ITMI20090366A1 - METHOD FOR THE REALIZATION OF A PANEL, IN PARTICULAR FOR THERMO-ACOUSTIC INSULATION, A PANEL MADE WITH SUCH A METHOD AND PLANT FOR THE CONSTRUCTION OF SUCH PANEL - Google Patents

Description

Description

The present invention relates to a method for manufacturing a panel in particular for thermo-acoustic insulation, a panel made with said method and a plant for manufacturing said panel. The need has long been felt to dispose of waste deriving from the production of non-woven fabrics, and non-woven fabrics reinforced with fiberglass nets.

This type of material has polyester fibers impregnated with acrylic and / or other resins of various kinds which, as a result of thermal and chemical processes, are polymerized and inseparable from the polyester fibers. It is therefore not possible or in any case not economically profitable to extract the polyester again from these scraps for reuse. Up to now, these scraps have been disposed of as waste with damage both from an ecological and economic point of view for the company.

Similar problems also arise from the disposal of all those industrial products in which the fibers of an artificial or natural material are linked together by means of a material of a chemical nature; such products include, for example, carpets, car mats, raffia packaging, etc.

In particular, the invention relates to the recycling of waste belonging to at least one of the following types of waste: polyester-based non-woven materials impregnated with acrylic resins, vegetable and / or artificial materials, polyester, rubber, carpet waste, materials textiles blended with plastic or rubber materials, wood.

The purpose of the present invention is to provide a method for the production of a panel in particular for thermal and acoustic insulation, a panel produced with said method and a plant for the production of said panel that allows recycling of waste in an economically advantageous way. , and an alternative to their disposal as waste.

These and other purposes which will appear evident to an expert in the art are achieved by a method for making a panel in particular for thermo-acoustic insulation, a panel made with said method and a plant for making said panel according to the characterizing part. of the attached claims.

For a better understanding of the present invention, a drawing is attached in which a plant for the production of a panel according to the invention is schematically represented.

The invention relates to a method for making a panel, in particular for thermo-acoustic insulation, starting from scraps of non-ferrous materials, said scraps belonging to at least one of the following types of materials: non-woven materials based on polyester impregnated with resins, vegetable materials, polyester, rubber, carpet waste, textile materials fused with plastic or rubber materials, wood.

This method includes the following steps:

- a phase in which the dimensions of the waste are reduced, through shredding and grinding processes, transforming them into a plurality of homogeneous portions having dimensions between 0.1 mm and 100 mm (variable thickness depending on the ground material),

- a distribution phase in which quantities of said plurality of homogeneous portions of waste are uniformly distributed on at least one surface of at least one previously formed web and composed of predefined quantities of at least the following components: a thermo binder, and at least one raw material, virgin or regenerated, based on fibers, belonging to at least one of the following types: synthetic man-made fibers, vegetable fibers, animal fibers,

- a forming phase, suitable for joining together said plies and homogeneous portions of waste, comprising the cold realization through a lapper of a carpet having a thickness between 5 cm and 70 cm, weight between 100 gr / m2 and 10,000 gr / m2 and density 10 kg / m3 and 500kg / m3,

- a thermo-bonding phase in which the components of said carpet are hot-bonded so as to obtain a finished product having a thickness between 4mm and 50 cm and a density between 10kg / m3 and 500kg / m3.

The phase in which the size of the scraps is reduced includes a first phase of shredding the scraps and a subsequent grinding phase of the shredded scraps (said two phases can also be carried out in a single mill), in said first phase of shredding the scraps are reduced in portions having dimensions between 100mm and 10mm and, in said second grinding step, said shredded portions being further reduced into portions having dimensions between 90mm and 0.1mm, hereinafter also referred to as "confetti".

