Vinyl chloride resin mat

Abstract

The present invention aims to provide a vinyl chloride resin base plate that can be used as a substitute for a steel plate even when using crushed vinyl chloride resin products as they are. [Solution] The present invention relates to a vinyl chloride resin mat containing pulverized vinyl chloride resin product containing 40% to 60% by mass of vinyl chloride resin, wherein the content of the pulverized material is 25% to 75% by mass of 100% by mass of the vinyl chloride resin mat. Preferably, the vinyl chloride resin mat contains 3.6% to 10.8% by mass of calcium carbonate, 0.9% to 2.7% by mass of glass fiber, and 2.1% to 6.2% by mass of pulp in 100% by mass of the vinyl chloride resin mat.

Description

Technical Field

[0001] The present invention relates to a floor board laid on the ground of a construction site, a building site, a factory, a warehouse, various event venues, etc., and can be used as an alternative to an iron plate.

Background Art

[0002] Conventionally, an iron plate having high bending strength and high hardness has been used as a floor board at a construction site or the like. However, since the iron plate is very heavy and a heavy machine is required for laying, and a great deal of labor is required for transporting it to the site, in recent years, there has been a trend towards replacement with a lightweight and workable plastic floor board.

[0003] As a material for plastic floor boards, polyethylene is the mainstream, but other thermoplastic resins such as polyvinyl chloride, polystyrene, polypropylene, and those obtained by mixing a rubber component with these thermoplastic resins are also known (Patent Document 1).

[0004] Further, according to Patent Document 1, by utilizing a thermoplastic resin derived from waste or a recycled rubber component as a material for a plastic floor board, it is possible to develop a plastic floor board that takes environmental considerations into account.

[0005] However, when polyethylene is used for a floor board, in order to withstand the weight of a heavy machine or the like, a thickness of 10 mm or more is required. However, since polyethylene is a resin with low flexibility, the thicker it is, the harder and more likely it is to crack, so it cannot withstand long-term use and the replacement frequency is high. Also, since it is difficult to follow an uneven laying surface, the floor board tends to be unstable.

[0006] Recently, floor boards made of vinyl chloride-based resins are in increasing demand due to their advantage of being flexible and difficult to crack.

[0007] On the other hand, polyvinyl chloride (PVC) resins are used in a wide variety of products, and their waste is often recycled. For example, PVC films and sheets, PVC wallpaper, PVC flooring, electric wires with PVC coatings, PVC carpets, and PVC synthetic leather are known products. When forming a base plate using waste from these PVC products, in order to maintain the high bending strength and hardness required for a base plate, it was necessary to remove materials other than PVC from the waste and recover only the PVC resin for recycling. Therefore, the materials that could be used for base plates were limited to waste from products such as sheets and films made of PVC, and electric wires with PVC coatings that are easy to recover. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] Japanese Patent Publication No. 2010-37808 [Overview of the Initiative] [Problems that the invention aims to solve]

[0009] Therefore, the present invention aims to provide a vinyl chloride resin base plate that can be used as a substitute for a steel plate even when using crushed vinyl chloride resin products as they are. [Means for solving the problem]

[0010] The inventors of this invention believed that if waste vinyl chloride resin products could be reused as a material for floor mats, the effort required to remove materials other than vinyl chloride resin from the waste would be reduced, and the range of vinyl chloride resin products that could be used as floor mats would be expanded. As a result of diligent research to achieve the above objective, they discovered that by adjusting the content ratio of vinyl chloride resin products containing a specific amount of vinyl chloride resin, that is, by adjusting the content ratio of materials other than vinyl chloride resin, it is possible to obtain a material that is perfectly usable as a floor mat, and surprisingly, it also has improved bending strength compared to conventional vinyl chloride resin floor mats.

[0011] In other words, the present invention relates to a vinyl chloride resin mat containing a vinyl chloride resin and a pulverized vinyl chloride resin product containing 40% to 60% by mass of vinyl chloride resin, wherein the content of the pulverized material is 25% to 75% by mass of 100% by mass of the vinyl chloride resin mat, and the vinyl chloride resin product contains calcium carbonate, glass fibers, and pulp.

