JP2001062832A - Method and equipment for recovering thermoplastic resin molded article having base layer and fiber layer, and carpet base constituted of thermoplastic resin recovered by the method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To recover a thermoplastic resin molded article comprising a base layer and a fiber layer, for each resin material constituting each layer. SOLUTION: A thermoplastic resin molded article 81 having a base layer and a fiber layer, which is an object of processing, is crushed into a plurality of small pieces 82 to be processed, by a cutter mill 120 or the like. The crushed small pieces 82 are charged in a separator 130 and the fiber layer is peeled off or separated from the base layer, with a force of impact-friction crushing given thereto. The separated fiber layer is turned into a fibrous resin material 82c on the occasion, while the base layer is subjected to size selection and turned into a size-selected resin material 83. The size-selected resin material 83 and the fibrous resin material 82c are selected by a force of airflow thereafter and recovered separately.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for regenerating a thermoplastic resin molded article.
For example, a base layer made of EVA or the like filled with a filler such as PE, PP, or calcium carbonate is provided with a PET, nylon, P
A thermoplastic resin molded article such as a floor carpet laid on an automobile floor or the like formed by compounding a fiber layer made of P or the like is to be treated, and the thermoplastic resin molded article including the base layer and the fiber layer is crushed. On a plurality of small pieces to be treated, the fiber layer and the base material layer in the small pieces to be treated are separated and separated, and the method and apparatus for individually collecting and sizing the base material layer,
The present invention relates to a carpet base material formed using the recovered base material layer as a raw material.

[0002]

2. Description of the Related Art EVA filled with PE, PP and filler
A thermoplastic resin molded product formed by combining a fiber layer made of PET, nylon, PP, or the like with a base material layer made of, for example, is used as a floor carpet or the like laid on the floor of an automobile or the like. An example of this floor carpet is shown in FIGS. 7A and 7B. The floor carpet shown in FIG. 7A is made of a nonwoven fabric such as polyester, polypropylene, or high-density polyethylene or a flat yarn woven fabric by combining resin fibers 263 forming a large number of loop yarns or cut pile yarns made of PET, nylon, PP, or the like. A fiber layer 262 which is woven into a base cloth 264 and formed in a raised state;
This is a so-called tuft carpet including a base material layer 260 such as EVA filled with a filler. The floor carpet shown in FIG. 7B attaches fibers entangled by needle punching to the base material layer 260 to form a fiber layer 262. It is a so-called needle punch carpet formed. FIG. 7 (b)
In the needle punch carpet shown in FIG.
2 and the material of the base material layer 260 can be the same as those of the tuft carpet shown in FIG.

[0003] In such a thermoplastic resin molded article such as a floor carpet, the base layer 260 and the fiber layer 262 are firmly adhered to each other. It was difficult to separate or separate the fiber 260 and the fiber layer 262. For this reason, in the related art, scraps and the like generated by cutting when producing a floor carpet are recycled in a state where the base material layer and the fiber layer are combined.

[0004] As an example, the floor material of a floor carpet made of a thermoplastic resin is melted in a state in which the base material layer and the fiber layer are kept in a composite state, and is alloyed with a compatibilizing agent to form pellets. It is blended with a plastic resin in the range of 10 to 50% by weight and is used again as a base layer of a floor carpet or the like by melt extrusion (JP-A-5-24139). There is disclosed a method in which crushing, heating and press-forming are performed as they are to obtain a panel-shaped molded product (Japanese Patent Application Laid-Open No. 9-1997).
No. 109164).

[0005]

SUMMARY OF THE INVENTION The above-mentioned Japanese Patent Laid-Open No. 5-24 is disclosed.
In the regeneration method described in No. 139, the composite material of the base material layer and the fiber layer, which are made of different materials, is melted and alloyed. Therefore, a compatibilizing agent is required for alloying, and pelletizing is performed. Cost and regeneration costs increase. When such a recycled material is used as a raw material, it is necessary to mix and use a virgin resin material of 50 wt% or more with the raw material.

Further, in the recycling method described in Japanese Patent Application Laid-Open No. 9-109164, a thermoplastic resin product composed of a base material layer and a fiber layer made of different materials is crushed and then directly pressed into a panel shape or the like. The fibers in the crushed carpet or the resin forming the base layer are not uniformly dispersed,
For this reason, the density tends to be non-uniform, and thus, for example, a panel-shaped product formed in this way has a reduced elasticity, and the non-uniform density tends to cause variations in rigidity. Having.

The publication also discloses a resin molded product reinforced with an aggregate made of an iron-based bar member or the like in order to improve the bending strength of the molded resin molded product.
In the case of reinforcing with such an aggregate, a relatively heavy resin molded product having a density of 0.8 to 1.0 g / cm ³ in the embodiment becomes heavier. Therefore, when such parts are used as parts for automobiles, the weight of the produced automobiles increases, and therefore, it is necessary to improve the fuel efficiency by reducing the weight, and consequently to reduce the emission of exhaust gas. Goes against the request.

Therefore, the present invention has been made to solve the above-mentioned drawbacks of the prior art, and is intended to process a thermoplastic resin molded article composed of a composite material of a base material layer and a fiber layer. By providing a method and an apparatus capable of separating or separating a base material layer and a fiber layer from a molded product by a relatively simple method and recovering them as separately materialized materials, more effective recycling of resources is achieved. The purpose is to promote the use.

Another object of the present invention is to regenerate a resin material recovered as a material separately prepared by the above-described method as a base material of a carpet, thereby obtaining a recovered resin thus recovered. The purpose is to promote effective reuse of materials.

[0010]

According to the present invention, as a result of a number of experiments, a thermoplastic resin molded article 81 made of a composite material of a base material layer 260 and a fiber layer 262 is impact-milled into small pieces 82 to be treated. When a force is applied, the base material layer and the fiber layer are separated or separated by the impact-milling force, and the synergistic effect of the generation of frictional heat and the grinding action accompanying the impact-milling force causes the base material layer 2
In the case of 60, the particle size is adjusted to a predetermined particle state, for example, a spherical shape by friction heat (in the present specification, the sized resin material is referred to as “granulated resin material”), and peeled or removed from the base material layer 260. The separated fiber layer 262 becomes a fibrous resin material in which a single fiber or a plurality of fibers are entangled (referred to as “fibrous resin material” in the present specification). Granulated sizing resin material 83
And the fibrous resin material 82c can be sorted out and collected as materialized materials.

