JP4339734B2 - Recycled molded body and method for producing the same - Google Patents

Description

  The present invention relates to a recycled molded body and a method for manufacturing the same, in which a structure made of a fiber reinforced resin is recycled and recycled.

  Synthetic wood with excellent corrosion resistance and strength instead of wood for sleepers used in railway tracks, pressure plates to prevent landslides on slopes, or cover lids installed in water tanks and waterways Is frequently used. This synthetic wood is made of a hard synthetic resin foam reinforced with glass fibers or the like oriented in the longitudinal direction, and is lightweight, highly corrosion-resistant, and can withstand long-term use.

  By the way, since synthetic wood contains a large amount of reinforcing fibers such as glass fibers, it has been difficult to dispose of the used synthetic wood as it is. For this reason, examination of the reduction | decrease of content, such as glass fiber, and the recycling method are made | formed.

  For example, one form of synthetic wood is proposed in which a core material made of a thermosetting resin containing a filler and a surface material made of a thermosetting resin containing a reinforcing fiber material are laminated (see Patent Document 1). ).

  The composite material described in Patent Document 1 includes a core material made of a thermosetting resin foam, and a surface material integrally laminated on at least one surface side and the opposite surface side of the core material. Is a composite material characterized by comprising a fiber reinforced resin obtained by reinforcing a thermosetting resin foam with long fibers along the longitudinal direction of the surface material.

  According to the embodiment of the composite material described in Patent Document 1, while the conventional synthetic wood contains approximately 15% by volume of glass fiber, the content can be reduced to less than 10% by volume. Further, for example, if a crushed synthetic wood structure to be discarded is used as a filler for the core material in the embodiment described in the above publication, it is possible to recycle synthetic wood that is difficult to discard.

  However, the strength and rigidity of the structure before crushing could not be expressed even if synthetic wood was regenerated using the crushed material containing the fiber reinforcement as it was. This is because most of the structure is occupied by the resin, so that a large amount of crushed material in which the resin phase is pulverized at the time of crushing, these resin powders do not contribute as aggregates, This is because the strength and rigidity cannot be improved.

  In particular, when a structure made of a fiber reinforced rigid synthetic resin foam is crushed, the resin phase is a foam, so that it is more easily pulverized, and only the crushed material from which the resin powder has been removed is reused. However, it is not possible to ensure the strength and rigidity as much as the molded material oriented by aligning the fibers in one direction as in the original structure. For this reason, it is not possible to recycle the waste material of synthetic wood to make a new recycled molding material, synthetic wood or synthetic sleeper having sufficient strength and rigidity, and improvement has been desired.

  As a method for solving this problem and a molding material, the invention described in Patent Document 2 has been made. The method for producing a regenerated molded material and the regenerated molded material, the regenerated structural material, the synthetic sleeper and the lightweight synthetic wood described in Patent Document 2 include a step of crushing a structure made of fiber-reinforced molded material, and a predetermined range from the crushed material. The step of sorting the elongated chip-shaped fragments having thickness, width and length, the step of attaching the binder to the surface of the sorted fragments, and the longitudinal direction of the fragments to which the binder is attached are the same direction Forming the plate-like aggregate of the crushed pieces in the thickness direction, and forming the plate-like aggregates of the crushed pieces in the thickness direction. A binder is attached to the surface of a slender chip-shaped shredded piece obtained by crushing a structure made of fiber-reinforced molding material, and the longitudinal direction of the shredded piece Crushing while aligning and orienting in the same direction Recycled molding material characterized in that it is formed into a plate shape so that the aggregate by the shape becomes long in the orientation direction, and the shaped aggregate of the crushed pieces is press-formed in the thickness direction It is.

  The manufacturing method of the recycle molding material and the recycle molding material described in Patent Literature 2 are a manufacturing method of manufacturing a recycle molding material having sufficient strength and rigidity by reusing a waste structure made of a fiber reinforced molding material. The molding material obtained by this manufacturing method can be provided.

