JP2006297626A - Recycling method of carpet, pile yarn drawing-out device and adhesive layer separating device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a recycling method of a carpet capable of separating loop-like pile yarns from a base fabric as long fibers, and a device used in this method. <P>SOLUTION: The recycling method of the carpet comprising the base fabric 3, the loop-like pile yarns 2 planted on the base fabric 3, a backing layer 5 and the adhesive layer 4 for bonding the backing layer 5 and the base fabric 3 comprises: a backing layer removing process for removing the backing layer from the carpet to obtain a laminate 12 equipped with the base fabric 3, the pile yarns 2 and the adhesive layer 4; and a pile yarn drawing-out process for individually gripping one end part 12e and other end part 12f of the laminate 12 and applying tension on the laminate 12 so as to relatively separate one end part 12e and other end part 12f to draw the pile yarns 2 out of the laminate 12. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  In the present invention, it is difficult to recycle the composite fiber products discharged as waste. For example, composite carpets such as tile carpets, dust control mats, roll carpets, and jutans, that is, loop pile yarns are planted. The present invention relates to a method and an apparatus for recycling a composite rug in which a planted base fabric and a backing layer formed of a resin, rubber, fiber, or the like are bonded by an adhesive layer.

  Conventionally, general waste fibers, such as old clothes and curtains, are diverted into felt by a repelling machine, a web card machine, etc., and are preferably recycled. On the other hand, for composite rugs, since the base fabric and the backing layer are fixed by an adhesive, the repelling technique cannot be used, and the pile yarn is mostly used for incineration or landfill together with the backing layer. is there.

  Therefore, Patent Document 1 proposes a method for separating and collecting pile yarns by slicing the pile yarns in a plane direction with a scraper knife or the like for a composite rug made of a laminate of at least two kinds of materials such as tile carpets. .

  However, since only a part of the pile yarn is sliced in this method, the root portion and the base fabric of the pile yarn embedded in the backing layer remain on the backing layer side, and the recovery rate decreases. Further, since the recovered fiber is a short fiber and its use is limited, it is difficult to circulate and recycle from fiber to fiber.

  In Patent Document 2, as an easy-to-separate manufacturing method based on the premise of recycling, the softening temperature of the adhesive layer is set lower than the softening temperature of the backing layer, and the surface mat original fabric (pile yarn + At the time of collecting and separating the base fabric), it has been proposed to easily separate the mat original fabric from the backing layer by heating and softening the adhesive layer.

  However, this method is subject to the use of a resin having a softening temperature difference, and has a disadvantage that the range of selection of the resin is relatively small and the resin itself is expensive.

  Furthermore, in Patent Document 3, a method of repeatedly cutting a pile yarn and a backing layer together and then performing shearing pulverization is repeated, and then a method of separating the resin and fiber using an air classifier or the like. Has proposed.

However, this method not only makes it difficult to completely separate the pile yarn and the backing layer, but also unavoidably shortens the fiber, and there is a concern about an increase in cost due to many processes.
Japanese Patent Laid-Open No. 2002-370080 JP 2002-282117 A JP 2003-127140 A

  As described above, there is a demand for an energy-saving rug recycling method that increases the recovery rate of pile yarn and base fabric in a rug, realizes reuse as a fiber, and requires fewer post-processes.

  Therefore, the present invention has been made to eliminate the above-mentioned disadvantages of the prior art, and is separated and recovered by means such as pulverizing the entire rug, or in the table of tufted loop pile yarns. Rather than recovering pile yarn as short fibers by slicing and cutting only the protruding part, the pile yarn can be separated from the base fabric with the long fibers in order to realize circulation recycling from fiber to fiber. An object of the present invention is to provide a possible method for recycling a rug and a device used therefor.

  The present inventors diligently studied, and after removing the backing layer from the rug to form a laminated body without the backing layer, by pulling both ends of the laminated body, the pile yarn was left in the state of long fibers from the base fabric. The inventors have found that they can be easily separated, and have come to the present invention.