Therefore, the method for recovering a thermoplastic resin molded article of the present invention targets a thermoplastic resin molded article 81 having a base material layer 260 and a fiber layer 262 and treats the thermoplastic resin molded article 81 with a plurality of articles. A crushing step of crushing into processing pieces 82;
An impact grinding force is applied to each of the crushed individual pieces to be processed 82 to peel or separate the fiber layer 262 from the base material layer 260 of the to-be-processed pieces 82 to separate the fibrous resin material 8.
2c, a separation / separation / granulation step of sizing the resin material forming the base material layer 260 to a granular state with the sizing resin material 83, and the sizing resin material 83 and the fibrous resin material 82c.
Is characterized by including at least a wind separation step of sorting by a wind force according to a difference in falling speed and separately collecting.

Further, in the above method, the fiber layer 262 separated or separated from the base material layer 260 in the crushing step is separated from the small pieces to be treated 82 by wind power before being introduced into the separating, separating and sizing step. It is preferable to include a step of performing the above.

Further, after cutting the fibrous resin material 82c obtained in the peeling / separating / sizing step into a predetermined length,
It is preferable to perform a wind separation process.

The crushing step comprises two steps of crushing a thermoplastic resin molded article to be treated, and further crushing the obtained small pieces into fine pieces to be processed. Can also.

The apparatus for recovering a thermoplastic resin molded article of the present invention treats a thermoplastic resin molded article 81 including a base material layer 260 and a fiber layer 262 as a processing object.
Crushing means 120 for crushing 1 into a plurality of small pieces 82 to be treated
And fixed-side peeling / separating / granulating on a fixed disk 131 having a central portion communicating with a supply / feed section 132 of the small piece 82 to be processed, and each fixing pin 134 is sequentially implanted on a plurality of rotation trajectories. A movable-side peeling / separating device in which each movable pin 144 is sequentially implanted on a plurality of rotation trajectories different from each of the fixed pins on a movable disk 141 provided rotatably opposite to the fixed disk 131; A separation / sizing unit 130 and a take-out unit for taking out the crushed small pieces to be processed into the take-out opening 153 are provided. The treated small piece 82 is ground to separate or separate the fiber layer 262 from the base material layer 260 to form the fibrous resin material 82c.
And separation to form a granulated resin material 83
It is characterized by including a sizing means and 130, a sieving resin material 83, and a wind force sorting means 30 for sorting the fibrous resin material 82c by wind force and separately collecting each by the sorting.

Further, it is possible to include means for selecting and recovering the fibrous resin material 82c contained in the small piece to be processed 82 before being introduced into the peeling / separating / granulating means 130 by wind force. A means for cutting the fibrous resin material 82c obtained by the separation / granulation means 130 into a predetermined length may be provided.

Further, the carpet base material of the present invention is obtained by melting and extruding the sized resin material recovered by the above method as it is or after repelletizing it, or by mixing it with a virgin resin material. It is characterized by being formed. This sized resin material and virgin resin material are
5-100 wt% of sizing resin material and virgin resin material 0
It can be blended at a ratio of ~ 95 wt%.

[0018]

Next, an embodiment of the present invention will be described below.

In the present embodiment, as a preferred embodiment of the present invention, the thermoplastic resin molded article 81 to be treated is separated into, for example, types, materials, etc. (separation step). The plastic resin molded article 81 is crushed into a predetermined size to form a small piece to be treated 82 (crushing step). The resin fibers 82 generated in the crushing step and mixed in the small piece to be treated 82 are crushed.
c is collected by wind force (preliminary wind sorting step), and the base layer 260 and the fiber layer 262 are separated or separated from the small piece 82 by applying an impact grinding force to the small piece 82 to be treated, The resin material forming the base material layer 260 is sized to a granular state and separated / separated / grained into the sized resin material 83 and the fibrous resin material 82c (separation / separation / grain sizing step). A fibrous resin material 82 obtained through a sizing process
c) into a predetermined length) [cutting step], the sized resin material 83 and the fibrous resin material 82c having passed through the cutting step.
Is subjected to wind sorting, and the sizing resin material 83 and the fibrous resin material 8
An example of recovering the resin material materialized from the thermoplastic resin molded article 81 by recovering each of the 2c as a materialized material [wind power sorting process] will be described. One or both of the [step] and the [cutting step] can be omitted depending on the type of the thermoplastic resin molded article 81 to be processed and other various processing conditions and the like. Step] can be performed as needed.

[Processing object] The thermoplastic resin molded article to be recovered in the present invention is a thermoplastic resin molded article comprising a base layer and a fiber layer. For example, resin fibers are raised on one side of the base layer. In the process of manufacturing floor carpets, floor mats, etc., which are laid in the interior of an automobile, which has been formed into a fibrous layer by sticking in a shape, scraps generated when cut into a predetermined shape, recovered from discarded automobiles The floor carpet, floor mat, and the like are to be processed.

The base layer is made of a thermoplastic material such as PP, filler-filled EVA, olefin rubber, PE or the like, and the fiber layer is made of a thermoplastic resin fiber such as nylon fiber, PP fiber, polyester fiber or the like. Are formed of resin materials having different materials.

Table 1 shows examples of floor carpets and floor mat materials used as interior materials for automobiles as examples of thermoplastic resin molded articles to be treated according to the present invention.

[0023]

Before being subjected to the [crushing step] to be described later, the thermoplastic resin molded article to be treated is separated according to the type and material of the thermoplastic resin molded article as necessary. ], The following processing of the present invention is preferably performed.

