JP5662404B2 - Waste carpet recycling method and recycled carpet produced from the resources obtained by the recycling method - Google Patents

Description

  The present invention relates to a method for recycling waste carpet and a recycled carpet manufactured by the recycling method.

  In recent years, millions of tons of fiber waste has been discharged annually, but the recycling rate is less than about 10%, and effective use of fiber waste has become an urgent task. Among them, the waste carpet is very little recycled, but most of it is incinerated as waste material. Therefore, there is a demand for securing resources using 100% of the waste carpet and reducing CO2 emissions.

  In this regard, conventionally, for example, as a manufacturing method for regenerating tufted fabric waste and recycling it to carpet, the one described in Japanese Patent Application Laid-Open No. 9-21050 (Patent Document 1) presented by the applicant is known. In the manufacturing method for reclaiming tufted fabric waste described in the above publication and recycling it to carpet, the surface of the new fiber web is obtained by passing the tufted fabric waste produced by the tufted fabric manufacturing process through a repelling machine. It is formed as an intermediate layer of a needle punching carpet formed with a non-woven fabric as a back layer.

JP-A-9-21050

  However, in the manufacturing method, only the tufted fabric waste produced in the tufted fabric manufacturing process is regenerated, and it can be said that it is sufficient from the viewpoint of recycling 100% of the desired waste carpet as described above. Absent. Moreover, the carpet manufactured by the said manufacturing method is a needle punching felt carpet, and is not recycled to the tufted carpet with much demand.

  The present invention has been made in view of the above points, and an object of the present invention is to provide a recycling method for recycling 90% or more of waste carpet, and to produce recycled carpet using the waste carpet with high efficiency. It is to secure resources.

  Another object of the present invention is to reduce the amount of CO2 emission by eliminating the amount of CO2 emitted by incinerating waste carpet and reusing it as a raw material for carpet again.

  The method for recycling waste carpet according to claim 1 includes a step of defibrating and cutting the waste carpet into fibers or fiber lumps of a predetermined size, and short fibers from the fibers or fiber lumps after defibration and / or after cutting. And a step of separating the latex powder, a step of opening the fiber that has been defibrated and cut in the first step, forming a web sheet, and separately adding felt to the web sheet formed in the step In addition, a second step comprising a step of forming a laminated felt as a raw material for recycled carpet by performing needle punching, and PET flakes are added to the fibers or fiber mass separated and dropped at the time of opening in the second step and melted. A step of forming a pellet, and a step of separately adding a pellet to the pellet formed in the above step and melting and spinning and drawing to form a pile yarn used as a raw material for a recycled carpet. And third step, characterized in that it comprises a fourth step comprising the step of forming the formulated latex short fibers and latex powder separated and added to the latex as a raw material for the reproduction carpet in the first step.

  In the waste carpet recycling method according to claim 1, it is possible to recycle 90% or more of the waste carpet, and it is possible to secure resources using the waste carpet with high efficiency and to reduce CO2 emissions.

  A method for recycling waste carpet according to a second aspect includes the first to fourth steps according to the first aspect, and further includes a step of tufting the pile yarn formed in the third step onto a base fabric; A step of applying the prepared latex formed in the four steps, a step of backing the felt formed in the second step on the base fabric coated with the prepared latex, and a step of sewing the carpet lined in the step. And a fifth step.

  In the waste carpet recycling method according to claim 2, 90% or more of the waste carpet can be recycled, and a recycled carpet can be manufactured using the recycled material as a raw material. CO2 emissions can be reduced.

  The waste carpet recycling method according to claim 3 is the waste carpet recycling method according to claim 2, wherein the first step is a step of defibrating the waste carpet into fibers or fiber masses of approximately 200 mm or less; A step of separating short fibers and latex powder of less than about 2 mm from a fiber or fiber mass of about 200 mm or less, a step of cutting the fiber or fiber mass into a fiber of about 100 mm or less, and about 2 mm from the fiber of about 100 mm or less A step of separating less than short fibers and latex powder, and the second step is to add a polyester cotton to the fibers of about 100 mm or less to open and form a web sheet; A process for forming a laminated sheet by adding felt, and a process for producing a recycled felt by performing needle punching on the laminated sheet And the third step includes adding PET flakes to the short fibers of approximately 2 mm to 30 mm separated at the time of opening in the second step, melting, cooling, and cutting to produce pellets; Adding a pellet, melting, spinning and drawing to produce a pile yarn, wherein the fifth step includes tufting the pile yarn formed in the third step onto a base fabric; and The method includes a step of applying the prepared latex formed in the step, and a step of backing the felt manufactured in the second step on the base fabric to manufacture a recycled carpet.

