EP1629968A1 - Recyclable floor covering for fairs and exhibitions - Google Patents

Recyclable floor covering for fairs and exhibitions Download PDF

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Publication number
EP1629968A1
EP1629968A1 EP05300665A EP05300665A EP1629968A1 EP 1629968 A1 EP1629968 A1 EP 1629968A1 EP 05300665 A EP05300665 A EP 05300665A EP 05300665 A EP05300665 A EP 05300665A EP 1629968 A1 EP1629968 A1 EP 1629968A1
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EP
European Patent Office
Prior art keywords
floor covering
polypropylene
polyethylene
powder
needled
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP05300665A
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German (de)
French (fr)
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EP1629968B1 (en
Inventor
Yannick Victoire
Jean-Michel Boudeau
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Le Commercialiste
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Le Commercialiste
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/488—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/544—Olefin series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0076—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0254—Polyolefin fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0263—Polyamide fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/042—Polyolefin (co)polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/06—Melt
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/10—Particulate form, e.g. powder, granule
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2207/00—Treatments by energy or chemical effects
    • D06N2207/06—Treatments by energy or chemical effects using liquids, e.g. water
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/06—Building materials
    • D06N2211/066—Floor coverings

Definitions

  • the present invention relates to a non-woven floor covering for fairs and exhibitions, a method of manufacturing a floor covering and a method of reprocessing a floor covering.
  • a floor covering for fairs and exhibitions has a small thickness, of the order of 4 mm, and must be resistant to pedestrian traffic for the duration of the fair or exhibition.
  • the needled sheet is made from short fibers obtained by an extrusion-spinning process.
  • the fibers of diameters and lengths adapted according to the applications of the products, are made of virgin or recycled thermoplastic polymers such as polyolefins, polyamides or polyesters or mixtures of these polymers.
  • the backing layer consists mainly of latex and synthetic resins based on styrene and butadiene.
  • the manufacture of the flooring consists of regularly coating the underside of the needled web with liquid latex and polymerizing the latex to form a flat, even backing layer.
  • the needlepunched web is also sometimes pre-impregnated with latex.
  • Patent document BE1006982 also discloses a floor covering for the automotive industry that does not have a backing layer of latex or PVC.
  • This flooring is formed from polyolefins, polyesters, polyamides and additives by melting and penetrating a powder into a web by compression. The recycling of such floor coverings, however, requires a separation of the various constituents.
  • the object of the present invention is to provide a fully recyclable floor covering in a simple manner, as well as methods for making and recycling the floor covering.
  • the invention relates to a non-woven flooring for fairs and exhibitions, characterized in that the coating is formed based on polyolefins and mineral fillers, the polyolefins being polypropylene and polyethylene in a proportion of at least 55% by weight of polypropylene and at most 38% by weight of polyethylene.
  • the flooring is therefore composed solely of polyolefins and mineral fillers, and a mixture of these compounds with such mass proportions can be used directly in other applications, for example by injection / molding to manufacture parts used in the process. automobile industry.
  • the mineral fillers are calcium carbonates or barium carbonates or alumina hydrates.
  • the floor covering is composed of a needled polypropylene sheet and a backing layer composed of polyethylene and mineral fillers.
  • the powder is melted and this molten powder is partially penetrated into the needle-punched sheet by means of an apron calender comprising a calendering drum.
  • the floor covering of said calendering drum by means of an overspeed cylinder and / or blowing air on the floor covering at the outlet of the apron grille to facilitate this detachment.
  • thermal energy released by the extruder is sent to the dryer and / or the steam washer.
  • Figure 1 is a schematic representation of a floor covering according to the invention.
  • Figure 2 is a schematic sectional view of the plant for manufacturing the flooring according to the invention.
  • Figure 3 is an enlarged view of the apron grille of Figure 2.
  • Figure 4 is a schematic view of the installation for recycling the flooring according to the invention.
  • FIG. 1 there is shown a floor covering 1 according to the invention which is formed, as in the prior art, of a needled sheet 2 and a backing layer 3. It is composed of polypropylene, of polyethylene and mineral fillers, with more than 55% by weight of polypropylene and less than 38% by weight of polyethylene. Mineral fillers, which can to be flame retardant fillers, are mainly calcium carbonates, barium carbonates, alumina hydrates or phosphors. Many products made by thermoplastic polymer molding or injection have a mass composition that falls within the product range proposed above for flooring 1. Therefore, by recycling and hot extruding the flooring according to In the invention, the thermoplastic raw material is obtained for directly manufacturing these molded / injected products. It is not necessary to add anything other than this raw material to manufacture such products, with the exception of sometimes thinners or thickeners. Thus, all the material of the flooring can be recycled in a simple way, which we will describe in more detail later, and no ultimate waste is created.
  • the overall mass composition desired for the floor covering 1 can be obtained in different ways.
  • the needled web 2 is formed solely of polypropylene and the backing layer 3 is formed of mineral fillers and polyethylene.
  • the manufacture of such a floor covering 1 requires a particular manufacturing method described below.
  • the needled web 2 is manufactured conventionally, preferably with polypropylene F fibers.
  • Polypropylene granules, mixed with dye granules which will give the color of the flooring, are melted in an autoclave and passed through a spin extruder to form polypropylene filaments which will be cut in a short fiber cutter of the order 75 mm long.
  • At least 35% of the fibers have a titer of 6.7 dtex and at least 35% of the fibers have a titer of 17 dtex to further facilitate the entrapment of their bases.
  • the polypropylene fibers then pass through a rotating card where they are combed and come out in a fine veil, then in a spreader - lath machine in which several fine sails are superimposed and crisscrossed to form a sheet about 3 cm thick.
  • This sheet is densified in a needling machine inside which a multitude of barbs need penetrates many times in the sheet and intermingles the fibers.
  • the density of the needled sheet depends on the number of needle hits per cm 2 .
  • the needled web 2 is then rolled before appending in another installation of the backing layer 3 on one of its faces.
  • the manufacturing parameters of the needled web are specific to the manufacture of floor coverings. Sizing a layer 3 on the needlepunched web 2 consolidates the fibers of the needled web 2 to make the floor covering 1 resistant. In addition, the backing layer 3 stiffens the floor covering 1 so that it does not crease underfoot.
  • Figure 2 shows a plant specially arranged to implement the method of manufacturing the floor covering according to the invention from a needled ply roll.
  • a roll 4 of needlepunched web 2 is installed on a peeler 5 and the needled web 2 is unwound continuously in the machine so that a backing layer is glued on it to make the flooring continuously.