The thermoplastic resin molded article to be treated is not limited to the one shown in FIGS. 7 (a) and 7 (b). For example, a resin fiber is directly implanted in a base material layer. ,
Various types of resin molded articles having a base material layer and a resin layer, such as those having a base material layer composed of multiple layers, can be treated.

[Crushing Step] The thermoplastic resin molded article 81 to be processed is separated as required, and then crushed in the crushing step to form small pieces to be processed having an appropriate size.

In FIG. 1, a thermoplastic resin molded product to be treated is a square having a long side or a long diameter of about 3 to 8 mm by a known crushing means (for example, in this embodiment, referred to as a "cutter mill" for convenience). Crushed into irregular small pieces such as square, triangle, trapezoid, rhombus, etc.
Get.

In the present embodiment, the resin molded article to be treated is roughly crushed by a cutter mill to about 10 to 20 mm, and then further introduced into a cutter mill to be crushed to 3 to 8 mm to obtain a small piece 82 to be treated. However, the crushing step may be performed, for example, in a single operation, or may be performed using two or more cutter mills.

The thermoplastic resin molded article 81 crushed in the crushing step by the cutter mill as shown in FIG.
As shown in FIG. 7A and FIG. 7B, a fiber layer 262 made of a resin fiber is provided on one side surface of the base material layer 260, and when the thermoplastic resin molded product 81 is crushed by the cutter mill 120 to the aforementioned size, The fibers constituting the fiber layer 262 are partially separated from the base material layer 260 or separated by cutting or the like, and the separated or separated fibers (fibrous resin material 82c) may be used as a single fiber or a plurality of fibers. The fibers to be treated 8 are in a state where the fibers of
Mixed in 2.

The small piece 82 to be processed comprising the crushed base material layer 260 was also formed by the small piece 82a leaving the fiber layer 262 on the surface and the crushed base material layer 260 after the fiber layer 262 was peeled off. Various states such as the small piece 82b are mixed.

However, the amount of the fibrous resin material generated depends on the type of the thermoplastic resin molded article to be treated, for example, the length of the resin fibers forming the fiber layer, and the size of the small pieces to be treated formed in the crushing step. Are different.

It should be noted that, in the present specification, the "piece to be processed" is referred to as the "piece to be processed" without particular notice.
2b and the fibrous resin material 82c produced by the crushing step mixed with the small pieces 82a and 82b.

FIG. 2 shows a cutter mill 1 as an example of the crushing means.
20 is shown. Reference numeral 121 denotes a cutter mill main body, which is a cylindrical casing having an input port 123 on the upper surface. A cutter support 124 which is rotatably supported by the cutter mill main body 121 and vertically rotated by rotation driving means (not shown) is provided in the cutter mill main body 121. Are provided on the outer periphery of the cutter support 124 so as to provide four horizontally long rotary blades 125 so as to form an equal angle of 90 degrees in the rotation direction of the cutter support 124, and the cutting edges of these four rotary blades 125 are provided. They are located on the same rotation locus. Further, the two fixed blades 126 are fixed to the cutter mill main body 121 at a position substantially symmetrical to the rotation locus of the cutting edge of the rotary blade 125 with a small gap between the rotation locus of the cutting edge of the four rotary blades 125. The inside of the cutter mill main body 121 is divided by the fixed blade 126, the cutter support member 124, and the rotary blade 125 to form a charging chamber 127 and a crushing chamber 128. The charging port 123 communicates with the charging chamber 127. The clearance between the second fixed blade 126 and the rotary blade 125 can be freely adjusted so that the object to be crushed can be cut into a desired size or, in a broad sense, crushed. The clearance of this embodiment is 0.
2 to 0.3 mm. The crushing chamber 128 is divided by the mesh screen 129 so as to surround the two fixed blades 126 around the rotation locus of the rotary blade 125. In this embodiment, the screen 129 is made of a punching metal in which holes having a diameter of 20 mm are formed at the time of coarse crushing and countless 5 mm at the time of crushing. Further, an outlet 131 for discharging the small piece to be processed 82 is provided below the crushing chamber 128.

In the above-mentioned cutter mill 120, the thermoplastic resin molded article 81 is introduced from the introduction port 123, and the cutter support 12 is rotated by a rotation driving means (power 5.5 KW) (not shown).
4 is rotated at 800 rpm.
The shape and area of the rotary blade 125 and the fixed blade 126 of the cutter support 124 through the screen 129 are undefined, but a punching metal having a diameter of 20 mm is formed on the screen 129.
When used as long side or long diameter is 10-20
rectangles such as rectangles or squares of about mm or less,
Or, it is crushed into irregular small pieces such as a triangle, a trapezoid, and a rhombus, and is discharged from the discharge port 131.

The small pieces thus obtained are further introduced into a cutter mill 120 using a punching metal having a hole of 5 mm in diameter as a screen 129, and the same operation is repeated to make the long side or long diameter 3 to 8 mm. A rectangular piece, such as a rectangle or a square, or an irregular shaped piece 82 such as a triangle, a trapezoid, a rhombus, or the like, having a size smaller than the size is discharged from the discharge port 131.

The crushing means is not limited to the above-mentioned cutter mill. For example, various mono-cutters, shredders such as Gainax Crusher manufactured by Horai Co., Ltd., or Roll Crusher manufactured by Nara Machinery Co., Ltd. A "crusher" such as a crusher can be used, and the cutter mill 120 can be used in combination with the "crusher". `` Crusher '' is, for example, provided in parallel two axes rotating inward each other in a crusher body having an input port of the crushed object in the upper part, while providing a plurality of rotating blades at a predetermined interval on each axis, Provided to cut the object to be crushed into crushed pieces composed of appropriately large pieces by three claw blades which are meshed with each other on the outer periphery of each rotary blade of the shaft and project from the outer peripheral surface of each rotary blade so as to form an equal angle. Have been. The crushed material introduced from the upper inlet is drawn into the inside by the claw blades of the biaxial rotating blades rotating inward to each other, and continuously between the outer peripheral edges of the rotating blades rotating in a meshed state. It is crushed and cut by the compressing force that acts at the time of retraction while slitting with the acting cutting force, and crushed pieces are formed. The crushed pieces pass through a screen provided below the biaxial rotary blade and are discharged from a discharge port.