  The method of recycling a rug according to the present invention includes a base fabric, a loop pile yarn planted on the base fabric, a backing layer, and a rug having a bonding layer that bonds the backing layer and the base fabric. This is a resource recycling method, and includes a backing layer removing step and a pile yarn drawing step.

  In the backing layer removing step, the backing layer is removed from the rug to obtain a laminate including a base fabric, a pile yarn, and an adhesive layer.

  In the pile yarn drawing step, the pile yarn is pulled from the base fabric by gripping one end and the other end of the laminate and applying tension to the laminate so that the one end and the other end are relatively separated from each other. Unplug.

  According to the present invention, a laminate having a relatively low strength without a backing layer can be obtained by the backing layer removing step. And in the pile yarn drawing process, the both ends of this laminate are pulled in opposite directions, and the loop pile yarn is pulled, and the pile yarn is pulled out from the base fabric, and the pile is unwound. Pile fiber in a long fiber state and a base fabric in a state in which the pile yarn is pulled out are obtained.

  Here, in the pile yarn drawing step, it is preferable to apply the above-described tension while bringing the cutting blade into contact with the base fabric in the laminate. In this case, when tension is applied to the laminate, the stress concentrates on the portion of the base fabric where the cutting blade contacts, and this portion of the base fabric is likely to be cut. Therefore, the pile yarn can be easily pulled out from the base fabric thereafter. Even if the cutting blade comes into contact with the pile yarn, the pile yarn itself is separated from the base fabric and has a sufficient length, so that the stress is not concentrated and is not cut.

  On the other hand, before the pile yarn drawing step, a base fabric cutting step of cutting the base fabric with a cutting blade or the like without cutting the pile yarn may be further provided. Also in this case, since the base fabric is cut in advance, it is easy to pull out the pile yarn in the pile yarn drawing step.

  Even if the base fabric is not cut in advance and the cutting blade is not brought into contact with the base fabric during the pile thread drawing process, the tension applied to the laminate is increased to ensure that the one end and the other end are securely connected. Since the base fabric is cut by applying a strong tension so as to separate, the base fabric and the pile yarn can be separated.

  By the way, there are many cases where an adhesive layer is attached to each of the pile yarn and the base fabric separated by the above-described method. For example, in the case of tile carpet, the pile yarn or base fabric is left with an adhesive layer such as PVC paste resin or latex, which is used as an adhesive to bond the backing layer to the base fabric. In many cases, the separation and recovery is desired. The weight of the adhesive layer is often as large as about 15 to 20% in terms of the weight ratio of the entire laminate.

  Therefore, the method for recycling a laminate according to the present invention further includes putting the pile yarn and / or the base fabric separated by the above-described method into a cylindrical container and rotating a rotating blade in the cylindrical container, It is preferable to provide an adhesive layer separating step for separating the adhesive layer from the pile yarn and / or the base fabric.

  According to this, the pile yarn and / or the base fabric is rotated in the cylindrical container. Then, the pile yarn and / or base fabric rotates and moves along the inner wall while being pressed against the inner wall of the cylindrical container by centrifugal force, and a large frictional force is generated between the pile yarn and / or the base fabric and the inner wall. The adhesive layer is separated from the pile yarn and / or the base fabric. Therefore, it becomes more preferable for the reuse of pile yarn and base fabric.

  Here, it is preferable to supply water into the cylindrical container together with the pile yarn and / or the base fabric. Such a wet process is suitable because the pile yarn and the base fabric can be washed in addition to the removal of the adhesive layer.

  At this time, it is also preferable to further supply an organic solvent having a weight ratio within 10% with respect to water in the cylindrical container.

  It is also preferable to bring an organic solvent into contact with the pile yarn and / or the base fabric before putting the pile yarn and / or the base fabric into the cylindrical container.

  By using these organic solvents, the peelability of the adhesive layer is improved.

On the other hand, it is also preferable to supply a media ball into the cylindrical container. This also improves the peelability of the adhesive layer.

