JP3755302B2 - Recycled sheet manufacturing method using carpet waste - Google Patents
Recycled sheet manufacturing method using carpet waste Download PDFInfo
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- JP3755302B2 JP3755302B2 JP16940298A JP16940298A JP3755302B2 JP 3755302 B2 JP3755302 B2 JP 3755302B2 JP 16940298 A JP16940298 A JP 16940298A JP 16940298 A JP16940298 A JP 16940298A JP 3755302 B2 JP3755302 B2 JP 3755302B2
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- Prior art keywords
- carpet
- waste
- recycled
- recycled sheet
- resin
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- 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.)
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Classifications
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/62—Plastics recycling; Rubber recycling
Landscapes
- Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
- Processing Of Solid Wastes (AREA)
Description
【０００１】
【産業上の利用分野】
この発明は、カーペット廃材のリサイクル技術に関する。
【０００２】
【従来の技術】
近年、カーペット廃材、特に自動車用途のカーペット廃材のリサイクル需要が高まっている。この種のカーペットは基布にパイル糸をタフティングしたタフトカーペットや短繊維のウェブをニードルで突き固めたニードルパンチカーペットであり、裏面に熱可塑性樹脂の裏打ちを施して敷設性や物性を改善したものである。
カーペットの廃材はその生産工程において製品の外周を所要の形状に裁断した後のトリミングロスとして生じ、また自動車等が廃棄される際に敷設されていたカーペットが分別回収されてくるものである。
【０００３】
カーペット廃材をリサイクルする従来の態様として、熱可塑性樹脂を主体としてなるカーペット廃材を加熱して溶融させ、（相溶化剤を混入して）均質化をはかり、リペレット化する例があった。たとえば特願平３−２０８８９４号はナイロンパイルカーペットの廃材を粉砕し、無水マレイン酸変性ポリオレフィンおよびパーオキサイド化合物と溶融混練するものである。この種のリサイクルによれば、得られたリサイクルペレットやリサイクルシートを二次加工することが可能である。
【０００４】
カーペット廃材を加熱溶融するリサイクルでは、以下の課題があった。
▲１▼カーペット廃材以外に、母材として相当量のバージン樹脂を必要とし、母材にカーペット廃材を混練するものであり、完全なリサイクルといえなかった。
▲２▼カーペット廃材の母材樹脂への分散性が悪いことから、母材への混入量が少なく限定されること、リサイクルシートのシーティングにおいて、均質のシーティングが困難なこと、また得られたシートが脆く、割れやすくなること。
▲３▼混練温度を高く（２６０℃以上に）する必要が生じ、樹脂の種類によっては分解温度に達し、ガスの発生をみてリサイクルできない場合があること。
【０００５】
【発明が解決しようとする課題】
本発明は上記課題にかんがみなされたものであり、カーペット廃材を主体にして成形可能なリサイクルシートの製造方法を提供する。
【０００６】
【課題を解決するための手段】
課題を解決する本発明の手段は、結晶化度が２０％未満、分解温度が２６０℃以上であるエラストマー系熱可塑性樹脂に充填材を含んだバックコーティング材料を裏打ちしたカーペットの廃材を、粉砕、混練し、他の母材樹脂や改質剤を本質的に配合しないで、前記バックコーティング材料の重量比率が６５％以上あるようにシーティングすることを特徴とする、カーペット廃材を用いたリサイクルシートの製造方法による。
【０００７】
本発明では、カーペット廃材を加工してリサイクルシートを得ており、本質的に他の母材樹脂を必要としない。これはカーペットの裏打ちにエラストマー系熱可塑性樹脂を用いることにより達成される。
この場合、エラストマー系熱可塑性樹脂の柔軟性を活かして混練温度を２６０℃以上とし、均質の混練をなすことができる。発明の条件に合うエラストマー系熱可塑性樹脂は、少なくとも結晶化度が２０％未満であるもの、また分解温度が２６０℃以上のものである。
【０００８】
【発明の実施の形態】
以下、本発明の好適の実施の形態を説明する。
【０００９】
（カーペット、裏打ち、他の充填材）
カーペットはエラストマー系熱可塑性樹脂の裏打ちをほどこしてなるものが用途に適する。エラストマー系熱可塑性樹脂は結晶化度が２０％未満であるもの、また分解温度が２６０℃以上のもの（ＰＰ、ＰＥ、ＥＰＲ等を３０重量％以上含むオレフィン系エラストマー）が好ましい。充填材は重質の粒子体（ＣａＣＯ３、ＢａＳＯ４等の粒子、タルク、自動車バンパー廃材、金属粉等、有機、無機の粒子）が好ましい。
【００１０】
（混練）
リサイクルシートの加工は、カーペットの粉砕、混練、シーティングの順におこなわれる。混練設備はバンバリミキサー、ニーダー、短軸／２軸押出機にて可能であるが、特に混練時に材料が発熱しやすい２軸押出機は好ましい。シーティングはカレンダー、Ｔダイ押出しが可能である。押出速度０．５〜５ｍ／ｍｉｎ、Ｔダイリップ間隔１．０〜１０ｍｍ。圧延ロール（ミラーロール）で０．５〜５ｍｍ厚のシートに冷却圧延する。
【００１１】
以下、表１に示す実施例（比較例）によって説明する。