JP-A-5-138797 (pages 1 to 6) Japanese Patent Application No. 2003-137558 (pages 1 to 27)

However, the invention of Patent Document 2, when using a molded article to align the chip-like fragments in one direction as such sleepers on e.g. track ballast, since the wood port is a collection of sharp edges of the tip a small gap can be easily between the chips, sometimes wood port is scraped by abrasion by the ballast. In addition, there is also a risk of corroding the screws of the fastening easier to water the water from the tree opening. In other words, there were problems of wear of the regenerated molding material and water absorption.

An object of the present invention is to reuse the waste structure that is manufactured by the fiber reinforced resin, having sufficient strength, rigidity, less wear of the wood opening, also water less play moldings from wood port And providing a manufacturing method thereof.

  The present invention has been made to achieve the above object, and the invention of claim 1 is characterized in that the ratio of the major axis to the minor axis obtained by crushing and selecting a structure made of fiber reinforced resin is selected. An adhesive is attached to the surface of two or more elongated chip-shaped crush pieces so that the aggregates of the crush pieces are elongated in the orientation direction while aligning the longitudinal direction of the crush pieces in the same direction. In a regenerated molded body formed by press-molding a plate-like assembly made of shaped crushed pieces in the thickness direction, the crushed pieces at both ends in the longitudinal direction of the regenerated molded body are A reclaimed molded body characterized by being shaped randomly.

Further, the invention of claim 2 is a step of crushing a structure made of fiber reinforced resin, and a step of selecting elongated chip-shaped crush pieces having a major axis / minor axis ratio of 2 or more from the crushed material, The process of attaching the adhesive to the surface of the selected crushed pieces and the aggregate of the crushed pieces are elongated in the alignment direction while aligning the longitudinal direction of the crushed pieces attached with the adhesive in the same direction. The step of shaping into a plate shape, the step of shaping both ends in the longitudinal direction of the plate-like assembly while randomly arranging the pieces to which the adhesive has been attached, and the plate-like set of shaped pieces And a step of press-molding the body in the thickness direction.

  The fiber reinforced resin that is a material of the structure to be crushed in the present invention is not particularly limited, but a thermosetting hard resin is preferable when the regenerated molded body is used as a structural material that requires strength. Specific examples include polyurethane resins, phenol resins, unsaturated polyester resins, diallyl phthalate resins, vinyl ester resins, epoxy resins, urea resins, melamine resins, polyimide resins, polyamideimide resins, acrylic resins, and the like. May be foamed using an auxiliary agent. In particular, in order to obtain a light-weight and high-strength recycled molded body, a foam of a hard polyurethane resin is preferable.

  In addition, the shape of the fiber contained in the fiber reinforced resin to be crushed is not limited as long as it has a function as a reinforcing fiber. For example, monofilaments, fibrillated fiber elements (those protruding from cocoon-like fibers), For example, weaving thread. Further, the reinforcing fiber may be, for example, only glass fiber, or may be a composite of glass fiber and reinforcing fiber such as carbon fiber or synthetic fiber.

  Although the volume ratio of the fiber contained in the produced | generated reproduction | regeneration molded object is not specifically limited, 5 volume%-40 volume% are preferable. When the volume ratio of the fibers is less than 5% by volume, the strength improvement effect due to the crushed pieces is low, and the strength of the recycled molded body cannot be ensured. On the other hand, when the fiber volume ratio exceeds 40% by volume, the workability such as cutting of the regenerated molded body and driving of nails is remarkably deteriorated.

When the fiber reinforced resin to be crushed is a foam, the average density of the resin is preferably 0.2 g / cm ³ or more. If the average density of the resin is less than 0.2 g / cm ³ , the strength decreases. The upper limit of the average density of the fiber reinforced resin is not particularly limited. Specific examples of the structure to be crushed include synthetic wood made of a hard urethane resin foam reinforced with long glass fibers aligned in one direction. The recycled molded body and the manufacturing method of the present invention can also be applied when recycling waste materials such as track sleepers made of this synthetic wood.

