JP2015502871A - カーペットをリサイクルするためのプロセス及び、かかるプロセスの製品 - Google Patents
カーペットをリサイクルするためのプロセス及び、かかるプロセスの製品 Download PDFInfo
- Publication number
- JP2015502871A JP2015502871A JP2014541066A JP2014541066A JP2015502871A JP 2015502871 A JP2015502871 A JP 2015502871A JP 2014541066 A JP2014541066 A JP 2014541066A JP 2014541066 A JP2014541066 A JP 2014541066A JP 2015502871 A JP2015502871 A JP 2015502871A
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- Japan
- Prior art keywords
- carpet
- backing material
- surface fiber
- backing
- temperature
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
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Classifications
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- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
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- B02C19/00—Other disintegrating devices or methods
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- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
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- Polymers & Plastics (AREA)
- Medicinal Chemistry (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Environmental & Geological Engineering (AREA)
- Textile Engineering (AREA)
- Toxicology (AREA)
- Food Science & Technology (AREA)
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Abstract
Description
[0090]ナイロンカーペットを細断し、ふるい分けして、表面繊維から裏打ちの粒状物を除去した。繊維の収率は、プロセスへの供給原料の約50%であった。表面繊維製品の組成は、ナイロン75%、ポリプロピレン18%、及び灰分7%であった。
[0091]ナイロンカーペットを細断して表面繊維を除去すると、裏打ち及び表面繊維の一部から構成された残骸が残った。表面繊維の収率は、プロセスへの供給原料の約23重量%であり、表面繊維は灰分約2重量%を含んでいた。
[0092]ナイロンカーペットのサンプルを、410°F(210℃)に保持した対流オーブン中、総滞留時間5〜10分で加熱して、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物をハンマーミルにかけて、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるいわけにより、裏打ち残渣のバルクから分離した。次いで繊維をカーディングにかけてさらに掃除した。表面繊維の収率は約43重量%であり、繊維を分析するとナイロン98%であった。繊維中の残存材料は、さらにカーディングすることによって除去できたかもしれない分解した裏打ち材料の余分な粒子からなっていた。
[0093]PETカーペットサンプルを、455°F(235℃)に保持した対流オーブン中、総滞留時間5分で通して、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物をハンマーミルにかけて、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるいわけにより、裏打ち残渣のバルクから分離した。次いで繊維をカーディングにかけてさらに掃除した。表面繊維の収率は約67重量%であり、繊維を分析するとPET96%であった。繊維中の残存材料は、さらにカーディングすることによって除去できたかもしれない分解した裏打ち材料の余分な粒子からなっていた。
[0094]PETカーペットの別のサンプルを、410°F(210℃)に保持した対流オーブン中、総滞留時間10分で通して、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物をハンマーミルにかけて、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるいわけにより、裏打ち残渣のバルクから分離した。次いで繊維をカーディングにかけてさらに掃除した。表面繊維の収率は約62重量%であり、繊維を分析するとPET92%であった。
[0095]PETカーペットの別のサンプルを、410°F(210℃)に保持したバッチ式オーブン中、総滞留時間30分保持し、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物をボールミルにかけて、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるいわけにより、裏打ち残渣のバルクから分離した。表面繊維の収率は約55重量%であった。
[0096]PETカーペットは、420°F(約216℃)に保持したバッチ式オーブン中、総滞留時間10分で保持し、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物を三枚刃一軸グラニュレーター中でハンマーミル中で粉砕して、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるいわけにより、裏打ち残渣のバルクから分離した。表面繊維の収率は約50重量%であった。
[0097]ナイロンカーペットのサンプルを、410°F(210℃)に保持したバッチ式オーブン中、総滞留時間25分加熱し、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物を二ロールミルを使用して粉砕し、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるいわけにより、裏打ち残渣のバルクから分離した。表面繊維の収率は約52重量%であった