[Preliminary Wind Separation Step] This step is performed when the fibrous layer 262 is separated or separated from the base layer 260 when the thermoplastic resin molded article 81 to be treated is crushed in the crushing step. This is a step in which the resin material 82c is selected from the small pieces 82a and 82b and separately collected, and the type of the thermoplastic resin molded article 81 to be processed is selected.
In the case where the fibrous resin material 82c is little generated due to various conditions such as the size of the small pieces 82a and 82b formed in the crushing step, this step can be omitted.

As described above, when the thermoplastic resin molded article 81 is crushed into small pieces 82 by the crushing step, as shown in FIG.
As shown in the figure, in the small piece to be treated 82, a small piece 82a having a fiber layer 262 left on its surface, a small piece 82b composed of a base material layer 260 from which the fiber layer 262 has been peeled or separated, A fibrous resin material 82c in which the fiber layer 262 separated or separated from the layer 260 is flocculated in a state where a single fiber or a plurality of fibers are intertwined with each other.
Are mixed.

When a large amount of the fibrous resin material 83c generated as described above is mixed, the small pieces 82a and 82b are used in the [separation, separation and sizing step] described later.
Is applied to the fibrous resin material 8.
2c, the fibrous resin material 82 generated in the crushing step in this step
This is to improve and improve the working efficiency in the subsequent steps (separation, separation and sizing steps).

Therefore, in the present step, the fibrous resin material 82 does not necessarily have to be completely sorted and recovered, and is removed to such an extent that the work efficiency of the following [peeling / separation / granulation step] is not reduced. Just do it. In addition, as described above, when the amount of the fibrous resin material 82c generated in the crushing step is small due to the material to be treated or the like, an amount that reduces the workability of [separation, classification, and sorting step] described below is used. If there is no such step, this step can be omitted as appropriate.

As described above, the means used in the book [preliminary wind sorting step] for sorting and recovering the fibrous resin material 82c in the small piece 82 to be treated is, for example, a cyclone 31 as shown in FIG. Can be used.

The wind separator 30 is a suction-type wind separator, which sucks the small piece 82 obtained through the crushing step as described above, introduces the small piece 82 into the cyclone 31, and compares the small piece 82 with the small piece 82. Pieces 82a, 82 with high initial falling speed
The b is collected at the bottom of the cyclone 31, and the fibrous resin material 82c having a relatively slow falling speed is separated and collected from the small pieces 82a and 82b sucked by the blower 33.

In this step, the fibrous resin material 82
The means used for sorting and collecting c is not limited to the above-mentioned wind sorter, but any means can be used as long as it can sort the small pieces 82a and 82b and the fibrous resin material 82c by wind force. it can. For example, sieve mesh 10 × 10
While the small pieces 82 to be processed are sieved with a sieve of about mm, the fibrous resin material 82c is also sorted by blowing a wind having a wind speed of about 6 m / s onto the small pieces 82 to be processed which have been dropped. The method and apparatus are not limited to those described above. For example, a method may be adopted in which the small pieces 82 to be processed, which have been scooped up by stirring blades or the like, are blown to separate the pieces according to the difference in the drop position.

[Peeling / Separation / Granulation Step] In this step, a small piece 82 obtained by crushing the thermoplastic resin molded article 81 by the above-mentioned [crushing step] or the [pre-crushing step] after the [crushing step] Wind sorting step], an impact grinding force is applied to the small piece 82 composed of the small pieces 82a and 82b from which the fibrous resin material 82c generated in the crushing step has been removed in the crushing step. The fibrous layer 262 combined with the small piece 82 to be processed is separated or peeled off by a force, and the resin material forming the base layer 260 and the fibrous resin material 82c formed by unraveling the separated or peeled fiber layer 262 are formed. And the fibrous layer 262 is separated or separated by the frictional heat generated when the impact grinding force is applied.
In this step, the 60 small pieces are formed into a sized resin material 83 that has been sized to, for example, a spherical shape.

FIG. 6 shows an example of the configuration of an entire apparatus including the peeling / separating / granulating means used in the present invention (referred to as a “separator” in this embodiment for convenience).

Referring to FIG. 6, first, the overall outline of the separator 130 will be described. The separator 130 has a supply inlet 132 into which the small pieces 82 to be treated are introduced. Outlet 153 for taking out the sized resin material 83 formed by peeling the fiber layer 262 from the small piece 82 to be processed
And a fibrous resin material 82c separated and pulverized from the sized resin material 83 and a discharge port 152 for discharging dust and the like generated by shaving the surface of the small piece 82 to be processed by impact grinding force.
And

The small pieces 82 processed in the previous step are supplied to the supply inlet 132 through the supply pipe 231. The outlet 153 is connected to the supply port 132 by the communication pipe 23.
5, and a pipe 236 from a compressed air supply source (not shown) is connected to the outlet side of the communication pipe 235. A flow straightening plate is provided at a communication portion of the pipe 236 so that compressed air mainly flows to the supply inlet 132 side.
A branch pipe 237 is provided for branching the communication pipe 235 and communicating with the recovery tank 240 for the recovered resin material 83a. A three-way solenoid valve 238 which is switched at predetermined intervals by a timer circuit at a branch point of the branch pipe 237 is provided. Is provided.
On the other hand, the discharge port 152 communicates with the collection tank 250 through a discharge pipe 239, and the synthetic paper 84 having the coating film 83 b discharged from the discharge port 152 and the dust are blower 157.
Is sucked into the discharge pipe 239 interposed therebetween, and is collected in the collection tank 250.

3 to 5, the internal structure of the separator 130 will be described.
Reference numeral 2 denotes an opening communicating with the center of the fixed disk 131, a fixed end plate 133 is opposed to the fixed disk 131 with a processing space 155 therebetween, and the outer peripheral edge of the fixed end plate 133 is fixed to the peripheral plate by the fixed disk 131. Fix at 135. In the processing space 155, there is provided a workable disk 141 which is rotationally driven by a rotating horizontal shaft 142.
143. The rotating horizontal shaft 142
Is rotationally driven by a rotational driving means such as a motor 161.

