to the work from FIG. 7 to FIG.

Explaining the thickness of each layer of the vacuum forming frame, that is, the laminate forming body 40, before the thermoforming, the total thickness is about 0.5 nm in one example! Set to ~ lmm. For example, when the total thickness is 0.725 mm, the thickness of the recycled PET layer 30 is 650 μm, and the thickness of the adhesive / adhesive resin layer (modified (Refin) 25 m, Erosion prevention layer 20 is formed with 50 μιη.

Returning to FIG. 11, after the curing and curing steps are completed, the exposed side of the cured curable material 60, that is, the basic structure 10, is cut or sanded in order to finish it sufficiently flat. The surface finishing work is performed mechanically or manually. The completed state is shown in FIG.

When laying, the basic structure 10 is exposed to the upper side as shown in FIG. 11, or the basic structure 10 is covered from above by the recycled PET layer 30 as shown in FIG. It will be installed on a double-floor structure, etc., as appropriate.

Next, a description will be given of a manufacturing process of a floor structure by a painting or coating manufacturing method, which is a basic structure shown in FIG. 3 and a specific floor structure shown in FIG. First, as shown in FIG. 13, the material of the recycled PET layer 30 formed in a sheet shape is set between a pair of dies 300-1 and 300-2, and this is vacuum-formed to form a sheet. As shown in FIG. 14, a vacuum formed frame 52 composed of only one layer of the recycled PET layer 30 is formed. The thickness of each portion of the illustrated frame 52 is exaggerated, as described above in connection with FIG.

Next, an operation of forming an erosion preventing layer by a painting process or a coating process will be described with reference to FIGS. 15A and 15B. That is, as shown in FIG. 15A, application or spraying of, for example, PP or PE resin or silicon oil as a coating material or a coating material is performed. In FIG. 15A, PP or PE resin is sprayed only on the inner side surface of the upper surface region of the vacuum forming frame 52.

In the method shown in FIG. 15B, since the erosion preventing layer 20 is formed over the entire inner surface of the vacuum forming frame 52, the resin is sprayed over the entire surface. Various methods such as a method of applying a PP or PE resin with a brush or the like may be applied to the coating treatment for forming the erosion preventing layer 20. The application or spraying of the PP or PE resin is performed at the stage where the sheet-like recycled PET layer 30 shown in FIG. 13 is formed, that is, at the stage before vacuum forming by the mold 300 is performed. Is also good.

Thereafter, the operation of filling the curable material and curing until it is cured may be the same as the operation described above with reference to FIG. 10, and a description thereof will be omitted. The manufacturing steps shown in FIGS. 13 to 15B correspond to the flow of FIG. 20B. Various processes may be used for the manufacturing process of the floor structure. For example, as shown in the flow of FIG. 20C, each of the two kinds of resin materials is injected almost simultaneously from different positions in the above-mentioned mold. At the same time, the two types of resin, that is, the recycled PET layer 30 and the erosion prevention layer 20 can be thermocompression-bonded or heat-welded with a roll coater by heat conduction to form a two-layer thin plate or sheet. It is.

In the co-extrusion method of these two resins, when the total thickness before molding is 0.70 70, the thickness of the recycled PET layer 30 is preferably 650 μππ and the thickness of the erosion prevention layer 20 is preferably 50 μm. It is. In addition, although the example of the two layers is described above, the present invention is not limited to this, and it is also possible to form three layers using three kinds of materials, for example, recycled PET, PE or PP, and modified olefin. Further, as a molding method, multi-layer coextrusion molding may be used.

In addition, for example, first, the first injection molding with recycled PET material is performed to form a frame, and then, before being cooled, the erosion prevention layer using the erosion prevention material is immediately formed in the second injection molding. Then, by further molding the frame, these are combined by heat during injection molding, and a two-layer frame made of different resin materials is formed. In the case of such an injection two-layer molding, if the total thickness is resin-molded, for example, from about two to five thighs, for example, the erosion prevention layer is configured to have a thickness of about about 30 μπι to 200 μιη. It is suitable. The thickness of each layer only needs to be such that the recycled PET layer can be sufficiently protected from alkali components after the hardening filler is fixed.