The next phase is that of uniform distribution of these "confetti" of waste in the middle of two plies previously formed by a usual carding system. Said plies are composed of predefined quantities of at least the following components: a heat-binding agent and one or more raw materials preferably based on synthetic polyester fiber, said materials being able to be virgin or regenerated. The two plies are obtained through usual processes for the skilled in the art (opening, mixing and carding) and are preferably composed of 5% to 50% of heat-binding agent, and of 20% to 90% of raw material such as polyester or other synthetic fibers. or natural, virgin or regenerated. The thermo-binder is preferably a binder based on at least two-component artificial fiber with said at least two components having different melting temperatures.

The fiber-based raw material provides a fiber denier between 1.5 and 100 deniers.

The distribution of the "confetti" of waste takes place right at the exit of the two plies produced by the card, and preferably just before the plies overlap in order to insert these "confetti exactly inside the flap that is created by the union of the two plies. The "confetti" are distributed on the upper face of the lower veil or on the upper face of the upper veil. According to the invention, the "confetti" are advantageously deposited on the upper face of the lower veil. confetti will be in the middle of a sandwich formed by veil-confetti-veil thus allowing a simpler folding and therefore processing phase. The quantity of "confetti" inserted varies in relation to the weight of the web coming out of the card and of the finished product to be obtained, and is preferably between 1% and 300% of the weight of each single layer and therefore between approximately 1 g / m2 and 210g / m2. The final obtained will therefore have a composition of the type: from 4% to 35% of thermo-binding agent, from 20% to 90% of raw material such as polyester or other synthetic or natural fibers and from 1% to 70% of waste product.

The sandwich of plies and "confetti" thus obtained is then diverted to a conventional lapper, which arranges on a flat conveyor a variable number of layers of said sandwich according to the thickness of the finished product to be obtained. The number of laps is between 2 and 60 obtaining in this way a carpet with a thickness between 5 cm and 70 era, weight between 80 gr / m2 and 10000 gr / m2 and density from 10 kg / m3. and 500k: g / m3. Thanks to the presence of the lapper, even if a homogeneous quantity of "confetti" is not distributed between the two plies, once the sandwich has been folded on itself several times in the lapper, the carpet exiting the lapper certainly presents a homogeneous distribution of "confetti".

The thermo-binding phase involves the use of an oven-press or a usual oven, with a feed speed of the unbound carpet between 1 and 25 meters per minute, and one or more chambers with differently adjusted parameters, for example in the case of a three-chamber oven: the first two for heating and the last for cooling.

The first chamber (or first step) at a temperature between 100 and 220 degrees, and ventilation air between 20 and 90%. Inside this furnace the material can pass through a series of pairs of flat calibrating calenders or pressing belts which regulate the desired final thickness, which advantageously is between 2 mm and 300 mm.

A second chamber (or second step) at a temperature between 100 and 220 degrees, and ventilation air between 20 and 90%. Also inside this chamber the material can pass through a series of pairs of flat calibrating calenders or pressing belts which regulate the desired final thickness, which advantageously is between 2 mm and 300 mm.

The third chamber (or third step) is cooling and provides a temperature between 5 and 40 degrees, and ventilation air between 10 and 60%.

The method provides a final longitudinal and transversal cutting step of the thermo-bonded carpet after the thermo-bonding phase, in parts having dimensions corresponding to the panels to be obtained and then stacked, rolled and / or bagged.

The panel according to the invention comprises the materials listed above in describing its production method which therefore will not be repeated here as well as the percentages and characteristics of said materials will not be repeated.

Preferably the heat binder is a polyester, or copolyester, or polypropylene, or polyethylene.

Preferably the homogeneous portions are polyester scraps, impregnated with acrylic resins and possibly also comprising glass fiber threads, deriving from the production of non-woven fabrics.