On the fixed disk 131, identification pins 134 are sequentially implanted on a plurality of concentric circles (relative to the movable disk 141) on rotation trajectories a1 to a6 (FIG. 5). On the other hand, on the movable disk 141, workable pins 144 that are alternately inserted between the rotation trajectories of the fixed pins 134 on the multiple laid rotation trajectories b1 to b6 different from the fixed pins 134 are sequentially planted. The fixed and movable pins 134 and 144 are arranged so that the fiber layer 262 on the surface of the small piece 82 to be treated can be separated or separated by the impact milling force between the fixed and movable pins 134 and 144.

More specifically, the number of the fixed pins 134 is 16 on the rotation trajectory a1 near the center of the fixed disk 131.
The rotation locus a located on the outer peripheral side of the rotation locus a1
24, 24 on the rotation trajectory a4, 40 on the rotation trajectory 5, and 42 on the rotation trajectory a6. Have been. On the other hand, the number of the movable pins 144 is 4 on the rotation locus b1 near the center of the movable disk 141.
The rotation locus b located on the outer peripheral side of the rotation locus b1
2, four rotation trajectories b3, four rotation trajectories b4, and four rotation trajectories sequentially located toward the outer peripheral side
Four are planted on the b5 and six are planted on the rotation locus b6.

In practice, the fixed and movable pins 134, 1
By increasing the clearance between each other, the grinding force applied to the small piece to be processed 82 is reduced, and by reducing the clearance, the grinding force is increased.

Further, in FIG. 3, a discharge gap 15 is provided on the outer peripheral side of the movable disk 141 and on the inner peripheral side of the peripheral side plate 135.
A screen 151 having a predetermined mesh formed by punching pores having a diameter of 1.2 to 1.7 mm is provided around the screen 6, and a discharge port 152 is provided below the discharge space 156. In this embodiment, the screen 151 is preferably a mesh having a diameter of 1.5 mm.

The screen 151 of the processing query 155
An outlet 153 is provided in the lower part of the
Reference numeral 3 denotes a collection tank 240 for communicating with the supply inlet 132 via the communication pipe 235 as described above, and for collecting the resin material collected via the branch pipe 237 which branches off the supply inlet side of the communication pipe 235. In communication with As another example, a plug valve for opening and closing control is provided in the outlet 153, and the outlet 153 is supplied and supplied through a blower 158 that sucks air in the separator 130 as shown in FIG. It can also communicate with the mouth 132.

Therefore, in the separator 130 described above, when the rotating horizontal shaft 142 is rotated by the rotation driving means of the motor 161 to rotate the movable disk 141 and supply the small pieces 82 to be supplied to the supply inlet 132, The small piece 82 is located at the center of the processing space 155 and has fixed and movable pins 13.
4,144 by the impact attrition force
2 is beaten by the impact of the fixed and movable pins 134 and 144, and the resin fibers forming the fiber layer 262 on the surface are finely crushed and separated from the surface of the small piece 82 to be processed, thereby forming the fibrous resin material 82c. The surface of a part of the resin material base of the small piece to be processed 82 is shaved by the application of the impact crushing force, and is peeled off together with the fiber layer 262.

Each of the small pieces 82 to be processed by the impact grinding force
The frictional heat from the above increases the temperature of the small piece 82 to be processed, and further facilitates the peeling of the fiber layer 262 from the surface of the small piece 82 to be processed. That is, the temperature of the small piece 82a that leaves the fiber layer 262 on the surface increases due to frictional heat, so that the small piece 82a having the fiber layer 262 is softened. In this state, the small piece 82a is repeatedly beaten by the impact of the impact grinding force. Crushed and peeled even faster.

Of the fibrous resin material 82c separated from the small piece 82 to be processed, the one existing in the state of a single fiber and the resin material scraped off from the base material layer 260 of each of the small pieces 82a and 82b are each a movable pin. After passing through the screen 151 by the centrifugal action of 144 and being classified into the discharge space 156, it is sucked and discharged from the discharge port 152 to the outside through the blower 157 (FIG. 6).

In this embodiment, as for the blower 157, 5.5 kw, 5 kg / cm ² / pressure,
m ³ / min, 3.7kw for medium size machine, 3kg / cm ² / pressure 1
A fibrous resin material 82c which is separated from the small piece 82 to be treated at a rate of ~ 1.5 m ³ / min and exists as a single fiber;
The dusty resin material scraped off from
It sucks in with the air in 30.

On the other hand, among the fibrous resin material 82c and the fibrous resin material 82c, a plurality of fibers that are entangled and flocculated in a cotton-like size that does not pass through the screen 151 are inside the screen 151. Stay in. Small pieces 82a having a fiber layer 262 attached to the surface thereof are still mixed in the sized resin material 83. However, since the outlet 53 and the supply inlet 132 communicate with each other via the communication pipe 235, the small piece 82 to be processed and the recovered resin material 83a taken out from the outlet 153 are supplied to the supply inlet 1
Then, the fiber layer 262 attached to the surface of the small piece 82 to be treated is peeled off from the small piece 82 to be treated, and the base material layer 260 has a particle diameter of 3 mm. From about 4 mm to a granular sized resin material 83. Further, the fiber layer 262 peeled from the base layer 260 is crushed into a fibrous resin material 83a having a length of about 1 mm to 7 mm, and a single fiber and a plurality of fibers are mixed in a flocculated state. . Of these, the fibrous resin material 82c in a single fiber state is further subjected to a pulverizing action, passes through the screen 151, and is discharged by the blower 157 to the discharge port 15c.
2 to the outside. Although the sizing resin material 83 is refluxed, most of the sizing resin material 83 remains in the screen 151 without being pulverized so finely as to pass through the screen 151. Further, the fibrous resin material 82c flocculated in a flocculent form
It is subject to attrition, but not completely attrited.
It remains in 51. The above-described peeling / separating / sizing process can be repeated a plurality of times as necessary until the fiber layer 262 of the small pieces 82 to be treated in one batch is almost separated from the base material layer 260.

