EP1339535A2 - Elastic article manufacture - Google Patents

Elastic article manufacture

Info

Publication number
EP1339535A2
EP1339535A2 EP20010986873 EP01986873A EP1339535A2 EP 1339535 A2 EP1339535 A2 EP 1339535A2 EP 20010986873 EP20010986873 EP 20010986873 EP 01986873 A EP01986873 A EP 01986873A EP 1339535 A2 EP1339535 A2 EP 1339535A2
Authority
EP
European Patent Office
Prior art keywords
process according
rubber
vulcanised
weight
mill
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.)
Withdrawn
Application number
EP20010986873
Other languages
German (de)
French (fr)
Inventor
Edward Fulflex International Company FLYNN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Innovative Elastics Ltd
Original Assignee
Innovative Elastics Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Innovative Elastics Ltd filed Critical Innovative Elastics Ltd
Publication of EP1339535A2 publication Critical patent/EP1339535A2/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L19/00—Compositions of rubbers not provided for in groups C08L7/00 - C08L17/00
    • C08L19/003—Precrosslinked rubber; Scrap rubber; Used vulcanised rubber
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L21/00—Compositions of unspecified rubbers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2021/00—Use of unspecified rubbers as moulding material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L7/00—Compositions of natural rubber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

  • Elastic threads, tapes and rings that are used particularly in garments such as underwear, swimwear and nappies are typically made from material of high elasticity and low plasticity such as natural or synthetic rubber or thermoplastic elastomer. These materials include vulcanised natural rubber, synthetic polyisoprene, synthetic nitrile polymers, ethylene, propylene diene rubber (EPDM) based polymers, and polybutadiene polymer. Such elastic materials are typically white or at least light in colour, have talc on their surface and include only a small quantity, typically less than 30% by weight of filler.
  • scrap material is produced.
  • scrap material produced during production and before vulcanisation can be recycled particularly where it is combined with more than 80% of virgin stock.
  • the scrap material is simply discarded and ends up in land-fill sites.
  • Considerable work and activity has taken place to produce technology that can attempt to recover material from vehicle tyres. Tyres contain considerable quantities of metal and textile reinforcement and are also made from very different material than is used for elastic tapes and threads.
  • the rubber material is heavily filled with more than 50% of carbon black and oil.
  • the technology that has been developed to recover material rom tyres can produce vulcanised rubber crumb and a form of de-vulcanised reclaim which can be used as an additive in tyre- manufacture.
  • a vulcanised, natural or synthetic rubber containing less than 30% by weight of filler material is compounded in a rubber mill with between 5 and 30% by weight of unvulcanised natural or synthetic rubber material including vulcanising agents and is broken down at least until the maximum particle size is less than 5 mm.
  • the rubber contains less than 25% by weight of filler material.
  • the material resulting from the compounding in a mill is then put under pressure and heated in a mould to produce a vulcanised moulded article.
  • the compounded material is heated under pressure in a mould the unvulcanised natural or synthetic rubber including vulcanising agents acts as a binding agent and forms strong adhesive bonds with the broken down scrap, previously vulcanised, material as well as itself becoming vulcanised.
  • the compounded material is heated to a temperature of between 120°C and 200°C in the mould to produce the vulcanised moulded article.
  • Moulded articles such as fatigue prevention mats for offices and factories, mats for the home and mats for use in horse boxes or cow barns can be produced as can solid tyres for fork lift truck wheels, solid tyres for wheel barrows or tyres for small wheels or trolleys.
  • the compounded material As an alternative to moulding the compounded material, if it is compounded until the maximum particle size for the pre-vulcanised scrap rubber material is less than 0.4 mm it is possible to add such a compounded material back into virgin stock provided that the total content of the pre- vulcanised material is less than 10 to 20% by weight of the virgin stock to produce low-gauge rubber sheeting which can then be converted into elastic tapes, threads and rings.
  • the size to which the vulcanised material is broken down in the mill can vary depending upon the time on the mill, the temperature at which the milling is carried out and the gap between the mill rolls.