  • the needled sheet 2 passes, face upwards, successively in the direction of arrow 6 on a conveyor 7, in a guidance and alignment system 8, under a dusting machine 9, under an infrared heating system 10, in a deck calender 11 and finally in a cooling chamber 12.
  • the needled sheet 2 has a width of about four meters and the guide and driving system 8 consists of a fixed cylinder 13 and a movable cylinder 14 allows to keep the needled web 2 in its axis of movement.
  • the shaker 9 distributes a powder 15, which is a mixture of powder of mineral fillers and of polyethylene powder, regularly on the reverse side of the needled sheet 2.
  • the particle size of the powder is between 20 and 700 micrometers .
  • the sprinkler 9 comprises a mobile hopper 16 which moves alternately in the direction of the width of the needled sheet 2 and pours powder 15 on a rough roller 17 which rotates and delivers a regular flow of powder on the reverse face of the tablecloth 2.
  • the shaker 9 also has an anti-clogging buzzer 18 at the hopper 16 and a broom 19 which rubs on the roller 17 to improve the regularity of the powder flow 15.
  • the thin regular layer of The powder 15 covering the needled web 2 is put into a mood or reactivated, ie fluidized by melting, in the infrared heating system 10 without the stability and flatness characteristics of the needled web 2 being deteriorated.
  • the powder 15 should have a melting temperature below the melting temperature of the fibers F composing the needled web 2 so that the powder 15 becomes fluid in the infrared heating system 10 without the fibers F melting.
  • the melting temperature of the powder is of the order of 120 ° C
  • the melting temperature of the fibers F is of the order of 180 ° C
  • the temperature in the infrared heating system 10 is thermoregulated at about 130 ° C.
  • the needled web covered with the thin layer of fluidized powder, penetrates for a finishing operation into the apron grille 11.
  • the apron grille 11 comprises a large heated rotating heating calender, about 1.5 meters in diameter, and a movable apron 21 which is an endless belt moving around driving or guiding rollers 22 and around the drum 20, the apron 21 surrounding substantially the entire circumference of the drum 20 and pressing against the drum 20 in turn.
  • the needled layer covered with fluidized powder enters between the drum 20 and the apron 21, the backside covered with fluidized powder being in contact with the drum 20, at a location where a roller 22 presses the apron 21 against the drum 20, and performs almost a turn around the drum 20 being pressed between the drum 20 and apron 21.
  • the drum 20 is heated to a temperature slightly lower than the temperature of the infrared heating system 10 to slightly cool the powder without compromising its fluidity this temperature is of the order of 125 ° C.
  • the continuous pressure exerted by the apron grille 11 on the fluidized powder forces it to penetrate partially into the back of the needled web 2 without crossing it completely, which makes it possible to trap the base of the fibers F constituting the needled web 2 in the backing layer 3 while retaining the textile appearance of the face of the needlepunched web 2.
  • the passage in the apron grille makes it possible to form a smooth and regular backing layer 3 in intimate contact with the needled web 2
  • the time of presence of the needled web 2 in the apron shell 11, therefore at high temperature, is short and as it is kept compressed between the drum 20 and the apron 21, it does not retract and leaves perfectly flat and ironed .
  • the apron 21 is more particularly made of aramid fabric known under the name of Nomex from Dupont Company in order to withstand the high temperatures generated by the calendering drum 20.
  • the surface of the calender drum 20 is Teflon closed porosity.
  • Stain removal of the backing layer 3 of the calendering drum 20 is facilitated by a diverting cylinder 23 or stain removal, a blower 24 and an overspeed cylinder 25, more visible in FIG. 3.
  • This overspray cylinder 25, coated with a perfectly adherent rough coating, has a slightly higher tangential velocity, of 1 to 2%, at the speed of displacement of the floor covering 1 and causes tension jolts in the detachment of the floor covering 1.
  • the floor covering 1 finally goes into an air cooling chamber 12 to be cooled to a temperature of around 20 ° C before being rolled, packaged and packaged.
  • the floor covering is held taut in the cooling chamber so that it does not deform. Cooling allows the thermoplastic material forming the backing layer to harden.
  • a floor covering 1 obtained in the manner described above with a polypropylene needled ply of 300 g / m 2 and a backing layer of 200 g / m 2 formed with a powder mixture comprising 80% by weight of polyethylene and 20% by weight of mineral fillers has suitable characteristics for use in an exhibition, fair or any place temporarily welcoming the public.
  • Such a floor covering therefore has a mass composition of 60% of polypropylene, 32% of polyethylene and 8% mineral fillers.
  • a raw material having this mass composition can be used in the field of plastics directly without adding other components to produce products by injection or molding.
  • the mass ratio between the backing layer and the needled web may vary
  • the needled web may be formed with a blend of polypropylene fibers and polyethylene fibers
  • the powder at the base of the backing layer may polypropylene, the important result of which is that the overall flooring is composed of polypropylene, at least 55% by weight, polyethylene, at most 38% by weight, and a material (fillers). mineral) which does not compromise the homogeneity of the thermoplastic mixture obtained by melting the flooring which is then usable for other applications in the field of plastics.
  • Recycled materials can be used in the manufacture of flooring.
  • the floor covering 1 is recovered for recycling. This recovery is done in collaboration with the customer, and can be encouraged by means of a deposit system.
  • the used floor covering 1 is introduced into a recycling plant 30 shown in FIG. 4. It is first cut into strips by means of a guillotine in 31. The floor covering strips are then transferred into a steam washer 32 at about 140 ° C to remove any dirt they contain. The strips are then dewatered in a centrifuge 33 to remove 80% of the water stored during washing and dried in a hot air dryer 34.
  • the flooring 1 is not very thick it is not necessary it can be grinded directly into an extruder 35 while it is still hot at about 70 ° C due to drying, thus allowing energy savings.
  • the preheated floor is melted at about 220 ° C and the resulting melt is mixed and extruded.
  • the extruded material may be molded directly to produce products or preferably be shaped into thermoplastic granules, the products or granules having the same mass composition as the initial flooring. The granules will serve as raw material in a thermoplastic product manufacturing line.
  • the heat energy or heat released during extrusion is recovered and used for steam washing as represented by arrow 36, as well as for drying as represented by arrow 37.
  • water intended for to cool the pellets at the extrusion outlet can be used to preheat the water to vaporize for steam washing by means of a heat exchanger. Hot air for drying can be picked up around the extrusion cylinder. Thus, 70% of the energy required for washing and drying comes from recovered energy.
  • the products manufactured by molding / injection using the granules from the recycling of a floor covering according to the invention have a mass composition of at least 55% polypropylene and at most 38% polyethylene.
  • Such products are, for example, car seats for children or car bumpers.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

Non-woven ground covering (I) for fairs and exhibitions, comprises a base of polyolefins (polypropylene (55 wt.%) and polyethylene (38 wt.%)) and mineral charges. Independent claims are also included for: (1) the preparation of (I); and (2) reprocessing (I) for the manufacture of a thermoplastic raw material, comprising: cutting (I) into straps; vapor washing and spinning the thin straps; drying the thin straps and preheating the dried straps at 70[deg]C in a to dryer before passing into an extruder which produces the thermoplastic material.