  In the waste carpet recycling method according to claim 3, 90% or more of the waste carpet can be recycled, and a recycled carpet can be manufactured using the recycled material as a raw material. CO2 emissions can be reduced.

  A recycled carpet according to claim 4 is a recycled carpet manufactured using a recycled carpet raw material obtained by the waste carpet recycling method according to claim 2 or claim 3, wherein the recycled carpet raw material ratio is The total is 10% by weight or more.

  In the recycled carpet according to claim 4, 90% or more of the waste carpet can be recycled, and a recycled carpet can be manufactured using the recycled carpet as a raw material at a high ratio, and securing of resources using the waste carpet with high efficiency is ensured. And CO2 emissions can be reduced.

  According to the method for recycling waste carpet according to claim 1, the step of defibrating and cutting the waste carpet into a fiber or fiber lump of a predetermined size, and the fiber or fiber lump after defibration and / or after cutting. Separating the short fibers and latex powder from the first step, opening the fibers defibrated and cut in the first step, forming a web sheet, and the web sheet formed in the step A PET flake is added to the fiber or fiber lump that has been separated and dropped at the time of opening of the second step, and a step of forming a laminated felt as a raw material for recycled carpet by adding a separate felt and performing needle punching A step of melting and forming pellets, and a step of adding piles separately to the pellets formed in the above step, melting, spinning and drawing to form pile yarns as raw materials for recycled carpet, A third step, a step of adding the short fibers and latex powder separated in the first step to the latex to form a blended latex that is a raw material for the recycled carpet, and a fourth step. % Can be recycled, and resources can be secured and CO2 emissions can be reduced using the waste carpet with high efficiency.

  According to the method for recycling waste carpet according to claim 2, the method includes the first to fourth steps according to claim 1, and further includes a step of tufting the pile yarn formed in the third step onto a base fabric; The step of applying the prepared latex formed in the fourth step, the step of backing the felt formed in the second step on the base fabric coated with the prepared latex, and sewing the carpet backed in the step. And the fifth step comprising the step, the waste carpet can be recycled 90% or more, and a recycled carpet can be produced using it as a raw material, ensuring resources using the waste carpet with high efficiency and CO2 emission. The amount can be reduced.

  According to the waste carpet recycling method according to claim 3, in the waste carpet recycling method according to claim 2, the first step is a step of defibrating the waste carpet into fibers or fiber lumps of approximately 200 mm or less. Separating the short fibers and latex powder of less than about 2 mm from the fibers or fiber mass of about 200 mm or less, cutting the fiber or fiber mass into fibers of about 100 mm or less, and fibers of about 100 mm or less Separating the short fibers and latex powder of less than about 2 mm from the above, the second step adding polyester cotton to the fibers of about 100 mm or less to open and forming a web sheet, and the web A process for forming a laminated sheet by adding polyester felt to the sheet, and making a recycled felt by performing needle punching on the laminated sheet And the third step includes adding PET flakes to the short fibers of about 2 mm to 30 mm separated at the time of opening in the second step, melting, cooling and cutting to produce pellets, and the pellets. And a step of producing a pile yarn by melting and spinning and drawing, and the fifth step includes a step of tufting the pile yarn formed in the third step onto a base fabric, and Since the step of applying the prepared latex formed in the fourth step and the step of backing the felt produced in the second step on the base fabric and producing a recycled carpet, the waste carpet is recycled 90% or more, Recycled carpet can be manufactured using the raw material as a raw material, and resources can be secured and CO2 emissions can be reduced using the waste carpet with high efficiency.

  According to the recycled carpet of Claim 4, it is the recycled carpet manufactured using the raw material of the recycled carpet obtained by the recycling method of the waste carpet of Claim 2 or Claim 3, Comprising: Moreover, the said waste carpet Since the sum total of the raw material ratio of the carpet is 10% by weight or more, the waste carpet can be recycled 90% or more, and a recycled carpet can be manufactured using the recycled carpet as a raw material at a high ratio. Resources can be secured and CO2 emissions can be reduced.

