DE4141023A1 - Flat recyclable material sheet mfr. for decorative floors or walls - by mixing recyclable granules from e.g. old tyres with binder and applying pigmented flocked pile with or without surface layer - Google Patents

Abstract

Process comprises mixing recyclable granules or regenerated prod. with binder and then adding a layer of flocked pile with or without a surfacing layer. A polyurethane or melamine resin is pref. mixed with used rubber ground down or in granules and made into 0.5-50 mm. thick mats. The constituents can be subjected to a corona discharge, flame, plasma, treated with F2 pre-primed or laminated etc. A suitably pigmented reactive flocking adhesive is pref. next applied e.g. by rolling, coating, spraying, screen printing or any other method. A coloured flocking material is pref. applied to the adhesive layer electrostatically to form a fabric exterior using e.g. polyester, polyamide, polyurethane, rayon, cotton, trilobal or cellulose fibres. The mix is pref. dried for 10 mins. at 120-150 deg.C and e.g. brushed, washed or vacuumed to clean it. The finished prod. is pref. a floor covering. ADVANTAGE - The procedure can utilise used rubber or plastics and therefore reduce environmental pollution. It also serves valuable resources.

Description

2. Description

The invention relates exclusively to a method which enables old rubber and old plastic in refined Form back to the economic and industrial cycle to lead. As a result, contaminated sites are reduced in this area built, as well as environmental damage caused by rubber and art burning of substances restricted or largely avoided. The use of recycling material makes this possible a moderate and careful handling of our Enables resources.

The claim is preferably in the floor area covering, mats and sheets made from waste rubber, rubber granulate or regrind from z. B. old tires, EPDM parts from the Automotive or other industry, as well as in the area of wall, Floor or ceiling panels made of resin-bonded old Plastic granules made, preferably from ge shredded old plastic (e.g. from cars, household and ver pack etc.) in sheet form or as a shaped body. By subsequent flocking or lamination he we hold z. B. a high quality carpet for everyone Areas of life such as B. Household, office, exhibition stand, car, Buses, trains etc.

All products described in the claim are like therefore recyclable and do not have to be landfilled or be burned.  

3. Claims 3.1. Manufacture of a plain-colored floor covering Waste rubber

For this purpose, mats consisting of a binder, e.g. As polyurethane, melamine resin or other, with one to with 90% waste rubber flour or granulate as subs kicked used. These mats can have a thickness of 0.5 - 50 mm.

If necessary, pretreatments can be done e.g. B. be:

• a) physical (corona, flame treatment, plasma treatment)
• b) chemical (fluorine, pre-primer, pre-coat e.g. B. vulcanization)

This is followed by rolling, casting, spraying, screen printing or their process, a pigmented in the desired color reactive flocking adhesive applied.

Such as B. in
DE 33 22 695 A1
DE 34 00 340 A1 described.

A correspondingly colored plock material is then electrostatically applied to the adhesive layer in order to obtain a textile exterior. The Plock fibers used can have any length, preferably 1-4 mm and each titer, preferably 10-50 dtex. They are usually made of polyester, polyamide ( 6 or 6.6 ), polyurethane, rayon, cotton, trilobal or cellulose fibers. The subsequent drying is carried out at 120 ° - 150 ° C for about 10 minutes. After cleaning (e.g. brushing, washing and or vacuum extraction) you get a floor covering such. B. in
DD 2 30 033 A1 describe, but without the use of PVC.

3 2.1. Manufacture of multi-colored flooring or Old rubber carpet

For this, the substrate (as described under 3.1.) coated, but the adhesive is colored white. The flock fibers used here are preferred made of polyamide or polyester (white or colorless). After drying or cleaning the flocked web or Matte, each in thermal transfer printing (sublimation) desired design, emblem or lettering, for a tempe temperature of 160 ° - 220 ° C evaporated onto the surface. This makes it possible without losing the textile character ters to produce carpets for almost all areas e.g. B. for household, exhibition stands, offices, offices, public Means of transport, cars etc.)

Publications to be considered for assessment:
DE 27 32 576 C2
DE PS 4 518
DE 23 21 592 B2
DE 26 51 392 A1
GB 20 84 931
GB 15 18 252
GB 14 52 130
DE 39 08 142 A1.