  • the scrap vulcanised material can be mixed with unvulcanised rubber of the same properties, i.e. unvulcanised rubber which, after vulcanisation will produce the same modulus, tensile elongation, etc., as the scrap vulcanised material.
  • unvulcanised rubber which, after vulcanisation will produce the same modulus, tensile elongation, etc.
  • a typical temperature for the material during its compounding in the mill is between 20 and 75°C and, by compounding the rubber at this temperature it does not give rise to undesirable odours which can arise from high temperature grinding or de-vulcanisation processes.
  • the mill roll gap is between 0 and 1 mm and preferably the amount of unvulcanised rubber material that is added in the compounding stage is 15 or 20% or between 10 and 20% by weight.
  • the generally white or light coloured scrap material also leads to the finished product being able to be white or light coloured or, by adding dye during the compounding stage being able to be produced in a range of attractive colours. It is also possible to add a blowing agent during the compounding stage to be able to obtain foamed or sponge rubber products.
  • Fig. 1 is a schematic illustration of an example of a process according to the present invention.
  • Figure 1 is a schematic representation showing the process steps according to one example of the present invention, in particular it shows an example of a scaled-up version of the process .
  • the constituent parts to be blended must be weighed, in order to ensure the correct composition is obtained.
  • a wide range of blends are possible using the present invention.
  • scrap 85%
  • a low percentage of other additives is desirable.
  • the weights of each component are as follows, scrap rubber at 21.25 kg (83%), unvulcanised rubber mix 3.75 kg (14.6%) and sulphur powder 0.6 kg (2.4%), giving a total of 25.6 kg.
  • the shredded material is then transferred to and held in a storage bin 2.
  • Batches of the shredded material are fed to a grinding mill as required.
  • the grinding mill includes a pair of mill rolls 4 and a hopper 3 positioned over the mill rolls to control the feed of the shredded material .
  • the mill rolls are 84 inches (2.13m) wide, smooth rolls and are mounted so as to have a mill nip setting of 0.7mm ⁇ 0.1mm.
  • the mill friction ratio is set to between 1.4 and 1.0.
  • Batches of the shredded material are fed between the mill rolls. Each batch is approximately 25 kg because each batch has to be manually lifted after it passes through the nip, as will be explained later on. Each pass through the nip takes 15 seconds .
  • the shredded material After the shredded material is passed through the mill nip it falls onto a conveyor 5 which conveys the shredded material to a bucket 6. Once the entire batch has been transferred to the bucket it is lifted to a bucket emptying position where it releases the shredded material back into the hopper 3 so that it can pass through the mill rolls again.
  • Each batch of material is passed through the mill nip 15 times in order to give adequate blending and size reduction. After the 15 passes the material temperature reaches 70°C ⁇ 5°C. After the final pass the material is spread in a layer about 2 cm thick and is left to cool to room temperature, which takes about 30 minutes. After cooling, the material is packed in plastic bags in 5 to 10 kg quantities and can be stored or shipped in this form to a moulding station.
  • moulding is conducted at a pressure of 3,500 psi (2.5 x 10.7 Pa) at a temperature of 140°C. Typically the moulding time is 20 to 25 minutes.
  • the properties of a couple of samples made according to the process of present invention are given.
  • Sample A was made using the mixture described above, 83% vulcanised scrap, 14.6% unvulcanised mixed rubber compound and 2.4% sulfur powder.
  • Sample B was made using 85% vulcanised scrap and 15% unvulcanised mixed rubber compound.
  • Sample B with a higher proportion of unvulcanised mixed rubber compound is softer and has a lower modulus than Sample A but has a higher breaking point .

Abstract

There is provided a process in which a vulcanised natural or synthetic rubber, containing less than 30 % by weight of filler material, is compounded in a rubber mill with between 5 and 30 by weight of unvulcanised, natural or synthetic rubber material including vulcanising agents, and is broken down (by repeatedly passing it through a narrow slit) until the maximum particle size is less than 5 mm. The broken down material can then be molded to form particles such as fatigue prevention mats for offices and factories, mats for the home and mats for use in horse boxes or cow barns. It is also possible to produce solid tyres for fork lift truck wheels, solid tyres for wheel barrows and tyres for small wheels or trolleys using the process of the present invention.

