CN100453312C - 废地毯作为地面覆盖物的背衬填料的用途 - Google Patents
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Abstract
在新的热熔融地毯的背面涂层(31)、屋顶材料或其它类似产品(28)的生产中,利用经特殊处理的废地毯作为填料来代替需要开采的矿物填料,从而显著减少了用填埋或其它方式处置的废地毯的量。收集废地毯(20)(使用过的和/或从新地毯生产中得到的废地毯)并进行粉碎(22),通常是进行第一次粗粉碎(22),然后压实(23),之后进行精细粉碎(24)。将经粉碎的废地毯作为填料(25或30)加入至少一种其它材料(例如标准乳胶、EVA或PVC地毯背面涂层中的聚合物)中,以提供在有用产品的生产中所使用的热熔融复合物,复合材料用于生产有用产品(例如在新地毯的生产中(28)用作第一背面涂层(26)或第二背面涂层(27)的地毯背面涂层)。
Description
技术领域
本发明涉及废地毯作为地面覆盖物的背衬(backing)填料的用途。
背景技术
在例如地毯和地毯块(下文有时统称为地毯)等地面覆盖物的传统生产方法中,通过第一背衬、通常还有第二背衬以及其它可能的层将簇绒纱线或类似饰面固定。至少某些地毯背衬(尤其是乳胶、乙烯-醋酸乙烯酯共聚物(EVA)、聚氯乙烯(PVC)或其它聚合物类背衬)采用填料作为其重要成分。所使用的标准填料是矿物填料,典型地是单独使用或与其它普通金属盐组合使用的碳酸钙。
在地毯的生产过程中会产生废地毯,通常将所述废地毯填埋或焚烧。当铺设新地毯来取代旧地毯时,将已使用过的废地毯(此时为使用后的废弃物)拆掉,并且还通常进行填埋或焚烧。在地毯背衬中所使用的碳酸钙等矿物填料被开采,因此使其伴随着与原料开采有关的传统问题。
发明内容
本发明提供了回收废地毯并利用所回收的材料制备地毯的方法,该方法基本上可以排除或显著减少上述问题。根据本发明,可以不使用所开采的碳酸钙作为地毯背衬的填料,而是在热熔融施加工艺中使用所回收的废地毯(来自新地毯的生产/或使用后的废弃物)作为填充材料,其中将包含这些废弃产物的熔融材料施加至地毯背衬上,以获得所需的物理特性例如强度和尺寸稳定性。这基本上消除或至少显著减少了对于废地毯所必需的进行填埋或进行其它废物处理的量,同时使得可以使用废地毯来生产新的地面覆盖物。
本发明还适用于其它含有填料的材料的生产,这类材料包括通常使用碳酸钙填料的各种挤压成型的热塑性材料和热固性材料,其中包括但不限于屋顶材料、铺路材料、雨篷和油布。
在本发明的优选实施方案中,提供了一种生产地面覆盖物的方法,该地面覆盖物使用废地毯作为所述覆盖物的至少部分背衬材料,该方法基本上依次包括以下步骤:(a)收集废地毯,(b)粉碎废地毯,(c)将经粉碎的废地毯作为填料加入至少一种其它材料中,以形成用于从背面涂布地面覆盖物的第一背衬的熔融混合物,(d)将所述熔融混合物和织物材料施加至所述第一背衬上以在所述第一背衬的地面侧形成叠层,和(e)冷却所述第一背衬上的叠层以形成地面覆盖物,该地面覆盖物在所述第一背衬的地面侧具有包含废地毯的背面涂层。
在所述方法中,可以进行步骤a),以基本上仅收集使用过的废地毯、基本上仅收集来自于新地毯生产的废地毯,或两者的混合物。如果需要或必要的话,在使用前可以用任何常规清洗技术对使用过的废地毯进行清洗。尽管所述方法通常采用所有的面纱和第一背衬以及背面涂层,但是在某些情况下,所述方法在a)和b)之间还可包括将面纱和第一背衬与废地毯背面涂层分离,以获得基本上不含有面纱和第一背衬的废地毯背面涂层,并且在步骤b)中基本上仅使用废地毯背面涂层。并且,可以将各种地毯背面涂层彼此分离,从而仅使用一种特定的地毯背面涂层,例如第一背面涂层或第二背面涂层。
