JPH0966527A - Reclaimed resin made of thermosetting resin foam, reclaiming method for thermosetting resin foam and molding method for molding made of the same reclaimed resin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make it possible to mold and reclaim various resin products by mixing a comminuted resin to be treated that a thermosetting resin foam is comminuted to enhance its bulk specific gravity with a thermoplastic resin molding material at a specific ratio, gelling it, kneading it, and granulating it to a specific grain size, thereby volume reducing a waste material or scrap. SOLUTION: A thermosetting resin molding material in an amount of 30-80wt.% is mixed with 20 to 70wt.% of comminuted resin to be treated that a thermosetting resin foam is comminuted to enhance its bulk specific gravity, the mixture is gelled, kneaded, and granulated to 15mm or less of grain size. The resin molding material is fixed to the surface of the comminuted resin to be treated to volume reduce the thermosetting resin foam. The method for recovering the thermosetting resin foam used as the raw material of a reclaiming apparatus from the discarded resin molding has the step of first roughly comminuting it by using a crusher 110 to form roughly comminuted pieces 61 having suitable size. Then, the method has the step of forming comminuted pieces 62 by using comminuting means. Thereafter, the method has the step of applying an impact compressing and attrition force by using a separating, classifying and straightening means to comminute it, granulating it to a substantially spherical, circularly cylindrical or other prepared unshaped size, and grain size selecting it.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a recycled resin comprising a thermosetting resin foam and a thermoplastic resin molding material, and a method for recycling the same, and more specifically, to waste resin products (waste resin molded products) and resin products. The raw material pellets used for injection molding or extrusion molding obtained by granulating and reducing the thermosetting resin foam and thermoplastic resin molding material obtained by collecting scraps generated when molding Powder recycled resin,
The present invention also relates to a method for regenerating a thermosetting resin foam to obtain the regenerated resin, and a method for molding a regenerated resin or a molded article made of a molding material that has undergone a step of further pelletizing the regenerated resin.

Thermosetting resin foams include, for example, polyurethane foams, silicon foams, and phenol foams.
Typical polyurethane foams of thermosetting resin foams include soft polyurethane foams and hard polyurethane foams. Soft polyurethane foam contributes to energy saving as 60% of the total production amount is used for automobiles as a lightweight foam to save running fuel, cushioning materials such as seat cushions, mattresses, vehicle and furniture seats, etc. It is used for carpet underlayment, packaging materials, sound absorbing materials, toys, as well as clothing and air filters. Rigid polyurethane foam has excellent performance as a heat insulating material and structural material,
For example, it is used as a building material that has both soundproofing and decoration, a heat insulating material for refrigerators, parts for aircraft, etc., and contributes to energy saving in each field. Further, due to its excellent feature that it can be foamed on site, it is used for heat insulation coating of storage tank trucks, ships, buildings, pipes and the like.

The thermoplastic resin molding material is light and durable, easy to mold, and has excellent properties such as beautiful, rust-free and inexpensive. Therefore, it can be used for building materials, automobiles, household appliances, etc. Used as a structural material, for example, as a structural material for machines, devices, boxes, containers, etc., or as a decorative material. Furthermore, it is used in a wide variety of applications such as clothing and daily necessities, and in large quantities. Each resin product is widely used by taking advantage of the excellent properties of the resin material.

A large amount of the thermosetting resin foam and the thermoplastic resin molding material are discarded, and particularly in the thermosetting resin foam, scraps such as sprues and runners are always by-produced by the injection molding method. To do.

BACKGROUND OF THE INVENTION In general, resin products formed by molding various resin materials such as natural resins or synthetic resins are used in a large number of types including interior and exterior parts of automobiles and household electric appliances. Used, but nowadays
The following various problems have been raised regarding the treatment after use in this type of resin product.

Most of the resin materials that make up resin products have the characteristics of excellent water resistance and weather resistance and are resistant to decay, but on the other hand, for example, when incinerated by an incinerator for disposal. It is well known that is harmful to the social environment by generating a large amount of harmful gas and smoke. In addition, there is a disadvantage that the resin material melted during incineration may adhere to the inside of the furnace and damage the furnace itself. Therefore, even if the waste resin product is buried in the ground in order to avoid this disadvantage, it remains undecomposed for a long period of time, which is considered to be a cause of environmental damage.

On the other hand, with respect to this type of resin material, there is a tendency toward depletion in terms of resources year by year, and it is demanded and recognized that the resin material after use should be reused without being discarded. In addition, it has been attempted to collect waste resin products by displaying the type of resin material used and the like to facilitate collection.

As an example, about 75% of the weight of an automobile
The materials are recycled, but most of them are metallic materials, and the remaining about 25% is discarded as dust, of which about 30% by weight of plastic is contained.

For example, as a thermosetting resin molded article used for the interior and exterior of an automobile, in addition to a seat cushion which is a lump of polyurethane foam having a density of 20 to 50 kg / m ³ , a base material layer of plastic is usually used. Layer of thermosetting resin foam to improve the cushioning property, surface layer of plastic for cosmetic use or for protecting cushioning property, abrasion resistance, weather resistance, etc. Are often laminated. In addition, a sheet-shaped resin molded product for protection, which covers the surface of a molded member (the molded member is made of various materials such as resin, metal, or wood) serving as a core material in various resin molded products. This sheet-shaped resin molded article has a surface layer made of a thermosetting resin foam on the surface of a sheet-shaped base material layer made of a cosmetic or abrasion resistant and weather resistant resin for the same reason as in the previous example. Laminated ones are often used.

That is, in various vehicle interior and exterior parts, in addition to the seat cushion, on the surface of the base material layer formed of polypropylene resin and having a thickness of about 1 to 2 mm,
A surface layer consisting of a polyurethane foam intermediate layer having a thickness of about 3 to 6 mm and two layers of vinyl chloride having a thickness of about 0.5 to 1 mm is laminated via an adhesive layer. Examples of this type of resin molded product include a molded product forming an instrument panel (in the present specification, simply referred to as "instrument panel member"), a dashboard, a console box, and the like.

Further, in various sheet-shaped resin molded articles as interior and exterior parts for vehicles, the sheet-shaped base material layer made of vinyl chloride having a thickness of about 0.5 to 1.5 mm has a thickness of 0. There is also one in which a surface layer made of a polyurethane foam having a thickness of about 4 to 15 mm is laminated via an adhesive layer. This type of sheet-shaped resin molded product covers the surface of a molded member that is a core material of various molded products, and laminates or tacks such as tacks or screws on the surface of the molded member through an adhesive or an adhesive. It is used by being fixed and used, for example, as a floor sheet material, a seat sheet material, a door lining sheet material, an armrest surface material, a headrest surface material, and the like. In general,
In the case of a sheet-shaped resin molded product, the surface layer made of a thermosetting resin foam is often placed inside and the sheet-shaped base material layer is placed outside to cover the surface of a molding member that is a core material of various molded products.

As described above, the polyurethane foam, which is a thermosetting resin foam, mainly saves the running fuel consumption of automobiles as a lightweight foam, and also has excellent heat insulating properties in refrigerators, warehouses, houses and plants. It is used in a wide range of fields such as piping and storage tanks. By the way, the amount of polyurethane foam used for one passenger car is generally about 30 kg. Moreover, the polyurethane foam ranks sixth in terms of the production weight of the resin material in 1991, but ranks second in terms of the volume-converted production amount after molding.
Therefore, considering not only the above-mentioned various vehicle interior / exterior parts but also molded articles that provide convenience in social life or dust in the living space, volume conversion is important, and effective reuse of thermosetting resin foam or Disposal is an important issue. Moreover, in order to solve this problem, it is a very important issue to reduce the volume of the discarded or scraped thermosetting resin foam.

[0013]

2. Description of the Related Art Conventionally, for the reuse of scraps and waste materials of thermosetting resin foams, taking polyurethane foams as an example, in the case of soft polyurethane foams, scraps are crushed into small pieces for cushioning. To pad or
Alternatively, an adhesive is used to harden the small pieces for reuse as a cushion material. Or as it is,
It is also used as a pad for packaging materials. On the other hand, in the case of scraps of hard polyurethane foams, except for being powdered and used as a plastic filler, they are completely scrapped and landfilled or incinerated in the mountain area.