It is a flowchart which shows the manufacturing method of the reproduction | regeneration carpet which concerns on this invention. It is the schematic which shows the manufacturing process (1st process) of a reproduction | regeneration carpet. It is the schematic which shows the manufacturing process (2nd process) of a reproduction | regeneration carpet. It is the schematic which shows the manufacturing process (3rd process) of a reproduction | regeneration carpet. It is the schematic which shows the manufacturing process (4th process) of a reproduction | regeneration carpet. It is the schematic which shows the manufacturing process (5th process) of a reproduction | regeneration carpet. It is a flowchart which shows the manufacturing process (1st process) of a reproduction | regeneration carpet. It is a flowchart which shows the manufacturing process (2nd process) of a reproduction | regeneration carpet. It is a flowchart which shows the manufacturing process (3rd process) of a recycled carpet. It is a flowchart which shows the manufacturing process (4th process) of a reproduction | regeneration carpet. It is a flowchart which shows the manufacturing process (5th process) of a reproduction | regeneration carpet. It is a cross-sectional schematic diagram of a recycled carpet.

  DESCRIPTION OF EMBODIMENTS Hereinafter, a method for recycling waste carpet according to the present invention and an embodiment for manufacturing a recycled carpet manufactured using a resource obtained by the recycling method as a raw material will be described with reference to the drawings.

  FIG. 1 is a flowchart showing a method for manufacturing a recycled carpet according to the present invention. As shown in FIG. 1, the recycled carpet RCP according to the present invention includes a first step 10 to a fourth step 40 (recycling method of waste carpet) for recycling the waste carpet CP to form resources, and the first step to The recycled carpet RCP is formed using the resources formed in the fourth step 40 and is manufactured through a fifth step 50.

  That is, the recycled carpet RCP defibrates the waste carpet CP, and then cuts it to make a fiber of an appropriate size (hereinafter referred to as “fiber C”). The first step 10 for separating latex powder (hereinafter referred to as “latex powder RLP”) and the fiber C defibrated and cut in the first step 10 are subjected to carding treatment, needle punch treatment, etc., and regenerated. A PET flake 31 is added to the second step 20 for forming the felt F, and the fibers D (hereinafter referred to as “fiber D”) that have been dropped and separated during the carding process in the second step, and the recycled pellets G are obtained. A third step 30 for forming the recycled pellet G into a recycled pile yarn H, and the latex powder RLP and the new latex LTX separated in the first step 10; The waste carpet CP is (1) fiber C (which becomes a raw material for recycled felt F in the second step) and (2) fiber D (third step) by the fourth step 40 of mixing to form the blended latex RLX. And 3) RLP such as latex powder (which becomes a raw material for the compounded latex RLX in the fourth step).

  Further, (a) the recycled pile yarn H formed in the third step is tufted onto the base fabric 51, and (b) the mixed latex RLX formed in the fourth step is then placed on the back side of the base fabric 51. The recycled carpet RCP is manufactured through a coating step and (c) a fifth step 50 in which the recycled felt F formed in the second step 20 is further lined on the base fabric 51 and then sewn. . Note that the fourth step 40 may be performed between the steps from the first step 10 to the fifth step 50, even though the fourth step 40 is not performed after the third step 30 in time series.

  Hereinafter, the first step 10 to the fifth step 50 will be described in detail.

  FIG. 2 is a schematic view showing a production process (first process) of a recycled carpet, FIG. 3 is a schematic diagram showing a production process (second process) of the recycled carpet, and FIG. 4 is a production process (first process) of the recycled carpet. FIG. 5 is a schematic view showing a recycled carpet manufacturing process (fourth process), and FIG. 6 is a schematic diagram showing a recycled carpet manufacturing process (fifth process).

  FIG. 7 is a flowchart showing a process for producing a recycled carpet (first process), FIG. 8 is a flowchart showing a process for producing a recycled carpet (second process), and FIG. 9 is a process for producing a recycled carpet (first process). FIG. 10 is a flowchart showing a recycled carpet manufacturing process (fourth process), and FIG. 11 is a flowchart showing a recycled carpet manufacturing process (fifth process).

  In the first step 10, as shown in FIGS. 2 and 7, first, the waste carpet CP that has been cut to a suitable size is carried into the repelling machine 12 by the conveyor 11, and a fiber or fiber lump A (approximately 200 mm or less). Hereinafter, it is defibrated to "fiber etc. A").

  Next, the fibers etc. A are fed into the first wind draft tower 13 by the dust collector 14 to collide with the collision plate 13a provided in the first wind draft tower 13, and the fibers etc. A that rise are moved downward. Are dropped by the dropping plate 13b that is dropped on the fiber, and the short fibers of less than about 2 mm and the RLP such as latex powder (hereinafter referred to as “latex powder RLP”) are separated from the fiber A, and the first vibrating conveyor. From 15, the RLP such as latex powder is separated by shaking while being moved, and is accommodated in an accommodating portion provided below.