Description

La présente invention concerne un revêtement de sol non tissé pour foires et expositions, un procédé de fabrication d'un revêtement de sol et un procédé de retraitement d'un revêtement de sol. Un revêtement de sol pour foires et expositions a une faible épaisseur, de l'ordre de 4 mm, et doit être résistant au trafic piétonnier pendant la durée de la foire ou exposition.The present invention relates to a non-woven floor covering for fairs and exhibitions, a method of manufacturing a floor covering and a method of reprocessing a floor covering. A floor covering for fairs and exhibitions has a small thickness, of the order of 4 mm, and must be resistant to pedestrian traffic for the duration of the fair or exhibition.

Un tel revêtement de sol non tissé a généralement une structure composite et est formé de deux couches :

  • un réseau fibreux ou filamenteux plus communément appelé "nappe aiguilletée" formant la couche supérieure du revêtement de sol
  • une matrice ou couche d'envers en contact intime avec la face envers de la nappe aiguilletée formant la couche inférieure du revêtement de sol.
Such a nonwoven flooring generally has a composite structure and is formed of two layers:
  • a fibrous or filamentary network more commonly referred to as a "needle-punched web" forming the top layer of the flooring
  • a backing die or layer in intimate contact with the back side of the needled web forming the lower layer of the flooring.

Actuellement, la nappe aiguilletée est réalisée à base de fibres courtes obtenues par un procédé d'extrusion - filage. Les fibres, de diamètres et de longueurs adaptées en fonction des applications du produits, sont en polymères thermoplastiques vierges ou recyclés tels que les polyoléfines, polyamides ou polyesters ou des mélanges de ces polymères. La couche d'envers est composée principalement de latex et de résines synthétiques à base de styrène et de butadiène. La fabrication du revêtement de sol consiste à enduire régulièrement l'envers de la nappe aiguilletée avec du latex liquide et à faire polymériser le latex de manière à former une couche d'envers plane et régulière. La nappe aiguilletée est aussi parfois pré-imprégnée avec du latex. L'inconvénient d'un tel revêtement de sol consiste en ce qu'il n'est pas totalement, ni facilement recyclable et doit donc être mis en décharge après son utilisation, c'est à dire à la fin de la foire ou exposition. Le latex n'est en effet pas recyclable, ainsi la couche d'envers n'est donc pas recyclable. Aussi, pour recycler les polymères thermoplastiques de la nappe aiguilletée, il est nécessaire de séparer préalablement la couche d'envers de la nappe aiguilletée. Enfin, lorsque la nappe aiguilletée est formée de polymères thermoplastiques appartenant à différentes familles, comme par exemple une nappe aiguilletée formée avec un mélange de fibres de polyoléfines et de fibres de polyester, il est nécessaire de séparer les différents polymères lors du recyclage, car ceux ci sont incompatibles du fait de leurs propriétés physiques et ne peuvent pas former un mélange homogène utilisable dans l'industrie de la plasturgie. De plus, il est généralement nécessaire d'ajouter d'autres constituants à la matière recyclée pour pouvoir l'utiliser.Currently, the needled sheet is made from short fibers obtained by an extrusion-spinning process. The fibers, of diameters and lengths adapted according to the applications of the products, are made of virgin or recycled thermoplastic polymers such as polyolefins, polyamides or polyesters or mixtures of these polymers. The backing layer consists mainly of latex and synthetic resins based on styrene and butadiene. The manufacture of the flooring consists of regularly coating the underside of the needled web with liquid latex and polymerizing the latex to form a flat, even backing layer. The needlepunched web is also sometimes pre-impregnated with latex. The disadvantage of such a floor covering is that it is not totally or easily recyclable and must therefore be landfilled after use, ie at the end of the fair or exhibition. The latex is not recyclable, so the backing layer is not recyclable. Also, to recycle the thermoplastic polymers of the needled web, it is necessary to previously separate the backing layer of the needled web. Finally, when the needled ply is formed of thermoplastic polymers belonging to different families, such as a needled ply formed with a mixture of polyolefin fibers and polyester fibers, it is necessary to separate the different polymers during the recycling, because those They are incompatible because of their physical properties and can not form a homogeneous mixture for use in the plastics industry. In addition, it is generally necessary to add other components to the recycled material in order to use it.

On connaît du brevet US 5 107 617 un revêtement de sol dans lequel la couche d'envers en latex a été remplacée par une couche d'éthylène vinyle acétate (EVA) pour des raisons environnementales. On connaît également du document de brevet BE1006982 un revêtement de sol pour l'industrie automobile dépourvu de couche d'envers en latex ou PVC. Ce revêtement de sol est formé à base de polyoléfines, polyesters, polyamides et d'additifs par fusion et pénétration d'une poudre dans une nappe par compression. Le recyclage de tels revêtements de sol nécessite toutefois une séparation des différents constituants.US Pat. No. 5,107,617 discloses a floor covering in which the latex backing layer has been replaced by an ethylene vinyl acetate (EVA) layer for environmental reasons. Patent document BE1006982 also discloses a floor covering for the automotive industry that does not have a backing layer of latex or PVC. This flooring is formed from polyolefins, polyesters, polyamides and additives by melting and penetrating a powder into a web by compression. The recycling of such floor coverings, however, requires a separation of the various constituents.

La présente invention a pour but de proposer un revêtement de sol recyclable entièrement et de manière simple, ainsi que des procédés pour fabriquer et recycler le revêtement de sol.The object of the present invention is to provide a fully recyclable floor covering in a simple manner, as well as methods for making and recycling the floor covering.

A cet effet l'invention a pour objet un revêtement de sol non tissé pour foires et expositions, caractérisé en ce que le revêtement est formé à base de polyoléfines et de charges minérales, les polyoléfines étant du polypropylène et du polyéthylène dans une proportion d'au moins 55% en poids de polypropylène et d'au plus 38% en poids de polyéthylène. Le revêtement de sol est donc composé uniquement de polyoléfines et de charges minérales, et un mélange de ces composés avec de telles proportions massiques peut être utilisé directement dans d'autres applications, par exemple par injection/moulage pour fabriquer des pièces utilisées dans l'industrie automobile.For this purpose the invention relates to a non-woven flooring for fairs and exhibitions, characterized in that the coating is formed based on polyolefins and mineral fillers, the polyolefins being polypropylene and polyethylene in a proportion of at least 55% by weight of polypropylene and at most 38% by weight of polyethylene. The flooring is therefore composed solely of polyolefins and mineral fillers, and a mixture of these compounds with such mass proportions can be used directly in other applications, for example by injection / molding to manufacture parts used in the process. automobile industry.

Selon un mode de réalisation préféré de l'invention, les charges minérales sont des carbonates de calcium ou des carbonates de baryum ou des hydrates d'alumine.According to a preferred embodiment of the invention, the mineral fillers are calcium carbonates or barium carbonates or alumina hydrates.