（試料の作成）実施例および比較例において、同一のカーペット（ポリエステルの基布にナイロンのパイルをタフト）に対して異なる樹脂（バックコーティング材料）の裏打ちをおこない（またバックコーティング材料には充填材を含み）、これを（８〜２０ｍｍ）に粉砕して、２軸押出機に投入、混練した。このとき、樹脂の温度は２６０〜２７０℃に達した。混練物をＴダイから厚さ２ｍｍのシートに押し出し、冷却してリサイクルシートとした。
（評価）評価は、シートの押出し加工性（均一なシーティングであること、樹脂の分解、発泡なきこと）と得られたリサイクルシートの物性（柔軟性、耐寒性）についておこなった。
【表１】
（結果）
評価結果は表１に示すとおり、実施例の組成において、リサイクルシートの加工性、物性に問題がなかったのに対して、比較例１では、エラストマー系でない樹脂の裏打ちをおこなったために、加工性に劣り、均一のシーティングがなされず、得られたシートは柔軟性と耐寒性の劣るものになった。また比較例２においては、裏打ち樹脂の分解温度が加工温度より低いために、樹脂の分解発泡がおこりシーティングが困難であった。
【００１３】
【発明の効果】
本発明によれば、カーペット廃材を主体にして、リサイクルシートを形成することが可能で、リサイクルシートのシーティング加工性にすぐれる。
得られたリサイクルシートは耐寒性、柔軟性があり、重質で遮音性にもすぐれる。[0001]
[Industrial application fields]
The present invention relates to a technique for recycling carpet waste.
[0002]
[Prior art]
In recent years, there has been an increasing demand for recycling carpet waste, particularly carpet waste for automobiles. This type of carpet is a tufted carpet in which pile yarn is tufted on a base fabric, or a needle punched carpet in which a short fiber web is hardened with a needle. Is.
Carpet waste is generated as a trimming loss after the outer periphery of the product is cut into a required shape in the production process, and the carpet laid when the automobile or the like is discarded is collected separately.
[0003]
As a conventional mode for recycling the carpet waste material, there is an example in which the carpet waste material mainly composed of a thermoplastic resin is heated and melted, homogenized (mixed with a compatibilizer), and re-pelletized. For example, Japanese Patent Application No. 3-208894 pulverizes a waste material of a nylon pile carpet and melt kneads it with a maleic anhydride-modified polyolefin and a peroxide compound. According to this kind of recycling, it is possible to secondary process the obtained recycled pellets and recycled sheets.
[0004]
The recycling of heating and melting carpet waste materials has the following problems.
(1) In addition to the waste carpet material, a considerable amount of virgin resin is required as a base material, and the waste carpet material is kneaded with the base material, which cannot be said to be completely recycled.
(2) Due to poor dispersibility of the carpet waste material in the base resin, the amount of incorporation into the base material is limited, the uniform sheeting is difficult in the sheeting of the recycled sheet, and the obtained sheet Is brittle and easy to break.
(3) It is necessary to increase the kneading temperature (260 ° C. or higher), and depending on the type of resin, it may reach the decomposition temperature and may not be recycled due to gas generation.
[0005]
[Problems to be solved by the invention]
The present invention has been considered in view of the above problems, and provides a method for producing a recycled sheet that can be formed mainly from carpet waste.