Conventionally, waste materials and scraps of thermosetting resin foams have completely lost fluidity due to the curing reaction, and therefore even if they are recovered, they cannot be molded alone and are difficult to reuse. Under such circumstances, some methods of reusing polyurethane foam such as material recycling, chemical recycling, energy recycling, etc. have been studied.

Bonding press molding as material recycling includes ribbon dead foam, elastic pavement material, etc. Ribbon dead foam is made by cutting soft polyurethane foam, crushing it, inserting it into a mold after applying an adhesive, and steaming. Through 100 ° C., 10 kg / cm ² , 10 minutes to cure, and demold to obtain a ribbon dead foam. The elastic pavement material is used, for example, in athletic fields, golf course paths, and water-permeable tennis courts as an elastic pavement material formed by crushing a RIM bumper and then forming it into a mat. Further, an adhesive is applied to the crushed product of the RIM bumper, and hot press molding is carried out in a mold to be recycled into a mudguard for automobiles and the like.

Since the soft polyurethane foam has a relatively low degree of intermolecular cross-linking and exhibits semi-thermoplasticity at high temperatures, hot press molding and the like have been proposed. In hot press molding, a flexible polyurethane foam is made into chips, and this is hot press molded to form a recycled sheet. For example, the hot pressing conditions are 160 to 220 ° C. when the thickness of the raw material foam is 20 to 100 mmn.
10 to 300 kg / cm ² G, 0.5 in a few tens of seconds to a few minutes (semi-form)
Recycled sheets of ~ 1.1 (non-foam) g / cm ³ are obtained.

The filler application is an example of using a waste material of a soft polyurethane foam as a filler, and the soft polyurethane foam of an automobile seat cushion is finely pulverized to several tens μ by a pulverizer combining a low-speed rotating roller and a high-speed rotating roller. Then, there is a method of adding up to 15 wt% of this to a resin and regenerating it into a seat cushion.

In an example of using a waste material of a rigid polyurethane foam as a filler, the rigid polyurethane foam is crushed to be a filler for cement, and the filler is used as an aggregate and mixed with cement, sand, and water to be heat-insulated and lightweight. It is a lightweight mortar for roofing base that has excellent workability such as chemical conversion and nailing. The specific gravity after curing is 1.3, which is lighter than the original 2.6.

Chemical recycling is the decomposition and recovery of waste materials of polyurethane foam into low molecular weight polyols and polyamines by glycosis, aminolysis or hydrolysis, and reused.

Energy recycling is a method of recovering energy by burning waste material as it is or cutting it into an appropriate size and burning it. Since polyurethane foam has a large fuel energy and relatively little harmful gas, it burns as it is. It is intended to recover energy and use it for heating and cooling.

[0021]

In the conventionally proposed method for reusing a thermosetting resin foam, in a material recycling adhesive press molding, a mixture of a powdery soft polyurethane foam and an adhesive is molded. When inserted and hot pressed, the adhesive heats and solidifies, but the individual soft polyurethane foam powders do not heat and solidify.
There is a problem that when the mold is opened, the elastic powder of the individual flexible polyurethane foam expands and deforms due to the elastic force. That is, there is a problem in that the elasticity of the powder of the soft polyurethane foam differs depending on the degree of penetration of the adhesive into the powder of the individual soft polyurethane foam, and as a result, the solid polyurethane cannot be uniformly solidified and molded. For example, 20% by weight of soft polyurethane foam of polyurethane foam is 8
It was attempted to produce a molded product by roughly crushing it into a size of about mm, mixing the urea-based adhesive with the crushed soft polyurethane foam, and then pressing with a hot press to perform solidification molding. However, the elastic force of each soft polyurethane foam is different due to the difference in the permeation state between the individual soft polyurethane foam and the urea-based adhesive, so that there is a problem that pressure cannot be applied uniformly.

Further, in hot press molding for material recycling, there is a problem that it is not applicable to rigid polyurethane foams, since it is limited to those having relatively low degree of intermolecular crosslinking such as soft polyurethane foams. It was

Further, conventionally, a method of reusing a rigid polyurethane foam has been used as a filler, but it has been difficult to process it into a molded product.

Further, when scrap or waste material of the thermosetting resin foam is discarded or incinerated, the thermosetting resin foam is foamed in an amount of about 30 times, so that the volume is large and it is transported, accumulated and stored. However, there is a problem that it is difficult to handle, and the disposal place is gradually limited and reduced.

Further, the polyurethane foam melts about 20% of the total amount at 200 ° C. to reduce the volume, but the others remain, so that there is a problem that it cannot be a solution for disposal.

In the adhesive press molding, the elasticity of the individual polyurethane foam powder itself cannot be suppressed by the adhesive to solidify it, so that it is not a method for reducing the volume of the waste polyurethane foam. Hot press molding is not a method of reducing the volume of waste polyurethane foam.

At present, chemical recycling is not an effective recycling method because of the various problems described below.

(1) Chemical recycling requires expensive equipment, and the energy consumption required in this step is larger than that of material recycling, so there is a limit to its practical application.

(2) Even if the polyurethane foam is pyrolyzed or hydrolyzed, it is necessary to establish a consistent quality control system for the pyrolysis recovery process from the discarded or scrap polyurethane foam to the polyol. However, in actuality, there are problems such as variations in the quality of the recovered polyol, selection of the raw material foam for recovery, and coloring of the recovered polyol, as well as the economical efficiency of the recovery process and other facilities.

In the energy recycling, even if the polyurethane foam is burned to recover energy, a place for storing the polyurethane foam before burning is necessary. Since it is foamed, it has a large volume and is difficult to handle. Further, although polyurethane foam generates relatively little harmful gas, it still requires treatment of harmful components of combustion gas and combustion ash, and this harmful component treatment technology is currently under development. . Therefore, the reuse of the thermosetting resin foam in this field remains an unsolved problem.

The present invention solves the above problems and
Reuse waste materials and scraps of various thermosetting resin foams and thermoplastic synthetic resin products, especially by reducing the waste materials and scraps of thermosetting resin foams that are difficult to reuse or dispose of, The main object of the present invention is to provide a recycled resin that can be molded into various resin products to be recycled, a method for recycling the resin, and a method for molding a molded product made of the recycled resin. Recovery of thermosetting resin foam by reducing the volume of thermosetting resin foam recovered from scraps generated during molding and forming the thermosetting resin foam into various molded products easily It is an object of the present invention to provide a recycled resin capable of effectively performing a recycling treatment, a method for recycling the recycled resin, and a method for molding a molded product made of the recycled resin.

[0032]

In order to achieve the above object, the recycled resin of the present invention is a crushed resin of 20 to 70 wt% which is obtained by crushing a thermosetting resin foam and has an increased bulk specific gravity.
% To 30% by weight of thermoplastic resin molding material,
Gelation and kneading, granulation to a particle size of 15 mm or less, the thermoplastic resin molding material is fixed on the surface of the crushed resin to be treated, and the thermosetting resin foam is reduced in volume. And

As a recycling method, a crushing step of forming a crushed resin having a high bulk specific gravity by crushing a thermosetting resin foam, and 20-70 wt% of the crushed resin to be treated
% To 30% by weight of the thermoplastic resin molding material together with a stirring impact force to generate a shear heat generation based on the stirring impact force, and the shear heat generation causes gelation and kneading to produce a particle diameter of 15 mm or less. It is characterized by at least including a step of granulating, fixing the thermoplastic resin molding material on the surface of the crushed resin to be treated, and reducing the volume of the thermosetting resin foam.

Preferably, the thermosetting resin foam comprises a crushed resin whose bulk specific gravity is increased to 0.1 to 0.2 by crushing, and the thermosetting resin foam has a bulk specific gravity of 0.3.
Reduce the volume to above.

As the thermoplastic resin molding material, another recovered resin material obtained from a waste material of a thermoplastic synthetic resin product is reused, or a virgin thermoplastic resin is added, or a virgin thermoplastic resin and the above-mentioned resin are used. Other recovered resin materials may be used, for example, 50% each.