  The adhesive used in the present invention is not particularly limited, and examples thereof include phenol, urea, isocyanate, urethane, epoxy, and other resin adhesives used for the wood industry. These can be used alone or in combination. . Moreover, although the quantity of an adhesive agent is based also on the shape, surface property, and density of a crushing piece, it is preferable to adhere 1-20 weight% normally with respect to the weight of a crushing piece. In particular, in order to reduce the weight of the recycled molded body, it is preferable to apply as little adhesive as possible to the crushed pieces, and a low-viscosity isocyanate adhesive is suitable. In addition, an isocyanate-based adhesive is particularly preferably used because it reacts with water vapor emitted from a water-soluble or water-dispersible (emulsion type) release agent to accelerate the curing reaction.

  The present invention uses elongated chip-shaped fragments obtained by crushing a structure made of fiber reinforced resin as a raw material. However, when the structure of fiber reinforced resin is crushed, the resin material is fixed around the fiber. The elongated chip-shaped crushed pieces and the crushed material in which only the resin is pulverized into a powder form are generated. According to the present invention, among these crushed materials, a new molding is performed by selectively reusing only the elongated chip-shaped crushed pieces containing fibers without using the crushed resin crushed into powder. It is to regenerate the body. Then, the longitudinal direction of the crushed pieces is aligned and oriented in the same direction, and the reclaimed molded body is obtained by molding so that the longitudinal direction of the reclaimed molded body becomes the orientation direction of the crushed pieces. Thereby, the fiber contained in the crushed piece functions as a reinforcing material, and can be made into a recycled molded body with improved bending rigidity and bending strength in the longitudinal direction, and can be manufactured.

Moreover, it is a reproduction | regeneration molded object by which the crushing piece of the both ends of the longitudinal direction of a reproduction | regeneration molded object is shape | molded at random. As for the both ends in the longitudinal direction of the molded product, the length from the end in the longitudinal direction is preferably 20 to 300 mm , and both sides of this range are described as both ends. If the length is too short, less wear of the wood port, not a water absorption less play moldings from wood port. On the other hand, if the length is too long, the bending performance of the molded product will deteriorate. Furthermore, if the step of shaping both ends in the longitudinal direction of the plate-like assembly is not applied to both ends of this range while randomly disposing the crushed pieces to which the adhesive has been attached, the recycled molded body is manufactured. I can't.

  In the present invention, there are various apparatuses for crushing a structure made of fiber reinforced resin. For example, a uniaxial crusher that crushes a structure with a roller having a rotary blade or a structure that passes between a pair of rollers arranged in parallel with a rotary blade so that both rotary blades are engaged with the structure. A biaxial crusher or the like for crushing can be employed. In addition, as an apparatus for sorting elongated chip-shaped crushed pieces having a predetermined range of thickness, width and length from crushed materials, for example, a wave roller type classifier can be used. A wave roller type classifier is a device that continuously classifies on the basis of the thickness and width of the crushed material, and pulverizes the chip into elongated chips having a predetermined range of thickness, width, and length. Pieces can be sorted out.

  In order to attach the adhesive to the selected crushed pieces, for example, a method in which the adhesive is sprayed on the crushed pieces put on the conveyor or in the drum blender and the adhesive is uniformly attached to the surface of the crushed pieces. Can be taken.

  In addition, various methods can be employed for aligning the sorted pieces in the longitudinal direction. For example, when dropping the crushed pieces onto a molding die or a conveyor, a method of orienting through a comb-like slit having a predetermined width and length, or an assembly of randomly arranged crushed pieces with a disk-like slit The method of orienting by passing can be adopted. It is also possible to use a disk orienter used for manufacturing a wood-based molding material. That is, when the crushed pieces are dropped, the longitudinal direction of the crushed pieces can be aligned and oriented in the molding line direction by the disc orienter.

  In order to randomly arrange the crushed pieces to which the adhesive is attached, various methods can be employed. For example, it is possible to spontaneously drop the crushed pieces on a molding die or a conveyor, a method of randomly shaping through a grid-shaped baffle plate having a predetermined width and length, or a method of randomly arranging crushed pieces A method of dropping the assembly through a rotating slit can be employed.

  Press molding is performed, for example, by pressing a shaped plate-like aggregate of crushed pieces while heating from both sides, whereby a regenerated molded body of a predetermined size can be obtained. The pressing time at this time is determined according to the repulsive force relaxation time and the adhesive curing time. Here, the repulsive force is a repulsive force that the press disk receives from the regenerated molded body when the regenerated molded body is compressed to a predetermined density.