Selon un autre mode de réalisation préféré de l'invention, le revêtement de sol est composé d'une nappe aiguilletée en polypropylène et d'une couche d'envers composée de polyéthylène et de charges minérales.According to another preferred embodiment of the invention, the floor covering is composed of a needled polypropylene sheet and a backing layer composed of polyethylene and mineral fillers.

L'invention s'étend également à un procédé de fabrication d'un revêtement de sol non tissé pour foires et expositions, caractérisé en ce qu'il comprend les étapes suivantes :

  • on réalise une nappe aiguilletée à partir de fibres en polyoléfines;
  • on saupoudre une face de la nappe aiguilletée avec une poudre composée de polyoléfines et de charges minérales;
  • on fait fondre cette poudre et on la fait pénétrer partiellement dans la nappe aiguilletée par compression, de telle manière à obtenir un revêtement de sol à base de polyoléfines et de charges minérales, les polyoléfines étant du polypropylène et du polyéthylène dans une proportion d'au moins 55% en poids de polypropylène et d'au plus 38% en poids de polyéthylène.
The invention also extends to a method of manufacturing a non-woven floor covering for fairs and exhibitions, characterized in that it comprises the following steps:
  • a needled web is made from polyolefin fibers;
  • one side of the needled sheet is dusted with a powder composed of polyolefins and mineral fillers;
  • this powder is melted and partially penetrated into the needled web by compression, so as to obtain a coating polyolefin based solids and mineral fillers, the polyolefins being polypropylene and polyethylene in a proportion of at least 55% by weight of polypropylene and at most 38% by weight of polyethylene.

Selon un mode de mise en oeuvre particulier du procédé de fabrication selon l'invention, on fait fondre la poudre et on fait pénétrer partiellement cette poudre fondue dans la nappe aiguilletée au moyen d'une calandre à tablier comportant un tambour de calandrage, on détache le revêtement de sol dudit tambour de calandrage grâce à un cylindre de survitesse et/ou on souffle de l'air sur le revêtement de sol à la sortie de la calandre à tablier pour faciliter ce détachement.According to a particular mode of implementation of the manufacturing method according to the invention, the powder is melted and this molten powder is partially penetrated into the needle-punched sheet by means of an apron calender comprising a calendering drum. the floor covering of said calendering drum by means of an overspeed cylinder and / or blowing air on the floor covering at the outlet of the apron grille to facilitate this detachment.

Enfin, l'invention s'étend à un procédé de retraitement d'un revêtement de sol tel que défini ci-dessus pour la fabrication d'une matière première thermoplastique, comprenant les étapes suivantes:

  • on découpe en lanières ledit revêtement de sol;
  • on lave à la vapeur lesdites lanières et on les essore;
  • on sèche les lanières et on les préchauffe à environ 70°C dans un séchoir avant de les faire passer dans une extrudeuse qui produit ladite matière thermoplastique.
Finally, the invention extends to a method of reprocessing a floor covering as defined above for the manufacture of a thermoplastic raw material, comprising the following steps:
  • said floor covering is cut into strips;
  • said strands are steamed and squeezed;
  • the strips are dried and preheated to about 70 ° C in a drier before being passed through an extruder which produces the thermoplastic material.

Selon un mode de mise en oeuvre particulier du procédé de retraitement selon l'invention, on envoi dans le séchoir et/ou dans la laveuse à vapeur de l'énergie thermique dégagée par l'extrudeuse.According to a particular embodiment of the reprocessing process according to the invention, thermal energy released by the extruder is sent to the dryer and / or the steam washer.

L'invention sera mieux comprise à la lecture de la description qui suit et à l'examen des figures qui l'accompagnent. Cette description n'est donnée qu'à titre d'exemple indicatif et nullement limitatif de l'invention.The invention will be better understood on reading the description which follows and the examination of the figures which accompany it. This description is given as an indicative and non-limiting example of the invention.

La figure 1 est une représentation schématique d'un revêtement de sol selon l'invention.Figure 1 is a schematic representation of a floor covering according to the invention.

La figure 2 est une vue schématique en coupe de l'installation pour fabriquer le revêtement de sol selon l'invention.Figure 2 is a schematic sectional view of the plant for manufacturing the flooring according to the invention.

La figure 3 est une vue agrandie de la calandre à tablier de la figure 2.Figure 3 is an enlarged view of the apron grille of Figure 2.

La figure 4 est une vue schématique de l'installation pour recycler le revêtement de sol selon l'invention.Figure 4 is a schematic view of the installation for recycling the flooring according to the invention.

Sur la figure 1, on a représenté un revêtement de sol 1 selon l'invention qui est formé, tout comme dans l'art antérieur d'une nappe aiguilletée 2 et d'une couche d'envers 3. Il est composé de polypropylène, de polyéthylène et de charges minérales, avec plus de 55% en poids de polypropylène et moins de 38% en poids de polyéthylène. Les charges minérales, qui peuvent être des charges ignifugeantes, sont principalement des carbonates de calcium, des carbonates de baryum, des hydrates d'alumine ou des phosphores. De nombreux produits fabriqués par moulage ou injection en polymère thermoplastique ont une composition massique qui entre dans la fourchette de produits proposée ci-dessus pour le revêtement de sol 1. Par conséquent, en recyclant et en extrudant à chaud le revêtement de sol selon l'invention, on obtient la matière première thermoplastique pour fabriquer directement ces produits moulés/injectés. Il n'est pas nécessaire d'ajouter autre chose que cette matière première pour fabriquer de tels produits, à l'exception parfois de fluidifiants ou d'épaississants. Ainsi, toute la matière du revêtement de sol peut être recyclée de manière simple, que nous décrirons plus en détails plus loin, et aucun déchet ultime n'est créé.In FIG. 1, there is shown a floor covering 1 according to the invention which is formed, as in the prior art, of a needled sheet 2 and a backing layer 3. It is composed of polypropylene, of polyethylene and mineral fillers, with more than 55% by weight of polypropylene and less than 38% by weight of polyethylene. Mineral fillers, which can to be flame retardant fillers, are mainly calcium carbonates, barium carbonates, alumina hydrates or phosphors. Many products made by thermoplastic polymer molding or injection have a mass composition that falls within the product range proposed above for flooring 1. Therefore, by recycling and hot extruding the flooring according to In the invention, the thermoplastic raw material is obtained for directly manufacturing these molded / injected products. It is not necessary to add anything other than this raw material to manufacture such products, with the exception of sometimes thinners or thickeners. Thus, all the material of the flooring can be recycled in a simple way, which we will describe in more detail later, and no ultimate waste is created.

La composition massique globale voulue pour le revêtement de sol 1 peut être obtenue de différentes manières. De préférence, la nappe aiguilletée 2 est formée uniquement de polypropylène et la couche d'envers 3 est formée de charges minérales et de polyéthylène. La fabrication d'un tel revêtement de sol 1 nécessite un procédé de fabrication particulier décrit ci-dessous.The overall mass composition desired for the floor covering 1 can be obtained in different ways. Preferably, the needled web 2 is formed solely of polypropylene and the backing layer 3 is formed of mineral fillers and polyethylene. The manufacture of such a floor covering 1 requires a particular manufacturing method described below.