本发明还在步骤b)和c)之间进一步包括将经粉碎的地毯压实,并对其进行进一步粉碎的步骤f)。并且还可以进行步骤c)以便作为经粉碎的废地毯提供约40~100%的地毯背面涂层填料。例如,在本发明的一个实施方案中,进行步骤c)和d)以生产具有约5~18%EVA共聚物、约32~45%树脂、约20~50%经粉碎的废地毯填料和约0~30%碳酸钙填料的地毯背面涂层。并且在本方法的实践中,可以进行步骤b)和f)以生产粒径和范围基本上与碳酸钙填料相同的的废地毯。
所述方法包括乳胶地毯背面涂层,且并不局限于热塑性树脂例如PVC地毯背面涂层、EVA或其它的聚合物类背面涂层。
本发明通常还进一步包括用地毯背面涂层生产新地毯。
作为选择,根据本发明,可以进行步骤c)和d)从而用粒径大约为20~100目的废地毯填料生产挤压成型热塑性产品或热固性产品,和/或生产雨篷、屋顶材料、铺路材料或油布。
本发明的另一方面提供了一种地毯,该地毯具有面和第一背衬、第一背面涂层和至少一个第二背面涂层;并且第一背面涂层和第二背面涂层中的至少一种含有聚合物和填料,其中至少约40%的填料是经粉碎的废地毯,第一背面涂层或第二背面涂层中的至少一种包含作为聚合物和填料的熔融混合物而施加的热熔融复合物。背面涂层中的至少一个可以含有约5~18%的EVA共聚物、约32~45%的树脂、约20~50%的经粉碎的废地毯填料和约0~30%的碳酸钙填料。经粉碎的废地毯可以包括经粉碎的使用过的地毯,并且填料可以具有基本上与碳酸钙填料相同的粒径和范围。
本发明的主要目的在于生产包括地面覆盖物或其它产品在内的新材料,该地面覆盖物利用了所回收的废地毯以消除处置问题,同时减少了矿物的开采和通常在地毯背衬中使用的其它填料材料的生产。本发明的这些和其它目的可通过查阅本发明的详细描述并由所附的权利要求而变得更加清楚。
附图说明
图1是传统地毯或根据本发明生产的地毯的横截面示意图;和
图2是根据本发明实施的方法的各个步骤的方框图。
具体实施方式
通过图1中标记10的示意图来说明地毯的标准结构。地毯包括绒头纱线11,绒头纱线11被植入称为第一背衬的机织织物或纺粘织物14。第一背衬14具有植入背衬14中并从一个面向外延伸的绒头纱线11、在相反面上的第一背面涂层或预涂层12以及至少一个第二背面涂层或主涂层13。地毯10还可以具有其它层。第一背面涂层或预涂层12通常包含乳胶、PVC、EVA或其它聚合物类材料,并且第二背面涂层13还可以含有或包含聚合物,该聚合物与诸如由聚丙烯纺成的织物等第二背衬材料15相连。通常第一背面涂层12或第二背面涂层13包含填料,或者两者都包含填料。最普通的填料是矿物填料,尽管可使用其它填料,但通常是碳酸钙,或将碳酸钙与其它普通金属盐结合使用。根据本发明,生产新的地毯10时,可以用粉碎的废地毯作为第一背面涂层12和/或第二背面涂层13的填料,以此来代替全部或部分碳酸钙填料。
取决于其用途,地毯10还可以具有任意数量的其它层。例如,地毯10可以具有常规的第二背衬(通常为适于与地面或垫板接触的机织织物或针刺织物)。因此,第一背面涂层12可以包括经粉碎的废地毯填料,并使一个或多个第二背面涂层13的层包含或不包含经粉碎的废地毯填料。然而,优选第二背面涂层13包含与层叠至第一背面涂层12的织物材料相连的经粉碎的废地毯填料。
图2图解了根据本发明的示范性方法。在该方法中,如图2中20所示,首先开始收集用过的地毯。所述收集可以包括收集使用过的废地毯、收集得自与新地毯生产有关的标准工序的废地毯,或同时包括两者。如果在20中收集的用过的地毯受到了任何明显方式的污染,则可以采用任何适当的常规技术进行清洗(可以在下述的粉碎之前或之后)。