[0012] As a second aspect of the present invention, the present invention relates to a vinyl chloride resin mat described in the first aspect, wherein 100% by mass of the vinyl chloride resin mat contains 3.6% to 10.8% by mass of calcium carbonate, 0.9% to 2.7% by mass of glass fiber, and 2.1% to 6.2% by mass of pulp. [Effects of the Invention]

[0013] The present invention provides a vinyl chloride resin base plate that can be used as a substitute for a steel plate even when using crushed vinyl chloride resin products as they are. [Modes for carrying out the invention]

[0014] The present invention relates to a pulverized vinyl chloride resin product containing 40% to 60% by mass of vinyl chloride resin, and a vinyl chloride resin mat containing vinyl chloride resin, wherein the content of the pulverized material is 25% to 75% by mass of 100% by mass of the vinyl chloride resin mat.

[0015] In the present invention, the vinyl chloride resin can be a copolymer such as vinyl chloride resin, vinyl chloride-vinyl acetate copolymer, vinyl chloride-ethylene copolymer, or vinyl chloride-acrylic copolymer. Unused vinyl chloride resin alone, recycled vinyl chloride resin alone, or a mixture of unused vinyl chloride resin and recycled vinyl chloride resin can be used. Herein, in the present invention, recycled vinyl chloride resin refers to vinyl chloride resin from which materials other than vinyl chloride resin have been removed from waste containing vinyl chloride resin, and is distinguished from vinyl chloride resin derived from vinyl chloride resin products described later.

[0016] In the present invention, the material may contain predetermined amounts of reinforcing fillers such as wet silica, fillers such as hard clay, tackifiers such as modified phenolic resin, anti-aging agents such as microcrystalline wax, lubricants such as stearic acid, and plasticizers for vinyl chloride resin, which are typically added to vinyl chloride resin base plates, according to the desired physical properties.

[0017] The present invention further includes crushed vinyl chloride resin products containing a specific amount of vinyl chloride resin. While these vinyl chloride resin products contain materials other than vinyl chloride resin, the present invention allows their use without removing these other materials. From a recycling perspective, the vinyl chloride resin products are preferably waste materials such as scraps, defective products, or used products generated during production.

[0018] In the present invention, the content rate of the pulverized product of a vinyl chloride resin product containing a specific amount of vinyl chloride resin is 25% by mass or more and 75% by mass or less in 100% by mass of the vinyl chloride resin-made floor board. If the content rate is less than 25% by mass, it will have the same performance as a conventional vinyl chloride resin-made floor board, and it will be difficult to improve the bending strength. If it exceeds 75% by mass, it will be difficult to obtain the bending strength required for a floor board.

[0019] In the present invention, the pulverizing method of the vinyl chloride resin product is not particularly limited, but the size of the pulverized product is preferably 5 mm or more and 60 mm or less in terms of particle diameter. In the present invention, the pulverized product used is the particles recovered by passing through a 60 mm mesh.

[0020] In the present invention, the vinyl chloride resin product contains 40% by mass or more and 60% by mass or less of vinyl chloride resin. If it is less than 40% by mass, it will be difficult to obtain the bending strength required for a floor board because the content of materials other than vinyl chloride resin increases. Also, if it exceeds 60% by mass, it will have the same performance as a conventional vinyl chloride resin-made floor board, and it will be difficult to improve the bending strength.

[0021] As the vinyl chloride resin product, it may contain calcium carbonate, glass fiber, and pulp. For example, vinyl chloride resin-made wallpaper, vinyl chloride resin-made flooring, vinyl chloride resin-made cushion floor, vinyl chloride resin-made carpet, vinyl chloride resin-made synthetic leather, etc. can be mentioned. Among them, vinyl chloride resin-made flooring and vinyl chloride resin-made cushion floor (collectively also called vinyl chloride-made flooring) are preferable.

[0022] In the present invention, it is preferable to contain 3.6% by mass or more and 10.8% by mass or less of calcium carbonate, 0.9% by mass or more and 2.7% by mass or less of glass fiber, and 2.1% by mass or more and 6.2% by mass or less of pulp in 100% by mass of the vinyl chloride resin-made floor board. Within the range of the said content, the bending strength required for a floor board can be greatly increased and high hardness can be maintained, and moreover, the bending strength can be improved compared with a conventional vinyl chloride resin-made floor board. [[ID=I8]]

[0023] In the present invention, the vinyl chloride resin-based flooring material is, for example, a laminate of a vinyl chloride resin layer and a base material layer. The vinyl chloride resin-based cushion floor is one in which the vinyl chloride resin layer of the flooring material is a foamed layer, or one having a vinyl chloride resin foamed layer on the back side thereof. Further, it may be a laminate of a decorative layer, a surface protection layer, etc. as long as it is a material conventionally used as a PVC flooring material, and it is not particularly limited.