An example in which the floor structure manufactured and completed as described above is actually applied as a supporting leg of a double floor will be described below. FIG. 16 is a schematic cross-sectional view of a double-floor structure using such a support 1 as a support leg. As shown in the drawing, a portion 400 corresponding to a connection between the supports 1 is shown. The space above is used as the wiring space S. In order to cover the wiring space S, a wiring cover 70 forming an upper floor surface is laid. Note that reference numerals 402, 404, 406, and 408 in the figure denote wirings installed in the wiring space S.

FIG. 17 is a view of the double floor structure using the support as shown in FIG. 16 as viewed from above, and shows a state where the wiring cover 70 is removed. From the figure, it can be seen that a block 410 of the support 1 concentrated in a block shape and a passage portion X for forming a wiring space are formed. Each block is formed with a lattice-shaped rib R1. The rib R1 improves the strength of the upper surfaces of the recycled PET layer 30 and the erosion prevention layer 20, which are formed frames, and improves the strength of the mortar 10. It is also effective in preventing detachment from the frame 50 and falling. FIG. 18 is a partial cross-sectional view of a block-shaped portion of the support 1, and it can be seen that a rib R1 having a predetermined depth is formed as shown.

Next, FIG. 19A shows a state in which the frame body 80 is viewed from the back side as a molded body molded from the recycled PET layer 30 and the erosion prevention layer 20. As shown in the figure, it can be seen that various reinforcing ribs are formed on the rib R1. In the present embodiment, such a rib composition makes the recycled PET frame formed more flexibly than a conventional frame made of ECR (ethylene copolymer resin) or PVC (polyvinyl alcohol). It can reinforce the strength of the body, especially the upper part.

Further, in this embodiment, a characteristic portion is a cutout portion forming a cutout portion of a rib indicated by reference numeral 90. In this manner, the cutout portion 90 is formed at a portion where the side wall portion 91 of the block, which is the edge of the floor structure, and the rib 92 that partitions the block as a small block are perpendicular to each other. By providing the cutout portion 90, when recycled PET is used, it is possible to effectively prevent the occurrence of molding sagging due to the deterioration of the flow of the recycled PET material during molding. That is, for example, it is possible to effectively prevent the formation of sagging and the generation of unnecessary small protrusions in the orthogonal portions of the side wall portions 91 and the ribs 92.

FIG. 19B shows a cross-sectional shape of each support 1 which is a small block in the present embodiment, and an inner portion of the frame 50 is provided at an edge portion of each frame portion, that is, at a boundary portion between adjacent support members. A bulged portion 94 slightly projecting toward is formed. The bulging portion 94 can effectively prevent the basic structure 10 from dropping or shifting from the frame after the completion of the structure.

As described above, according to the present embodiment, the recycled PET layer 30 functioning as a frame covering the basic structure 10 is formed of a hardening material such as concrete, cement, and mortar containing an alkali component. Since there is no direct contact with the structure 10, the generation of cracks and cracks due to the decomposition of the recycled PET due to the alkali component is effectively prevented. As a result, the strength of the frame body, for example, the load resistance is improved, and the reliability is improved. The recycled PET layer 30 may optionally contain a small amount of a resin material as a modifier for ensuring strength and flexibility during regeneration. Also, in the field of floor structures, recycled PET materials are used only in mold release molds for molding and partially mixed with molded resin materials, and only from a few percent to tens of percent are being used. Was. However, by applying the present invention, it is possible to increase the utilization rate of recycled PET material from 50% of the whole to about 90% at the maximum.

Furthermore, the interposition of the erosion prevention layer 20 between the basic structure 10 and the recycled PET layer 30 not only protects the recycled PET layer 30 from alkali components, but also causes shrinkage due to temperature changes in the manufacturing process or storage conditions. The stress between the recycled PET layer 30 and the basic structure 10 due to external factors such as stress, for example, the stress due to the close contact state is also reduced, and it is possible to effectively avoid the occurrence of cracks caused by these stresses. It is possible. In addition, although the strength can be improved by the use of the modifier and the close contact state as described above, the impact strength can be further improved by adopting a multilayer structure.

