JP4378933B2 - Recycled tile carpet and its manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a recycled tile carpet that is effective for recycling and using a used recovered product of a tile carpet lined with a vinyl chloride-based resin on the back side of a base material or an end material at the time of manufacture, and a method for manufacturing the same.
[0002]
[Prior art]
Cutting tiles were generated during the manufacture of tile carpets, and used carpets, particularly tile carpets, were discarded without being recycled as construction waste. However, in recent years, from the viewpoint of protecting the global environment and effectively utilizing resources, there is a problem of disposal of waste materials and scraps of waste tile carpets and waste materials associated with renewal. Currently, many of the backing layers of tile carpets are made of vinyl chloride resin, and the development of appropriate processing and recycling methods is desired.
[0003]
Various methods have been proposed for recycling tile carpets. For example, after pulverization, as a resin lining layer of carpet, a method of spreading a pulverized product of tile carpet on a virgin raw material sol, sandwiching and laminating it, and regenerating it as a resin lining layer (see, for example, Patent Document 1), carpet A method of making a sheet by adding a filler and a binder to waste materials (see, for example, Patent Document 2), using a pulverized waste carpet material as part of the resin backing layer of a tile carpet, kneading with a Banbury mixer, and calendar rolling. Have proposed a method of manufacturing carpet tiles (see, for example, Patent Document 3).
[0004]
On the other hand, as a method of pulverizing and separating a carpet, a carpet whose backing material has specific physical properties is pulverized by applying an impact force at a low temperature, and the surface pile layer and the backing material are separated (for example, see Patent Document 4). ). Also, in order to recycle the waste carpet material, the resin backing layer is separated from three separation stages including at least two pulverization stages and a vibration sieving process, and a recycling method as a backing material by a melt extrusion method (for example, And Patent Document 5). When recycling the resin backing layer of a tile carpet, it is necessary to accurately separate the surface pile layer. As an efficient method, a method of crushing and separating by hitting the carpet with an impeller is known. It is.
[0005]
[Patent Literature]
Japanese Examined Patent Publication No. 7-153030 [0006]
[Patent Document 2]
Japanese Patent Laid-Open No. 11-105096
[Patent Document 3]
Japanese Patent Laid-Open No. 7-32520
[Patent Document 4]
JP-A-9-173197 [0009]
[Patent Document 5]
At present, most of the tile carpets used are roughly divided into an upper layer and a lower layer. Many of the upper fiber materials are nylon, polyester, and polypropylene, and the lower resin materials are often made of PVC. The tile carpet manufactured by the paste sol coat method has a surface pile layer embedded in the resin backing layer, so the surface pile layer and the resin backing layer are difficult to peel off, and it is easy to separate and recycle both layers. It was not.
[0010]
Moreover, in order to pulverize the tile carpet and recycle the resin backing layer as a resin material as the sol material of the backing layer, it is necessary to accurately separate the fiber component composed of the surface pile layer.
When reclaiming and recycling tile carpet backing resin, the vinyl chloride resin used as the backing resin has a large amount of fiber constituting the surface pile layer when the resin backing layer of tile carpet is formed by the paste sol coat method. If mixed in, the surface of the lining resin layer becomes uneven due to air entrainment, and the surface property is impaired, or the paste sol tends to increase in viscosity and the molding processability is deteriorated, and the quality of the finished product is impaired. There was a problem. Therefore, in order to recycle the backing resin of tile carpet waste material, the fiber component consisting of the surface pile layer is accurately separated, the amount of fiber component mixed in is reduced, and the fiber component is accurately separated in the paste sol. It was necessary to disperse the finely pulverized product uniformly.
[0011]
[Problems to be solved by the invention]
In the present invention, the backing resin of the tile carpet waste material is used for forming a resin backing layer of a high-quality recycled tile carpet easily and inexpensively by the paste sol coating method after accurately separating the fiber component composed of the surface pile layer. It aims to provide a method for
[0012]
[Means for Solving the Problems]
That is, the present invention
( 1 ) The backing layer of the waste tile carpet lined with vinyl chloride resin is scraped off, the cutting powder is further pulverized and separated, and the fineness of the backing layer in which the fiber component comprising the surface pile layer is separated to 7% by weight or less After the pulverized material is mixed with the vinyl chloride resin paste sol in a ratio of 0.5 wt% to 20 wt%, the coated belt is coated with a coater, and then a base material with a pile tuft is laminated on the base fabric. Recycled tile carpet in which a resin backing layer is formed on the back surface of ( 1 ).