The above separator 130 is rotated by the rotation driving means 1
61, the downstream side of the communication pipe 235 is opened by a three-way solenoid valve 238 and the branch pipe 237 side is closed,
By supplying the compressed air from the pipe 236 to the communication pipe 235, the compressed air generates an airflow that circulates from the communication pipe 235 to the supply inlet 132, the processing space 155, the outlet 153, and again to the communication pipe 235. When each piece 82 to be processed of one batch is supplied to the supply inlet 132 through the supply pipe 231, the piece 8 to be processed is processed in the separator 130 and is processed.
Of the fibrous resin material 82c generated from the fiber layer 262 peeled off from the surface of No. 2, the one in a single fiber state passes through the screen 151 and is blown by the blower 157 to the collection tank 2.
The sizing resin material 83 or the fibrous resin material 82c left in the screen 151 is sucked into the communication pipe 235 by the circulating airflow and fed again to the processing space 155 to be processed in the separator 130. This series of steps is repeated a plurality of times as necessary until most of the fiber layers 262 in one batch are separated and removed. Next, after the above processing is completed, the downstream side of the communication pipe 235 is closed with a three-way solenoid valve 238 and the branch pipe side is opened, so that the sized resin material 83 or the sized resin left in the screen 151 is left. Of the material 83 and the fibrous resin material 82c, the flocculated one is collected from the communication pipe 235 to the collection tank 240 via the branch pipe 237.

Note that, instead of the three-way solenoid valve 238, a solenoid valve for opening and closing the branch pipe 237 and the communication pipe 2
An electromagnetic valve that opens and closes the downstream side of 35 may be provided, and these two electromagnetic valves may be alternately opened and closed.

[Cutting Process of Fibrous Resin Material]
In the [peeling / separation / granulation process] screen 15
1 is cut by the same crushing means as in the above-mentioned [crushing step]. When the above-mentioned cutter mill is used, the mesh diameter of the screen 129 is 4 to 10 mm. And

Of the fibrous resin material 82c recovered through the aforementioned [peeling / separation / granulation process], the screen 15
The fibrous resin material remaining in 1 is 1 to 7 when viewed for each single fiber.
However, when a grinding impact force is applied by the [separation, classification, and sizing step], the fibrous resin material 82c is recovered as a state in which a plurality of fibers are entangled and flocculated. Is done. When the sized resin material 83 is mixed in the agglomerated fibrous resin material 82c, it is difficult to remove and collect the sized resin material 83 from the agglomerated fibrous resin material 82c. From
The agglomerated fibrous resin material is cut into a size of about 4 to 10 mm so that the internal sized resin material can be easily taken out, and subsequent sorting and collection can be facilitated. Therefore, if the fiber aggregation does not make the subsequent sorting difficult, such as when the fiber length of the fibrous resin material collected through the [peeling / separation / granulation step] of the previous step is short, this step is performed. Can be omitted.

As described above, when the recovered fibrous resin material is put into the cutter mill 120 provided with the screen 129 having a mesh diameter of 4 to 10 mm, the fibrous resin material 82c which has flocculated in a floc shape is finely cut. However, the sized resin material 83 sized to a particle size of about 3 mm passes through the screen 129 almost without being cut.

The fibrous resin material 82c cut in this manner is less likely to be entangled thereafter, and the sized resin material 83 mixed in the entangled flocculent fibrous resin material 82c is easily taken out. [Wind sorting process] described later
The efficiency at the time of selection by the method is improved, and the purity of each resin material that can be recovered is improved.

[Wind sorting step] As described above, the fibrous resin material recovered through the [peeling / separation / granulation step] or the [peeling / separation / granulation step] and further through the [cutting step] 82c and the sized resin material 83 are subjected to the present [wind sorting process] to be separated into the fibrous resin material 82c and the sized resin material 83, and are separately collected.

In the wind separation process, the fibrous resin material 82c and the sized resin material 8 collected through the above-described process are used.
3 are separated by the wind force and collected separately according to the difference in the falling speed, and the collected fibrous resin material and the sized resin material become the collected resin materials. The fibrous resin material remaining in the sized resin material collected through this step is 0.1 wt% or less based on the sized resin material.

As the wind separator used in this step, the same wind separator as that used in the aforementioned [preliminary wind separator step] can be used. In addition, it is also possible to perform the wind separation using the above-described sieve in the same manner as in the [preliminary wind separation step]. A screen having a large sieve of about 3.2 × 3.2 mm is used, and a wind speed of about 3 m / s is used for sorting.

[Embodiment] An embodiment in which a sized resin material and a fibrous resin material are collected by the method of the present invention for a floor carpet for automotive interiors, which is a thermoplastic resin molded article, will be described.

The floor carpet to be treated is made of a PE layer on a base material 260 made of EVA filled with a filler.
The fiber layer 262 is formed by implanting T fibers, and has a cross-sectional structure shown in FIG.

The contents of the floor carpet to be processed are as shown in Table 2.

[0071]

[Table 2]

Fifty kilograms (cut pieces) generated during the production of the floor carpet having the above-mentioned contents are roughly crushed into small pieces of about 50 mm on a side by a cutter mill, and the crushed small pieces are cut by a cutter mill on one side. The pieces were crushed into small pieces of about 5 mm.

In the small pieces to be treated after the crushing, fibrous resin materials generated during the crushing are mixed, and the small pieces in which the fibrous resin materials are mixed are subjected to preliminary wind separation. .

This wind sorter is a suction type wind sorter capable of processing objects of 20 to 50 kg / h. The wind sorter removes fibrous resin material mixed in small pieces to be treated at 6 m / s.
It was removed by suction at the wind speed.

In this manner, 43 kg of the small pieces from which the fibrous resin material had been removed were put into a separator rotating at 50 Hz and 940 rpm, and subjected to impact grinding for about 3 minutes.