La nappe aiguilletée 2 est fabriquée de façon classique, préférablement avec des fibres F de polypropylène. Des granulés de polypropylène, mélangés avec des granulés de colorant qui donneront la couleur du revêtement de sol, sont fondus dans un autoclave et passés dans une extrudeuse fileuse pour former des filaments de polypropylène qui seront sectionnés dans une coupeuse en fibres courtes de l'ordre de 75 mm de longueur. Au moins 35% des fibres ont un titre de 6,7dtex et au moins 35% des fibres ont un titre de 17dtex pour faciliter ultérieurement le piégeage de leurs bases. Les fibres de polypropylène passent ensuite dans une carde rotative où elles sont peignées et ressortent en un voile fin, puis dans une étaleuse - nappeuse dans laquelle plusieurs voiles fins sont superposés et entrecroisés pour former une nappe d'environ 3 cm d'épaisseur. Cette nappe est densifiée dans une aiguilleteuse à l'intérieur de laquelle une multitude d'aiguilles à barbes pénètre de nombreuses fois dans la nappe et entremêle les fibres. La densité de la nappe aiguilletée dépend du nombre de coup d'aiguille par cm2. La nappe aiguilletée 2 est alors mise en rouleau avant apposition dans une autre installation de la couche d'envers 3 sur une de ses faces. Les paramètres de fabrication de la nappe aiguilletée sont propres à la fabrication des revêtements de sol. L'encollage d'une couche d'envers 3 sur la nappe aiguilletée 2 consolide les fibres de la nappe aiguilletée 2 pour rendre le revêtement de sol 1 résistant. De plus la couche d'envers 3 rigidifie le revêtement de sol 1 afin qu'il ne plisse pas sous les pieds.The needled web 2 is manufactured conventionally, preferably with polypropylene F fibers. Polypropylene granules, mixed with dye granules which will give the color of the flooring, are melted in an autoclave and passed through a spin extruder to form polypropylene filaments which will be cut in a short fiber cutter of the order 75 mm long. At least 35% of the fibers have a titer of 6.7 dtex and at least 35% of the fibers have a titer of 17 dtex to further facilitate the entrapment of their bases. The polypropylene fibers then pass through a rotating card where they are combed and come out in a fine veil, then in a spreader - lath machine in which several fine sails are superimposed and crisscrossed to form a sheet about 3 cm thick. This sheet is densified in a needling machine inside which a multitude of barbs need penetrates many times in the sheet and intermingles the fibers. The density of the needled sheet depends on the number of needle hits per cm 2 . The needled web 2 is then rolled before appending in another installation of the backing layer 3 on one of its faces. The manufacturing parameters of the needled web are specific to the manufacture of floor coverings. Sizing a layer 3 on the needlepunched web 2 consolidates the fibers of the needled web 2 to make the floor covering 1 resistant. In addition, the backing layer 3 stiffens the floor covering 1 so that it does not crease underfoot.