The gellable range of the crushed resin (PUR) to be treated, which is made of polyurethane foam for each thermoplastic resin molding material, is shown below. If the thermoplastic resin molding material is PP, PU
R is 20-70 wt%, PP amount is 30-80 wt%, preferably PUR is 40-58 wt%, PP amount is 52-
Particularly preferred is 60 wt%, PUR 55 wt% and PP 45 wt%.

When the thermoplastic resin molding material is ABS, PU
R is 30-70 wt%, PC amount is 30-70 wt%, preferably PUR is 45-65 wt%, PC amount is 35-
Especially preferred is 55 wt%, PUR 55 wt% and PC 45 wt%.

The thermoplastic resin molding material is nylon or PVC
In the case of, PUR is 30-80 wt%, nylon or PV
The amount of C is 20 to 70 wt%, and preferably the PUR is 40.
~ 70wt%, the amount of nylon or PVC is 30 ~ 60wt%
And, PUR is 45wt%, Nylon or PVC is 55wt%
% Is particularly preferable.

As a method for molding a molded product made of the recycled resin, the recycled resin is heated and kneaded, and extruded into a molding die 10 with a screw 71.
9 is extruded to a molding portion of a molding die 10 having a fluororesin sheet attached to the inner wall surface or coated with a fluororesin to be molded to a predetermined wall thickness, and gradually cooled in the molding portion to be extruded. It is characterized by at least including a step of increasing the density of the extruded material 79 in the molding part by applying a suppressing force against the extruding force of the molded product. Further, as another molding method of the present invention, the regenerated resin is heated and kneaded by a known means such as extrusion molding to form raw material pellets, which is then injected into a molding die with a screw to give a predetermined molded article. It can be a step of demolding after being shaped into a shape and gradually cooled.

The recycled resin has a bulk specific gravity of about 3 times or more the bulk specific gravity of the thermosetting resin foam, and the volume thereof is a volume which is largely reduced from the volume of the thermosetting resin foam. Therefore, it is much easier to transport, store, or bury it, as compared with the lump of the thermosetting resin foam before recycling. Further, this regenerated resin is granulated to have a particle size of 15 mm or less, but in reality, each powdered pulverized resin to be treated becomes a mother particle, and the surface of the pulverized resin to be treated is treated. The whole is a form in which the thermoplastic resin molding material is attached so as to cover it as child particles, and the thermoplastic resin molding material that is the child particles is, so to speak, a cross-linking agent and several crushed resins to be treated are aggregated. It has been granulated.

Therefore, when the recycled resin is heated and kneaded by an extruder, an injection molding machine or the like, the thermoplastic resin molding material is fixed on the thermosetting resin foam which is thermally and chemically stable. The mixed and dispersed state of the crushed resin to be treated and the thermoplastic resin molding material is constantly maintained, and good fluidity is obtained. As a result, the friction resistance of the crushed resin to be treated is reduced and the thermosetting resin It is possible to manufacture a molded product having a uniform density using a foam as a molding material.

The thermosetting resin foam containing the thermoplastic resin molding material is crushed by a stirring impact force. Further, the thermoplastic resin molding material is melted by the shearing heat generation based on the stirring impact force. However, since the thermosetting resin foam hardly melts, the crushed crushed resin to be treated and the thermoplastic resin molding material are gelled and kneaded, and the thermoplastic resin molding material becomes the entire surface of each crushed resin to be treated. The state in which the so-called thermoplastic resin molding material is fixed to the thermally and chemically stable ground resin to be processed is formed, and the mixed dispersion state of the ground resin to be processed and the thermoplastic resin molding material is kept steady. To maintain
A recycled resin is formed which gives good flowability. Moreover, the volume of this recycled resin is 14% of the volume of the thermosetting resin foam.
The volume is greatly reduced.

A restraining force is applied by the braking means 30 to the pushing force applied to the molded article 29 by the extruder 70.
Extruded material 79 in the molding chamber 22 through the molded product 29.
When a reaction force against the extrusion force is applied to the molding chamber 2 as compared with the case where this suppression force is not applied to the extrusion material 79,
The extruded material 79 in 2 has a more uniform and high density.

[0044]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described with reference to the drawings. The target waste resin molded product is an instrument panel member used in various automobiles. This instrument panel member is a 5 mm thick polyurethane foam formed on the surface of a 2 mm thick base material layer molded from polypropylene resin (PP). A 0.5 mm thick vinyl chloride surface layer is laminated on the intermediate layer of the body and its surface via an adhesive layer. That is,
The base material layer of the PP is a member molded into a desired shape and serves as a core material of an instrument panel member. A polyurethane foam for further enhancing cushioning property is laminated on the surface of the PP, and the polyurethane foam is formed. It is a laminate of vinyl chloride on the surface of the body for cosmetic use or for protection to improve abrasion resistance and weather resistance.

1. Recovery of Thermosetting Resin Foam from Instrument Panel Member The method of recovering the thermosetting resin foam used as a raw material for recycled resin from a waste resin molded product is not particularly limited. Member P
A method of separating P, polyurethane, and vinyl chloride to recover each resin material will be described.

[Crushing Step] As shown in FIG. 1, a thermosetting resin foam or a waste resin molded product containing the same, depending on the type, laminated structure, shape and size, will be described later in the [crushing step]. Prior to the above, a crusher 110 shown below (for convenience in the present specification, referred to as a "crusher") can be used to perform a crushing process to form a crushed piece of an appropriate size (coarse crushing step), or a cutter mill. It is also possible to obtain the crushed resin to be treated only by the crushing or crushing step in step 1. Alternatively, the crushing or crushing step in the cutter mill and the coarse crushing step in the crusher can be performed in reverse order. Alternatively, it is possible to crush or crush with a crusher while omitting the step performed with a cutter mill.

The "crusher" is a coarse crushing means such as various mono cutters, shredders, crushers, such as Gainax crusher manufactured by Horai Co., Ltd. or roll crusher manufactured by Nara Machinery Co., Ltd. In the crusher body having an inlet for the material to be crushed, two shafts that rotate inward toward each other are provided in parallel, and a plurality of rotary blades are provided at predetermined intervals on each shaft. At the same time, the three claw blades that mesh with each other on the outer circumference of each rotary blade of the shaft and project so as to form an equal angle on the outer peripheral surface of each rotary blade, collect the coarsely crushed material into coarse crushed pieces of appropriately large fragments. Disconnect. When the instrument panel member is introduced from the upper insertion port, the instrument panel member 60 is drawn inward by the claw blades of the two-axis rotary blades that rotate inward with each other, and is continuously formed between the outer peripheral edges of the rotary blades that rotate in a meshed state. While being slit by the shearing force that acts on the ground, the material is roughly crushed and cut by the compressing force that acts at the time of drawing, and the crushed pieces 61 are formed. The coarsely crushed pieces are discharged from a discharge port provided below the biaxial rotary blade.

[Crushing Step] In the above-mentioned step, the instrument panel member 60, which has been made into the coarsely crushed pieces 61, is cut into pieces of an appropriate size by using a crushing means as shown in FIG. , For example, a rectangular or square or other irregular shape, and a crushed piece 62 with a side of 2 × 2 mm or less
To form

FIG. 2 shows a cutter mill 1 which is an example of crushing means.
20 is shown.

Reference numeral 121 denotes a cutter mill body which is a cylindrical casing having an upper surface opening, and the opening is covered with a lid 122 which can be opened and closed. The lid 122 is provided with a charging port 123 for charging the instrument panel member 60, which is a coarsely crushed piece 61 as a crushed object, in the cutter mill body 121.