  On the other hand, a pile yarn drawing device according to the present invention includes a pair of gripping portions and a driving portion. The pair of gripping portions are formed by removing the backing layer from a rug comprising a base fabric, a loop pile yarn planted on the base fabric, a backing layer, and an adhesive layer that bonds the backing layer and the backing fabric. The both ends of the laminate are gripped. The drive unit relatively moves the pair of gripping units so that the distance between the gripping units is increased.

  Such a pile yarn drawing device is suitable for realizing the above-described method.

  Here, it is preferable that the drive unit relatively moves the pair of gripping units so that the pile yarn is pulled out from the base fabric.

  Moreover, it is preferable to further provide the cutting blade which contact | abuts with respect to the base fabric in the said laminated body hold | gripped by a pair of holding part.

  The adhesive layer separation device according to the present invention includes a cylindrical container in which a pile yarn to which an adhesive layer is attached and / or a base fabric to which an adhesive layer is attached is accommodated, and a rotating blade that rotates in the cylindrical container.

  Such an adhesive layer separation device is suitable for realizing the above-described method.

  According to the present invention, it is possible to separate the pile yarn from the base fabric with the long fibers, and it is possible to effectively recycle the pile yarn and the base fabric of the rug at a low cost. In particular, since pile yarns are separated as long fibers, they can be widely reused as fibers, opening the way to efficient material recycling. Of course, material recycling is also possible for the base fabric and the removed backing layer.

  As the best mode for carrying out the present invention, as shown below, an example in which waste tile carpet (PVC backing specification) is recycled as an example of a waste composite rug will be described.

  FIG. 1 is an example of an embodiment of the present invention, and is a process diagram of recycling waste tile carpet. As shown in FIG. 2, the waste tile carpet 10 to be recycled is planted (tufted) on the base fabric 3 for tufts and a loop pile on the surface thereof. It is a rug made of a composite material having the pile yarn 2 formed, the backing layer 5 located on the back surface side, and the adhesive layer 4 that bonds the backing layer 5 and the back surface side of the base fabric 3.

  The material of the pile yarn 2 is not particularly limited, and examples thereof include nylon fiber, polypropylene fiber, and polyester fiber.

  Although the material of the base fabric 3 is not specifically limited, For example, the textile fabric of a polyester fiber, a nonwoven fabric, etc. are mentioned.

  The material of the backing layer 5 is not particularly limited, and examples thereof include thermoplastic resin, rubber, and fiber. Examples of the thermoplastic resin include vinyl chloride, calcium carbonate as a filler, and a mixture of plasticizers.

  Although the material of the contact bonding layer 4 is not specifically limited, For example, resin, rubber latex, etc. are mentioned. Examples of the resin include paste vinyl chloride, which is a mixture of vinyl chloride and a plasticizer.

  For example, the specifications of the most popular tile carpets on the market are size 500mm x 500mm, weight 1.25kg, overall thickness 6.5mm (backing layer 1.3-2.0mm, adhesive layer 1.5-2.0mm, base fabric and pile yarn 3.0 ~ 4.0mm). The adhesive layer 4 and the backing layer 5 are often made of polyvinyl chloride, the pile yarn 2 is made of nylon (registered trademark), and the base fabric 3 is often a polyester fiber fabric.

  First, in step S101 of FIG. 1, a front surface dust removal process and a back surface adhesion removal process of the waste tile carpet 10 are performed as preprocessing. In general, dust adheres to the surface of the waste tile carpet 10, such as the pile yarn 2, and the adhesive or mortar for adhering to the floor adheres to the surface of the backing layer 5 of the waste tile carpet 10. These are unfavorable for recycling. Therefore, these are removed in advance in this step. Specifically, this step can be performed by an adhering matter removing apparatus including a removing brush that removes adhering matter on the back surface and a suction unit that sucks dust adhering to the pile yarn 2 and the like. A rotary brush or the like can be used as the removal brush, and a vacuum cleaner or the like can be used as the suction means.

  Subsequently, in step S103, the backing layer 5 is removed from the waste tile carpet 10 to obtain a laminate 12 having the pile yarn 2, the base fabric 3, and the adhesive layer 4. For example, as shown in FIG. 3, the backing layer 5 can be easily removed by cutting the backing layer 5 with a rotary blade B provided with a large number of blades on the surface of a cylinder. In this case, it is important that the pile yarn 2 is not damaged, and a slight amount of the backing layer may remain in the laminate 12.