[0006]
[Means for Solving the Problems]
The means of the present invention for solving the problem is to pulverize a waste material of a carpet lined with a back coating material containing a filler in an elastomeric thermoplastic resin having a crystallinity of less than 20% and a decomposition temperature of 260 ° C. or higher, A recycled sheet using waste carpet material, characterized by kneading and sheeting so that the weight ratio of the back coating material is 65% or more without essentially blending other base resin or modifier. Depends on manufacturing method .
[0007]
In the present invention, a recycled sheet is obtained by processing a carpet waste material, and essentially no other base material resin is required. This is accomplished by using an elastomeric thermoplastic for the carpet backing.
In this case, taking advantage of the flexibility of the elastomeric thermoplastic resin, the kneading temperature can be set to 260 ° C. or higher to achieve homogeneous kneading. The elastomeric thermoplastic resin that meets the conditions of the invention has a crystallinity of at least less than 20% and a decomposition temperature of 260 ° C. or higher.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described.
[0009]
(Carpet, backing, other fillers)
Carpets with an elastomeric thermoplastic backing are suitable for use. The elastomer-based thermoplastic resin preferably has a crystallinity of less than 20% and a decomposition temperature of 260 ° C. or higher (olefin-based elastomer containing 30% by weight or more of PP, PE, EPR, etc.). The filler is preferably a heavy particle body (particles such as CaCO 3 and BaSO 4 , organic particles and inorganic particles such as talc, automobile bumper waste, metal powder, etc.).
[0010]
(Kneading)
Processing of the recycled sheet is performed in the order of pulverization, kneading, and sheeting of the carpet. The kneading equipment can be a Banbury mixer, a kneader, or a short-shaft / double-screw extruder, but a twin-screw extruder that easily generates heat during kneading is preferable. Sheeting can be performed by calendar or T-die extrusion. Extrusion speed 0.5-5 m / min, T die lip interval 1.0-10 mm. The sheet is cooled and rolled into a sheet having a thickness of 0.5 to 5 mm with a rolling roll (mirror roll).
[0011]
Hereinafter, an example (comparative example) shown in Table 1 will be described.
(Preparation of sample) In the examples and comparative examples, the same carpet (polyester base fabric with nylon pile tuft) is lined with a different resin (back coating material) (and the back coating material has a filler) hints), by grinding it to (8 to 20 mm), put into a biaxial extruder, and kneaded. At this time, the temperature of the resin reached 260 to 270 ° C. The kneaded product was extruded from a T die onto a sheet having a thickness of 2 mm and cooled to obtain a recycled sheet.
(Evaluation) Evaluation was performed on the sheet extrudability (uniform sheeting, resin decomposition, no foaming) and the physical properties (flexibility, cold resistance) of the obtained recycled sheet.
[Table 1]
(result)
As shown in Table 1, the evaluation results showed that there was no problem in the processability and physical properties of the recycled sheet in the composition of the example, whereas in Comparative Example 1, the non-elastomeric resin was lined. The sheet thus obtained was inferior in flexibility and cold resistance. In Comparative Example 2, since the decomposition temperature of the backing resin was lower than the processing temperature, the resin was decomposed and foamed, making it difficult to seat.
[0013]
【The invention's effect】
According to the present invention, it is possible to form a recycled sheet mainly using carpet waste, and the sheeting processability of the recycled sheet is excellent.
The obtained recycled sheet has cold resistance and flexibility, is heavy, and has excellent sound insulation.
Claims (1)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP16940298A JP3755302B2 (en) | 1998-06-17 | 1998-06-17 | Recycled sheet manufacturing method using carpet waste |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP16940298A JP3755302B2 (en) | 1998-06-17 | 1998-06-17 | Recycled sheet manufacturing method using carpet waste |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2000000869A JP2000000869A (en) | 2000-01-07 |
| JP3755302B2 true JP3755302B2 (en) | 2006-03-15 |
Family
ID=15885946
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP16940298A Expired - Fee Related JP3755302B2 (en) | 1998-06-17 | 1998-06-17 | Recycled sheet manufacturing method using carpet waste |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3755302B2 (en) |
-
1998
- 1998-06-17 JP JP16940298A patent/JP3755302B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JP2000000869A (en) | 2000-01-07 |
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