Further, inside the cutter mill body 121, there is provided a cutter support body 124 which is supported on the bottom surface of the cutter mill body 121 and rotates in a horizontal direction by a rotation driving means (not shown). 3 long rotary blades 125 are provided in the same direction. These three rotary blades 125 are arranged so as to form an equal angle of 120 degrees in the rotation direction of the cutter support 124, and the blade tips of the three rotary blades 125 are the same. It is located on the rotation locus of. Furthermore, the three rotary blades 1
The second fixed blade 126 is fixed to the cutter mill body 121 at a position substantially symmetrical to the rotation locus of the blade tip of the rotary blade 125 via a slight gap with respect to the rotation locus of the blade tip of 25.
The inside of the cutter mill main body 121 is divided into two by 6 and the cutter support body 124 and the rotary blade 125 to form a charging chamber 127 and a crushing chamber 128. The charging port 123 of the lid 122 is the charging chamber 1
Connect to 27. The second fixed blade 126 and the rotary blade 12
The clearance with 5 cuts the crushed material to the desired size,
Or, in a broad sense, it can be adjusted freely so that it can be crushed. The clearance here is 0.2 to 0.3 mm. Also,
The crushing chamber 128 has a rotary blade 125 between the two fixed blades 126.
Mesh screen that surrounds the rotation trajectory of
It is divided by 29. The screen 129 is formed of a mesh through which the crushed pieces 62 each having a size of about 5 mm can pass. Further, a discharge port for discharging the crushed pieces 62 is provided at the lower end of the cutter mill body 121 of the crushing chamber 128.

In the cutter mill 120 described above, the lid 12
When the coarsely crushed pieces 61 are charged from the second charging port 123 and the cutter support body 124 is rotated by a rotation driving means (not shown), the coarsely crushed pieces 61 are fixed to the rotary blade 125 of the cutter support body 124 and the fixed blade 1.
The shape and area are indefinite between 26 through the screen 129, but almost all of them are rectangular or square or indefinite, and are formed into square crushed pieces 62 with a side of about 2 mm or less. It is discharged to the next process. In addition,
In each crushed piece 62, the intermediate layer and the surface layer are wholly or partially laminated on the surface of the base material layer. That is, one made of PP, polyurethane foam and vinyl chloride, one made of PP and polyurethane foam (one in which vinyl chloride is separated, or one in which polyurethane foam is partially separated in vinyl chloride), or PP The crushed pieces 62 are crushed in various states such as one having an adhesive layer remaining on the surface, and each crushed piece 62 is basically in a state where the polyurethane foam and vinyl chloride are not separated from PP.

The crushing means is not limited to the above-mentioned cutter mill, and for example, like the hard crusher manufactured by Horai Co., Ltd., the rotary shaft of the rotary blade 125 is provided in the horizontal direction, and the second fixed blade 126. In some cases, a screen 129 between them is provided at the bottom.

[Separation / Classification / Sizing Step] In this [separation / classification / sizing step], each crushed piece 62 crushed by the crushing means in the above-mentioned [crushing step] will be described later in [separation -Classification and sizing means] is applied to give an impact compression and grinding force to give an impact and a compression action to pulverize the crushed pieces 62 to form PP as a base material layer having a diameter of about 1.5 to 3 mm. Granules having a substantially spherical shape or a cylindrical shape having a diameter of 1 to 2 mm and a length of about 3 to 5 mm and other irregular shapes are sized and sized. At the same time, the crushed pieces 62 are impacted and compressed by the impact compression grinding force to be crushed, the polyurethane foam and vinyl chloride of each crushed piece 62 are separated from PP, and the crushed and sized particles are sized. Polyurethane, vinyl chloride, and PP are classified, and vinyl chloride, polyurethane, and PP are respectively recovered as a crushed resin to be treated or another recovery resin material. The above steps can be repeated any number of times as necessary.

[Separation / Classification / Sizing Method] The separation / classification / sizing method is referred to as a “separator” for convenience. In FIGS. 3 and 4, the separator 130 has a supply opening 132 through which each crushed piece 62 is inserted in the center of the fixed disk 131, and the fixed end plate 133 is crushed and sized into the fixed disk 131. And the fixed disk 13
1, the outer peripheral edge of each fixed end plate 133 is attached to the peripheral side plate 13
Fix at 5. A movable disk 141, which is rotationally driven by a rotary horizontal shaft 142, is provided in the crushing / sieving space 155, and the rotary horizontal shaft 142 is pivotally supported by bearings 143, 143. The rotation horizontal shaft 142 is driven to rotate by a rotation driving means such as a motor (not shown).

Then, on the fixed disk 131, fixed pins 134 are sequentially planted on a plurality of concentric circles (relative to the movable disk 141) on a rotational trajectory a (FIG. 4), while On the movable disk 141, movable pins 144 that alternately enter on a plurality of rotation loci b different from the fixed pins 134 are sequentially planted, and the fixed and movable pins 134 and 144 are mutually interlocked. A clearance is provided between the pins 134 and 144 so that impact, compression, crushing, and sizing action can be obtained by the impact compression grinding force. Further, a discharge screen 156 is provided between the outer periphery of the movable disk 141 and the peripheral side plate 135. A screen 151 having a predetermined mesh formed by punching pores having a desired diameter is provided around the discharge disk 156. An outlet 152 is provided. A blower 157 communicates with the separator 130 through the discharge port 152 as shown in FIG. In this embodiment, the screen 151 is a mesh having a diameter of 2 mm.

Further, an outlet 153 is provided in the lower part of the screen 151 of the crushing and sizing space 155, and the outlet 153 is provided with a plug valve 154 for opening / closing control. In addition, as shown in FIG.
A blower 158 for sucking the air inside 30 is communicated with the blower 158, and the blower 158 is communicated with the supply inlet 132.

Therefore, in the separator 130, the rotary horizontal shaft 142 is rotated by the rotation driving means (not shown) to rotate the movable disk 141, and the crushed pieces 62 are supplied to the feed inlet 1.
When it is supplied to 32, each crushed piece 62 is crushed and sized 1
Fixed and movable pins 134 and 1 at the center of 55
Impact, compression, crushing or polishing, and particle size adjusting action and centrifugal action are received together by the impact compression grinding force between 44, and the peripheral speed of the movable pin 144 at the outer peripheral portion is diffused while spreading in the outer peripheral direction. Becomes faster as the number of rows increases, so it is crushed by the impact and compression action of a larger impact compression attrition force. In this process, the polyurethane (PUR) and vinyl chloride (PVC) laminated on the surface of PP of each crushed piece 62 are finely crushed into irregular shapes with one side of 1.5 mm or less, while PP and PVC have a diameter of 1 .5-3
mm approximately spherical or 1-2 mm in diameter and 3-5 mm in length
Crushed into a cylindrical shape or other irregular shape, or
Other recovered resin material 63 is formed by polishing and sizing, and polyurethane and vinyl chloride are separated from PP. In addition,
Some of the PP of the crushed pieces 62 may be powder crushed into an irregular size with one side of 1.5 mm or less. In some cases, polyurethane and vinyl chloride cannot be separated from PP by only one treatment step with a separator.
Polyurethane or vinyl chloride may remain on the surface of P. In addition, polyurethane or vinyl chloride having a size that does not pass through the screen 151 may be mixed.

After the pulverized polyurethane (and in some cases, a small amount of vinyl chloride and a part of PP) passes through the screen 151 by the centrifugal action of each movable pin 144 and is classified into the discharge space 156, From the discharge port 152, it is sucked and discharged to the outside through the blower 157 (FIG. 1), and is classified and collected in the next step.

On the other hand, the recovered resin material 63 of the sized PP
Also, polyurethane or vinyl chloride having a size that does not pass through the screen 151 remains in the screen 151, but since the outlet 153 and the supply inlet 132 are communicated via the blower 158 with the plug valve 154 open. , PP recovery resin material 63 and a trace amount of polyurethane or vinyl chloride having an average particle size of more than 1.5 mm on one side is refluxed to the supply inlet 132, and is subjected to impact compression grinding force again in the separator 130 to be ground or polished, The polyurethane or vinyl chloride that has been sized and remains on the surface of PP is crushed so that it can pass through the screen 151, separated from PP, and discharged from the discharge port 152 to the outside as described above. Although the recovered resin material 63 of PP is refluxed, most of it remains in the screen 151 without being finely pulverized to pass through the screen 151, and the plug valve 154 is opened to take out the recovered resin material from the outlet 153. Be done. The above-mentioned separation, classification and sizing steps can be repeated a plurality of times as necessary.

Further, each of the polyurethane and the trace amount of vinyl chloride and PP discharged from the discharge port 152 after passing through the screen 151, if necessary, a centrifugal force type classifier using air or water utilizing a difference in specific gravity. It is classified by a classifying means such as, and is recovered as a crushed resin to be treated or other recovered resin material.