[0024] The vinyl chloride resin layer constituting the PVC flooring material is formed by mixing a vinyl chloride resin, a plasticizer, a filler, a stabilizer, and other additives and shaping this into a sheet form by various methods. As the vinyl chloride resin, copolymers such as vinyl chloride resin, vinyl chloride-vinyl acetate copolymer, vinyl chloride-ethylene copolymer, vinyl chloride-acrylic copolymer, etc. can be used. As the plasticizer, phthalic acid-based plasticizers such as dioctyl phthalate (DOP) and diisononyl phthalate (DINP), and adipic acid-based plasticizers such as diisononyl adipate (DINA) etc. can be used. The phthalic acid-based plasticizer may be used alone, or a phthalic acid-based plasticizer and an adipic acid-based plasticizer may be used in combination. As the filler, calcium carbonate, aluminum hydroxide, talc, silica, clay, calcium silicate, alumina, etc. can be preferably used. These may be used alone, or a plurality of them in an appropriate combination may be used together. As the stabilizer, barium-based, potassium-based, zinc-based, etc. can be used. In addition, common additives blended in ordinary vinyl chloride resins such as colorants such as pigments and dyes, foaming agents, flame retardants, antioxidants, etc. can be used and added in an appropriate amount according to the application.

[0025] The base layer constituting the PVC flooring material can be any material that has been conventionally used as a base material for flooring. For example, this could be a woven fabric, knitted fabric, nonwoven fabric, or laminate thereof, made from fibers selected from natural animal or plant fibers; synthetic fibers such as polyamide, polyester, polyolefin, and polyacrylonitrile; regenerated fibers such as rayon; inorganic fibers such as glass fiber and rock wool; or blends thereof, to which inorganic fillers, synthetic resin binders, etc., are added as needed. In terms of dimensional stability, sheets made by blending at least two types of inorganic and / or organic fibers such as glass fiber, carbon fiber, pulp, and polyester; glass fiber nonwoven fabric (glass paper); paper; etc., or laminates thereof, are particularly preferred.

[0026] The polyvinyl chloride resin foam layer that makes up PVC flooring materials can be formed by applying a mechanically foamed polyvinyl chloride resin paste, a polyvinyl chloride resin paste to which a foaming agent or thermal expansion agent has been added and dispersed, or a polyvinyl chloride resin paste to which hollow balloons have been added and dispersed, then heating to gel, and finally drying and solidifying it. The foaming ratio of the polyvinyl chloride resin foam layer can preferably be around 2 to 30 times.

[0027] As such, since PVC flooring materials often contain calcium carbonate, glass fibers, and pulp, using crushed PVC flooring materials as a material for the vinyl chloride resin flooring board of the present invention tends to contribute to improving the bending strength of the resulting flooring board.

[0028] The vinyl chloride resin mat of the present invention can be manufactured by conventionally known methods. For example, unused and / or recycled vinyl chloride resin, pulverized vinyl chloride resin product containing a specific amount of vinyl chloride resin, and various additives as needed can be mixed, kneaded in a Banbury mixer or the like while heating at a temperature (50-100°C) at which the vinyl chloride resin does not decompose, and then manufactured by compression molding in a press.

[0029] The vinyl chloride resin mat of the present invention may have multiple anti-slip features such as grooves and protrusions on its surface and / or back surface, as well as through holes for drainage and for passing connecting fittings to connect the mats together. The shape of the protrusions in the present invention can be arbitrarily selected, such as circular, square, a combination thereof, or a figure or pattern that also serves as a design element.

[0030] The vinyl chloride resin mat of the present invention has a density of 1.1 to 1.5 g / cm³. 3 It is preferable that this is the case. The size of the base plate varies, but for example, if the size is 10 to 15 mm thick, 910 to 1250 mm wide, and 1820 to 2400 mm long, the mass can be 30 to 55 kg. If an iron plate is used as the base plate, its mass is approximately 300 kg to 1800 kg, so within this density range, significant weight reduction is possible. In this invention, the method for measuring density is as shown in the examples.

[0031] The vinyl chloride resin mat of the present invention has a D hardness of 50 or higher and a bending strength of 2.4 N / mm². 2 The above is preferable. If the D hardness and bending strength are within this range, it can withstand use as a base plate. In this invention, the method for measuring the D hardness and bending strength is as shown in the examples. [Examples]

[0032] The present invention will be described in more detail below with reference to examples, but is not limited to these examples.