As described above, according to the floor structure using the recycled PET material and the method for manufacturing the same according to the present invention, the basic structure accommodated in the frame, which is a molded body formed of the recycled PET material, is used. The alkali component can effectively prevent the adverse effects on recycled PET, improving the possibility of effective use of recycled PET materials in the field of floor substructures and double floor structures, and improving the recyclability of floor structures. In addition, costs can be reduced.

2001.December 21, 2001 Japanese patent application filed on December 16, 2002, the specifications, claims, and attachments of Japanese Patent Application Nos. 2001-390213 and 2002-363482, respectively. All disclosures, including drawings and abstracts, are hereby incorporated by reference in their entirety.

Although the present invention has been described with reference to particular embodiments, the present invention is not limited to these embodiments. It should be recognized that those skilled in the art can change or modify these embodiments without departing from the scope and concept of the invention.

Claims

The scope of the claims

1. In a floor structure (1) including a basic structure (10) including a curable material having an alkaline component and a molded body (50) accommodating the basic structure (10),

The molded body (50) is obtained by molding at least a recycled PET (polyethylene terephthalate) material and an erosion-preventing material (20) for preventing erosion of aluminum alloy. Erosion control material (20) is formed to be located,

By disposing the erosion preventing material (20) inside the molded body (50), the alkali component of the basic structure (10) is reduced by the contact between the basic structure (10) and the recycled PET material. A floor structure using a recycled PET material, wherein the floor structure prevents erosion of the recycled PET material.

2. The floor structure according to claim 1, wherein the erosion preventing material (20) contains a olefin-based resin.

3. A floor structure (1) including a basic structure (10) including a curable material constituting a floor structure, and a molded body (50) at least in contact with the basic structure (10);

The molded body (50) has at least a three-layer structure including a contact preventing material (20), an adhesive (21), and a recycled PET (polyethylene terephthalate) material (30);

The contact preventing material (20) forms a lowermost layer of the molded body (50) on which the recycled PET material (30) does not contact the basic structure (10) on the upper surface of the basic structure (10). ,

The adhesive (21) forms an intermediate layer on the upper surface of the contact preventing material (20), which has an adhesive property that the contact preventing material (20) securely holds the recycled PET material (30). ,

The floor structure using a recycled PET material, wherein the recycled PET material (30) has an uppermost layer of the molded body (50) formed on an upper surface of the adhesive (21).

4. The floor structure according to claim 3, wherein the molded body (50) is formed with a rib portion for capturing, and the rib portion from the lip portion to an edge region of the molded body (50). A floor structure having a rib removal portion (90) provided at a transition portion to prevent accumulation of resin.

5. The floor structure according to claim 3, wherein an edge of a portion where the molded body (50) is housed has a bulge for stably retaining the basic structure bulging inward of the portion. A floor structure having a protrusion (94) formed thereon.

6. A method for manufacturing a floor structure (1) in which a basic structure (10) containing a curable material is housed in a molded body, the method comprising:

A two-layer structure forming step of forming a two-layer structure of a recycled PET layer (30) containing a recycled PET (polyethylene terephthalate) material and an erosion prevention layer (20) containing an anticorrosion material; A molded body (50) having a storage portion for the basic structure (10) is formed by molding a layer structure so that the erosion prevention layer (20) is on the inner surface side and the recycled PET layer (30) is on the outer surface side. A) forming a molded body,

A filling step of filling the storage section with the curable material. A method of manufacturing a floor structure using recycled PET.

7. The floor according to claim 6, wherein, in the two-layer structure forming step, the recycled PET layer (30) and the erosion prevention layer (20) are united by laminating. The method of manufacturing the structure.

8. The method according to claim 6, wherein, in the step of forming a molded body, the molded body (50) is formed by vacuum molding.

9. The method according to claim 6, wherein a total thickness of the molded body (50) including the recycled PET material (30) and the erosion preventing material (20) is substantially 480 μm before molding. A method for producing a floor structure, characterized by satisfying a range of πι or ΙΟΟΟμππ.