可以预料的是,根据本发明,随后在新地毯的生产中使用的废地毯,基本上利用了废地毯的所有成分,包括面纱、第一背衬和第一背面涂层和第二背面涂层以及可能的其它成分。然而在某些情形,对于部分或者全部废地毯,在进一步处理之前,需要将面、第一背衬和背面涂层彼此分开。图2中的21图解了任选的地毯成分的分离。取决于是否将面与所有的背衬和背面涂层分离,可以利用任何适当的常规技术来完成分离,例如通常在美国专利5,728,741中所公开的方法(其公开内容以参考的方式引入本文)。如果仅使用某种背衬或背面涂层,可以尝试使其与基本上相同类型的新背衬或背面涂层(例如乳胶背面涂层)的生产相匹配。
无论是否应用工序21,均对废地毯进行粉碎。如图2的22所示,粉碎优选包括第一粗粉碎,该第一粗粉碎可以用任何适当的常规切碎设备来完成,例如美国专利5,728,741和5,814,673中所公开的切碎设备。
虽然在某些情形下仅使用了粉碎工序22,但时常必需或希望对废地毯进行压实和进一步的粉碎。如图2中23所示的压实,包括增加得自22的经粉碎的废地毯的密度或比重,从而在进一步的加工中使材料更易于处理。得自图2中步骤22的经粉碎的颗粒可能太大且过于松软,以至于不易处理,并且在随后的工序中可能会无法充分混和。因此需要23中的压实工艺。可以利用任何适当的常规技术进行23中的压实,例如,如美国专利5,728,741所述的condux压实或使用造粒机。
优选在23中的压实之后,如表2中的24所示,存在更细的废地毯的第二粉碎工序。在许多情况下均进行24的第二粉碎,以便生产基本上具有与碳酸钙填料相同粒径和范围的废地毯,例如在标称为约200~325目的范围。可以用本来的常规技术进行24的第二粉碎,例如磨碎或用辊磨机处理。
在根据本发明的优选工序中,将得自步骤20~24的经粉碎的废地毯和其它标准地毯背面涂层成分用作第一背面涂层或第二背面涂层或地毯的其它背衬组件(通常统称为主涂层)的填料。例如,常规结构的乳胶、EVA或PVC背面涂层特别适合于应用得自图2中步骤20~24的废地毯填料。废地毯基本上可以作为唯一的填料而使用,或者替换显著量的所使用的填料。
虽然根据本发明可以使用多种聚合物或其它材料来生产地毯背面涂层,但下面将描述一个示例性的地毯背面涂层。诸如Lees UnibondTM背面涂层体系等标准的热熔融背面涂层可以含有,例如[除非另有说明,这里所给出的所有百分数都是重量百分数]:
a.5~18%EVA共聚物
b.32~45%树脂,例如得自Exxon的ECR-171
c.50%碳酸钙填料,JR-78。
根据本发明,可以用得自图2中的步骤20~24的经粉碎的废地毯来代替显著量的通常加入至熔融树脂和共聚物中的碳酸钙,而不是完全使用碳酸钙作为填料。例如,大约40~100%的地毯背面涂层(例如预涂层12或第二背面涂层13)的填料可以是经粉碎的废地毯。则在上述例子中,大约20~50%的地毯背面涂层为经粉碎的废地毯填料,并且大约0~30%为碳酸钙填料,例如作为填料的经粉碎的废地毯(标称为大约200~325目)和碳酸钙各自均为约25%。
如25所示,用标准热熔融混合设备和技术将本发明的废地毯填料与其它一种或多种成分混合。在图2中步骤26所示的优选实施方案中,将聚合物、树脂和经粉碎的废地毯的热熔融混合物施加至第一背衬或背面涂层。如27所示,还向热熔融混合物上施加第二背衬材料,例如机织织物、毡合织物或针刺织物材料,所述第二背衬材料与如26所示添加的含有废地毯填料的熔融混合物一起在第一背衬的地面侧上形成叠层。如27所示,用涂布辊将熔融混合物以热熔融形态施加至第一背衬的背面,从而与织物材料一起在第一背衬的地面侧形成一个或另一个背面涂层,或同时形成两个背面涂层。如图2中的28所示,然后再用常规技术冷却背面涂层。再用常规技术施加得自步骤26的附加的背面涂层以制造新地毯。得自步骤27的背衬可以用作第一背面涂层12;或与织物材料或不与织物材料一起用作地毯的第二背面涂层13,优选与织物材料一起用作地毯的第二背面涂层13;或者在所有的背面涂层中用作填料。应当理解的是,在上述过程中也可以使用具有乳胶背衬的废地毯来代替热塑性材料或热固性材料。