In the above-described embodiment, the instrument panel member is the waste resin molded product to be collected, but the sheet-shaped resin molded product applied to various vehicles and other resin products are the waste resin molded product to be collected. And as a base material layer, for example, ABS
Resin, polyethylene, polycarbonate, vinyl chloride,
Similarly, in the case of a resin product made of polystyrene or the like, various thermosetting resin foams can be separated and various resin materials can be collected and recovered as crushed resin to be treated or other recovered resin material.

The bulk specific gravity of the polyurethane foam recovered from the instrument panel is 0.118, but the bulk specific gravity of the pulverized resin to be treated of polyurethane in the above process is 0.140.
Met.

[Crushing of Seat Cushion] A polyurethane foam constituting a seat cushion obtained by removing a plastic sheet or a surface layer made of leather or the like and a spring from an automobile seat is, if necessary, subjected to the above-mentioned crushing step. Then, in this step (without going through the above-mentioned separation and classification step), it is recovered as the crushed resin to be treated.

A cube having a size of about 2 × 2 mm or less on one side, which is obtained by crushing the polyurethane foam by a cutter mill or the like,
It is crushed into an indeterminate shape such as a rectangular parallelepiped, a sphere, or a cylinder. The bulk specific gravity of the polyurethane foam recovered from the seat cushion was 0.028, but the bulk specific gravity of the crushed resin to be treated of polyurethane after this crushing step was 0.153.

The bulk specific gravity in the present specification is a loose bulk specific gravity, and after the above-mentioned material is piled up in a container of 100 cc in a container and then scraped off, the total weight of the material in this container is 100%. It is shown by the value divided by.

2. In the present example, a recycled resin using a thermosetting resin foam, in the present embodiment, a polyurethane foam that is a thermosetting resin foam crushed to a particle size or less recovered from the instrument panel member described above, and the instrument panel member or Thermoplastic resin molding material P recovered from other resin moldings
P (polypropylene) or virgin PP is used as the raw material for the recycled resin.

2.1. Outline of Regenerated Resin Manufacturing Process The outline of the recycled resin manufacturing process of the present invention will be described below.

(1) PP is charged together with the crushed resin to be treated into the mixer 80, which is a fluid mixing and kneading means, and the PP and polyurethane in the mixer 80 are gel-kneaded to form a "kneading material". To do. This kneaded material is sent to the cooling mixer 100. The true specific gravity of PP is 0.9
2. (2) The kneaded material is sufficiently cooled and granulated in the cooling mixer 100 to form granular "regenerated resin" having a diameter of 15 mm or less. (3) "Recycled resin" is sucked with a blower and fed to a cyclone, where dust and recycled resin are classified,
The dust is sent to the dust collector, while the recycled resin is sent to and stored in the storage tank below the cyclone. The kneading material discharged from the mixer 80 is 100 to 150 mm.
When there is a granulated raw material in the form of lumps, it is desirable to crush it with a crusher if necessary. Also, the crushed kneading material may be sucked by a blower and fed to a cyclone, and the dust and the kneading material may be classified in the cyclone, the dust may be sent to a dust collector, and the kneading material may be sent from the cyclone to the cooling mixer 100. it can. The above-mentioned main manufacturing steps are a crushing step of a thermosetting resin in a mixer 80 which is a fluid mixing and kneading means, and a gelation kneading step of a thermosetting resin and a thermoplastic resin molding material. Can be added or omitted as required.

2.2. Details of Manufacturing Process of Recycled Resin Hereinafter, an example of the main manufacturing process and an apparatus used in each manufacturing process will be described with reference to the drawings.

The recycled resin of the present invention is produced by the following means.

In FIG. 5, reference numeral 80 denotes a crushing means and a fluid mixing and kneading means for the thermosetting resin foam, which is called a "mixer" for convenience in this embodiment.

Reference numeral 81 denotes a mixer main body, which is a cylindrical casing having an upper surface opening and having a capacity of 300 liters. The opening is used for charging the crushed resin of the raw thermosetting resin into the mixer main body 81. The opening 94 is covered with the upper lid 82 which can be opened and closed. An air supply pipe 96 for supplying dry air is connected to the upper lid 82, and an exhaust pipe 95 for discharging a large amount of vaporized gas such as water vapor generated from the crushed resin to be processed in the mixer body 81 is also connected to the upper lid 82. . Further, one outlet 88 is provided on the outer peripheral surface near the bottom surface of the mixer main body 81, and a lid 89 for covering the outlet 88 is provided at the tip of the rod of the cylinder 91. It can be opened and closed freely. A discharge duct 93 communicates with the discharge port 88.

Further, at the center of the bottom surface of the mixer main body 81, a shaft 83 which rotates at a high speed by a rotational driving means of a motor (not shown) having a horsepower of 37 kw (DC) is supported upward in the mixer main body 81. A scraper 84, stirring impellers 85, 86, 87 in this order from bottom to top on the shaft 83.
And tightened with a tightening nut 92 from the tip of the shaft 83. The shape of each of the stirring impact blades 85, 86, 87 is not particularly limited, but in the present embodiment, it is two blades symmetrical about the axis 83. When three pairs of stirring impact blades are stacked as shown in FIG. 5, it consists of a total of six blades.
The blades are equally angled (60
Degrees) and overlap with each other. When a plurality of stirring impact blades are provided, it is preferable to overlap the stirring impact blades with each other at an angle that is equal to the total number of stirring impact blades, which is 360 degrees, from the viewpoint of efficiently kneading the raw materials.

Furthermore, the shape of the stirring impact blade 87 located at the top is bent so that the tip portion of the two blades is higher than the portion attached to the shaft 83, and the tip portion is located above the tip of the shaft 83. It is placed in a high position. As a result, a shearing force by the stirring impact blades 87 can be applied to the upper layer portion of the crushed resin to be treated put into the mixer 80,
This is a desirable shape in terms of efficiently crushing and drying the crushed resin to be treated.

The scraper 84 is rotated by slightly sliding the bottom surface of the mixer body 81 into contact with the mixer body 8.
The raw material in 1 is stirred and circulated upward so as not to stay on the bottom surface, and further, the processed raw material is scraped out so as not to remain on the bottom surface of the mixer main body 81.

Production Example of Recycled Resin A crushed resin to be treated is put into a mixer 80 together with PP which is a thermoplastic resin molding material, and gelled and kneaded by the same mixer 80 which is a fluid mixing and kneading means to form a “recycled resin”. To do. The details will be described below.

By rotating the motor of the mixer 80, the stirring impact blades 85, 86, 87 and the scraper 84 are rotated at a rotation speed of 9
It is rotated at a high speed of 00 rpm, the upper lid 82 of the mixer 80 is opened, and the crushed resin to be treated and the thermoplastic resin molding material are charged into the mixer main body 81 through the charging port 94.

By the motor, the stirring impact blades 85, 86,
87 and scraper 84 were rotated at a rotation speed of 900 rpm to stir the above raw materials.

It is also possible to supply the dry air (pressure 0.5 kg / cm ² ) into the mixer main body 81 via the air supply pipe 96 from a dry air supply source composed of a compressor or a blower equipped with a dehumidifier (not shown). it can. The volatilized gas is contained in the dry air and discharged from the exhaust pipe 95, and is sucked into the dust collector by a blower (not shown).

When the shear rate of the stirring impact blade is too fast, the centrifugal force of the stirring impact blade causes the crushed resin to be treated to rise, so that the mixing effect is lowered. When the shear rate is too low, the stirring impact blade is too slow. The shear rate is preferably 800 to 950 rp because the drying efficiency and the crushing efficiency are reduced because the amount of heat generated by shearing due to the shearing force is low.
m, more preferably 850 to 900 rpm.

Further, in this embodiment, as described above, the stirring impeller blades are three pairs of stirring impeller blades 85, 86, and 87 in total, and the scraper 84 is included in total of seven blades. When the number is small, for example, when the total number of the stirring impact blades 85 and the scraper 84 is three, the amount of shearing heat generated by the shearing force of the stirring impact blades is reduced. It is 7 or more, and more preferably 7 or more, including the scraper 84.