According to the invention, a plant for manufacturing the method and the panel described above comprises, with reference to Figure 1) the following devices:

a shredding device 1 for reducing the size of said scraps, adapted to transform them into a plurality of homogeneous portions having dimensions between 10 mm and 100 mm, a grinding device 2 able to grind predefined quantities of said plurality of homogeneous portions of waste and transform them into a plurality of homogeneous portions or "confetti" with dimensions between 0.1 mm and 90 ml, a bagging machine designed to collect the ground waste material in big bags or silos 3, one or more 4-act loaders to measure and introduce in the production line the adequate percentage of each single raw material by weighing {said raw materials including for example, a thermo binder (stored in a 4 A loader), and one or more raw material based on fibers, virgin and / or regenerated, belonging to at least one of the following types: synthetic artificial fibers, vegetable fibers, animal fibers (of which, for example, a stored virgin raw material in the loader 4 B and a re-ignited one stored in the loader 4C), an opener 5 for a first mixing of the raw materials,

6 mixer box for further mixing,

fine opener 7 for a final mixing, a forming device 8 for cold forming a carpet 8 A starting from said components mixed together, having the characteristics described above,

A carding device 9 suitable for carding, parallelizing and forming two plies 9 A, B

A distribution device 10 adapted to distribute the previously described "confetti" of waste in a uniform manner, preferably inside the two plies 9 A, B at the outlet of the card 9,

A feeding device 11 adapted to continuously feed the distribution device 10 with the previously described scraps, taking them from the storage silos and / or from the big-bag 3,

A folding device 12 suitable for forming a carpet 12 A, preferably in the direction perpendicular to that of entry of the sandwich (plies and "confetti"), having the characteristics previously described

a thermo-binding device 13 suitable for hot binding the components of said carpet so as to obtain a finished product having the characteristics described above,

a cutting-rolling bagging-stacking device 14 suitable for longitudinally and transversely cutting the carpet of finished product thus obtained and for rolling or bagging or stacking the finished product thus obtained.

The device 1 for reducing the size of the scraps comprises a usual shredder (for example of the type produced by Satrind model 3K10 / 80) suitable for achieving a first reduction in the size of the scraps in first portions having dimensions between 100mm and 10mm and a mill 2 (for example of the type produced by Molinari model MG1200) suitable to receive said first portions and to further reduce their dimensions so as to obtain second portions having homogeneous dimensions between them and between 100mm and 0.1mm. These operations can also be carried out by a single mill device.

The ground waste coming out of the mill can be dedusted through usual filters (for example of the type produced by Lorandi Silos model D2400). The ground waste is bagged or stowed in silos (for this purpose the same device D2400 previously mentioned is used) by means of a usual automatic weighing bagging machine 3 (for example of the type produced by Paglierani model TP35) to then move on to the actual production line .

The plant includes for each material to be mixed its own 4A-C loader-weigher device (for example of the type produced by Laroche model CHPC) designed to convey through a conveyor belt to the opening device 5 -box mixer 6 - fine opener 7 (for example of the type produced by Laroche model OH) the desired quantity of said materials to be mixed together.

The mat forming device 8 is of the FBK type (for example of the type produced by TRUTZSCHLER).

The carpet thus formed is processed by a carding device 9 (for example of the type produced by Spinnbau) obtaining at the output a double ply from 10 to 70 grams / m2 each and varying height, preferably 2.50 m.

According to the invention, at the outlet of the card 9, a further previously ground waste raw material is distributed between the two plies, or on at least one of them.

The feeding device 11 of this further ground raw material or "confetti", previously stored in silos or big-bags, is, for example, of the generic screw type, and is able to pick up such waste and continuously feed the feeding device. distribution 10. The latter is for example of the type produced by RP International srl model "confetti spreading device" It is positioned innovatively between the two outlets of the card webs and is able to distribute the confetti evenly between the two webs 9A and 9B and / or on at least one of their surfaces.

The lapping device 12 is a common lapper (for example of the Texnology type) for the formation of a homogeneous carpet preferably formed from 2 to 60 laps.