( 2 ) The particle size of the finely ground and separated backing layer is 1.5 mm or less, and ( 2 ) the recycled tile carpet according to claim 2 ( Claim 2 ), and ( 3 ) the waste tile backed with vinyl chloride resin The backing layer of the carpet is scraped off, the cutting powder is further pulverized and separated, the particle size of the pulverized product of the separated backing layer is 1.5 mm or less , and the fiber component comprising the surface pile layer is 7 wt% or less Is mixed with vinyl chloride resin paste sol at a ratio of 0.5% by weight or more and 20% by weight or less, coated on a coating belt with a coater, and then a base material with a tufted pile is laminated on the base fabric. The present invention relates to a method for producing a recycled tile carpet in which a resin backing layer is formed on the back surface of a base material ( Claim 3 ).
[0013]
DETAILED DESCRIPTION OF THE INVENTION
The present invention is described in more detail below.
[0014]
In the present invention, the product shape of the tile carpet that is the object to be treated is, for example, a 50 cm × 50 cm market-recovered product or a defective product, or cut end material waste generated during the manufacture of the carpet. It is lined with a thermoplastic resin. Nylon filaments, polypropylene filaments, wool, acrylics, and polyester filaments are used as the fiber material for the surface pile layer, and among these, nylon filaments are preferred. The gist of the tile carpet of the present invention and the method for producing the tile carpet is that the resin component comprising the backing layer is scraped off and then finely pulverized, and the finely pulverized product is further subjected to sieve selection or specific gravity separation, and then included in the resin component. The tile carpet pet manufactured by the paste sol coating method in which the fiber component is 7% by weight or less and 0.5% by weight or more and 20% by weight or less is mixed with the vinyl chloride resin sol and the manufacturing method thereof.
(I) Cutting and separating the pile layer and the resin backing layer constituting the tile carpet In separating the pile layer and the backing layer of the tile carpet, first, sand, mortar, adhesive layer, etc. attached to the backing layer If adhering, remove with a wire brush, drum sander, grinder, sand paper, belt paper or the like while sucking, then known as a known cutting machine, for example, JP-A-11-179335. The backing layer can be scraped off with a cutting machine. When the vinyl chloride resin agglomerates due to heat generation when scraping off, the tile carpet itself can be cooled to, for example, -20 ° C., and / or cold air of, for example, −20 ° C. can be sent to the cutting place of the cutting machine for cutting. The normal tile carpet is 50 cm square, but may be cut to a size of about 10 cm in width and 50 cm in length according to the size of the equipment. The thickness of the backing layer to be scraped is governed by the fiber content in the finely pulverized product after cutting. If you want to reduce the fiber content as much as possible, you can stop cutting before hitting the fiber content, and if you want to increase the amount of recycling, cut to the very end of the fiber content.
(II) Finely pulverizing separation resin The surface pile layer and the resin backing layer constituting the tile carpet are separated by cutting. If the recovered resin backing layer cut is almost 1.5 mm or less, it is particularly fine with a fine pulverizer. There is no need to grind, but from the viewpoint of cutting productivity, the cut sol is finely pulverized, and then the paste and / or wind separation is used to remove the cut and fiber content exceeding 1.5 mm. It becomes easy to mix and disperse uniformly. The size of the finely pulverized product is a paste sol coating method. When a large finely pulverized product is mixed, the surface of the backing resin layer becomes uneven and the surface property is impaired. The following is preferable, and if it is 1 mm or less, it is more preferable. As the fine pulverizer, a known pulverizer can be used, and a pulverizer in which a screen having an opening diameter of 2 mm or less is installed in a vortex impact type pulverizer (turbo mill) or a horizontal swing hammer crusher is used. It is more preferable from the viewpoint of workability and productivity to finely pulverize the resin from which the fiber component has been separated at a high speed rotation below the rotation.
[0015]
If the sieve opening is larger than 1.5 mm, the particle size distribution of the finely pulverized resin pulverized product is widened, the uniformity of the recovered finely pulverized product is lowered, and the appearance is deteriorated when paste sol coating is performed. Moreover, since the resin pulverized product and the fiber fragments that have not become a finely pulverized product remain on the sieve by sorting with a sieve, the recovery rate can be improved by repeatedly pulverizing with a fine pulverizer.