  Further, the removal of the backing layer 5 is not limited to the cutting method, and may be, for example, a slicing method. In addition, about the removal method of a part layer of such a composite layer, the method disclosed by Unexamined-Japanese-Patent No. 2003-88772 etc. can be used, for example.

  Here, the backing layer 5 separated from the waste tile carpet 10 is in the form of cutting powder. Then, the cutting powder 14 of the backing layer 5 is classified in step S120 of FIG. 1 and after removing some of the excluded products 14B, it is made into a recycled PVC compound raw material 14A and can be recycled.

  On the other hand, the structure of the laminate 12 after the backing layer 5 is separated is, for example, 50 to 60% of the base fabric 3 and the pile yarn 2 by weight ratio, and 40 to 50% of the adhesive layer (mainly vinyl chloride paste resin). It becomes.

  Subsequently, in step S <b> 104, the pile yarn in the laminate 12 is pulled out from the base fabric 3. Here, the pile yarn drawing device 100 shown in FIG. 4 is used. The pile yarn pulling device 100 moves the gantry 102, the first gripping portion 110 fixed to the gantry 102, the second gripping portion 120 movable with respect to the first gripping portion 110, and the second gripping portion 120. And a drive unit 140 to be pulled.

  The first grip 110 includes a jig 112 and a jig 111 that are spaced apart from each other in the vertical direction. The jig 112 is fixed to the gantry 102, and the jig 121 is connected to a hydraulic cylinder 118 fixed to the gantry 102. And after inserting the end part 12e of the laminated body 12 between the jig | tool 111 and the jig | tool 112, the hydraulic cylinder 118 is operated and the jig | tool 111 is pressed with respect to the jig | tool 112, and a 1st holding | grip is carried out. The part 110 grips and fixes the one end part 12 e of the laminate 12.

  On the other hand, the second grip part 120 similarly includes a jig 122, a jig 121, and a hydraulic cylinder 128 for pressing the jig 121 against the jig 122. In the same manner, the other end 12 f of the laminate 12 is held and fixed between the jig 122 and the jig 121. Here, the jig 122 and the hydraulic cylinder 128 of the second grip 120 are fixed to a guide device 135 that can move in the horizontal direction on the gantry 102. The guide device 135 includes a guide roller 132, and the guide roller 132 enables the guide device 135 to reciprocate in the horizontal direction along the horizontal guide rail 105 provided on the gantry 102.

  Each gripping portion of the present embodiment grips the stacked body 12 as an object to be gripped by the action of the hydraulic cylinder 128, but may hold the stacked body 12 by the action of pneumatic pressure, toggle clamp, or the like. .

  Further, the pile yarn drawing device 100 includes an endless chain 138B that is stretched horizontally with respect to the gantry 102 and a motor 138A that drives the endless chain 138B. An end portion 135a of the guide device 135 is an endless chain. It is fixed to a part of 138B. When the endless chain 138B rotates by driving the motor 138A, the guide device 135 moves in the right direction in the drawing, and the second holding portion 120 moves in the right direction in the drawing so as to be separated from the first holding portion 110. To do. Here, the endless chain 138 </ b> B, the motor 138 </ b> A, and the guide device 135 constitute the drive unit 140.

  And in this process, as shown to (a) of FIG. 5, after fixing the both ends 12e and 12f of the laminated body 12 with the 1st holding part 110 and the 2nd holding part 120, respectively, the drive part 140 is driven. Then, the second grip 120 is moved to the right side of the figure, and by applying tension in the in-plane direction to the laminate 12, the base fabric 3 of the laminate 12 is cut as shown in FIG. Further, the loop-shaped pile yarn 2 is pulled out from the base fabric 3 and unraveled. Thereby, the laminated body 12 is isolate | separated into the pile yarn 2 in which the pile was unwound, and the base fabric 3 of the state from which the pile was removed. Further, a part of the adhesive layer 4 remains adhered to the pile yarn 2 and the base fabric 3.