The thermobinding device 9 is a furnace-press (for example of the type produced by Strahm model HYPER THERM) with a feed speed of the unbound belt between 1 and 25 meters per minute, and three chambers with differently adjusted parameters: the first two for heating and the last for cooling. The first chamber (or first step) at a temperature between 100 and 220 degrees, and ventilation air between 20 and 90%. Inside this kiln, the material passes through a series of pairs of flat calibrating calenders which regulate the desired final thickness, which advantageously is between 2 min and 300 mm.

A second chamber (or second step) at a temperature between 100 and 220 degrees, and ventilation air between 20 and 90%. Also inside this chamber the material passes through a series of pairs of flat calibrating calenders which regulate the desired final thickness, which advantageously is between 2 mm and 300 mm.

The third chamber (or third step) is cooling and provides a temperature between 5 and 40 degrees, and ventilation air between 10 and 60%.

The plant provides automatic cutting means 10 of the thermo-bound carpet leaving the thermo-binding device, able to automatically divide said carpet into a plurality of panels (said cutting means are for example of the type produced by Strahm model HIPER STRAHM).

The plant according to the invention provides that said devices are preferably connected in a continuous way to each other by conventional handling means suitable for moving the product leaving the mixing device to the inlet of the forming device and the product leaving the feeding device. forming at the inlet of the heat-sealing device.

An example of the method described above is provided below.

Example of realization of a panel Composition of the finished panel:

homogeneous portions of ground waste obtained from production waste of non-woven fabrics in polyester, glass fibers and resins, having dimensions between 8 and 15 mm,

thermal binder: two-component artificial fibers with low melting temperature (about 110 ° C-150 ° C), polyester fiber (PET).

Method for making the panel:

1) SHREDDING: rolls of non-woven resin with 10% glass inside are placed in the shredding machinery; output piece thickness adjustment: about 10 cm2

2) GRINDING: the shredded pieces are diverted to the grinding; output diameter / grain size adjustment: 8 mm

3) STORAGE: through suction systems, the product obtained is automatically bagged in BIG-BAG or stored in sylos.

4) PRODUCT MIX:

50% ground waste,

15% thermo-binder

35% polyester fiber (PET)

Through three loaders / bale openers I regulate the mix of materials through continuous controlled weighing:

-0.6 Kg TBM 4.5 dtex mm51 Bico 110 ° C

-1.4 Kg PET 15 dtex 60 mm anthracite color

5) MIXING: the raw materials are mixed through a large opener that amalgamates the compound, then through the mixer box which feeds a fine opener. These three machines are self-adjusting in line according to the need and speed of the forming machine.

6) CARPET FORMATION: I set the various parameters of the FBK, in our example:

- carpet thickness: 11

7) Carding: you set the feeding speed which automatically generates the weight of the two output plies:

- feeding belt speed: 2,5

8) Distribution: I set the weight to be deposited on the veil:

- g / m2: 40

9) Folding: set the number of layers:

- number of layers: 25

- height: right 110, left 110

10) THERMAL BINDING: I set the parameters of the three chambers:

-1st chamber: speed: 3 m / min

Temperature: 180 â € œC

Ventilation: from above 70%

calibration: 40 mm

-2 â € œchamber: speed: 3 m / min

Temperature: 190 ° C

Ventilation: from above 80%

calibration: 40 mm

-3 â € œchamber: speed: 3 m / min

Temperature: 15 ° C

Ventilation: from above 40%

11) CUTTING-ROLLING-STACKING: I set the longitudinal and transversal blades to obtain single panels of dimensions equal to 1 m x 1.5 m which in turn are stacked in pieces of 10 and bagged and then stored.

Finally, we want to reiterate that the embodiment illustrated up to now has been described purely by way of example and that numerous variants fall within the scope of protection of the invention, for example the card could produce a single web at the output on which the "confetti" and / or the oven for thermobinding could have a number of chambers other than that described, for example five chambers with ventilation and calibrations different from those described by way of example above.