  As a heating method, a method of heating the regenerated molded body by heating the press plate and transferring the heat to the upper and lower molds, or a method of heating by embedding a heater in the mold can be used. You may use the method of heating directly the inside of a reproduction | regeneration molded object using electromagnetic waves, and a crush piece and an adhesive agent. According to the latter method in which the inside is directly heated, the molding time is further shortened and the working efficiency is improved. A heating method from the inside of the press plate or the mold may be taken through steam, or a method of blowing steam from the inside of the mold into the crushed pieces.

  The heating temperature is 100 ° C. or higher because it is necessary to evaporate water, and the upper limit is generally 250 ° C. or lower although it depends on the heat resistance temperature of the chip-like crushed pieces and the heat resistance temperature of the adhesive. desirable.

  As for the shape of the chip-shaped fragment, the ratio between the major axis direction and the minor axis direction is 2 or more. If it is less than that, the difference between the long axis and the short axis of the crushed pieces will be small, and it will be difficult to orient the crushed pieces in one direction, and it will be difficult to improve the bending properties of the recycled molded product in the long axis direction. .

  The crushed pieces are oriented after being glued and shaped into a plate shape, and this is press-molded to obtain a molded product. The crushed pieces inside can be easily compacted, and if the proportion of small pulverized crushed products (pulverized products) is too large, a large amount of binder is required or the same amount of binder is used. Then, the amount of the binder is insufficient and it is difficult to adhere uniformly, and in any case, the strength variation of the final product becomes large.

  For the strength variation of the final product, a crushed piece having no dimensional variation or a crushed piece having a small content of pulverized material may be used. Therefore, in the production method of the present invention, a step of selecting the crushed piece may be provided. Needless to say, the smaller the amount of crushed pieces or pulverized materials that are not used after sorting, the higher the efficiency of use of the raw materials, and it is therefore preferable.

  However, when crushing fiber reinforced resin, it is difficult to break the fiber, and in the case of a machine that crushes by shearing or a machine that crushes by hitting, the breaking position of the fiber greatly varies, and the shape of the crushing pieces is not constant. A lot of pulverized material is generated.

  For this reason, in the crushing process, the length of the structure previously made of fiber reinforced resin may be cut to 50 mm to 200 mm and then crushed. If the length of the structure made of fiber reinforced resin, that is, the length of the fiber in the structure is greater than 200 mm, if the fiber is crushed, the length of the fiber in the crushed material is less than 2 mm In some cases, 30% by weight or more is generated. Moreover, if it is less than 50 mm, the length of the pulverized product having a length of less than 2 mm increases, and in any case, the strength of the final product is lowered.

As an effect of the present invention, the present invention adheres to the surface of a slender chip-shaped crushed piece having a ratio of a major axis to a minor axis of 2 or more obtained by crushing and selecting a structure made of fiber reinforced resin. An agent is attached, and the aggregates of the crushed pieces are shaped into a plate shape so as to be elongated in the orientation direction while aligning the longitudinal direction of the crushed pieces in the same direction. in reproducing the molded body formed by heat press molding a plate-like aggregate in the thickness direction, reproducing the molded body, characterized in that the crushed pieces of both ends in the longitudinal direction of the reproducing compact is shaped randomly because it reuses waste structure that is manufactured by the fiber reinforced resin, sufficient strength, rigid, less wear of the wood port, also, provides a water absorption less play moldings from wood port it can.

Further, the present invention includes a step of crushing a structure made of fiber reinforced resin, a step of selecting elongated chip-shaped crush pieces having a major axis / minor axis ratio of 2 or more from crushed material, The step of attaching the adhesive to the surface of the crushed pieces and the plate so that the aggregates of the crushed pieces are elongated in the orientation direction while aligning the longitudinal direction of the crushed pieces with the adhesive aligned in the same direction. A step of shaping the plate-like aggregates, a step of shaping both ends in the longitudinal direction of the plate-like aggregates while randomly arranging the pieces to which the adhesive is attached, and a thickness of the plate-like aggregates of the shaped fragments since the manufacturing method of reproducing moldings and a step of press-molding in the direction, by reusing the waste structure that is manufactured by the fiber reinforced resin, it has sufficient strength, rigidity, wear wood port provide less, a method of manufacturing a water absorbing little play moldings from wood port Kill.