As described above, in the mixer body 81,
26.4 kg (55 wt%) of the crushed resin to be treated and 21.6 kg (45 wt%) of PP powder as a thermoplastic resin molding material were added, and a total of 48 kg of polyurethane and PP was kneaded at a shearing speed of the stirring impact blade of 900 rpm. . In this embodiment, the PP is a mixture of virgin pellets and PP recovered from the instrument panel member in an amount of 50 wt%. By the way, the bulk specific gravity of the crushed resin to be treated is 0.140, and the bulk specific gravity of PP is 0.54.

The rotation speed, that is, the shearing speed of the stirring impact blade is 9
Since it rotates at a high speed of 00 rpm, the stirring impact blades 85, 86,
Since the shearing force by 87 is high, the crushed resin to be treated in the mixer 80 is shock-ruptured by the shearing force and pulverized into powder, and the stirring impact blade and the crushed resin to be treated or the crushed resins to be treated or the thermoplastic resin The amount of frictional heat generated by friction of the molding material with PP, that is, the amount of heat generated by shearing, is increased, and the temperature in the mixer 80 is increased. The temperature inside the mixer main body 80 was 200 ° C. as the temperature inside the mixer 80 increased.

Since the melting point of PP is 170 to 200 ° C. and the crushed resin to be treated is a thermosetting resin, it does not melt.
Does not form a large lump, and does not aggregate even when mixed and dispersed, and gels into a clay form. In this step, the clay-like gelled material became a lump-shaped "kneading material" having a diameter of about 10 to 100 mm. This kneading material is formed in a state in which the individual crushed resin to be treated has the thermoplastic resin adhered to the entire surface of the crushed resin to be treated, and the crushed resin to be treated is coated with PP.

Discharge of Kneading Material The motor of the mixer 80 is set at a low speed of 400 to 450 rpm, the cylinder 91 is operated, the lid 89 is retracted, and the discharge port 8 is discharged.
Open 8. The gelled raw material in the mixer main body 81 is scraped out from the discharge port 88 by the scraper 84 rotating at a low speed, and discharged to the next step through the discharge duct 93. The temperature at the time of discharging is 190 ° C., and it takes 12 minutes from the input of the crushed resin to be treated and the PP to the discharging, and a powder having a constant particle size is formed in the cooling granulation step described later.

(4) Cooling Granulation In FIG. 6, 100 is a "cooling granulation means", which is called a "cooling mixer" in this embodiment.

The kneaded material formed by the mixer 80 passes through the discharge duct 93 and the charging port 1 of the cooling mixer 100.
It is thrown into the mixer main body 101 having an inverted conical shape from 13. An arm 103, which is axially supported in the upper wall of the mixer body 101, is connected to a motor 11 via a reduction gear 112.
1 rotates horizontally at a speed of 3 rpm. A screw-type stirring impact blade 104 is supported at the tip of the arm 103, and the rotation axis direction of the stirring impact blade 104 is downward substantially parallel to the inner peripheral wall surface of the mixer body 101 near the lower end of the mixer body 101. Has been extended to. The stirring impact blade 104 is connected to a rotating shaft connected to the output shaft of the motor 105 via a rotation transmitting means such as a gear provided in the arm 103, and is rotationally driven at a speed of 90 rpm. The stirring impact blade 104 rotates so as to draw a cone along the inner peripheral wall surface of the mixer body 101, and stirs the kneading material in the arm 103.

Cooling water is constantly supplied from the water supply pipe 108 to the drain pipe 109 in the jacket 102 formed in the outer peripheral wall of the mixer main body 101, and the kneading material stirred by the stirring impact blades 104 is cooled in the jacket 102. On the inner wall surface of the mixer main body 101 cooled by water, a "recycled resin" is formed which is cooled to near the melting point of PP and granulated to a diameter of about 15 mm or less. It is discharged from 107.

The melting point of PP is 170 to 200 ° C., and in this production example, it is 185 to 210 ° C. in the mixer 80 described above.
In about 15 minutes after the gelled kneaded material is put into the cooling mixer 100, it is cooled to 58 to 100 ° C., and efficiently cooled and granulated by this cooling mixer. Regarding the cooling water in the jacket 102 at this time, the temperature of the cooling water supplied from the water supply pipe 108 is 16 ° C.
The temperature of the cooling water drained from the drain pipe 109 is 35 ° C.
Met.

It is desirable that the kneading material is cooled to the freezing point, that is, the melting point or lower of the thermoplastic resin molding material. It is not necessary to lower the temperature, and in reality, the recycled resin may be cooled to a temperature at which it can be discharged from the discharge port 107.

The cooling and granulating means is not limited to the above-mentioned device such as the cooling mixer, and a stirring blade for stirring the kneaded material in the mixer main body is provided and the outer peripheral wall surface of the mixer main body is as described above. What is necessary is just to provide a jacket and cool the kneading material in the mixer main body with the cooling water flowing in the jacket.

The kneaded material formed by the mixer 80 can be cooled by only stirring with a general mixer not equipped with the jacket 102, but in terms of efficient cooling, It is desirable to use a cooling mixer as in this example.

In the regenerated resin thus obtained, the individual pulverized resin to be treated is used as the mother particles, and the pulverized powder of PP becomes the child particles, so that the entire surface of the pulverized resin to be treated is coated with PP. PP which is a child particle
In other words, it is a cross-linking agent, and several crushed resins to be treated are aggregated and granulated to a diameter of 15 mm or less. Although the polyurethane foam itself does not have good fluidity, since the periphery of the crushed resin to be treated is coated with PP having good fluidity, the recycled resin is excellent at the time of molding such as extrusion molding and injection molding. It becomes a molding material that exhibits fluidity.

The bulk specific gravity of the obtained recycled resin is 0.4.
39. Therefore, since the bulk specific gravity of the product before recovery was 0.118, the volume of the recycled resin of the present invention was significantly reduced to about 27%, and the volume reduction was extremely effective. It is possible.

In the above examples, the polyurethane foam was mainly used as the thermosetting resin foam, but the thermosetting resin obtained by recovering from various other discarded resin moldings was used. It is possible to use a phenolic foam, a silicon foam, or the like, which is made from a resin foam.

Although PP has been mainly described as the thermoplastic resin molding material, the thermoplastic resin obtained by recovering from other discarded various resin moldings is used as the thermoplastic resin molding material. ABS resin, polystyrene,
PE (polyethylene), PVC (vinyl chloride), PC
One type of resin such as (polycarbonate), nylon, or a mixture of several types thereof can be used.

3. Manufacturing Example of Molded Article Using Recycled Resin The above-mentioned recycled resin can be charged into the above molding machine and heated to be molded by various molding methods, or this recycled resin and the above-mentioned other recovered resin material, or thermoplastic resin. Or by mixing the reclaimed resin alone or together with the above-mentioned other recovered resin materials by known extrusion molding or the like, or in the form of raw material pellets as a molding material such as a compound, injection molding or It is possible to produce a molded product by various molding methods by putting it into a molding machine used in various molding methods such as extrusion molding and compression molding and kneading by heating. 3.1. Example of Production of Molded Article by Injection Molding An example of production of a molded article of various automobile panels molded by injection molding using the recycled resin of the present invention is shown below.

Raw material pellets made of polyurethane foam and recycled resin made of PP are charged as a molding material into a hopper of a horizontal injection molding machine. The regenerated resin is sent from the hopper into the heating cylinder in association with the reciprocating motion of the injection ram, and is heated and kneaded in the heating cylinder to be softened and become fluid. This kneaded dough is extruded with a plunger into the cavity of the mold by an injection ram. That is, the dough passes through a nozzle at one end of a heating cylinder, passes through a mold sprue, and is injected into a mold cavity from a mold gate (gate). It becomes a molded product of. The operations such as the reciprocating motion of the injection ram and the opening and closing of the mold are fully automated, and the injection ram is repeatedly operated by the automatic operation to repeat the above-mentioned injection molding process to mass-produce body panels.