  Next, the fiber A or the like is carried into a pulverizer 16 having a plurality of pulverizing blades 16a rotating therein, pulverized by the pulverizing blade 16a, and a porous plate (between the pulverizing blade 16a and a discharge port ( The diameter of the fiber (not shown) is optimized and pulverized to a fiber B of approximately 100 mm or less (hereinafter referred to as “fiber B”).

  Then, the fiber B discharged from the pulverizer 16 is fed into the second wind draft tower 17 by the dust collector 14 and collides with a collision plate 17 a provided in the second wind draft tower 17. By dropping the rising fiber B by the dropping plate 13b that drops downward, the latex powder or the like RLP is further separated from the fiber B, and further the latex powder or the like RLP is moved from the second vibrating conveyor 18. The fiber B is pulverized into a fiber C (hereinafter referred to as “fiber C”) of approximately 2 mm to 100 mm.

  Through the first step 10 described above, the fiber C and the RLP such as the latex powder are obtained from the waste carpet CP.

  In addition, in the said 1st process, although the process of isolate | separating RLP, such as said latex powder, was arrange | positioned after the said defibration and the said cutting | disconnection, you may arrange | position to any one.

  In the second step 20, as shown in FIGS. 3 and 8, the fiber C obtained in the first step 10 is mixed with normal recycled PET cotton 21, and is carried into the card machine 24 by the conveyor 23, and opened. Then, a carding process for forming the web sheet E is performed. Then, approximately 2 to 30 mm of fibers D (hereinafter referred to as “fibers D”) that fall off during the carding process are separated and accommodated.

  Then, a normal recycled PET felt 25 is laminated on the web sheet E, and a needle punching process is performed by a needle punch machine 26 to produce a recycled felt F.

  In the third step 30, as shown in FIGS. 4 and 9, the fiber D obtained in the second step 20 is mixed with a PET flake 31 formed by crushing a PET bottle into small pieces, and a melt extruder 32 is mixed. Is formed by extrusion molding, cooled in a water cooling tank 33, and cut into small pieces by a cutting machine 34 to form recycled pellets G.

  Further, the regenerated pellet G is mixed with the dark color pellet 35 to adjust the color, melt extrusion processing is performed by the melt extruder 36, and the regenerated pile yarn H is formed through the spinning 37 and the stretching processing 38. .

  As shown in FIGS. 5 and 10, the fourth step 40 is a part of calcium carbonate blended in the latex LTX by mixing the latex powder or the like RLP separated in the first step 10 with the new latex LTX. It is added as an alternative to form a modified latex RLX. As described above, the fourth step 40 may be performed between the steps from the first step 10 to the fifth step 50 even if not performed after the third step 30 in time series. .

  In the fifth step 50, as shown in FIGS. 6 and 11, the recycled pile yarn H obtained in the third step is tufted onto a base fabric 51 by a tuft machine 52, and the tufted base fabric 51 is applied to the back surface of the adjustment latex RLX, and the base fabric 51 is sewed through the step 54 of backing the regenerated felt F obtained in the second step. The recycled carpet RCP is manufactured.

  As described above, through the first to fourth steps, the waste carpet CP is roughly separated into three types of RLP such as the fiber C, the fiber D, and the latex powder to be recycled resources. By forming the recycled soundproof felt using the fiber C as a raw material, forming the recycled pile yarn H using the fiber D as a raw material, and using RLP such as the latex powder as an extender of the adjusted latex RLX, 90% or more can be used as a raw material for the recycled carpet RCP.

  FIG. 12 is a schematic cross-sectional view of a recycled carpet.

  That is, in the recycled carpet RCP manufactured as described above, as shown in FIG. 12, the recycled pile yarn H tufted to the base fabric 51, the blended latex RLX applied to the back of the base fabric 51, and As a part of the raw material of the regenerated felt lined on the back surface of the base fabric 51, 2-30 mm fiber D, 2-100 mm fiber C, latex powder, etc., which are resources recycled from the waste carpet CP, respectively. RLX is used.

  Then, the distribution of the raw materials is optimized so that the total ratio of the raw materials recycled from the waste carpet CP is 10% by weight or more of the recycled carpet RCP.

  In the recycling method of the waste carpet CP shown in the first step 10 to the fourth step 40 and the recycled carpet using the resource obtained by the recycling method as a raw material, the waste carpet is recycled by 90% or more. The waste carpet is not incinerated, and the waste carpet is used with high efficiency. As a result, CO2 emission can be reduced.