10. A method for manufacturing a floor structure (1) in which a basic structure (10) containing a curable material is housed in a molded body, the method comprising:

Forming a sheet-like member from recycled PET (polyethylene terephthalate) material (30);

A molded body forming step of molding the sheet member to form a molded body (50) for storing the basic structure so that the recycled PET material is on the outer surface side;

An erosion-preventing layer forming step of forming an erosion-preventing layer as an erosion-preventing material (20) on the entire inner surface of the storage portion of the basic structure of the molded body (50);

Filling the curable material into the storage section of the molded body (50) on which the erosion prevention layer (20) is formed. A method for manufacturing a floor structure using recycled PET .

11. The method according to claim 10, wherein the erosion protection layer (20) is coated by a coating process. A method for producing a floor structure, wherein the floor structure is formed by treatment or coating.

11. The floor structure according to claim 10, wherein in the erosion prevention layer forming step, the erosion prevention layer is formed only in an upper surface area substantially inside the storage section. Manufacturing method. '

13. A method of manufacturing a floor structure (1) in which a basic structure (10) containing a curable material is housed in a molded body, the method comprising:

Recycled PET (polyethylene terephthalate) material (30); contact preventing material (20) for preventing the recycled PET material (30) from contacting the basic structure (10); and contact preventing material (20) And an olefin adhesive (21) for surely holding the recycled PET material (30) are co-extruded at substantially the same time, whereby the recycled PET material (30). ), And an intermediate layer in which the olefin adhesive (21) enables adhesion between the recycled PET material (30) and the contact preventing material (20). Forming a lowermost layer so that the touch-preventing material (20) is in contact with the basic structure (10), and forming a sheet-like member having at least three layers;

A thermoforming step of thermoforming the three-layer sheet member to form the molded body (50) such that the contact preventing material (20) is located on the inner surface thereof;

A filling step of filling the curable material into a housing portion of the basic structure on the inner surface of the molded body (50). A method of manufacturing a floor structure using recycled PET.

14. The method according to claim 13, wherein the contact-preventing material (20) is made of at least a resin sheet or a resin film before molding, and has a thickness of the recycled PET material (30). A method for producing a floor structure, characterized by satisfying a thickness not in contact with the basic structure (10), that is, a range of substantially more than 0 m and 200 μπι or less.

15. The floor structure according to claim 13, wherein the thickness of the recycled PET material (30) satisfies at least approximately 450 in to 800 im before molding. How to make the body.

16. The method according to claim 13, wherein the contact preventing material (20) includes an olefin-based adhesive for bonding the recycled PET material (30) and the basic structure (10), Before molding, the thickness should be substantially 20 m to 30 μπι (substantially 25 Αί η ± 5 μ m) A method for producing a floor structure, characterized by satisfying the range of:

17. The method according to claim 13, wherein a total thickness of the molded body (50) including the recycled PET material (30), the olefin-based adhesive (21), and the contact prevention material (20) is: A method for producing a floor structure, which substantially satisfies a range of 500 μιη to 1030 / m (including a case where an olefin-based adhesive is 0 m) before growth.

18. A method of manufacturing a floor structure (1) in which a basic structure (10) containing a curable material is housed in a molded body, the method comprising:

A first sheet forming step of forming a recycled PET (polyethylene terephthalate) material (30) into a substantially sheet-shaped recycled PET member;

An anti-reflective adhesive (21) for enabling close contact with the recycled PET material (30), and a contact preventing material for preventing the recycled PET material (30) from contacting the basic structure (10). (20) a second sheet forming step of forming a substantially sheet-shaped contact prevention member,

An uppermost layer so that the recycled PET member does not come into contact with the basic structure (10); and an intermediate layer that allows the olefin-based adhesive (21) to bond the recycled PET member to the contact preventing member. A third sheet-like forming step of forming a lowermost layer so that the contact preventing member is in contact with the basic structure (10) to form at least three substantially sheet-like layer members;

A thermoforming step of thermoforming the three layer members and forming the molded body (50) such that the contact preventing member is located on the inner surface thereof;

A filling step of filling the curable material into a housing portion of the basic structure (10) on the inner surface of the molded body (50). A method for manufacturing a floor structure using recycled PET.