(III) Manufacture of vinyl chloride paste sol and mixing with backing layer The vinyl chloride paste sol of the present invention is a plasticizer, filler, stabilizer, pigment, foam when foamed to vinyl chloride paste resin. It is adjusted in a mixing tank equipped with a stirrer by blending agents and various additives. And (1) The mixing of the vinyl chloride paste sol and the resin finely pulverized product from which the fiber component comprising the surface pile layer has been separated and removed can be carried out in the same tank, or (2) the vinyl chloride paste sol The paste sol is pumped to a mixing tank equipped with a stirrer in a separate tank, and is stirred and mixed with the finely pulverized resin material separated and removed from the surface pile layer to be homogenized. In this case, it is preferable to install two or more tanks for mixing the finely pulverized resin from which the fiber component consisting of the surface pile layer has been separated and removed. This is because the resin finely pulverized product and the vinyl chloride paste sol mixture from which the fiber component consisting of the surface pile layer has been separated and removed are easy to thicken and have a short pot life. This is because it is necessary to make a mixture.
[0016]
Thereafter, the mixture is pumped to a line for forming a resin backing layer, coated with a coater on a coating belt [usually a Teflon (registered trademark) belt is preferably used], and then piled on a base fabric. A base material having a tufted layer is laminated and gelled by heating to form a resin backing layer of the tile carpet. Further, as a backing material, it can be used in combination with an extruded product or a calendar molded product. Glass fiber can also be added to the backing material.
[0017]
In addition, the vinyl chloride paste sol for forming the resin backing layer in the tile carpet of the present invention is preferably blended and used in the following ratio, and further blended (a) to (f). Additives such as a hygroscopic agent, an antioxidant, a lubricant, a processability improver, and an ultraviolet absorber can be selected and added to the vinyl chloride paste sol.
(A) Vinyl chloride paste resin 100 parts by weight (b) Plasticizer 50-150 parts by weight (C) Filler 100-500 parts by weight (d) Stabilizer 1-10 parts by weight (e) Pigment 1-10 parts by weight (F) Anti-bubble agent 0 to 5 polymerization parts As the vinyl chloride paste resin used in the present invention, polyvinyl chloride resin, vinyl chloride-vinyl acetate copolymer, vinyl chloride-ethylene-vinyl acetate copolymer, etc. The vinyl chloride copolymer is included.
[0018]
Examples of the plasticizer used in the present invention include dibutyl phthalate, dihexyl phthalate, di-2-ethylhexyl phthalate (DOP), di-isononyl phthalate, phosphate ester, chlorinated paraffin, trimellitic acid ester, epoxidation large Although bean oil etc. are used individually or in mixture, it is preferable from the point of workability to use di-2-ethylhexyl phthalate (DOP).
[0019]
The filler used in the invention is an inorganic filler such as calcium carbonate, calcium oxide, barium carbonate, barium sulfate, magnesium hydroxide, aluminum hydroxide, clay, talc, mica, and these are used alone or in combination. Among them, it is preferable to use heavy calcium carbonate. The hardness of the resin backing layer is adjusted by the blending amount of the filler, and sound insulation can be improved by using a material having a high specific gravity of the filler.
Furthermore, as the stabilizer, calcium stearate, Ca-Zn stearate, Ba-Zn stearate, Pb-based metal soap, and organotin stabilizer are known, but it is preferable to use calcium stearate. Examples of the pigment include carbon black and titanium dioxide. A foaming agent can be added depending on the type of tile carpet.
[0020]
The resin finely pulverized product from which the fiber component consisting of the surface pile layer is separated and removed is mixed and dispersed at 0.5 wt% or more and 20 wt% or less with respect to the vinyl chloride paste sol prepared by the above blending. It is preferable to apply a coater or the like on a Teflon (registered trademark) belt, laminate a base material in which a pile is tufted in a loop shape on a base fabric, and heat-gelate to form a resin backing layer of a tile carpet.
[0021]
This is because when the resin finely pulverized product is mixed in an amount of more than 20% by weight, the amount of plasticizer absorbed in the finely pulverized product increases, and the viscosity of the sol mixture rises and the coater cannot be applied. Moreover, it is because recycling efficiency is too low when it is less than 0.5 weight%. The resin finely pulverized product from which the fiber component consisting of the surface pile layer is separated and removed is more preferably blended at 0.5 wt% or more and 10 wt% or less in view of viscosity and recyclability. Further, it is preferable that the fiber component composed of the surface pile layer contained in the finely divided and separated backing layer is 7% by weight or less, particularly when the fiber content is 4% or less. When the fiber component comprising the surface pile layer contained in the finely pulverized and separated backing layer exceeds 7% by weight, the viscosity of the sol mixture increases, and it may be difficult to apply with a coater.