虽然本发明的优选实施方案是在新地毯的生产中使用废地毯,但是也可以用于其它用途。例如,如图2中30所示,可以将得自步骤20~24的经粉碎的废地毯作为填料添加至其它材料中以制造其它有用的产品,例如通常使用碳酸钙或其它矿物填料的挤压成型的热塑性材料和热固性材料。在步骤30中所使用的废地毯同样可以代替部分或基本上全部的碳酸钙常规填料。可制得的大量其它产品包括通常使用碳酸钙(或其等价物)作为填料的几乎所有的产品和某些可制得的新产品-如图2中的31所示-包括屋顶材料、雨篷、路面材料和油布,所有这些产品均含有矿物填料。对于这些应用,粒径可以不必与用于地毯背面涂层时一样小,例如大约为20~100目。
在上述任何工艺中均可以采用各种常规的精制处理。为了生产具有所需特性的产品,根据需要可以进行例如筛分或其它的杂质清除处理,同时可以进行测试、取样或任何其它必要的或所需的适当技术。
因此可以看出,通过实施本发明,通过使用经处理的废地毯作为用于新地毯的背面涂层、屋顶材料或其它情形中的填料,基本上可以消除或显著地减少废地毯的填埋或其它处理,同时可以减少矿物填料的开采,而不会牺牲新产品的质量。
虽然本发明已经描述了据认为是与最实用和优选的实施方案相关的内容,但应当理解本发明并不局限于所公开的实施方案,相反,本发明涵盖包括在本发明精神和所附权利要求范围之内的各种改进的和等同的技术方案。
Claims (20)
1.一种生产地面覆盖物的方法,该方法使用废地毯作为所述覆盖物的背衬材料的至少一部分,该方法依次包括以下步骤:
a)收集废地毯;
b)粉碎废地毯;
c)将经粉碎的废地毯作为填料加入至包括乙烯-醋酸乙烯酯共聚物和增粘剂树脂的至少两种其它材料中,以形成用于从背面涂布所述地面覆盖物的第一背衬的熔融混合物;
d)将所述熔融混合物和织物材料施加至所述第一背衬上,以在所述第一背衬的地面侧形成叠层;和
e)冷却所述第一背衬上的叠层,以形成在所述第一背衬的地面侧具有包含废地毯的背面涂层的地面覆盖物。
2.如权利要求1所述的方法,所述方法在步骤b)和c)之间还包括将所述经粉碎的地毯压实,并对其进行进一步粉碎的步骤f)。
3.如权利要求2所述的方法,其中步骤d)包括用涂布辊将所述熔融混合物施加至所述第一背衬。
4.如权利要求3所述的方法,其中实施步骤c)以便使经粉碎的废地毯为地面覆盖物背面涂层填料的40~100重量%。
5.如权利要求4所述的方法,其中实施步骤c)和d)以生产具有5~18重量%乙烯-醋酸乙烯酯共聚物、32~45重量%增粘剂树脂、20~50重量%经粉碎的废地毯填料和0~30重量%碳酸钙填料的热熔融地面覆盖物背面涂层。
6.如权利要求1所述的方法,其中步骤a)包括收集具有乳胶背衬的废地毯,并且步骤c)包括添加经粉碎的具有乳胶背衬的废地毯以形成熔融混合物。
7.如权利要求1所述的方法,其中实施步骤c)、d)和e)以生产乳胶、乙烯-醋酸乙烯酯共聚物或聚氯乙烯地面覆盖物背面涂层。
8.如权利要求1所述的方法,所述方法在步骤a)和b)之间还包括,从所述废地毯中分离面纱和第一背衬,以生产基本上不含有面纱和第一背衬的废地毯背面涂层,并且在步骤b)和接下来的步骤中基本上仅使用所述的废地毯背面涂层。
9.如权利要求2所述的方法,其中实施步骤b)和f)以生产标称粒径范围为200~325目的废地毯。
10.如权利要求1所述的方法,其中实施步骤a)以基本上仅收集使用过的废地毯。