  Here, the tensile force required for cutting the base fabric 3 by tension is, for example, about 1000 to 2000 kg in the laminate 12 of 500 mm × 500 mm, and the loop pile yarn 2 is pulled out from the base fabric 3. The tensile force for separation is about 500 to 600 kg in the laminate 12 of 500 mm × 500 mm. Therefore, it is preferable that the drive unit 140 can apply a tension of about 3000 to 5000 kg to the laminate 12 per rug having a width of 500 mm.

  By the way, in this embodiment, in order to cut the base fabric 3 at the most efficient position, as shown in FIG. 6A, the laminated body 12 held horizontally by the holding portions 110 and 120, in particular the base It is preferable to apply tension to the laminated body 12 in a state where the cutting blade 160 formed with a blade such as a chevron is in contact with the cloth 3. Specifically, the pile thread drawing device 100 may be further provided with a cutting blade 160 and a cutting blade holding portion 162 that holds the cutting blade 160 so as to contact the base cloth 3.

  And when the 2nd holding | grip part 120 is pulled in the illustration right direction and tension is given to the laminated body 12 in the state which contacted and fixed the cutting blade 160 to the base fabric 3 of the laminated body 12, it shows to (b) of FIG. As described above, stress concentration occurs at the portion of the base fabric 3 where the cutting blade 160 is in contact, and this portion of the base fabric 3 is selectively cut. Further, the tension required for this cutting contacts the cutting blade 160. If not, it will be sufficiently lower than the tension required. For example, the force required for cutting the base fabric 3 drops to about 400 kg. Therefore, the drive unit 138 only needs to be capable of applying a tension of about 1000 kg, which leads to energy saving and compactness of the apparatus. At this time, the pile yarn 2 is increased in length by unwinding, so that even if it contacts the cutting blade 160, it is hardly cut. Here, the cutting blade 160 is preferably brought into contact with a portion of the base fabric 3 close to the non-moving side gripping portion 110.

  On the other hand, as shown in FIG. 7, before gripping both end portions of the laminate 12, the first grip portion 110 and the second grip portion 120 grip two places on one end side of the laminate 12, and the second grip portion The base cloth 3 may be actively cut by pressing the cutting blade 160 downward with a predetermined force against the laminated body 12 by the cutting blade pressing device 163 in a state where the 120 is fixed without being moved. Also in this case, it is preferable not to cut the pile yarn 2. Usually, the pile yarn 2 is pulled out and extends, so that it is difficult to cut.

  Then, after the base fabric 3 is cut, the second grip 120 releases the grip of the laminate 12, grips the other end of the laminate 12, and pulls the pile yarn 2 from the base fabric 3 by pulling in the same manner as described above. Can be pulled out. Further, the base fabric 3 may be cut in advance by the cutting blade 160 or the like using a device different from the pile yarn drawing device 100. The shape of the cutting blade 160 is not particularly limited.

  Furthermore, the combination of the jig 111 and the jig 112 and the combination of the jig 121 and the jig 122 in the first gripping part 110 and the second gripping part 120 are mutually flat as shown in FIG. Is not limited. For example, when it is desired to increase the gripping force, as shown in FIG. 8A, a jig 111A (121A) having a wedge-shaped convex portion a and a jig having a concave portion b corresponding to the convex portion a. 112A (122A) may be adopted, and as shown in FIG. 8B, the gripping force may be improved by the wedge effect by winding the end of the laminate 12 into the recess b.

  Further, as shown in FIG. 9A, a jig 111B (121B) having a convex portion c and a jig 112B (122B) having a concave portion d corresponding to the convex portion c are adopted. As shown in 9 (b), the gripping force may be increased by meshing the convex part c and the concave part d.