[0033] [Examples 1-4] We prepared two types of crushed materials: Crushed material A, which was obtained by crushing vinyl chloride resin cushion flooring to a particle size of 50 mm, and Crushed material B, which was obtained by crushing the vinyl chloride resin coating of waste electrical wires to a particle size of 5 mm as recycled vinyl chloride resin. For the crushed materials, we used particles that had passed through meshes of the respective sizes and been collected. Next, pulverized material A and pulverized material B were mixed in the proportions shown in Table 1 and kneaded in a Banbury mixer for 10 minutes while heating at 90°C. After that, compression molding was performed in a 100t press for 6 minutes to obtain a vinyl chloride resin base plate with a thickness of 13 mm, a width of 1250 mm, and a length of 2000 mm. The content of calcium carbonate, glass fiber, and pulp in 100% by mass of the vinyl chloride resin base plate was calculated from the proportions of pulverized material A and B, and is shown in Table 1.

[0034] [Comparative Examples 1 and 2] A vinyl chloride resin mat was obtained in the same manner as in the examples, except that crushed material A and crushed material B were mixed in the proportions shown in Table 2. The content of calcium carbonate, glass fiber, and pulp in 100% by mass of the vinyl chloride resin mat was calculated from the proportions of crushed material A and B and is shown in Table 2.

[0035] [Reference example 1] A vinyl chloride resin mat was obtained in the same manner as in the example, except that crushed material A was not mixed in.

[0036] The density (g / cm³) of the vinyl chloride resin mats obtained in Examples 1-4, Comparative Examples 1 and 2, and Reference Example 1 is as follows: 3 ), D hardness and bending strength (N / mm 2 The following measurements were taken, and the results are shown in Tables 1 and 2.

[0037] [Materials used] Vinyl chloride resin product (crushed material A): Vinyl chloride resin cushion floor (manufactured by Achilles Corporation, 44.9% by mass of vinyl chloride resin, 14.4% by mass of calcium carbonate, 3.5% by mass of glass fiber, 8.3% by mass of pulp, 28.1% by mass of other materials (plasticizers, pigments, stabilizers)) Vinyl chloride resin (crushed material B): Recycled vinyl chloride resin (vinyl chloride resin recovered from electrical wire waste with a vinyl chloride resin coating)

[0038] [Density: g / cm 3 ] The 13mm thick vinyl chloride resin base plates obtained in the examples and comparative examples were cut to a length of 100mm and a width of 100mm, and their mass was measured using an electronic balance (A&D Corporation, product name "FX-3000i"), which was then divided by the area to calculate the mass.

[0039] [D hardness] Based on JIS K 6253, the surface (the side pressed by the press) of the vinyl chloride resin base plates obtained in the examples, comparative examples, and reference examples was measured at five randomly selected points using a Shore D hardness tester (Teclock Co., Ltd., product name "GS-720"), and the average value was used.

[0040] [Bending strength: N / mm 2 ] Based on JIS K 7171, the 13 mm thick vinyl chloride resin base plates obtained in the examples, comparative examples, and reference examples were cut to a length of 80 mm and a width of 10 mm to prepare test specimens, and their bending strength was measured using a precision universal testing machine (manufactured by Shimadzu Corporation, product name "AG-X plus") under the conditions of a support distance of 64 mm and a test speed of 2 mm / min.

[0041] [Table 1]

[0042] [Table 2]

[0043] Tables 1 and 2 show that the vinyl chloride resin mats of Examples 1 to 4, even when using crushed vinyl chloride resin products containing calcium carbonate, glass fibers, and pulp as is, have the same hardness as Reference Example 1 used as a mat, and moreover, have superior bending strength compared to Reference Example 1. In other words, the present invention provides a vinyl chloride resin mat that can replace steel plates even when using crushed vinyl chloride resin products as is.

Claims

1. A pulverized vinyl chloride resin product containing 40% to 60% by mass of vinyl chloride resin, and a vinyl chloride resin mat containing vinyl chloride resin, In the vinyl chloride resin base plate, the content of the pulverized material is 25% by mass or more and 75% by mass or less, The vinyl chloride resin product contains calcium carbonate, glass fiber and pulp. A floor mat made of polyvinyl chloride resin.

2. The vinyl chloride resin matting according to claim 1, wherein 100% by mass of the vinyl chloride resin matting contains 3.6% to 10.8% by mass of calcium carbonate, 0.9% to 2.7% by mass of glass fiber, and 2.1% to 6.2% by mass of pulp.

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