La figure 2 montre une installation spécialement agencée pour mettre en oeuvre le procédé de fabrication du revêtement de sol selon l'invention à partir d'un rouleau de nappe aiguilletée. Un rouleau 4 de nappe aiguilletée 2 est installé sur une dérouleuse 5 et la nappe aiguilletée 2 est déroulée en continu dans la machine afin qu'une couche d'envers soit collée dessus pour fabriquer le revêtement de sol en continu. La nappe aiguilletée 2 passe, face envers vers le haut, successivement dans le sens de la flèche 6 sur un transporteur 7, dans un système de guidage et d'alignement 8, sous une saupoudreuse 9, sous une installation de chauffage par infrarouge 10, dans une calandre à tablier 11 et enfin dans une chambre de refroidissement 12. La nappe aiguilletée 2 a une largeur d'environ quatre mètres et le système de guidage et d'entraînement 8 composé d'un cylindre fixe 13 et d'un cylindre mobile 14 permet de bien garder la nappe aiguilletée 2 dans son axe de déplacement. La saupoudreuse 9 distribue une poudre 15, qui est un mélange de poudre de charges minérales et de poudre de polyéthylène, de façon régulière sur la face envers de la nappe aiguilletée 2. Avantageusement, la granulométrie de la poudre est comprise entre 20 et 700 micromètres. La saupoudreuse 9 comporte une trémie mobile 16 qui se déplace alternativement dans le sens de la largeur de la nappe aiguilletée 2 et déverse de la poudre 15 sur un rouleau rugueux 17 qui tourne et délivre un débit régulier de poudre sur la face envers de la nappe aiguilletée 2. La saupoudreuse 9 dispose en outre d'un vibreur anti-colmatage 18 au niveau de la trémie 16 et d'un balai 19 qui frotte sur le rouleau 17 pour améliorer la régularité du débit de poudre 15. La fine couche régulière de poudre 15 recouvrant la nappe aiguilletée 2 est mise en humeur ou réactivée, c'est à dire fluidifiée par fusion, dans l'installation de chauffage par infrarouge 10 sans que les caractéristiques de stabilité et de planéité de la nappe aiguilletée 2 ne soient détériorées. La poudre 15 doit avoir une température de fusion inférieure à la température de fusion des fibres F composant la nappe aiguilletée 2 de manière à ce que la poudre 15 se fluidifie dans l'installation de chauffage par infrarouge 10 sans que les fibres F ne fondent. Par exemple, la température de fusion de la poudre 15 est de l'ordre de 120°C, la température de fusion des fibres F est de l'ordre de 180°C et la température dans l'installation de chauffage par infrarouge 10 est thermorégulée à environ 130°C. La nappe aiguilletée, recouverte de la fine couche de poudre fluidifiée pénètre pour une opération de finissage dans la calandre à tablier 11. La calandre à tablier 11 comporte un gros tambour de calandrage 20 rotatif chauffant, d'environ 1,5 mètre de diamètre, et un tablier mobile 21 qui est une courroie sans fin se déplaçant autour de rouleaux d'entraînement ou de guidage 22 et autour du tambour 20, le tablier 21 entourant la quasi totalité de la circonférence du tambour 20 et pressant contre le tambour 20 en se déplaçant avec la même vitesse tangentielle, qui est également la vitesse de déplacement de la nappe aiguilletée, pour éviter toute friction. La nappe aiguilletée recouverte de poudre fluidifiée pénètre entre le tambour 20 et le tablier 21, la face envers recouverte de poudre fluidifiée étant en contact avec le tambour 20, à un endroit ou un rouleau 22 presse le tablier 21 contre le tambour 20, et effectue quasiment un tour autour du tambour 20 en étant pressée entre le tambour 20 et tablier 21. Le tambour 20 est chauffé à une température légèrement inférieure à la température de l'installation de chauffage par infrarouge 10 afin de refroidir légèrement la poudre sans compromettre sa fluidité, cette température est de l'ordre de 125°C. La pression continue exercée par la calandre à tablier 11 sur la poudre 15 fluidifiée la force à pénétrer partiellement dans l'envers de la nappe aiguilletée 2 sans la traverser complètement, ce qui permet de piéger la base des fibres F composant la nappe aiguilletée 2 dans la couche d'envers 3 tout en conservant l'aspect textile de la face endroit de la nappe aiguilletée 2. Le passage dans la calandre à tablier permet de former une couche d'envers 3 lisse et régulière en contact intime avec la nappe aiguilletée 2. Le temps de présence de la nappe aiguilletée 2 dans la calandre à tablier 11, donc à haute température, est court et comme elle est maintenue comprimée entre le tambour 20 et le tablier 21, elle ne se rétracte pas et sort parfaitement plane et repassée. Le tablier 21 est plus particulièrement en tissu aramide connu sous le nom de Nomex de la société Dupont afin de résister aux températures élevées générées par le tambour de calandrage 20. Afin d'éviter l'adhésion de la poudre 15 fluidifiée sur la surface du tambour de calandrage 20 et de pouvoir détacher facilement la couche d'envers 3 du tambour de calandrage 20, la surface du tambour de calandrage 20 est en téflon à porosité fermée.Figure 2 shows a plant specially arranged to implement the method of manufacturing the floor covering according to the invention from a needled ply roll. A roll 4 of needlepunched web 2 is installed on a peeler 5 and the needled web 2 is unwound continuously in the machine so that a backing layer is glued on it to make the flooring continuously. The needled sheet 2 passes, face upwards, successively in the direction of arrow 6 on a conveyor 7, in a guidance and alignment system 8, under a dusting machine 9, under an infrared heating system 10, in a deck calender 11 and finally in a cooling chamber 12. The needled sheet 2 has a width of about four meters and the guide and driving system 8 consists of a fixed cylinder 13 and a movable cylinder 14 allows to keep the needled web 2 in its axis of movement. The shaker 9 distributes a powder 15, which is a mixture of powder of mineral fillers and of polyethylene powder, regularly on the reverse side of the needled sheet 2. Advantageously, the particle size of the powder is between 20 and 700 micrometers . The sprinkler 9 comprises a mobile hopper 16 which moves alternately in the direction of the width of the needled sheet 2 and pours powder 15 on a rough roller 17 which rotates and delivers a regular flow of powder on the reverse face of the tablecloth 2. The shaker 9 also has an anti-clogging buzzer 18 at the hopper 16 and a broom 19 which rubs on the roller 17 to improve the regularity of the powder flow 15. The thin regular layer of The powder 15 covering the needled web 2 is put into a mood or reactivated, ie fluidized by melting, in the infrared heating system 10 without the stability and flatness characteristics of the needled web 2 being deteriorated. The powder 15 should have a melting temperature below the melting temperature of the fibers F composing the needled web 2 so that the powder 15 becomes fluid in the infrared heating system 10 without the fibers F melting. For example, the melting temperature of the powder is of the order of 120 ° C, the melting temperature of the fibers F is of the order of 180 ° C and the temperature in the infrared heating system 10 is thermoregulated at about 130 ° C. The needled web, covered with the thin layer of fluidized powder, penetrates for a finishing operation into the apron grille 11. The apron grille 11 comprises a large heated rotating heating calender, about 1.5 meters in diameter, and a movable apron 21 which is an endless belt moving around driving or guiding rollers 22 and around the drum 20, the apron 21 surrounding substantially the entire circumference of the drum 20 and pressing against the drum 20 in turn. moving with the same tangential velocity, which is also the speed of movement of the needled web, to avoid friction. The needled layer covered with fluidized powder enters between the drum 20 and the apron 21, the backside covered with fluidized powder being in contact with the drum 20, at a location where a roller 22 presses the apron 21 against the drum 20, and performs almost a turn around the drum 20 being pressed between the drum 20 and apron 21. The drum 20 is heated to a temperature slightly lower than the temperature of the infrared heating system 10 to slightly cool the powder without compromising its fluidity this temperature is of the order of 125 ° C. The continuous pressure exerted by the apron grille 11 on the fluidized powder forces it to penetrate partially into the back of the needled web 2 without crossing it completely, which makes it possible to trap the base of the fibers F constituting the needled web 2 in the backing layer 3 while retaining the textile appearance of the face of the needlepunched web 2. The passage in the apron grille makes it possible to form a smooth and regular backing layer 3 in intimate contact with the needled web 2 The time of presence of the needled web 2 in the apron shell 11, therefore at high temperature, is short and as it is kept compressed between the drum 20 and the apron 21, it does not retract and leaves perfectly flat and ironed . The apron 21 is more particularly made of aramid fabric known under the name of Nomex from Dupont Company in order to withstand the high temperatures generated by the calendering drum 20. In order to prevent the adhesion of the fluidized powder to the surface of the drum 20 and can easily detach the backing layer 3 of the calender drum 20, the surface of the calender drum 20 is Teflon closed porosity.

Le détachage de la couche d'envers 3 du tambour de calandrage 20 est facilité par un cylindre de détour 23 ou de détachage, une soufflante 24 et un cylindre de survitesse 25, plus visibles sur la figure 3. Un cylindre de détour 23 autour duquel est tendu le revêtement de sol 1 en sortie de la calandre à tablier 11 est disposé de manière à ce que le revêtement de sol 1 quitte le tambour de calandrage 20 très progressivement en suivant la tangente du tambour 20 pendant un moment, créant ainsi un cisaillement progressif entre la surface du tambour de calandrage 20 et le revêtement de sol 1. A partir du point où le revêtement de sol 1 n'est plus pressé contre le tambour de calandrage 20 par le tablier 21, le revêtement de sol 1 se détache en se déplaçant entre le tambour de calandrage 20 et la tangente au tambour de calandrage 20 en ce point, représentée en 26 par une ligne en pointillés sur la figure 3. De plus, sur le trajet entre ce point et le cylindre de détour 23, une soufflante 24 pulse de l'air froid à 20°C sur la face endroit du revêtement de sol 1, cet air froid traverse la nappe aiguilletée 2 et refroidit la couche d'envers 3 de quelques degrés de manière à ce qu'elle se gélifie et se détache aisément. Enfin un cylindre de survitesse 25, disposé après le cylindre de détour 23 sur le trajet du revêtement de sol 1 force le détachement du revêtement de sol 1 en tirant légèrement dessus. Ce cylindre de survitesse 25, recouvert d'un enrobage rugueux adhérant parfaitement, a une vitesse tangentielle légèrement supérieure, de 1 à 2 %, à la vitesse de déplacement du revêtement de sol 1 et provoque des à-coups de tension dans la zone de détachement du revêtement de sol 1.Stain removal of the backing layer 3 of the calendering drum 20 is facilitated by a diverting cylinder 23 or stain removal, a blower 24 and an overspeed cylinder 25, more visible in FIG. 3. A diverting cylinder 23 around which The floor covering 1 is stretched out at the outlet of the apron grille 11 and is arranged so that the floor covering 1 leaves the calendering drum 20 very gradually along the tangent of the drum 20 for a moment, thus creating a shear. progressively between the surface of the calendering drum 20 and the floor covering 1. From the point where the floor covering 1 is no longer pressed against the calendering drum 20 by the apron 21, the floor covering 1 comes off in moving between the calendering drum 20 and the tangent to the calendering drum 20 at this point, shown at 26 by a dashed line in FIG. 3. Furthermore, on the path between this point and the detent cylinder 23, a blower 24 pulses cold air at 20 ° C on the face of the floor 1, this cold air passes through the needle ply 2 and cools the back layer 3 a few degrees so that it gels and detaches easily. Finally an overspeed cylinder 25, disposed after the detour cylinder 23 in the path of the floor covering 1 forces the detachment of the floor covering 1 by pulling slightly on it. This overspray cylinder 25, coated with a perfectly adherent rough coating, has a slightly higher tangential velocity, of 1 to 2%, at the speed of displacement of the floor covering 1 and causes tension jolts in the detachment of the floor covering 1.