3.2.2. When using z. B. cotton or viscose flakes, the coloring can also be done by direct printing procedure (e.g. screen printing).

3.3. Making a doormat for the household, the Indus or the car

3.3.1 For this purpose, a punched or cut Recycling mat in screen printing, RSD, embossing or with Spray technology (spray mask) in the desired design with adhesive provided fabric and then flocked. After drying and cleaning you get a high quality doormat made of old material that can be recycled itself.

3.3.2. When using white pigmented adhesive, as well white or colorless flock material, it is possible foot mats for household, industrial or automotive in all colors or Making designs. The procedure used for this was under point 3.2.1. addressed. (Thermal transfer printing or sublimation)

3.4. Manufacture of an afterglow carpet for Emergency exits, cinemas, hotels, department stores, airports, public buildings, shelters, cellars etc. e.g. B. as an escape route marker

For this, a recycling mat with a transparent, flexi pale, but pigmented (afterglow pigment) paint painted. Then a transparent flocking adhesive (2-component or 1-component reactive) applied and  flocked electrostatically white or transparent. After drying and cleaning the mat you get one Carpet that is laid flat or partially the usual Safety regulations are sufficient.

The afterglow pigment can cover the entire surface, in writing (e.g. emergency exit) or in graphic form (e.g. arrows) be upset.

Patent literature on this:
EP O 1 73 762 A1
FR A - 2-1 76 559
FR A - 2-3 84 836
DE A - 29 49 901
US A - 28 38 762,

3.5. All recycled mats made from waste rubber can instead flocking, also by any type of lamination be refined (e.g. textile, leather, plastic, etc.), also by coating with mica, cork, quartz sand, Pebbles etc.

3.6. Manufacture flocked wall, floor or ceiling panels

3.6.1. For this purpose, the recycling granules are made Provide plates with an appropriate surface that it allows an adhesive even with poor adhesion to the Substrate a tarpaulin mechanically anchored adhesive film to build. For this, the surface z. B. in small Gaps milled or drilled lengthways and / or crossways, to give a firm hold to an approx. 100% solid adhesive. (see drawing, sheet 8)

This is achieved after flocking and drying  a statically and dynamically stable sandwich element is present, which is a decorative by the flocking Has character and can be used as a component can.

All from 3.1. until 3.5. described methods can be applied.

3.7. All of the above products can also be found in so-called MC processes can be designed decoratively. (Inventor: Maag + Schenk, Reutlingen).

Claims (9)

1. A process for the production of recyclable plate-shaped articles which can be used as a decorative and technically usable floor covering, as a mat, as a web and as a wall, floor and ceiling plate, characterized in that recycling granulate or regenerate with a binder (= Adhesive) and then a flock pile layer and / or a laminated layer is applied. 2. The method according to claim 1, characterized, that a physical pretreatment such as Corona flame and plasma treatment and / or a chemical Pretreatment such as fluorine treatment, pre-primer pre-coating and / or vulcanization treatment. 3. The method according to claim 1-2, characterized, that one in the rolling, casting, spraying, screen printing process in the desired color pigmented reactive flocking adhesive applies and then one in the adhesive layer accordingly applies colored flock material. 4. The method according to claim 3, characterized, that the flock material is applied electrostatically. 5. The method according to claim 1-4, characterized, that after drying and / or cleaning the flocked layer in the thermal transfer process (sublimation process) a design, emblem or lettering layer.   6. The method according to claim 5, characterized, that the application of the design, emblem or lettering layer preferably at a temperature of 160 ° C - 220 ° C on the upper surface by evaporation. 7. The method according to claim 1-6, characterized, that the resulting from gluing the individual particles Base layer pre-coated with a pigmented night-luminescent varnish, then apply a transparent flocking adhesive and then flocked electrostatically white or transparent. 8. The method according to claim 1-7, characterized, that after the flocking stage you have your own drying and / or Cleaning stage connects. 9. The method according to claim 1-8, characterized, that the surface of the plate-shaped product along and / or transversely milled and / or hollow drilled and if necessary a solid Adhesive gives up, and then the flocking operation leads.