KR101886411B1 - Functionality pannel using waste fiber and manufacturing method of the same - Google Patents

Abstract

According to the present invention, provided are a functional panel using waste fibers, capable of heat insulation, soundproof, warming, and shock absorption; and a manufacturing method thereof. According to a preferred embodiment of the present invention, the manufacturing method comprises: a step (a) of collecting and classifying waste fibers; a step (b) of unwinding fibers to be formed in a cotton shape through a scutcher; a step (c) of introducing the fibers into a mixing tank to mix the same; a step (d) of separately forming a soft and flat felt from the mixed fibers through a molding machine; a step (e) of temporarily combining each felt in a net structure; a first heating compression step (f); a second cooling compression step (g); and a step (h) of cutting a cured panel into a desired size by using a laser or a water jet.

Description

TECHNICAL FIELD The present invention relates to functional panels using waste fibers,

The present invention relates to a functional panel using waste fibers and a method of manufacturing the same, and more particularly, it relates to a functional panel capable of joining fiber panels without using an adhesive or a resin and capable of high density fabrication having a network structure by a needle punching process, The present invention also relates to a functional panel using the waste fiber and a method for manufacturing the functional panel.

There is a known method of recycling fiber waste as a filler, a nonwoven fabric, a mat, a lug, a kit and a bag, or as a solid fuel, a reinforced plastic, a caprolactam or a SRF solid fuel. In domestic technology, it is known to manufacture artificial wood by using fibers and waste plastics, manufacture of building interior materials using fibers and stones, automobile interior materials using waste fibers, and plate materials made of fibers and waste paper. In the case of overseas technology, it is known to manufacture waste paper by using cotton, manufacture paper by using waste fiber, and manufacture insulation board using fiber waste.

However, this technology is not able to recycle cotton fiber, and it is necessary to use resin adhesive. In case of cotton fiber, cotton fiber has thermosetting property, so it can be reused because it is destroyed when heat is applied, but recycling is difficult. The use of resin adhesives emits harmful substances to the human body. Therefore, there is a need for a panel having a uniform strength, which uses waste fibers, and which does not require a resin adhesive, which is a harmful substance, and a manufacturing method thereof.

As a background of the present invention, Korean Patent Registration No. 10-0644099 discloses a method for manufacturing a sheet material including steps of cutting, rubbing, mixing, flattening, pressurizing rollers, and rapid cooling and cutting waste fibers Korean Patent Laid-Open No. 10-2003-0047237 proposes a method for producing a waste synthetic fiber sheet material by cutting, rubbing, heating, pressurizing and cooling polyester-based and cotton fibers, and disclosed in Korean Patent Publication No. 10-2002-0060413 Japanese Unexamined Patent Application Publication No. 10-292517 discloses a method for manufacturing a construction plywood by selecting, cutting and rubbing waste fibers, polyester and cotton mixed molding, cooling and cutting molding, And a panel member made by laminating and fusing the panel member.

However, the above background arts have difficulty in achieving a product having a uniform strength because of lack of continuity due to overlapping and intermixing of fibers.

Korean Patent Registration No. 10-0644099 Korean Patent Publication No. 10-2003-0047237 Korean Patent Publication No. 10-2002-0060413 Japanese Patent Laid-Open No. 10-292517

The present invention is capable of bonding fiber panels without the use of an adhesive or a resin, capable of high-density production with a network structure by a needle punching process, and having uniform strength and being insulated, soundproofed, And to provide a functional panel using the waste fiber and a method of manufacturing the same.

According to a preferred embodiment of the present invention, there is provided a method of manufacturing a functional panel using waste fibers,

(a) collecting waste fibers and sorting them into polyester, cotton and other fibers;

(b) cutting polyester, cotton, and other fibers classified from waste fibers to a predetermined size through a cutter, and then loosening the fibers through a cotton machine to form a cotton pad;

(c) feeding the other side and interfacial cotton-like fibers into a mixing tank and mixing them;

(d) making the mixed fibers have a predetermined width and thickness by using a card machine and a face machine, and then forming soft and flat felt through the molding machine, respectively;

(e) crossing each felt with a long needle up and down using a needle punching machine to bind the loosened fibers to a network structure uniformly with a density of 1.18 g / cm 2 or more;

(f) A plurality of outer panels and inner panels 13, which have been manufactured through the steps (a) through (e), are laminated and laminated, and the laminate is heated at a temperature of 150 ° C to 220 ° C and a pressure of 100 kg / Cm < 2 > to cure the upper and lower layers;

(g) a second cooling and compressing step of cooling and compressing the heat-compressed outer panel and the inner panel through a cooling press at a temperature of 5 ° C to 15 ° C and a pressure of 300 kg / cm 2 to harden the panel to form a high density;

(h) cutting the panel cured to a desired size using a laser or a water jet.

Further, the outer panel disposed in the outermost layer in the step (f) to be heat-bonded is characterized in that 100% of polyester fiber regenerated in waste plastics or PET bottles is used.