Description

ELASTIC ARTICLE MANUFACTURE
Background to the Invention
Elastic threads, tapes and rings that are used particularly in garments such as underwear, swimwear and nappies are typically made from material of high elasticity and low plasticity such as natural or synthetic rubber or thermoplastic elastomer. These materials include vulcanised natural rubber, synthetic polyisoprene, synthetic nitrile polymers, ethylene, propylene diene rubber (EPDM) based polymers, and polybutadiene polymer. Such elastic materials are typically white or at least light in colour, have talc on their surface and include only a small quantity, typically less than 30% by weight of filler.
Inevitably during the production and conversion process of such materials, scrap material is produced. In general, scrap material produced during production and before vulcanisation can be recycled particularly where it is combined with more than 80% of virgin stock. However, after the rubber is vulcanised, unless the scrap material is in pieces that are sufficiently large for it to be used for other purposes, it is simply discarded and ends up in land-fill sites. Considerable work and activity has taken place to produce technology that can attempt to recover material from vehicle tyres. Tyres contain considerable quantities of metal and textile reinforcement and are also made from very different material than is used for elastic tapes and threads. Typically, the rubber material is heavily filled with more than 50% of carbon black and oil. The technology that has been developed to recover material rom tyres can produce vulcanised rubber crumb and a form of de-vulcanised reclaim which can be used as an additive in tyre- manufacture. Summary of the Invention
According to the present invention there is provided a process in which a vulcanised, natural or synthetic rubber containing less than 30% by weight of filler material is compounded in a rubber mill with between 5 and 30% by weight of unvulcanised natural or synthetic rubber material including vulcanising agents and is broken down at least until the maximum particle size is less than 5 mm. Preferably, the rubber contains less than 25% by weight of filler material.
Typically, the material resulting from the compounding in a mill is then put under pressure and heated in a mould to produce a vulcanised moulded article. When the compounded material is heated under pressure in a mould the unvulcanised natural or synthetic rubber including vulcanising agents acts as a binding agent and forms strong adhesive bonds with the broken down scrap, previously vulcanised, material as well as itself becoming vulcanised. Typically, the compounded material is heated to a temperature of between 120°C and 200°C in the mould to produce the vulcanised moulded article. Moulded articles such as fatigue prevention mats for offices and factories, mats for the home and mats for use in horse boxes or cow barns can be produced as can solid tyres for fork lift truck wheels, solid tyres for wheel barrows or tyres for small wheels or trolleys.
As an alternative to moulding the compounded material, if it is compounded until the maximum particle size for the pre-vulcanised scrap rubber material is less than 0.4 mm it is possible to add such a compounded material back into virgin stock provided that the total content of the pre- vulcanised material is less than 10 to 20% by weight of the virgin stock to produce low-gauge rubber sheeting which can then be converted into elastic tapes, threads and rings. Depending upon the final product to be produced, the size to which the vulcanised material is broken down in the mill can vary depending upon the time on the mill, the temperature at which the milling is carried out and the gap between the mill rolls. In general, the longer the milling process the more finely the pre-vulcanised scrap material is ground and the smoother and more homogeneous the final moulded article. Increasing the milling time naturally reduces the throughput of the process and leads to greater cost so that, inevitably a compromise is reached depending upon the intended use of the material .