Le revêtement de sol 1 passe enfin dans une chambre de refroidissement à air 12 pour être refroidit à une température avoisinant les 20°C avant d'être mis en rouleaux, emballé et conditionné. Le revêtement de sol est maintenu tendu dans la chambre de refroidissement de manière à ce qu'il ne se déforme pas. Le refroidissement permet à la matière thermoplastique formant la couche d'envers de durcir.The floor covering 1 finally goes into an air cooling chamber 12 to be cooled to a temperature of around 20 ° C before being rolled, packaged and packaged. The floor covering is held taut in the cooling chamber so that it does not deform. Cooling allows the thermoplastic material forming the backing layer to harden.

Un revêtement de sol 1 obtenu de la manière décrite ci-dessus avec une nappe aiguilletée de 300 g/m2 en polypropylène et une couche d'envers de 200 g/m2 formée avec un mélange de poudre comportant 80% en poids de polyéthylène et 20% en poids de charges minérales a des caractéristiques adéquats pour une utilisation dans une exposition, une foire ou tout lieu accueillant temporairement du public. Un tel revêtement de sol a donc une composition massique de 60% de polypropylène, 32% de polyéthylène et 8% de charges minérales. Une matière première ayant cette composition massique peut être utilisée dans le domaine de la plasturgie directement sans ajout d'autres constituants pour fabriquer des produits par injection ou moulage.A floor covering 1 obtained in the manner described above with a polypropylene needled ply of 300 g / m 2 and a backing layer of 200 g / m 2 formed with a powder mixture comprising 80% by weight of polyethylene and 20% by weight of mineral fillers has suitable characteristics for use in an exhibition, fair or any place temporarily welcoming the public. Such a floor covering therefore has a mass composition of 60% of polypropylene, 32% of polyethylene and 8% mineral fillers. A raw material having this mass composition can be used in the field of plastics directly without adding other components to produce products by injection or molding.

Bien entendu, le rapport massique entre la couche d'envers et la nappe aiguilletée peut varier, la nappe aiguilletée peut être formée avec un mélange de fibres de polypropylène et de fibres de polyéthylène, la poudre à la base de la couche d'envers peut comprendre du polypropylène, l'important résultant dans le fait que le revêtement de sol dans son ensemble est composé de polypropylène, à au moins 55% en poids, de polyéthylène, à au plus 38% en poids, et d'une matière (charges minérales) qui ne compromet pas l'homogénéité du mélange thermoplastique obtenu par fusion du revêtement de sol qui est alors utilisable pour d'autres applications dans le domaine de la plasturgie. Des matériaux recyclés peuvent servir à la fabrication du revêtement de sol.Of course, the mass ratio between the backing layer and the needled web may vary, the needled web may be formed with a blend of polypropylene fibers and polyethylene fibers, the powder at the base of the backing layer may polypropylene, the important result of which is that the overall flooring is composed of polypropylene, at least 55% by weight, polyethylene, at most 38% by weight, and a material (fillers). mineral) which does not compromise the homogeneity of the thermoplastic mixture obtained by melting the flooring which is then usable for other applications in the field of plastics. Recycled materials can be used in the manufacture of flooring.

A la fin d'une exposition, lorsque l'usage du revêtement de sol 1 est terminé, on récupère le revêtement de sol 1 afin de le recycler. Cette récupération est effectuée en collaboration avec le client, et peut être incitée au moyen d'un système de consigne. Après un tri vérificatif pour éviter tout mélange avec d'autres produits, le revêtement de sol 1 usagé est introduit dans une installation de recyclage 30 représentée sur la figure 4. Il est tout d'abord découpé en lanières au moyen d'une guillotine dans une découpeuse 31. Les lanières de revêtement de sol sont alors transférées dans une laveuse à vapeur 32 à environ 140°C afin de les débarrasser de toutes les salissures qu'elles contiennent. Les lanières sont ensuite essorées dans une centrifugeuse 33 afin d'éliminer 80% de l'eau emmagasinée lors du lavage et séchées dans un séchoir à air chaud 34. Le revêtement de sol 1 n'étant pas très épais il n'est pas nécessaire de procéder à son broyage et on peut l'amener directement dans une extrudeuse 35 alors qu'il est encore chaud à environ 70°C du fait du séchage, permettant ainsi un gain d'énergie. Le revêtement de sol préchauffé est fondu à environ 220°C et le fondu obtenu est mélangé et extrudé. La matière extrudée peut être moulée directement pour fabriquer des produits ou préférablement être conformée en granulés thermoplastiques, les produits ou les granulés ayant la même composition massique que le revêtement de sol 1 initial. Les granulés serviront de matière première dans une ligne de fabrication de produits en matière thermoplastique.At the end of an exhibition, when the use of the floor covering 1 is finished, the floor covering 1 is recovered for recycling. This recovery is done in collaboration with the customer, and can be encouraged by means of a deposit system. After a verification sorting to avoid mixing with other products, the used floor covering 1 is introduced into a recycling plant 30 shown in FIG. 4. It is first cut into strips by means of a guillotine in 31. The floor covering strips are then transferred into a steam washer 32 at about 140 ° C to remove any dirt they contain. The strips are then dewatered in a centrifuge 33 to remove 80% of the water stored during washing and dried in a hot air dryer 34. The flooring 1 is not very thick it is not necessary it can be grinded directly into an extruder 35 while it is still hot at about 70 ° C due to drying, thus allowing energy savings. The preheated floor is melted at about 220 ° C and the resulting melt is mixed and extruded. The extruded material may be molded directly to produce products or preferably be shaped into thermoplastic granules, the products or granules having the same mass composition as the initial flooring. The granules will serve as raw material in a thermoplastic product manufacturing line.