  As described above, in step S104 of FIG. 1, the pile yarn 2 is pulled out from the base fabric 3, and the separation between the base fabric 3 and the pile yarn 2 is completed. The structure of the separated base fabric 3 is 30 to 35% of the base fabric (mainly polyester) and 65 to 70% of the adhesive layer (mainly PVC paste resin). On the other hand, the structure of the separated pile yarn 2 is 55 to 60% pile yarn (mainly nylon) and 40 to 45% adhesive layer (mainly vinyl chloride paste resin). That is, a part of the adhesive layer 4 is firmly attached to the separated base fabric 3 and pile yarn 2. At this time, the base fabric 3 and the pile yarn 2 are almost separated except for the end portions 12e and 12f sandwiched between the gripping portions 110 and 120, and then the end portions 12e and 12f are cut off. Separation of the base fabric 3 and the pile yarn can be easily completed.

  Subsequently, in step S <b> 106, the adhesive layer 4 is separated from the base fabric 3 and the pile yarn 2.

  Here, the adhesive layer 4 is separated by using an adhesive layer separation device called a high-speed fluid type centrifugal separation cleaning device as shown in FIG.

  As shown in FIG. 10, the adhesive layer separating apparatus 300 includes a cylindrical container 302 having both ends extending in the horizontal direction closed. A rotation shaft 304 is disposed in the container 302 so as to be rotatable along the axial direction of the container. The rotating shaft 304 penetrates the container 302 in the horizontal direction. The rotation shaft 304 is rotatable by a bearing 315A of a rotation shaft portion 315 disposed on both outer sides in the axial direction of the container 302. The rotating shaft 304 is not in contact with the container 302. A motor 309 capable of controlling the number of rotations is connected to an end of the rotation shaft 304, and the rotation shaft 304 is rotated.

  Within the container 302, the rotating shaft 304 is provided with a large number of rod-shaped rotating blades 306 provided so as to extend radially outward from the rotating shaft 304. When the rotary shaft 304 is viewed from the axial direction (see FIG. 9B), a large number of the rotary blades 306 are arranged radially around the rotary shaft 304, and these rotary blades are arranged radially. A plurality of stages 306 are also provided in the axial direction of the rotating shaft 304 (see FIG. 9A).

  The tip of the rotary blade 306 is separated from the inner wall 302b of the container 302 by a predetermined distance, for example, about 5 to 20 mm so as not to contact the inner wall 302b of the container 302. The rotation diameter 2R defined as 2R when the rotation radius when the rotating blade 304 rotates about the rotation axis 304 is R is set to be about 300 to 600 mm. If the rotating blade 306 is rotated at 3000 rpm when the rotating diameter 2R is about 600 mm, the peripheral speed at the tip of the rotating blade 306 is about 100 m / s, and a strong centrifugal force can be generated on the contents. .

  An end of one side of the container 302 in the axial direction is opened upward to form a charging port 314. On the other hand, the end of the container 302 on the other side in the axial direction is opened downward to form a discharge port 316.

  In such an adhesive layer separating apparatus 300, a mixture of water and pile yarn 2 is introduced into the container 302 from the inlet 314, and a plurality of rotary blades 306 are rotated by the motor 309 via the rotating shaft 304. . Then, a layer L of a mixture of water and pile yarn 2 is formed on the inner wall 302b of the container 302 by centrifugal force, and the pile yarn 2 is rubbed or struck in this layer L. Thereby, the adhesive layer 4 adhering to the pile yarn 2 in the shape of a knob is separated from the pile yarn 2. The separation efficiency generally depends largely on the peripheral speed of the tip of the rotary blade 306. Here, by setting the peripheral speed of the tip of the rotary blade 306 to, for example, 25 to 100 m / s, preferably 50 to 100 m / s, separation in an extremely short time of 10 to 30 seconds becomes possible.

  In the above description, the pile yarn 2 and water are supplied into the container 302. Similarly, the adhesive layer 4 can be separated from the base cloth 3 by supplying the base cloth 3 and water into the container 302. Further, the mixture of the pile yarn 2 and the base fabric 3 and water may be supplied into the container 302.