By the application of the grinding impact, the EVA filled with the filler forming the base material layer and the PET fiber forming the fiber layer are peeled off or separated, and the EVA filled with the filler forming the base material layer is crushed. The particle size is adjusted to about 3 mm by frictional heat due to the impact force to obtain a sized resin material. Also, PE
The T fiber is separated as a fibrous resin material in a state in which a single fiber or a plurality of fibers are entangled and flocculated. The separator clearance was 16 mm, the charging speed was 5.28 kg / min, the charging time was 21.8 sec, and the processing time was 18
0 to 300 sec and discharge time 40 sec.

The single fibers of the sieved resin material and the fibrous resin material thus separated are subjected to the pulverizing action of the separator 130, and the sieved resin material is partially dusted. Further, the finely crushed single fiber passes through the screen 151 and is discharged to the outside from the discharge port 152 by the blower 157. On the other hand, the communication pipe 235
The downstream side of the screen is closed by a three-way solenoid valve 238 and the branch pipe side is opened, so that the sized resin material and the aggregated fibrous resin material remaining in the screen 151 can be communicated with the communication pipe 235.
From the collecting tank 240 through the branch pipe 237.
In this step, the total amount of the single fibers collected through the screen and the dust of the crushed sized resin material is 19.7.
kg, a total of 23.3 kg of a flocculent fibrous resin material and a sized resin material were collected.

In this embodiment, the above-mentioned [peeling / separation /
Granulating step), the fiber length of the fibrous resin material obtained through the process is short, and the fibers are not agglomerated to such an extent that the wind separation becomes difficult. Sorting process].

The wind separator used in this [wind separator process] uses the same wind separator as that used in the above [preliminary wind separator process], and has a wind speed of 3.
Wind separation was performed at 1 m / s. The fibrous resin material was suctioned by this wind separator, separated from the sized resin material, and collected separately.

In this way, 22.4 kg of the sized resin material having a particle diameter of about 3 mm and 0.9 g of the flocculent fibrous resin material were used.
kg was recovered. There was almost no adhesion or mixing of the fibrous resin material in the recovered sized resin material. Further, the following measurement was performed to measure the mixing ratio of the slightly mixed fibrous resin material.

Sample 100 was collected from the collected sized resin material.
g, and confirm this sample with a 30-fold loupe.
The fibrous resin material still mixed in the sized resin material was selected.

As a result of measuring the weight of each of the sized resin material and the fibrous resin material thus selected, the amount of the fibrous resin material contained in 100 g of the sample was 0.01 g.

From the above results, the amount of the fibrous resin material mixed in the recovered sized resin material is about 0.01% by weight, and high-purity EVA resin (containing filler) is recovered as the sized resin material. Was completed.

[Production Example of Carpet Base Material] Next, a carpet base material made from the sized resin material recovered by the above-described method and apparatus will be described.

The base material of this carpet is a composite of a raised fiber layer formed on the surface thereof to form a carpet used as, for example, an interior part of an automobile.
The sized resin material is a material obtained by converting a base material layer of a thermoplastic resin molded article (carpet) to be treated into a material, and is collected. The material is formed as it is or after re-pelletization, by itself or mixed with a virgin resin material, and the material is melted and extruded by, for example, a T-die.

The sized resin material and the virgin resin material can be mixed with a virgin resin material at a ratio of 95 to 5 wt% with respect to 5 to 100 wt% of the sized resin material. Not only can be mixed in a large amount, but also the carpet base material can be manufactured using only the sized resin material as a raw material. Is possible.

In the present embodiment, only the sized resin material collected by the above-mentioned method is used as a raw material for a resin molded product (carpet) in which EVA mixed with calcium carbonate as a filler is used as a base material layer. This sized resin material was extruded from a T-die and regenerated as a carpet base material.

The base material of the carpet formed as described above was evaluated by the following test. As a test example, a needle punch carpet having a polyester pile of 400 g / m ² as a fiber layer and a resin molded product having a base layer layer weight of 1000 g / m ² were used as test pieces.

The comparative example is a virgin EVA mixed with calcium carbonate as a filler, and other conditions are the same as those of the carpet substrate of the present invention.

[0090]

[Table 3]

In the above test, the following samples were used.

Fiber layer: Needle punched carpet with 400 g / m ² of polyester Base layer: Example of the present application / 100% by weight of separated resin of the present application 1000 g / m ² Comparative example / 100% by weight of virgin resin 1000 g / m ² The conditions in each test are as follows. Is as follows.

Tensile strength test: 150 mm long x 100 mm wide
Test speed 200mm / min Tear strength test: 150mm long x 50mm wide, 50 in length direction
(See Fig. 8) Heat shrinkage test: 250 mm long x 250 mm wide test piece
Heating at 0 ° C. for 5 hours As a result, the base material of the carpet manufactured using the sized resin material recovered by the above-described method and apparatus was compared with the base material of the carpet manufactured using the virgin resin material. Even if the carpet base material is manufactured using only the recycled material as the raw material, the base material of the carpet has substantially the same performance as the base material of the carpet manufactured with the virgin resin material. Could be obtained.

Therefore, it is possible to improve the ratio of the recycled material reused as a raw material without deteriorating the performance of the base material of the carpet, and to improve the utilization efficiency of the recycled material, thereby more effectively reducing the edge of the carpet. Reuse of materials and waste materials can be promoted.

The base material of the above-mentioned carpet can be suitably used as a carpet, for example, by forming resin fibers on one side thereof in a raised manner to form a fiber layer.

[0096]

According to the method and the apparatus of the present invention described above, according to the method and the apparatus of the present invention, a resin molded article composed of a base material layer and a fiber layer made of different materials can be suitably separated for each layer. Thus, the base material layer and the fiber layer could be separately recovered as raw resin materials.

Therefore, the resin material thus recovered is used as a raw material for producing various thermoplastic resin molded articles by reusing the same, for example, a carpet having the same constitution as that to be treated in the present invention. It can be used as a raw material or the like when producing a base material layer.