11.如权利要求6所述的方法,所述方法在步骤b)和c)之间还包括将所述经粉碎的地毯压实,并对其进行进一步粉碎的步骤f)。
12.如权利要求7所述的方法,所述方法在步骤b)和c)之间还包括将所述经粉碎的地毯压实,并对其进行进一步粉碎的步骤f)。
13.如权利要求8所述的方法,所述方法在步骤b)和c)之间还包括将所述经粉碎的地毯压实,并对其进行进一步粉碎的步骤f)。
14.如权利要求3所述的方法,其中实施步骤b)和f)以生产标称粒径范围为200~325目的废地面覆盖物。
15.一种生产地面覆盖物的方法,该方法使用废地毯作为所述覆盖物的背衬材料的至少一部分,该方法依次包括以下步骤:
a)收集废地毯;
b)粉碎废地毯;
c)将经粉碎的废地毯作为填料加入至包括乙烯-醋酸乙烯酯共聚物和增粘剂树脂的至少两种其它材料中,以形成用于从背面涂布所述地面覆盖物的第一背衬的熔融混合物;
d)将所述熔融混合物的涂层和织物材料施加至所述第一背衬上,以在所述第一背衬的地面侧形成叠层;
e)使机织、毡合或针刺的第二背衬结合至经涂布的所述第一背衬;和
f)冷却所述第一背衬上的所述叠层,以形成在地面覆盖物的地面侧上具有包含废地毯的背面涂层的地面覆盖物。
16.一种地毯,该地毯具有面、第一背衬、第一背面涂层和至少一个第二背面涂层;其中所述第一背面涂层和第二背面涂层中的至少一种含有聚合物和填料,其中至少40重量%的所述填料是经粉碎的废地毯,所述第一背面涂层或第二背面涂层中至少一种包含作为聚合物和填料的熔融混合物而施加的热熔融复合物。
17.如权利要求16所述的地毯,其中至少一个所述背面涂层含有5~18重量%的乙烯-醋酸乙烯酯共聚物、32~45重量%的增粘剂树脂、20~50重量%的经粉碎的废地毯填料和0~30重量%的碳酸钙填料的熔融混合物。
18.如权利要求16所述的地毯,其中所述经粉碎的废地毯含有经粉碎的使用过的废地毯,并且其中所述填料具有200~325目的标称粒径。
19.如权利要求16所述的地毯,其中所述第二背面涂层包含聚合物和填料的热熔融复合物和与其一起层叠至所述第一背衬的织物材料。
20.一种生产挤压成型的热塑性产品或热固性产品的方法,所述方法包括以下步骤:
c)将经粉碎的废地毯作为填料加入至包括乙烯-醋酸乙烯酯共聚物和增粘剂树脂的至少两种其它材料中,以形成用于从背面涂布所述地面覆盖物的第一背衬的熔融混合物;
d)将所述熔融混合物和织物材料施加至所述第一背衬上,以在所述第一背衬的地面侧形成叠层。
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- 2003-11-12 EP EP20030783304 patent/EP1599336A1/en not_active Withdrawn
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Also Published As
Publication number | Publication date |
---|---|
AU2003290721A1 (en) | 2004-09-28 |
EP1599336A1 (en) | 2005-11-30 |
CN1753783A (zh) | 2006-03-29 |
US6814826B1 (en) | 2004-11-09 |
JP2006519034A (ja) | 2006-08-24 |
WO2004078473A1 (en) | 2004-09-16 |
US20050042413A1 (en) | 2005-02-24 |
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