  Further, in the adhesive layer separating apparatus 300 according to the present embodiment, since the rotating shaft portion 315 is disposed outside the container 302, it is not necessary to seal the rotating blade 306 and the container 302, and the structure of the container 302 is simple. The bearings 315A are well maintained and the cost is reduced. Further, a recess 302c having a depth P is formed on the inner wall 302b of the container 302, and the cylindrical layer L formed by the water, the pile yarn 2 and the like formed when the rotating blades 302 are rotated has this depth. (Thickness) P is maintained, and water and pile yarn 2 and the like exceeding this depth P overflow the weir 305 having a height P provided in front of the discharge port 316 and are discharged from the discharge port 316. It will be. Therefore, separation work by continuous operation is easy. Further, since the pile yarn 2 and the water inlet 314 are provided on the upper side of the container 302 and the outlet 316 is provided on the lower side of the container 302, continuous operation is further facilitated.

  In addition, since the constantly injected water overflows and discharges, it is easy to circulate the water. Therefore, the pile yarn 2, the base cloth 3, and the peeled adhesive layer 4 powder (for example, PVC powder). Etc. are easily discharged by the flow of water.

  Furthermore, since water is supplied into the container 302 together with the pile yarn 2 and the like, it is preferable that the pile yarn 2 and the like can be washed at the same time.

  When the adhesive force of the adhesive layer 4 is strong, a hard media ball such as a zirconia ball or alumina ball used in a ball mill or the like is mixed in the container 302 and stirred together with the pile yarn 2 and the like. Therefore, separation of the adhesive layer 4 from the base fabric 3 and the pile yarn 2 may be promoted. In this case, only the media ball is mixed in the container 302, and separation can be performed very efficiently without using water.

  Furthermore, it is preferable to supply a small amount of an organic solvent that reacts only with the resin of the adhesive layer into the container 302 together with water, because the peelability of the adhesive layer 4 is increased. The concentration of the organic solvent is preferably within 10% by weight with respect to water, and examples of the organic solvent include NMP, MEK, THF, and the like. In addition, before being put into the container 302, the adhesiveness of the adhesive layer may be relaxed by immersing or spraying the small amount of the organic solvent described above on the base fabric 3 and the pile yarn 2 after separation. .

  In the case of using a solvent, it is desirable to use as little as possible because of the need for solvent recovery in the subsequent process, and after loosening the adhesion of the adhesive layer by a technique such as immersion or spraying in advance as described above. It is effective to perform cleaning and separation by a wet method.

  In the above description, water is put in the container 302 in addition to the pile yarn 2 and the like. However, the adhesive layer 4 can be separated from the pile yarn 2 and the like without adding water.

  In this manner, as shown in FIG. 1, the pile yarn 2 from which the adhesive layer 4 has been removed, the base fabric 3 from which the adhesive layer 4 has been removed, and the powder 15 of the adhesive layer are obtained. Separation itself between the pile yarn 2, the base fabric 3, and the powder 15 of the adhesive layer can be easily performed by an air sieve, a sieve, or the like. And since the pile yarn 2 is still a long fiber, it can be easily recycled as a regenerated yarn or the like through a rebound process or the like. Further, the base fabric 3 can also be recycled as a raw material of the base fabric 3, and the adhesive layer powder 15 can be recycled as a raw material for a recycled PVC compound or the like, similar to the cutting powder 14 of the backing layer.

  In addition, this invention is not restricted to the said embodiment, All the deformation | transformation aspects are possible. For example, in the said embodiment, although the vinyl chloride-type rug was demonstrated, the composition of each layer of a laminated body is not limited. Moreover, even if the pile yarn or the base fabric of the rug is made of the same material, the pile yarn can be efficiently separated and recovered from the base fabric, so that there is a sufficient effect.

  Moreover, the drive method of the 2nd holding part 120 of the above-mentioned pile thread drawing apparatus is not restricted to the method using a motor and an endless chain, For example, hydraulic pressure etc. may be sufficient. Further, the shape of the stirring blade of the above-mentioned adhesive layer separation device is not limited to a rod shape.

  According to the present invention, since the backing layer, the pile yarn, and the base fabric can be separated in waste tile carpets and the like that have been almost discarded conventionally, recycling can be performed efficiently. In particular, since expensive pile yarns are separated as long fibers, the effect of recycling is remarkably large.