3.2. Production Example of Molded Product by Extrusion Molding A production example of a molded plate molded by extrusion molding using the recycled resin of the present invention is shown below. The recycled resin is charged into the hopper 73 of the extruder 70, heated and kneaded in the extruder 70, discharged from the extrusion die 77 to the molding die 10, and molded into a molding plate by the molding die 10.

In FIG. 7, 70 is a single-screw extruder.
Generally, the extruder is a screw type as shown in the drawing, and there are a single screw extruder and a multi-screw extruder, or a variant thereof and a structure in which these are combined. As the extruder of the present invention, one having any of the above structures can be used. Reference numeral 71 denotes a screw, which is a single screw type in this embodiment.

The screw 71 is driven by a motor via a gear reducer 72 and rotates in a barrel 74. The regenerated resin charged from the hopper 73 is kneaded by the rotating screw 71 and extruded forward of the screw 71. A band heater 75 is provided on the outer surface of the barrel 74.
The band heater 75 is provided with a barrel 74.
Recycled resin inside, namely polyurethane and P of crushed resin to be treated
P is heated to 180 ° C. and transferred forward along the groove of the screw 71, PP is gradually melted, PP around the crushed resin to be treated is melt-bonded, and polyurethane is uniformly kneaded. Then, the extruded material 79 is extruded from the screen 76 and the extrusion die 77 to the forming die 10.

The molding die 10 has a shape similar to that of a so-called T-die type molding die. The molding die 10 is connected to the extruder 70 through the extrusion die 77, and has an inlet connected to the extrusion die 77. It has a molding chamber for molding the extruded dough 79 introduced from the inlet into a wide plate having a predetermined thickness. In this molding chamber, a melting portion in which a heater is arranged is formed on the outer periphery of the molding chamber up to about 1/5 of the length of the molding chamber from the vicinity of the inlet toward the extrusion direction of the extrusion dough 79, and the other portion. Has a gradual cooling portion in which a cooling pipe is disposed on the outer periphery of the melted portion from the boundary to the die exit in the extrusion direction of the extruded material 79.

The extruded dough 79 extruded from the extrusion die 77 connected to the extruder 70 is introduced from the inlet of the forming die 10 and flows in the width direction of the forming chamber of the forming die 10.
The extruded dough 79 flowing in the melting portion of the molding chamber is extruded while maintaining a good kneading state.

As an example, the molding die 10 has a width of 640 m.
It has a slender rectangular cross section of m and a height of 12 mm, and the distance from the inlet of the molding chamber to the die outlet (distance in the extrusion direction) is 6
00 mm. Sheets made of fluororesin having a thickness of 0.25 mm are attached to the inner wall surfaces of the upper, lower, left and right sides of the molding chamber. The sheet is particularly preferably a glass woven fabric coated with a fluororesin, and the fluororesin includes Teflon TFE, Teflon FEP, Teflon CTFE, Teflon VdF and the like, as described above. The glass woven fabric may be a nonwoven fabric of glass fiber.

The fluororesin has a heat resistance of about 300 ° C.,
Since the surface is smooth, the coefficient of friction is small, and the coefficient of thermal conductivity is lower than that of metal, the polyurethane in the extruded material 79 passing through the molding chamber flows smoothly without receiving a large resistance. . Therefore, the kneaded state of the extruded dough 79 maintains a good state and flows.

A braking force is applied to the forming plate 29 extruded from the die outlet 23 of the forming die 10 in the direction opposite to the extruding direction by the braking means 30 to suppress the extruding force of the forming plate 29. 8 and 9, a bearing 34a that supports both ends of the shafts of the three free pinch rollers 31b.
Are fixed to the bearing fixing frame 36, and a fixed pinch roller 31a is provided on each shaft, and the gear 116 and the gear 117 meshing with the gear 116 work together to fix one of the three fixed pinch rollers 31a. The input shaft of the powder brake 115 is connected to the shaft of the pinch roller 31a. The powder brake 115 is a so-called electromagnetic brake, and can electrically finely adjust the friction torque.

Further, the frame 114 is erected on the bearing fixing frame 36, and two block-shaped guide bodies 119 each having a guide groove are provided on the wall surface of the frame 114, and the axial direction of the guide body 119 is vertically changed. Bearings 34b that are provided substantially parallel to each other and that support the ends of the shafts of each of the three free pinch rollers 31b are vertically movable along the guide grooves of the guide body 119, and the bearings 34b are respectively provided to the frame 114. Are connected to the tips of rods of three air cylinders 118 provided on the upper surface of the.

Therefore, when the cylinder 118 is actuated, each of the three free pinch rollers 31b is used to form the molding plate 2.
The fixed pinch roller 31a is pressed through 9 to fix one of the three fixed pinch rollers 31a.
The rotation of the shaft a is suppressed by the powder brake 115, and the gear 116 provided on the shaft of the fixed pinch roller 31a is connected to the gears 116 and 116 provided on the shafts of the other two fixed pinch rollers 31a and 31a. Since they are meshed with each other via 117, the same rotation suppressing force due to the friction torque of the powder brake 115 acts on the three fixed pinch rollers 31a.

By the way, the friction torque for suppressing the rotation of the fixed pinch roller 31a by the powder brake 115 is
It is adjusted according to the thickness of the forming plate 29 to be formed.

Therefore, the friction torque of the powder brake 115 becomes a restraining force against the pushing force of the molding plate 29,
The extruded dough 79 in the introduction chamber 12 of the molding die 10 is made even more dense and uniform, and this extruded dough 79 having a uniform and high density is suppressed by the braking means 30 by the extruding force of the extruded dough 79 by the extruder 70. Advance against the force,
It is cooled in the molding chamber 22 and the molding plate 29 is molded. The molded plate 29 resists the restraining force of the powder brake 115 and the fixed pinch roller 31a and the free pinch roller 31b.
Move forward while rotating.

The suppressing force is applied to the forming chamber 2 via the forming plate 29.
2 and the extrusion dough 79 in the introduction chamber 12 is given a resistance against the extrusion force of the extrusion dough 79 in the molding chamber 22 applied by the extruder, so that the entire extrusion dough 79 in the molding chamber 22 is further enhanced. Uniform and high density.
Since the density of the extruded material 79 is increased by applying the restraining force to the molding plate 29, the adhesion of the recycled resin is enhanced and the formation of bubbles, cavities or the like in the molding plate is prevented. Therefore, a uniform and high-density molded plate is molded.

The extruded dough 79 is introduced into the slow cooling section of the molding chamber and gradually cooled, and the melt-bonded PP around the crushed resin to be treated is gradually hardened. Next, the cooling pipe 2 in the slow cooling section
PP, which has been cooled by the cooling water flowing through the inside of 5 and hardened, is used as a cross-linking agent and is combined with the crushed resin to be treated to form a molded plate having a wall thickness of 12 mm, which is extruded by the extrusion material 79. As a result, a molded plate using a polyurethane foam having a uniform density as a main molding material is molded.

After that, the molded plate is cut into a desired length with a cutting machine such as a cutter, a shearing machine or a saw. By reducing the height of the forming chamber of the forming die, a thin forming plate or sheet material is formed. If this thin molded plate or sheet material, use a cutting machine such as a cutter.
If the molded plate has a thick wall such as 2 mm, it is cut with a cutting machine such as a shirring machine or a saw.

Table 1 below shows an example of the production of the molded plate obtained in the above examples.

[0116]

【Example】

[0117]

[Table 1]

Molded plate as the above product W: 640 m
m, H: 12 mm was cut by a saw blade every 1820 mm to obtain a molded plate having a weight of 14.5 kg. In addition, wall thickness 10-12
Molded plates of about mm are also used for other applications such as cushioning materials, cushioning materials, sound absorbing materials, and heat insulating materials for refrigerators. By the way,
The specific gravity of the molded plate was 0.94, which shows that a high-density molded plate was obtained by the above extrusion molding method.

[0119]

Since the present invention is configured as described above, it has the following effects.

(1) A bulk specific gravity of about 7 to 8 times the bulk specific gravity of the thermosetting resin foam before gelling and kneading the thermosetting resin foam and the thermoplastic resin molding material. Since the recycled resin can be formed, the volume of the recycled resin is reduced to about 14% to 12.5% of the volume of the thermosetting resin foam before gelling and kneading. The volume can be significantly reduced, and it is effective not only for recycling as raw material pellets but also for disposal.