Hereinafter, embodiments of the present invention will be described based on examples with reference to the drawings.
1 (a) to 1 (e) are explanatory views showing a process for producing a recycled molded body of the present invention.
FIG. 2 is an explanatory view showing a recycled molded body of the present invention.
FIG. 3 is an explanatory view showing a conventional recycled molded body.

(Example 1)
In the present embodiment, synthetic wood (Eslon Neo Lumber FFU74 manufactured by Sekisui Chemical Co., Ltd.) made of a long glass fiber reinforced hard urethane resin foam is used as the structure to be discarded. First, in the crushing process of the structure to be discarded, the synthetic wood was crushed using a biaxial crusher. Then, the crushed material is put into a wave roller type classifier and classified, and as shown in FIG. 1A, an elongated chip-shaped crushed piece 10 having an average major axis length of 30 mm and an average minor axis length of 5 mm is obtained. Sorted. The sorting yield of the crushed pieces 10 was about 35%. The density of the sorted fragments 10 was ^{0.5g / cm 3 ~0.8g / cm 3} .

  Next, in the adhesive attaching step, as shown in FIG. 2 (b), an isocyanate adhesive (MDI: Methylene Diphenyl Isocyanate; “Sumijour 44V10” manufactured by Sumika Bayer Urethane Co., Ltd.) together with the crushed pieces 10 in the drum blender 11. ) Was added in an amount of 15% by weight based on the total amount of the crushed pieces, and the mixture was uniformly stirred to apply the adhesive to the surface of the crushed pieces 10.

As shown in FIG. 1 (c), in the edge shaping step, the crushed pieces 10 coated with adhesive are dropped from the upper belt conveyor 19, and the crushed pieces 10 are randomly placed in the molding die 15. The chip-like crushing pieces 10a arranged at random were formed at the ends of the plate-like crushing piece aggregate 18 in the longitudinal direction. The chip-shaped crushing pieces 10a arranged at random were pressed in the thickness direction while rotating the pressing roller 12, and were shaped so that no extra space was formed. The length from the end of the random shaping part was 50 mm .

  In the orientation step, as shown in FIG. 1 (d), an orienter 13 having a slit 14 at the lower part is arranged, and the crushed pieces 10 coated with the adhesive are dropped from the upper belt conveyor so that the crushed pieces 10 While aligning the longitudinal direction in the molding line direction, the crushed pieces 10 were put into the molding die 15 to shape the aggregate 18 of crushed pieces shaped into a plate shape. The orientation of the orienter 13 was slid from the position perpendicular to the longitudinal line of the assembly 18 when the irregular orientation process at the end was completed.

Furthermore, at the other end, the orienter 13 is removed from the longitudinal line, and the crushed pieces 10 coated with the adhesive are dropped again from the upper belt conveyor 19, and the crushed pieces 10 are randomly placed in the molding die 15. And the chip-shaped crushing piece 10a arrange | positioned at random at the other edge part was shaped. The length from the other end of the other random shaping part was 50 mm .

Then, as shown in FIG. 1 (e), the shaped plate-like assembly 18 of the crushed pieces 10 is inserted into the press device 16, and a water-soluble mold release agent (Chukyo oil and fat mold release agent 916) is applied in advance. The regenerated molded product 1 having a thickness of 140 mm, a width of 200 mm, a length of 2100 mm, and an average density of 1.2 g / cm ³ was obtained between the heated plates while being heated at 180 ° C. The press time was 30 minutes.

The performance evaluation of the regenerated molded product 1 was performed as follows.
The bending strength was evaluated by bending the regenerated molded product 1 at a span of 1120 mm at three points, measuring the breaking strength, and obtaining the bending strength.

  The water absorption evaluation was performed by immersing the regenerated molded product 1 in a water tank, measuring the weight increment after 7 days, and calculating the number obtained by dividing this value by the surface area to obtain the water absorption.