The scrap vulcanised material can be mixed with unvulcanised rubber of the same properties, i.e. unvulcanised rubber which, after vulcanisation will produce the same modulus, tensile elongation, etc., as the scrap vulcanised material. However, it is also possible to compound the scrap vulcanised material with unvulcanised rubber having properties which are lower or higher in, for example, modulus tensile and elongation to give products with a range of properties.
A typical temperature for the material during its compounding in the mill is between 20 and 75°C and, by compounding the rubber at this temperature it does not give rise to undesirable odours which can arise from high temperature grinding or de-vulcanisation processes. Typically, the mill roll gap is between 0 and 1 mm and preferably the amount of unvulcanised rubber material that is added in the compounding stage is 15 or 20% or between 10 and 20% by weight.
The generally white or light coloured scrap material also leads to the finished product being able to be white or light coloured or, by adding dye during the compounding stage being able to be produced in a range of attractive colours. It is also possible to add a blowing agent during the compounding stage to be able to obtain foamed or sponge rubber products. Brief Description of the Drawing
Fig. 1 is a schematic illustration of an example of a process according to the present invention.
Detailed Description
Figure 1 is a schematic representation showing the process steps according to one example of the present invention, in particular it shows an example of a scaled-up version of the process . Initially the constituent parts to be blended must be weighed, in order to ensure the correct composition is obtained. A wide range of blends are possible using the present invention. To keep costs down a high percentage of scrap (85%) and a low percentage of other additives is desirable. In this example, for approximately 25kg of final product, the weights of each component are as follows, scrap rubber at 21.25 kg (83%), unvulcanised rubber mix 3.75 kg (14.6%) and sulphur powder 0.6 kg (2.4%), giving a total of 25.6 kg. These components are mixed and undergo a pre-grind or shredding process in a shredding mill 1. The shredded material is then transferred to and held in a storage bin 2. Batches of the shredded material are fed to a grinding mill as required. The grinding mill includes a pair of mill rolls 4 and a hopper 3 positioned over the mill rolls to control the feed of the shredded material . The mill rolls are 84 inches (2.13m) wide, smooth rolls and are mounted so as to have a mill nip setting of 0.7mm ± 0.1mm. The mill friction ratio is set to between 1.4 and 1.0. Batches of the shredded material are fed between the mill rolls. Each batch is approximately 25 kg because each batch has to be manually lifted after it passes through the nip, as will be explained later on. Each pass through the nip takes 15 seconds . After the shredded material is passed through the mill nip it falls onto a conveyor 5 which conveys the shredded material to a bucket 6. Once the entire batch has been transferred to the bucket it is lifted to a bucket emptying position where it releases the shredded material back into the hopper 3 so that it can pass through the mill rolls again. Each batch of material is passed through the mill nip 15 times in order to give adequate blending and size reduction. After the 15 passes the material temperature reaches 70°C ± 5°C. After the final pass the material is spread in a layer about 2 cm thick and is left to cool to room temperature, which takes about 30 minutes. After cooling, the material is packed in plastic bags in 5 to 10 kg quantities and can be stored or shipped in this form to a moulding station.
Typically moulding is conducted at a pressure of 3,500 psi (2.5 x 10.7 Pa) at a temperature of 140°C. Typically the moulding time is 20 to 25 minutes. In the table below the properties of a couple of samples made according to the process of present invention are given.
Sample A was made using the mixture described above, 83% vulcanised scrap, 14.6% unvulcanised mixed rubber compound and 2.4% sulfur powder.
Sample B was made using 85% vulcanised scrap and 15% unvulcanised mixed rubber compound.
Both mixtures were moulded in a laboratory at a temperature of 143°C, under a pressure of 3,500psi, for 40 minutes.
Clearly, Sample B with a higher proportion of unvulcanised mixed rubber compound is softer and has a lower modulus than Sample A but has a higher breaking point .