(2) Since the thermosetting resin foam is crushed by the stirring impact force, and the thermoplastic resin molding material is melted by the shearing heat generated by the stirring impact force, but the thermosetting resin foam is not melted. In this process, the pulverized resin to be treated and the thermoplastic resin molding material are gelled and kneaded, and the thermoplastic resin molding material adheres to the entire surface of the individual pulverized resin to be processed, so-called thermoplastic resin molding material A state of being immobilized on the thermally and chemically stable treated pulverized resin is formed,
In order to constantly maintain the mixed and dispersed state of the crushed resin to be treated and the thermoplastic resin molding material, it was possible to form a regenerated resin that gives good fluidity.

(3) When the regenerated resin is molded by a molding method such as extrusion molding or injection molding, an extruded dough having a good kneading state is formed, and the friction resistance of the crushed resin to be treated can be reduced, and the thermosetting It is possible to mold a molded product with a uniform density using a resin foam as the main molding material. In particular, in the case where the recycled resin is used alone, or together with the above-mentioned other recovered resin materials, or in the form of raw material pellets as a molding material such as a compound, the characteristics of the above (2) and (3) are further improved. To do.

(4) For the reason of the above item (3), a recycled resin capable of increasing the mixing ratio of the thermosetting resin foam in the molded product and efficiently reusing the thermosetting resin foam. Could be formed. Therefore, the recycled resin and the method for recycling the same according to the present invention is a method without serious problems typified by conventional chemical recycling, and is not limited to a narrow range of passive recycling such as energy recovery by mere filler or incineration. In addition, it is possible to provide a positive recycling method that can be widely reused as raw material pellets and has high utilization efficiency.

(5) The recycled resin is heated and kneaded, and the extruded dough extruded to the forming die with the screw is gradually cooled, and the extruded dough is restrained against the extruding force to reduce the density of the extruded dough. The extruded material is extruded into the molding die in a state where the extruded material heated and kneaded is in a good kneading state and the friction resistance of the recycled resin is reduced, and the extruded material is extruded. Since a restraining force against the pushing force is added to, a uniform and high-density molded product can be molded.

[Brief description of drawings]

FIG. 1 is a systematic explanatory diagram of a processing step showing in principle and schematically the outline of an example of recovering a polyurethane foam used as a raw material of a recycled resin from an instrument panel member of a waste resin molded product in an example of the present invention.

FIG. 2 is an overall perspective view showing a main part of a cutter mill (crushing means) used in the embodiment.

FIG. 3 is a vertical cross-sectional view schematically showing a schematic configuration of a separating / classifying / grading means (separator) used in the above-mentioned embodiment.

FIG. 4 is a front view for explaining the separation / classification / particle size regulating operation in FIG.

FIG. 5 is an overall front view showing a cross section of a main part of a mixer (crushing means and fluidized mixing / kneading means) used in an example of the present invention.

FIG. 6 is an overall front view showing a cross section of a main part of a cooling mixer (cooling granulation means) used in an example of the present invention.

FIG. 7 is an overall front view showing a cross section of a main part of an extruder used in an example of the present invention.

FIG. 8 is a plan view showing a cross section of a main part of the braking means of the embodiment of the present invention.

9 is a vertical cross-sectional view taken along the line NN of FIG.

[Explanation of symbols]

 29 forming plate 30 braking means 31 pinch roller 31a fixed pinch roller 31b universal pinch rollers 34a, 34b bearing 36 bearing fixed frame 60 instrument panel member 61 coarse crushed piece 62 crushed piece 63 collected resin material 70 extruder 71 screw 72 gear reducer 73 hopper 74 Motor 75 Band heater 76 Screen 77 Base plate 79 Extrusion dough 80 Mixer (crushing means and fluid mixing and kneading means) 81 Mixer main body 82 Upper lid 83 Shaft 84 Scraper 85,86,87 Stirring impact blade 88 Discharge port 89 Lid 91 Cylinder 92 Tightening nut 93 Discharge Duct 94 Input Port 95 Exhaust Pipe 96 Air Supply Pipe 100 Cooling Mixer (Cooling Granulation Means) 101 Mixer Main Body 102 Jacket 103 Arm 104 Stirring Blade 105 Motor 106 Valve 107 Discharge Port 108 Water Supply Pipe 109 Drain Pipe 111 Motor 112 Reduction Gear 113 Input Port 114 Frame 115 Powder Brake 116 Gear 117 Gear 118 118 Cylinder 119 Guide Body 114 Frame 120 Cutter Mill (Crushing Means) 121 Cutter Mill Main Body 122 Lid 123 Input Port 124 Cutter support 125 Rotating blade 126 Fixed blade 127 Feeding chamber 128 Grading chamber 129 Screen 130 Separation / classification / grinding device (separator) 131 Fixed disc 132 Supply feed port 133 Fixed end plate 134 Fixing pin 135 Circumferential plate 141 Movable disc 142 Rotating horizontal axis 143 Bearing 144 Movable pin 151 Screen 152 Discharge port 153 Outlet port 154 Plug valve 155 Grinding and sizing space 156 Discharge space 157, 157a Blower 58,158a blower

Continuation of front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display area B29K 105: 04 105: 26

Claims (6)

[Claims] 1. A thermoplastic resin molding material 30 to 80 wt% is mixed with 20 to 70 wt% of a pulverized resin to be treated having a high bulk specific gravity obtained by pulverizing a thermosetting resin foam, and the mixture is gelled and kneaded. A reclaimed resin characterized by being granulated to have a particle size of 15 mm or less, the thermoplastic resin molding material being fixed on the surface of a crushed resin to be treated, and the thermosetting resin foam being reduced in volume. . 2. A crushed resin to be treated 20 to 7 having a bulk specific gravity of 0.1 to 0.2 obtained by crushing a thermosetting resin foam.
30-80 wt% of a thermoplastic resin molding material is mixed with 0 wt%, gelled and kneaded, and granulated to have a particle diameter of 15 mm or less, and the thermoplastic resin molding material is fixed on the surface of the crushed resin to be treated, A recycled resin, characterized in that the thermosetting resin foam is reduced in volume to a bulk specific gravity of 0.3 or more. 3. A crushing step of forming a crushed resin having a high bulk specific gravity by crushing a thermosetting resin foam, and a thermoplastic resin molding material 30 to 30 to 20% by weight of the crushed resin to be processed. A stirring impact force is applied together with 80 wt% to generate a shear heat generation based on the stirring impact force, and the shear heat generation causes gelation and kneading to granulate to a particle size of 15 mm or less, and the thermoplastic resin molding material is coated. A method for regenerating a thermosetting resin foam, comprising at least the step of fixing the treated pulverized resin on the surface and reducing the volume of the thermosetting resin foam. 4. A crushing step of forming a crushed resin having a bulk specific gravity increased to 0.1 to 0.2 by crushing a thermosetting resin foam, and 20 to 70 wt% of the crushed resin to be processed. 30-80 wt% of the thermoplastic resin molding material is added with a stirring impact force to generate shear heat generation based on the stirring impact force, and the shear heat generation causes gelation and kneading to produce a particle diameter of 15 mm.
At least including the steps of granulating, immobilizing the thermoplastic resin molding material on the surface of the crushed resin to be treated, and reducing the volume of the thermosetting resin foam to a bulk specific gravity of 0.3 or more. A method for regenerating a thermosetting resin foam. 5. The regenerated resin is heated and kneaded, and is extruded into a molding die with a screw, and the extruded material is extruded into a molding portion of a molding die having a fluororesin sheet attached to the inner wall surface or coated with the fluororesin. At least a step of increasing the density of the extruded dough in the molding part by applying a suppressing force against the extruding force of this molded product while molding at a predetermined wall thickness and gradually cooling in the molding part. A method of molding a molded article made of the recycled resin, comprising: 6. The recycled resin is heated and kneaded to form a raw material pellet, which is then injected into a molding die with a screw, molded into a predetermined molded product shape, and slowly cooled, and then demolded. And a method of molding a molded article comprising the recycled resin.