Claims (6)

CLAIMS 1) Method for making a panel, in particular for thermal and acoustic insulation, starting from scraps of non-ferrous materials, said scraps belonging to at least one of the following types of materials: non-woven polyester-based materials impregnated with acrylic resins , vegetable and / or artificial materials, polyester, rubber, carpet waste, textile materials blended with plastic or rubber materials, wood, said method comprising the following steps: - a phase in which the dimensions of said waste are reduced, transforming them into a plurality of homogeneous portions having dimensions between 0 .Imm and 100mm, a distribution phase in which predefined quantities of said plurality of homogeneous portions of waste are distributed over at least a surface of at least one web previously formed starting from a combination of at least two of the following components: a thermo-binder, and a virgin raw material and / or regenerated based on fibers belonging to at least one of the following types: synthetic man-made fibers, vegetable fibers, animal fibers a forming step comprising the multiple superposition of sections of said web on which said waste portions have been distributed, so as to create a carpet - a thermo-bonding phase in which the components of said carpet are hot-bonded so as to obtain a finished product having a lower thickness than said carpet, preferably between 2mm and 30 cm and density between 10kg / m3 and 400kg / m3, and that preferably said carpet has a composition of the type: from 4% to 35% of heat-binding agent, from 20% to 90% of raw material such as polyester or other synthetic or natural fibers and from 1% to 70% of waste product. 2) Method according to claim 1 characterized by the fact that the distribution of predefined quantities of the homogeneous portions of rejects takes place precisely at the outlet of a device suitable for forming the at least one web or at the exit of a device suitable for forming two distinct webs just before the plies overlap, so as to insert these portions exactly inside the flap that is created by the union of the two plies. 3) Method according to claim 3 characterized by the fact that the waste portions are distributed on the upper face of the lower web and / or that the quantity of distributed waste portions is between 1% and 300% of the weight of each single web. 4) Method according to claim 1, characterized by the fact of using a lapper for the forming phase, which arranges on a flat conveyor a variable number of laps of the at least one web on which predefined quantities of the plurality of homogeneous portions of rejects are distributed , which preferably have a number of folds comprised between 2 and 60. 5) Method according to claim 1 characterized by the fact that the step in which the size of the waste is reduced comprises a first step of shredding the waste and a subsequent step of grinding the shredded waste, in said first step of shredding the waste being reduced in portions having dimensions between 100 mm and 10 mm, in said second grinding phase said shredded portions being further reduced into portions having dimensions between 90 mm and 0.1 mm, or a single grinding and shredding phase, and / or that the thermo-binder is a binder based on at least two-component artificial fiber with said at least two components having different melting temperatures, and / or that the non-waste raw material based on fibers has a denier of the fibers between 1.5 and 100 deniers. 6) Method according to claim 1 characterized by the fact that the carpet has a thickness between 5 cm and 70 cm, weight between 100 gr / m2 and 10000 gr / m2 and density 10 kg / m3 and 500kg / m3, and that the product finished it has a thickness between 2mm and 50 cm and density between 10kg / m3 and 500kg / m3. 7} Panel in particular for thermo-acoustic insulation, made according to the method referred to in the preceding claims, comprising scraps of non-ferrous materials that are not directly recyclable, said scraps belonging to at least one of the following types of scraps: non-woven polyester-based materials impregnated with resins, vegetable and / or artificial materials, polyester, rubber, carpet waste, textile materials fused with plastic or rubber materials, wood, characterized by comprising from 1% to 70% of homogeneous portions of said waste, from 4 % to 35% of a heat binder, and from 20% to 90% of virgin or regenerated fiber-based raw material, in which said fibers belong to at least one of the following types:. artificial fibers, synthetic fibers, vegetable fibers, animal fibers and which preferably have a thickness between 2mm and 50 cm and density between 10kg / m3 and 500kg / m3, and in which said homogeneous portions of waste have dimensions between 100mm and 0, 1 miran. 