The sized resin material recovered by the above method and apparatus is composed of a base material layer in which the fiber layer is almost completely separated, so that the sized resin material recovered at a very high rate in the raw material is obtained. Granular resin material can be mixed in, and the recovered sized resin material alone can be recycled into carpet base material as a raw material, improving the utilization rate of recycled material and effectively recycling carpet offcuts and waste materials. Could be used.

Further, the performance of the carpet base material obtained from the sized resin material is comparable to that of the carpet base material manufactured from the virgin resin material. Was.

[Brief description of the drawings]

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an explanatory diagram of a series of processing steps showing in principle and schematically an outline of a case where a method of a basic embodiment of a method for collecting a thermoplastic resin molded article which is an example of a processing object of the present invention is applied. It is.

FIG. 2 is an overall perspective view showing a main part of a cutter mill (crushing means) used in the embodiment of the present invention.

FIG. 3 shows a separator (peeling / separation) used in an embodiment of the present invention.
It is a front view which shows the principal part of (separation / sizing means).

FIG. 4 is a plan view of FIG. 3;

FIG. 5 is a cross-sectional view of a main part taken along line VV in FIG. 3;

FIG. 6 shows a separator (peeling / separation) used in an embodiment of the present invention.
FIG. 2 is an overall perspective view of each device communicating with the separator (separation / granulation means).

FIGS. 7A and 7B are enlarged cross-sectional views of a thermoplastic resin molded article to be processed in an example of the present invention, wherein FIG. 7A is a tuft carpet and FIG. 7B is a needle punch carpet.

FIG. 8 is an explanatory view of a test piece used for a tear test.

[Explanation of symbols]

 Reference Signs List 30 wind separator (wind separator) 31 cyclone 33 blower 81 thermoplastic resin molded article 82 small piece to be treated 82a small piece (containing base material layer and fiber layer) 82b small piece (comprising base material layer) 82c fibrous resin Material 83 Sizing resin material 120 Cutter mill (crushing means) 121 Input roller 124 Cutter support 125 Rotary blade 126 Fixed blade 127 Input chamber 128 Screen 130 Separator (peeling / separation / size control means) 131 Fixed disk 132 Supply / input roller 133 Fixed End plate 134 Fixed pin 135 Peripheral side plate 141 Movable disk 142 Rotating horizontal shaft 143 Bearing 144 Movable pin 151 Screen 152 Outlet 153 Outlet 155 Processing space 156 Discharge space 157 Blower 158 Blower 161 Motor 231 Supply pipe 237 Pipe connectionBranch pipes 238 three-way solenoid valve 239 discharge pipe 240 recovery tank 250 collecting tank 260 base layer 262 fiber layer 263 resin fibers 264 base fabric

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Makoto Tokawachi 1-1 Shimo-Inaba, Kitakawa-cho, Kisogawa-cho, Hagiri-gun, Aichi Prefecture 1-1 F-term in Toyota Kako Co., Ltd. (Reference) 4D004 AA07 BA07 CA04 CA08 CA14 CB13 4F301 AA13 AA25 AA20 AA25 AA27 BA21 BA29 BD05 BE29 BF05 BF09 BF15 BF25 BF32

Claims (9)

[Claims] 1. A crushing step of crushing a thermoplastic resin molded product having a base material layer and a fiber layer into a plurality of small pieces to be processed, and crushing each of the crushed individual processed products. An impact-milling force is applied to the small pieces to separate or separate the fiber layer from the base material layer of the small piece to be treated to obtain a fibrous resin material, and the resin material forming the base material layer is adjusted to a granular state. A separation / separation / grain sizing step to form a granulated sizing resin material with the sizing resin material; and a wind separation step for separating and collecting the sizing resin material and the fibrous resin material by wind force according to a difference in falling speed. A method for recovering a thermoplastic resin molded product, comprising: 2. A process for selecting and recovering from the small pieces to be treated by wind force before introducing the fiber layer separated or separated from the base material layer in the crushing step to the separating, separating and sizing step. The method for recovering a thermoplastic resin molded product according to claim 1, wherein: 3. The thermoplastic resin according to claim 1, wherein the fibrous resin material obtained in the peeling / separating / granulating step is cut into a predetermined length and then subjected to a wind separation step. How to collect molded products. 4. The process according to claim 1, wherein, in the crushing step, after the resin material to be treated is crushed, the small pieces obtained by the crushing are further finely crushed into small pieces to be treated. The method for recovering a thermoplastic resin molded product according to the above item. 5. A crushing means for processing a thermoplastic resin molded product including a base material layer and a fiber layer, and crushing the thermoplastic resin molded product into a plurality of small pieces to be processed; A fixed-side peeling / separating / granulating means in which each fixed pin is sequentially implanted on a plurality of rotation trajectories on a fixed disk communicating with the central portion thereof, and rotatably driven in opposition to the fixed disk. A movable-side peeling / separating / granulating means on the movable disk provided, on which a plurality of movable pins are sequentially implanted on a plurality of rotation trajectories different from the fixed pins, and an outlet for taking out the crushed small pieces to be treated And a take-out means for taking out the fibrous resin material between each of the fixed pins and each of the movable pins, by peeling or separating the fiber layer from the base material layer by grinding the small pieces to be treated by impact grinding force. And sizing the base material layer to a granular state to form a sizing resin material. Peeling
Separation and sizing means; and a sizing resin material and a fibrous resin material, which are separated by wind force, and a wind force sorting means for individually collecting the separated resin materials by this sorting. apparatus. 6. A means for selecting and collecting a fiber layer separated or separated from a substrate layer in the crushing step by a wind force from a piece to be treated before introducing the fiber layer to the separating / separating / sizing means. The thermoplastic resin molded product recovery device according to claim 5, characterized in that: 7. The recovery of a thermoplastic resin molded product according to claim 5, further comprising means for cutting the fibrous resin material obtained by the peeling, separating and sizing means into a predetermined length. Method. 8. A carpet base material in which a fiber layer is composited to form a carpet, wherein the sized resin material recovered by the method according to any one of claims 1 to 4 is melted, extruded and molded. Carpet base material. 9. The carpet substrate according to claim 8, wherein a virgin resin material is mixed into the sized resin material.