[0022]
In addition, when a vinyl chloride resin paste sol containing (a) to (f) is prepared in advance and then mixed with the finely pulverized product of the backing layer, DOP or the like is mixed with the finely pulverized product of the backing layer. Further plasticizers can be added. By doing so, it is possible to adjust the viscosity of the paste sol containing the finely pulverized backing layer.
[0023]
The Teflon (registered trademark) belt preferably used as the coating belt includes a Teflon (registered trademark) simple substance, a tetrafluoroethylene copolymer, and a modified Teflon (registered trademark) belt, and tetrafluoroethylene on a metal belt. A belt coated with a copolymer and modified Teflon (registered trademark) may be used.
[0024]
【Example】
Hereinafter, the present invention will be described in more detail with reference to examples, but the present invention is not limited to the examples.
(I) Separation of the surface pile layer and the resin backing layer constituting the tile carpet (I-A) A 50 cm square tile carpet was used, and the backing was sucked after being cut into a width of about 10 cm and a length of 50 cm. Cutting stripper formed by spirally winding a serrated wire around the outer peripheral surface of a wide rotating body after removing the adhesive and sand adhering to the layer (of the type described in JP-A-11-179335) Then, the backing layer was scraped off by 2 mm.
[0025]
The resin part was installed in a turbo mill T-400 type manufactured by Turbo Kogyo Co., Ltd., and a finely pulverized material recovery device consisting of a suction duct, a blower, a cyclone separator, and a dust collector was installed, and finely pulverized at 3000 revolutions. As a result, a finely pulverized product was recovered. The content of the fiber component in the pulverized resin composed of the resin backing layer of the tile carpet was 0.8%.
(IB) Using a 50 cm square tile carpet, cutting it into a width of about 10 cm and a length of 50 cm, and then removing the adhesive and sand adhering to the backing layer while sucking, then in the refrigerator Cooled to -20 ° C. Thereafter, the backing layer was scraped off by 2 mm with a flat cutting blade using a cutting machine (of the type described in JP-A-11-179335). The resin part was installed in a turbo mill T-400 type manufactured by Turbo Kogyo Co., Ltd., and a finely pulverized material recovery device consisting of a suction duct, a blower, a cyclone separator, and a dust collector was installed, and finely pulverized at 3000 revolutions. As a result, a finely pulverized product was recovered. The content of the fiber component in the pulverized resin composed of the resin backing layer of the tile carpet was 0.5%.
(I-C) Using a 50 cm square tile carpet, cutting this into a width of about 10 cm and a length of 50 cm, and then removing the adhesive and sand adhering to the backing layer while sucking, wide width Cutting stripping machine (of the type described in Japanese Patent Laid-Open No. 11-179335) formed by spirally winding a sawtooth wire around the outer peripheral surface of a rotating body. Including 4 mm. The resin part was installed in a turbo mill T-400 type manufactured by Turbo Kogyo Co., Ltd., and a finely pulverized material recovery device comprising a suction duct, a blower, a cyclone separator, and a dust collector was installed. As a result, a finely pulverized product was recovered. The content of the fiber component in the pulverized resin composed of the resin backing layer of the tile carpet was 9%.
[0026]
The fiber content in the recovered resin finely pulverized product was determined by the following procedure.
[0027]
The recovered resin pulverized product was precisely weighed and then dissolved in 30 times by weight of tetrahydrofuran (THF), and then the insoluble matter was precipitated and filtered. Next, THF-insoluble matter was dissolved in 12% hydrochloric acid, and further, the insoluble matter was allowed to settle, separated by filtration, dried and precisely weighed. The insoluble matter separated by filtration was sintered at 600 ° C., the residual amount was weighed, and the difference was defined as the fiber component content.
[0028]
(1-D) Using a tile carpet of 50 cm square, cutting this into a width of about 10 cm and a length of 50 cm, then removing the adhesive and sand adhering to the backing layer while sucking, then shearing The pulverized product was pulverized by attaching a 3 mm screen with a pulverizer.
(II) Preparation of vinyl chloride paste sol Heavy calcium carbonate was added to a paste sol containing 100 parts by weight of vinyl chloride paste resin, 100 parts by weight of plasticizer (DOP), 1 part by weight of calcium stearate and 1 part of carbon black. Was added and mixed and homogenized to prepare a vinyl chloride paste sol.