8) Panel according to claim 7 characterized by the fact of comprising a carpet comprising a plurality of layers of at least one ply, formed starting from a combination of at least two of the following components: a thermo-binding agent, and a virgin and / or regenerated raw material fiber base belonging to at least one of the following types: synthetic artificial fibers, vegetable fibers, animal fibers, in which a predefined quantity of a plurality of homogeneous portions of waste belonging to at least one of the following is distributed on at least one surface of said web types of materials: polyester-based non-woven materials impregnated with acrylic resins, vegetable and / or artificial materials, polyester, rubber, carpet waste, textile materials fused with plastic or rubber materials, wood, in which said folds are thermo-bonded and pressed between them. 9) Panel according to claim 7, in which preferably the virgin or regenerated fiber-based raw material has a thickness of the fibers between 1.5 and 100 deniers, and / or in which preferably the artificial thermo-binder is of the at least two-component type with said at least two components having different melting temperatures and / or that the thermo-binder is of the fiber-based type, and / or in which preferably the homogeneous portions are waste materials comprising at least two components chemically bonded together and / or which said homogeneous portions are polyester scraps impregnated with acrylic resins deriving from the production of non-woven fabrics. 10) Plant for the realization of the method and of the panel according to the preceding claims, for the production of a panel in particular for thermo-acoustic insulation, starting from scraps of non-ferrous materials, said scraps belonging to at least one of the following types of materials : polyester-based non-woven materials impregnated with resins, plant and / or artificial materials, polyester, rubber, carpet waste, textile materials fused with plastic or rubber materials, wood, characterized in that they include the following devices: a device for reducing the size of said waste, suitable for transforming them into a plurality of homogeneous portions having dimensions between 0.1mm and 100mm, a distribution device capable of distributing predefined quantities of said plurality of homogeneous portions of waste on at least one surface of at least one web previously formed starting from a combination of at least two of the following components: a thermo-binder, and a virgin raw material and / or regenerated based on fibers belonging to at least one of the following types: synthetic man-made fibers, vegetable fibers, animal fibers, - a forming device suitable for providing the multiple overlapping of portions of said web on which said waste portions have been distributed, so as to create a carpet, - a thermo-binding device suitable for hot binding the components of said carpet. so as to obtain a finished product having a thickness lower than that of said carpet, in which preferably at least the device for forming the at least one web, for distributing the waste portions on a surface of said web, for folding and thermo-binding are arranged in series with each other. 11) Plant according to the preceding claim characterized by providing the device for distributing the predefined quantities of the homogeneous portions of rejects right at the outlet of a device suitable for forming the at least one web and / or at the outlet of a device suitable for forming two distinct plies and just before the plies overlap, so as to insert these portions exactly inside the flap created by the union of the two plies. 12) Plant according to claim 10 characterized by the fact that the forming device is a lapper, which arranges on a flat conveyor a variable number of laps of at least one web on which predefined quantities of the plurality of homogeneous portions of waste, and / or that the dispensing device is of the type suitable for distributing material having dimensions between 90mm and 0.1mm. 13) Plant according to claim 10 characterized by the fact that the device for reducing the size of said scraps comprises a shredder suitable for achieving a first reduction in the size of the scraps in first portions having dimensions between 100mm and 10mm and a mill suitable for receiving said first portions and to further reduce their dimensions so as to obtain second portions having homogeneous dimensions between them and between 100mm and 0.1mm, and / or to include for each material to be mixed its own load-weighing device, able to convey to the device the desired quantity of said materials, and / or that the mixing device includes at least one opener, and / or that the carpet forming device is a lapper, and / or that the thermo-binding device is an oven and / or a kiln-press, and / or that said kiln / press has a feed speed of the unbound belt between 1 and 25 meters per minute , and one or more chambers and / or that the mixing phase requires the use of at least one opener and / or provided automatic cutting means of the thermo-bound carpet coming out of the thermo-binding device able to automatically divide said carpet into a plurality of panels.