FIG. 1 is a flowchart of a total process for converting waste tile carpets into recycled materials. FIG. 2 is a schematic cross-sectional view of a waste tile carpet targeted in the embodiment. FIG. 3 is a schematic diagram showing a process of obtaining the laminate 12 by removing the backing layer of the waste tile carpet. FIG. 4 is a schematic diagram of a pile yarn drawing device. FIG. 5 is a schematic view showing a state of cutting the base fabric of the laminate and collecting the pile yarn by the pile yarn drawing device of FIG. FIG. 6 is a schematic diagram showing another form of cutting the base fabric of the laminate. FIG. 7 is a schematic view showing another form of cutting the base fabric of the laminate. FIG. 8 is a schematic diagram illustrating another example of the gripping device. FIG. 9 is a schematic diagram illustrating still another example of the gripping device. FIG. 10 is a schematic diagram of an adhesive layer separation device (high-speed fluidized centrifugal separation washing device).

Explanation of symbols

DESCRIPTION OF SYMBOLS 3 ... Base fabric, 2 ... Loop pile yarn, 5 ... Backing layer, 4 ... Adhesive layer, 10 ... Rug, 12 ... Laminated body, 12e ... One end part of laminated body, 12f ... Other end part of laminated body, 100 ... Pile thread drawing device, 110, 120 ... gripping part, 140 ... driving part, 160 ... cutting blade, 302 ... cylindrical container, 306 ... rotating blade, 300 ... adhesive layer separating apparatus.

Claims (12)

A method for recycling a rug comprising a base fabric, a loop pile yarn planted on the base fabric, a backing layer, and an adhesive layer that bonds the backing layer and the base fabric,
A backing layer removing step of removing the backing layer from the rug to obtain a laminate comprising the base fabric, the pile yarn, and the adhesive layer;
The pile yarn is pulled from the base fabric by gripping one end and the other end of the laminate and applying tension to the laminate so that the one end and the other end are relatively separated from each other. A pile thread drawing process to pull out;
Recycling method for rugs.   The rug recycling method according to claim 1, wherein, in the pile yarn drawing step, the tension is applied while a cutting blade is brought into contact with a base fabric in the laminated body.   The rug recycling method according to claim 1, further comprising a base cloth cutting step of cutting the base fabric without cutting the pile yarn before the pile yarn drawing step.   The pile yarn and / or the base cloth separated in the pile yarn drawing step is put in a cylindrical container and a rotating blade is rotated in the cylindrical container, and the adhesion from the pile yarn and / or the base cloth is performed. The rug recycling method according to any one of claims 1 to 3, further comprising an adhesive layer separation step of separating the layers.   The rug recycling method according to claim 4, wherein water is further supplied into the cylindrical container together with the pile yarn and / or the base fabric.   The method for recycling a rug according to claim 5, wherein an organic solvent having a weight ratio of 10% or less with respect to the water is further supplied into the cylindrical container.   The rug according to any one of claims 4 to 6, wherein an organic solvent is brought into contact with the pile yarn and / or the base fabric before putting the pile yarn and / or the base fabric into the cylindrical container. Recycling method.   The rug recycling method according to any one of claims 4 to 7, further comprising supplying a media ball into the cylindrical container. One end of a laminate formed by removing the backing layer from a rug comprising a base fabric, a loop pile yarn planted on the base fabric, a backing layer, and an adhesive layer for bonding the backing layer and the base fabric A pair of gripping parts for gripping the part and the other end part,
A drive unit that relatively moves the pair of gripping units so that the distance between the gripping units is separated;
A pile yarn drawing device comprising:   The pile yarn drawing device according to claim 9, wherein the driving unit relatively moves the pair of gripping portions so that the pile yarn is pulled out from the base fabric.   The pile yarn drawing device according to claim 9 or 10, further comprising a cutting blade that comes into contact with a base fabric in the laminated body held by the pair of holding portions.   An adhesive layer separating apparatus comprising: a cylindrical container that houses a pile yarn to which an adhesive layer is attached and / or a base fabric to which an adhesive layer is attached; and a rotating blade that rotates in the cylindrical container.

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