  The amount of wear is evaluated by cutting out the lip portion of the regenerated molded product 1 and placing it on the ballast and pressing it against the lip and applying vibration to the regenerated molded product 1 at 30 Hz for 3 days. Was measured as the amount of wear.

(Example 2)
In Example 1, it is the same as Example 1 except the length from the edge part of the random shaping part of both ends being 150 mm.

  FIG. 2 is an explanatory view showing a recycled molded body of the present invention. The reproduction | regeneration molded object manufactured in Example 1 and 2 is shown. 10a is randomly arranged chip-shaped crushed pieces, 10b is a chip-shaped crushed piece oriented in the longitudinal direction, and the tip of the chip-shaped crushed pieces is arranged randomly, so it is difficult to absorb water, Hard to wear.

(Comparative Example 1)
In Example 1, it is the same as Example 1 except the length from the edge part of the random shaping part of both ends being 150 mm. That is, it is the same as Example 1 except not providing the shaping process of the chip-shaped crush pieces 10a arranged at random.

  FIG. 3 is an explanatory view showing a conventional recycled molded body, and shows the recycled molded body manufactured in Comparative Example 1. In the conventional reclaimed molded product A, 10b indicates chip-shaped crushed pieces oriented in the longitudinal direction, and the chip end is oriented with chip-shaped crushed pieces, so that it is easy to absorb water and wear easily.

(Comparative Example 2)
In Example 1, it is the same as Example 1 except the length from the edge part of the random shaping part of both ends being 500 mm.

  The evaluation results for Examples 1 and 2 and Comparative Examples 1 and 2 are summarized in Table 1.

As seen from Table 1, the present invention is to reuse the waste structure that is manufactured by the fiber reinforced resin, sufficient strength, rigid, less wear of the wood opening, also water from the tree outlet Is a regenerated molded body and a method for producing the same.

As an example of use of the present invention, it is used for a sleeper used for railroad tracks and a pressure receiving plate for preventing a landslide on an inclined land, or used as a cover for a water tank or a water channel, etc. Reusable synthetic wood waste structure with excellent strength, that is, waste structure made of fiber reinforced resin, can be used as a sleeper on a ballast track, etc., with sufficient strength and rigidity , less wear of the wood opening, also water less play moldings from wood port and can be used as a manufacturing method thereof.

(A)-(e) is explanatory drawing which shows the manufacturing process of the reproduction | regeneration molded object of this invention. It is explanatory drawing which shows the reproduction | regeneration molded object of this invention. It is explanatory drawing which shows the conventional reproduction | regeneration molded object.

DESCRIPTION OF SYMBOLS 1 Recycled molded body 2 Synthetic sleeper 10 Chip-shaped crushing piece 10a Randomly arranged chip-like crushing piece 10b Chip-shaped crushing piece 11 oriented in the longitudinal direction Drum blender 12 Presser roller 13 An orienter having a slit in the lower part 14 Slit 15 Molding die 16 Press device 18 Assembly of crushed pieces

Claims (2)

  An adhesive is attached to the surface of an elongated chip-shaped fragment having a ratio of the major axis to the minor axis of 2 or more obtained by crushing and selecting a structure made of fiber reinforced resin, and the length of the fragment While aligning the directions in the same direction and orienting them, shape the plate-like aggregates made of crushed pieces into a plate shape so that the aggregates made of crushed pieces are elongated in the direction of orientation, and in the thickness direction A reclaimed molded article formed by hot press molding, wherein the crushed pieces at both ends in the longitudinal direction of the reclaimed molded article are randomly shaped.   A step of crushing a structure made of fiber reinforced resin, a step of sorting out slender chip-shaped crush pieces having a major axis / minor axis ratio of 2 or more from the crushed material, and a surface of the crushed crush pieces A step of adhering the adhesive, and a step of shaping the aggregate of the crushed pieces into a plate shape so as to be elongated in the orientation direction while aligning and orienting the longitudinal direction of the crushed pieces to which the adhesive is attached in the same direction; , A step of shaping both ends of the plate-like assembly in the longitudinal direction while randomly arranging the pieces to which the adhesive has been attached, and press-molding the plate-like assembly of the shaped pieces in the thickness direction A method for producing a regenerated molded body comprising the steps.