Claims

1. A process in which vulcanised, natural or synthetic rubber containing less than 30% by weight of filler material is compounded in a rubber mill with between 5 and 30% by weight of unvulcanised natural or synthetic rubber material including vulcanising agents and is broken down at least until the maximum particle size is less than 5 mm.
2. A process according to claim 1, in which the rubber contains less than 25% by weight of filler material.
3. A process according to claim 1 or 2 , in which the material resulting from the compounding in a mill is then put under pressure and heated in a mould to produce a vulcanised moulded article.
4. A process according to claim 3, in which the material is heated to a temperature between 120 and 200°C in the mould.
5. A process according to claim 3 or 4, in which the moulded articles are fatigue prevention mats for offices and factories, mats for the home, mats for use in horse boxes or cow barns, solid tyres for fork lift truck wheels, solid tyres for wheel barrows or tyres for small wheels or trolleys .
6. A process according to claim 1 or 2 , in which the compounded material is compounded until the maximum particle size for the pre-vulcanised rubber material is less than 0.4 mm and then such compounded material is added into virgin stock provided that the total content of the pre-vulcanised material is less than 10 to 20% by weight of the virgin stock.
7. A process according to claim 6, in which the material is used to produce low-gauge rubber sheeting for conversion into elastic tapes, threads and rings.
8. A process according to any one of the preceding claims, in which the temperature of the material during its compounding in the mill is between 20 and 75°C.
9. A process according to any one of the preceding claims, in which the mill roll gap is between 0 and 1 mm.
10. A process according to any one of the preceding claims, in which the amount of unvulcanised rubber material that is added in the compounding stage is between 10 and 20% by weight.
11. A process according to any one of the preceding claims, in which a dye is added during the compounding stage .
12. A process according to any one of the preceding claims, in which a blowing agent is added during the compounding stage .
EP20010986873 2000-12-04 2001-12-04 Elastic article manufacture Withdrawn EP1339535A2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB0029544 2000-12-04
GB0029544A GB0029544D0 (en) 2000-12-04 2000-12-04 Elastic article manufacture
PCT/EP2001/014704 WO2002045930A2 (en) 2000-12-04 2001-12-04 Elastic article manufacture

Publications (1)

Publication Number Publication Date
EP1339535A2 true EP1339535A2 (en) 2003-09-03

Family

ID=9904405

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20010986873 Withdrawn EP1339535A2 (en) 2000-12-04 2001-12-04 Elastic article manufacture

Country Status (4)

Country Link
EP (1) EP1339535A2 (en)
AU (1) AU2002238429A1 (en)
GB (1) GB0029544D0 (en)
WO (1) WO2002045930A2 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2446592A (en) * 2007-02-16 2008-08-20 Polymer Recyclers Ltd Rubber recycling
DE102009025925A1 (en) * 2009-06-05 2010-12-09 Mewa Recycling Maschinen Und Anlagenbau Gmbh Rubber reactivation device and method

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Publication number Priority date Publication date Assignee Title
US2554607A (en) * 1950-07-18 1951-05-29 William H Woolf Process of remolding vulcanized rubber
JPS6031920A (en) * 1983-07-29 1985-02-18 Kiyoshi Ando Preparation of composite rubber product
DE4011794A1 (en) * 1989-04-18 1990-10-25 Phoenix Ag Matrix prodn. from scrap rubber
ES2052092T3 (en) * 1989-04-18 1994-07-01 Phoenix Ag PROCEDURE FOR THE RECOVERY OF RUBBER RESIDUAL PRODUCTS.
CA2088845A1 (en) * 1992-08-19 1994-02-20 Thomas George Burrowes Process for making rubber articles and rubber articles made thereby
US5591794A (en) * 1994-04-19 1997-01-07 Sumitomo Rubber Industries, Ltd. Rubber composition for tire tread
US5510419A (en) * 1994-09-16 1996-04-23 National Rubber Technology Inc. Polymer-modified rubber composition
CA2350719A1 (en) * 1998-11-06 2000-05-18 Bennet Intellectual B.V. Rubber composition
US6458883B1 (en) * 1999-01-14 2002-10-01 Jsr Corporation Conductive rubber composition and manufacturing method and conductive rubber member thereof
AU2000227880A1 (en) * 2000-02-17 2001-08-27 Centre De Recherche Industrielle Du Quebec Process for producing batches of rubber-based composition

Non-Patent Citations (1)

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Title
See references of WO0245930A2 *

Also Published As

Publication number Publication date
WO2002045930A3 (en) 2003-01-16
AU2002238429A1 (en) 2002-06-18
GB0029544D0 (en) 2001-01-17
WO2002045930A2 (en) 2002-06-13

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