  The resources obtained by the recycling method of the waste carpet are used as raw materials for the recycled carpet RCP, as well as raw materials for synthetic resin molded products such as soundproofing materials such as automobiles, vibration-proofing materials or planters, benches, and car stops. It can also be used as part.

DESCRIPTION OF SYMBOLS 10 1st process of manufacturing recycled carpet 11 Conveyor 12 Repelling machine 13 1st draft tower 13a Colliding plate 13b Falling plate 14 First vibrating conveyor 15 Second vibrating conveyor 16 Crusher 16a Grinding blade 17 Second draft tower 17a Colliding Plate 17b Falling plate 18 Second vibrating conveyor

20 Second process of manufacturing recycled carpet 21 Recycled PET cotton 23 Conveyor 24 Card machine 25 Recycled PET felt 26 Needle punch machine

30 Third Step of Recycled Carpet Production 31 Recycled PET Flakes 32 Melt Extruder 33 Water Cooling Tank 34 Cutting Machine 35 Dark Color Pellets 36 Melt Extruder 37 Spinning 38 Drawing

40 4th process of manufacturing recycled carpet

50 Fifth Process for Manufacturing Recycled Carpet 51 Base Fabric 52 Tuft Machine 53 Latex Coating Treatment 54 Backing Treatment

A Fiber or fiber mass B of approximately 200 mm or less B Fiber of approximately 100 mm or less C Fiber of approximately 2 mm to 100 mm D Fiber of approximately 2 to 30 mm E Web sheet F Regenerated felt G Regenerated pellet H Regenerated pile yarn

CP Waste carpet RLP Short fiber and latex powder LTX less than about 2 mm New latex RLX Formulated latex RCP Recycled carpet

Claims (4)

A first step comprising the steps of defibrating and cutting the waste carpet into fibers or fiber lumps of a predetermined size and separating the short fibers and latex powder from the fibers or fiber lumps after defibration and / or after cutting. Process,
The step of opening the fiber that has been defibrated and cut in the first step to form a web sheet, and adding the felt separately to the web sheet formed in the step and performing needle punching to produce a laminated felt as a raw material for recycled carpet A second step comprising the step of forming;
A process of adding PET flakes to the fibers separated and dropped at the time of opening in the second step and melting them to form pellets, and separately adding pellets to the pellets formed in the previous steps, melting them, spinning and drawing, and raw materials for recycled carpet Forming a pile yarn to be a third step,
A fourth step comprising the step of adding the short fibers and latex powder separated in the first step to the latex to form a blended latex to be a raw material for the recycled carpet ;
A method for recycling waste carpet, comprising: 1st process thru | or 4th process of Claim 1,
Further, the step of tufting the pile yarn formed in the third step onto the base fabric, the step of applying the prepared latex formed in the fourth step, and the forming of the base fabric coated with the prepared latex in the second step A fifth step comprising a step of lining the felt, and a step of sewing the carpet backed in the step;
Recycling method of waste carpet characterized by comprising
The first step includes a step of defibrating waste carpet into fibers or fiber masses of approximately 200 mm or less, a step of separating short fibers and latex powder of less than approximately 2 mm from the fibers or fiber clusters of approximately 200 mm or less, and Cutting a fiber or fiber lump into fibers of approximately 100 mm or less, and separating the short fibers of less than approximately 2 mm and latex powder from the fibers of approximately 100 mm or less,
In the second step, polyester cotton is added to the fibers of about 100 mm or less to open and form a web sheet, a felt is added to the web sheet to form a laminated sheet, and the laminated sheet It has a process of producing a regenerative felt by performing needle punching,
In the third step, PET flakes are added to the short fibers of about 2 mm to 30 mm separated at the time of opening in the second step, melted, cooled and cut to produce pellets, and the pellets are added separately to the pellets. A process for producing a pile yarn by melting and spinning and drawing,
The fifth step includes a step of tufting the pile yarn formed in the third step onto a base fabric, a step of applying the prepared latex formed in the fourth step to the base fabric, and the second step on the base fabric. The method for recycling waste carpet according to claim 2, further comprising a step of backing the felt produced in the step and producing a recycled carpet.
A recycled carpet manufactured using recycled carpet materials obtained by the waste carpet recycling method according to claim 2 or 3, wherein a total ratio of the waste carpet materials ratio is 10% by weight or more. Recycled carpet featuring.

Images