実施例7
[0098]PETカーペットの別のサンプルは、480°F(約249℃)に保持したバッチ式オーブン中、総滞留時間3分加熱して、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物をボールミルを使用して粉砕して、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるい分け及び吸引により、裏打ち残渣のバルクから分離した。表面繊維の収率は約58重量%であった。
[0099]PETカーペットの別サンプルは、440°F(約227℃)に保持したバッチ式オーブン中、総滞留時間6分で加熱して、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物をボールミルを使用して粉砕し、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるいわけ及び吸引により、裏打ち残渣のバルクから分離した。表面繊維の収率は約64重量%であった。
[0100]PETカーペットを、455°F(235℃)に保持した対流オーブン中、総滞留時間6分で通して、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物をハンマーミルにかけて、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるいわけにより、裏打ち残渣のバルクから分離した。次いで繊維をカーディングにかけてさらに掃除した。表面繊維の収率は約63重量%であり、繊維を分析するとPET94%であった。繊維中の残存材料は、さらにカーディングすることによって除去できたかもしれない分解した裏打ち材料の余分な粒子からなっていた。
[00101]Shaw「ソフトバック」のついたPETカーペットの別のサンプルを、455°F(235℃)に保持した対流オーブン中、総滞留時間10分で通して、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物をボールミルにかけて、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるいわけにより、裏打ち残渣のバルクから分離した。表面繊維の収率は約58重量%であった。
[00102]ナイロンカーペットのサンプルを、410°F(210℃)に保持したバッチ式オーブン中、総滞留時間10分加熱して、カーペット裏打ちを部分的に分解させた。次いでオーブン生成物をハンマーミルにかけて、表面繊維から裏打ち残渣を遊離させた。表面繊維をふるいわけにより、裏打ち残渣のバルクから分離した。表面繊維の収率は約41重量%であった。
Claims (25)
- 表面繊維材料及び裏打ち材料を含むカーペットから表面繊維材料を回収するためのプロセスであって、
(a)前記カーペットを、前記表面繊維材料の融点よりも低い温度であるが、前記裏打ち材料の熱分解温度よりも高い温度に、前記裏打ち材料の少なくとも一部を熱的に分解させるのに十分な時間及び温度に加熱して、前記裏打ち材料を砕けやすい状態にする;及び
(b)砕けやすい前記裏打ち材料から前記表面繊維材料を遊離させるために、カーペットに機械力を適用する、各段階を含む、前記プロセス。 - 前記カーペットを段階(a)において、約175℃〜約260℃の温度に加熱する、請求項1に記載のプロセス。
- 前記表面繊維材料はナイロン6を含み、且つ段階(a)において前記カーペットを175℃〜215℃の温度に加熱する、請求項1に記載のプロセス。
- 前記表面繊維材料がナイロン66を含み、且つ段階(a)において前記カーペットを175℃〜245℃の温度に加熱する、請求項1に記載のプロセス。
- 前記表面繊維材料がポリエチレンテレフタレートを含み、且つ段階(a)において前記カーペットを175℃〜260℃の温度に加熱する、請求項1に記載のプロセス。
- 前記段階(a)において前記カーペットを約0.1分〜約120分加熱する、請求項1に記載のプロセス。
- 前記段階(a)及び(b)を同一装置で実施する、請求項1に記載のプロセス。
- 前記段階(a)及び(b)を順次実施する、請求項1に記載のプロセス。
- 前記段階(a)及び(b)を同時に実施する、請求項1に記載のプロセス。
- 前記段階(a)及び(b)を連続プロセスで実施する、請求項1に記載のプロセス。
- 前記カーペットを段階(a)と(b)との間で冷却して、前記裏打ち材料の少なくとも一部を自然に破砕させる、請求項1に記載のプロセス。
- 前記表面繊維材料はポリエステルを含む、請求項1に記載のプロセス。
- 前記表面繊維材料はポリアミドを含む、請求項1に記載のプロセス。
- 前記裏打ち材料はポリオレフィンを含む、請求項1に記載のプロセス。
- 前記裏打ち材料は天然繊維を含む、請求項1に記載のプロセス。
- 請求項1のプロセスに従って回収した表面繊維材料。
- 請求項16に記載の表面繊維材料を含む押出し成形品。
- 請求項16に記載の表面繊維材料を含む射出成形品。
- 前記表面繊維材料を化学的にリサイクルすることをさらに含む、請求項1に記載のプロセス。
- 砕けやすい前記裏打ち材料からすべての無機充填材を分離することをさらに含む、請求項1に記載のプロセス。
- 請求項20に記載のプロセスに従って分離した無機充填材。
- 表面繊維材料と、前記表面繊維材料と異なる化学組成の裏打ち材料とを含むカーペットから表面繊維材料を回収するためのプロセスであって、
(a)前記カーペットを、前記表面繊維材料の融点よりも低い温度であるが、前記裏打ち材料の初期熱分解温度よりも高い温度に、前記裏打ち材料の少なくとも一部を熱的に分解及び/または酸化させるのに十分な時間及び温度に加熱して、裏打ち材料を未処理裏打ち材料よりも砕けやすい状態にする;
(b)砕けやすい前記裏打ち材料から前記表面繊維材料を遊離させるために、カーペットに機械力を適用する;及び
(c)一つ以上の機械的手段により前記表面繊維材料から全ての汚染物質を除去する、各段階を含む、前記プロセス。 - 請求項22に記載のプロセスに従って回収した砕けやすい裏打ち材料。
- 請求項22に記載のプロセスに従って回収した砕けやすい裏打ち材料を含む脱硫剤。
- 絡まっている少なくとも第一のタイプの繊維と第二のタイプの繊維とを分離する方法であって、
(a)絡まっている繊維を、前記第一のタイプの繊維の融点よりも低い温度であるが、前記第二のタイプの繊維の熱分解温度よりも高い温度に、前記第二のタイプの繊維の少なくとも一部を熱的に分解させるのに十分な時間及び温度に加熱して、前記第二のタイプの繊維を砕けやすい状態にする;及び
(b)砕けやすい前記第二のタイプの繊維から前記第一のタイプの繊維を遊離させるために、絡まった繊維に機械力を適用する、各段階を含む、前記プロセス。
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