Préférablement, l'énergie thermique ou chaleur dégagée lors de l'extrusion est récupérer et utilisée pour le lavage à la vapeur comme représenté par la flèche 36, ainsi que pour le séchage comme représenté par la flèche 37. Par exemple, l'eau destinée à refroidir les granulés en sortie d'extrusion peut servir à préchauffer l'eau à vaporiser pour le lavage à la vapeur au moyen d'un échangeur thermique. L'air chaud pour le séchage peut être capté autour du cylindre d'extrusion. Ainsi, 70% de l'énergie nécessaire au lavage et au séchage provient d'énergie récupérée.Preferably, the heat energy or heat released during extrusion is recovered and used for steam washing as represented by arrow 36, as well as for drying as represented by arrow 37. For example, water intended for to cool the pellets at the extrusion outlet can be used to preheat the water to vaporize for steam washing by means of a heat exchanger. Hot air for drying can be picked up around the extrusion cylinder. Thus, 70% of the energy required for washing and drying comes from recovered energy.

Les produits fabriqués par moulage/injection grâce aux granulés provenant du recyclage d'un revêtement de sol selon l'invention ont une composition massique d'au moins 55% en polypropylène et d'au plus 38% en polyéthylène. De tels produits sont par exemple des sièges de voiture pour enfants ou des pare chocs de voitures.The products manufactured by molding / injection using the granules from the recycling of a floor covering according to the invention have a mass composition of at least 55% polypropylene and at most 38% polyethylene. Such products are, for example, car seats for children or car bumpers.

Claims (10)

Revêtement de sol (1) non tissé pour foires et expositions, caractérisé en ce que le revêtement est formé à base de polyoléfines et de charges minérales, les polyoléfines étant du polypropylène et du polyéthylène dans une proportion d'au moins 55% en poids de polypropylène et d'au plus 38% en poids de polyéthylène.Non-woven flooring (1) for fairs and exhibitions, characterized in that the coating is formed from polyolefins and mineral fillers, the polyolefins being polypropylene and polyethylene in a proportion of at least 55% by weight of polypropylene and not more than 38% by weight of polyethylene. Revêtement de sol selon la revendication 1, dans lequel les charges minérales sont des carbonates de calcium ou des carbonates de baryum ou des hydrates d'alumine.The flooring of claim 1, wherein the mineral fillers are calcium carbonates or barium carbonates or alumina hydrates. Revêtement de sol selon l'une des revendications 1 et 2, composé d'une nappe aiguilletée (2) et d'une couche d'envers (3), dans lequel la nappe aiguilletée est en polypropylène et la couche d'envers est composée de polyéthylène et de charges minérales.Floor covering according to one of claims 1 and 2, consisting of a needled web (2) and a backing layer (3), in which the needled web is polypropylene and the backing layer is composed polyethylene and mineral fillers. Procédé de fabrication d'un revêtement de sol (1) non tissé pour foires et expositions, caractérisé en ce qu'il comprend les étapes suivantes : - on réalise une nappe aiguilletée (2) à partir de fibres en polyoléfines; - on saupoudre une face de la nappe aiguilletée avec une poudre (15) composée de polyoléfines et de charges minérales; - on fait fondre cette poudre et on la fait pénétrer partiellement dans la nappe aiguilletée par compression, de telle manière à obtenir un revêtement de sol à base de polyoléfines et de charges minérales, les polyoléfines étant du polypropylène et du polyéthylène dans une proportion d'au moins 55% en poids de polypropylène et d'au plus 38% en poids de polyéthylène. A process for manufacturing a non-woven floor covering (1) for fairs and exhibitions, characterized in that it comprises the following steps: a needle ply (2) is made from polyolefin fibers; - Powdering a face of the needled web with a powder (15) composed of polyolefins and mineral fillers; this powder is melted and is partially penetrated into the needled layer by compression, so as to obtain a floor covering based on polyolefins and mineral fillers, the polyolefins being polypropylene and polyethylene in a proportion of at least 55% by weight of polypropylene and at most 38% by weight of polyethylene. Procédé de fabrication selon la revendication 4, dans lequel on fait fondre la poudre et on fait pénétrer partiellement cette poudre fondue dans la nappe aiguilletée au moyen d'une calandre à tablier (11) comportant un tambour de calandrage (20).A manufacturing method according to claim 4, wherein the powder is melted and this molten powder is partially penetrated into the needle-punched web by means of a deck calender (11) having a calender drum (20). Procédé de fabrication selon la revendication 5, dans lequel on détache en outre le revêtement de sol (1) dudit tambour de calandrage (20) grâce à un cylindre de survitesse (25).The manufacturing method according to claim 5, wherein the floor covering (1) is further detached from said calendering drum (20) by means of an overspeed cylinder (25). Procédé de fabrication selon l'une des revendications 5 et 6, dans lequel on souffle de l'air sur le revêtement de sol à la sortie de la calandre à tablier (11) pour faciliter le détachement du revêtement de sol (1) dudit tambour de calandrage (20).Manufacturing method according to one of claims 5 and 6, wherein air is blown on the floor covering at the outlet of the apron grille (11) to facilitate the detachment of the floor covering (1) of said drum calendering (20). Procédé de retraitement d'un revêtement de sol (1) selon l'une des revendications 1 à 3 pour la fabrication d'une matière première thermoplastique, comprenant les étapes suivantes: - on découpe en lanières ledit revêtement de sol; - on lave à la vapeur lesdites lanières et on les essore; - on sèche les lanières et on les préchauffe à environ 70°C dans un séchoir (34) avant de les faire passer dans une extrudeuse (35) qui produit ladite matière thermoplastique. Process for the reprocessing of a floor covering (1) according to one of claims 1 to 3 for the manufacture of a thermoplastic raw material, comprising the following steps: said floor covering is cut into strips; the said strips are steamed and they are wrung out; - The strips are dried and preheated to about 70 ° C in a dryer (34) before being passed through an extruder (35) which produces said thermoplastic material. Procédé de retraitement selon la revendication 8, dans lequel on envoie dans le séchoir de l'énergie thermique dégagée par l'extrudeuse.A reprocessing method according to claim 8, wherein the thermal energy released by the extruder is fed into the dryer. Procédé de retraitement selon la revendication 8 ou 9, dans lequel on utilise de l'énergie thermique dégagée par l'extrudeuse pour le lavage à la vapeur.A reprocessing method according to claim 8 or 9, wherein thermal energy released by the extruder for steam washing is used.
EP20050300665 2004-08-23 2005-08-16 Recyclable floor covering for fairs and exhibitions Expired - Fee Related EP1629968B1 (en)

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FR0451888A FR2874389B1 (en) 2004-08-23 2004-08-23 RECYCLABLE FLOORING FOR FAIRS AND EXHIBITIONS

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FR2874389A1 (en) 2006-02-24
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FR2874389B1 (en) 2006-09-22
DE602005000806T2 (en) 2008-01-10

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