[0029]
Example 1 In FIG. 1, 95% by weight of the vinyl chloride paste sol (II) above and 5% by weight of a resin pulverized product composed of the resin backing layer of the tile carpet (I-A) were put into a pulverized product charging tank ( After mixing uniformly for 15 minutes in A), the mixed solution was transferred to a sol coater with a pump and applied to a Teflon (registered trademark) belt with a coater, and then the pile was tufted into a loop on the base fabric. The substrate was laminated and gelled in a heating furnace adjusted to 140 ° C., thereby forming a resin backing layer to produce a tile carpet.
[0030]
After 15 minutes from the start of transfer to the sol-coater, the mixture is uniformly mixed in the pulverized product charging tank (B) for 15 minutes with the same composition, and then transferred from the pulverized product charging tank (A) to the pulverized product charging tank (B). It was switched (the sol coater transfer time in the pulverized product charging tank (A) was 30 minutes) and continued for 30 minutes. The appearance of the manufactured tile carpet was clean.
[0031]
Example 2 In FIG. 1, 88% by weight of the above-mentioned (II) vinyl chloride paste sol, 7% by weight of the resin lining of the tile carpet of (IB) and 7% by weight of DOP were ground. The mixture was uniformly mixed in the charging tank (A), and after 1 hour as in Example 1, the pulverized product charging tank (B) having the same composition as the pulverized product charging tank (A) was switched. The appearance of the manufactured tile carpet was clean.
[0032]
(Example 3) In the above (IA), when selecting with a sieve without performing fine pulverization, using a material selected with a sieve with an opening of 3 mm instead of using an opening of 1 mm, the same as in Example 1 When performed, the appearance of the tile carpet produced was lower than that obtained in Example 1.
[0033]
( Reference Example 1 ) In the same manner, when (IC) was used instead of (IA) in Example 1 to produce a tile carpet, the appearance of the tile carpet was caused by thickening of the paste sol. A decrease in appearance was seen from that obtained in Example 1.
[0034]
(Comparative Example 1) In FIG. 1, 60% by weight of the above-mentioned vinyl chloride paste sol (II), 30% by weight of the resin backing layer of the tile carpet of (IA), and 10% by weight of DOP were ground. The mixture was uniformly mixed in the charging tank (A), and after 30 minutes in the same manner as in Example 1, the pulverized product charging tank (B) having the same composition as the pulverized product charging tank (A) was switched. The appearance of the tile carpet produced was clumsy and not worth using due to the thickening of the paste sol.
[0035]
(Comparative Example 2) Instead of (I-A) in Example 1, using (ID) in the same manner, when a tile carpet is manufactured, the appearance of the tile carpet is the thickening of the paste sol, Diminished for use.
[0036]
【The invention's effect】
After separating the fiber component comprising the surface pile layer of the waste tile carpet with high accuracy, a resin lining layer of a good quality recycled tile carpet can be easily and inexpensively formed by the paste sol coating method.
[Brief description of the drawings]
FIG. 1 is a schematic view showing a method for producing a waste material recycled tile carpet of the present invention.

Claims (3)

The backing layer of the waste tile carpet lined with vinyl chloride resin is scraped off, the cutting powder is further pulverized and separated, and the pulverized backing layer in which the fiber component consisting of the surface pile layer is separated to 7% by weight or less is obtained. After mixing with vinyl chloride resin paste sol at a ratio of 0.5% by weight or more and 20% by weight or less, after applying to the coating belt with a coater, a base material with tufted pile is laminated on the base fabric, and the back surface of the base material is laminated. Recycled tile carpet formed by forming a resin backing layer. 2. The tile carpet according to claim 1 , wherein the finely ground and separated backing layer has a particle size of 1.5 mm or less. Scrap off the backing layer of the waste tile carpet backed with vinyl chloride resin, further pulverize and separate the cutting powder, the particle size of the pulverized product of the separated backing layer is 1.5 mm or less , and from the surface pile layer contained After mixing a fine powder having a fiber component of 7% by weight or less into a vinyl chloride resin paste sol at a ratio of 0.5% by weight or more and 20% by weight or less, coating the coated belt with a coater, and then applying a pile to the base fabric. A method for producing a recycled tile carpet in which a tufted base material is laminated and a resin backing layer is formed on the back surface of the base material.

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