In the step (f), the inner panel disposed on the intermediate layer to be heat bonded is composed of 40 to 70% by weight of polyester fibers, 20 to 40% by weight of cotton, and 10 to 20% by weight of other fibers.

Further, in the step (d), it is further characterized in that a step of applying charcoal powder to the middle of the mixed yarn is further included.

In addition, the method further comprises the step of interposing a surface of the natural fiber in the middle of the mixing.

In order to increase the intermolecular bonding of the porous crystals between the molecular materials in the step (d), nanoceramic powders, elvan powders, zeolite powders, bentonites, antibacterial ceramic powders (CERAMIC POWDER), montmorillonite (MONTORILLONITE), and the like.

In addition, in the step (f), 2 to 4 parts by weight of non-slip is included in a joint surface of the outer panel and the inner panel with respect to 100 parts by weight of the outer panel or the inner panel. The non-slip agent may be a non-metal powder, a ceramic powder, Iron oxide powder, or a mixture of these species, and has a particle size of 200 mesh or less.

In addition, in the step (f), 2 to 4 parts by weight of non-slip is included in a joint surface of the outer panel and the inner panel with respect to 100 parts by weight of the outer panel or the inner panel. The non-slip agent may be a non-metal powder, a ceramic powder, Iron oxide powders, or a mixture of these species, and is formed into a cylindrical rod shape having a different length and is irregularly coated.

Meanwhile, the functional panel using the waste fiber according to the present invention comprises: an outer panel manufactured by processing 100% of polyester fibers; And an inner panel formed by processing 40 to 70% by weight of polyester fibers, 20 to 40% by weight of cotton, and 10 to 20% by weight of other fibers, and having the outer panel on both sides and interposed therebetween .

According to the functional panel using the waste fiber of the present invention and the method of manufacturing the same, a panel made of a waste fiber panel containing a face and a polyester fiber of 100% is bonded by heating and cooling compression, Excellent bonding is achieved between the panels. Thus, an environmentally friendly panel product in which harmful substances such as various formaldehyde are excluded can be obtained.

In addition, polyester and cotton can be manufactured in a high density with a network structure by needle punching process, and it is possible to secure a uniform high strength panel product, and it is used as MDF, plywood, partition board and gypsum board It is possible to use it as a covering block, a deck, a bench, a furniture, an interior / exterior finishing material which are other application products.

In addition, it is possible to use insulation fiber, soundproofing, heat insulation and impact absorption by synthesized cotton fiber as various insulation materials and soundproofing materials.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate exemplary embodiments of the invention and, together with the description, serve to explain the principles of the invention, Shall not be construed as limiting.
1 is a perspective view of a functional panel according to the present invention;
2 is a view showing a manufacturing process of a functional panel according to the present invention.
3 is a perspective view of an inner panel according to an embodiment of the present invention;
4 is an exemplary view showing a needle punching process applied to the present invention.
Fig. 5 is an operational view of a long needle up and down during needle punching in Fig.
Fig. 6 is an exemplary view showing heating and compression using a heat compression molding machine according to the present invention; Fig.
7 is an exemplary view showing cooling compression using a cooling press according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the embodiments shown in the accompanying drawings, but the present invention is not limited thereto.

1, the functional panel 10 using the waste fiber according to the present embodiment comprises outer panels 11 and 12 fabricated by processing 100% of polyester fibers, 40 to 70 wt% polyester fibers, 40% by weight of the other fibers and 10 to 20% by weight of the other fibers, and then the inner panels 13 are bonded to each other with the outer panels 11 and 12 therebetween.

Here, the outer panels 11 and 12 and the inner panel 13 are each fabricated as one unit panel through cutting, rubbing, mixing, and needle punching processes as described below, Are interposed between the outer panels 11 and 12 and are bonded to each other through a sequential two-stage compression process of heat compression and cooling compression, and are fabricated as a functional panel through a cutting process of a desired size.

A manufacturing method of the functional panel 10 using the waste fiber structured as described above will be described.

First, as shown in FIG. 2, the waste collection and sorting step S11 is performed. At this stage, waste fibers are collected and classified into cotton, polyester and other fibers. Polyester fiber can be produced by regenerating in PET bottles, for example waste plastics.

Then, it has a cutting and rubbing step S12. This is a step of cutting the cotton, polyester fiber and other fibers classified from the waste fiber into a predetermined size through a known rotary cutter and then passing through the process. The cutting size can be 3-5 cm x 3-5 cm. The riding process is a step of loosening the fibers through the rim (interface) so as to be in a cotton form.

Then, it has a mixing step S13. This is to blend the other and the interfaced yarns into a well-known mixing tank.

For example, when making the outer panels 11 and 12, 100% of the polyester fibers are mixed. When the inner panel 13 is manufactured as shown in Table 1 below, it may be blended with 40 to 70% by weight of polyester fibers, 20 to 40% by weight of cotton, and 10 to 20% by weight of other fibers. This is because when the polyester fiber content is less than 40% by weight, the heat bonding becomes poor, and when the polyester fiber content is more than 70% by weight, the content of the cotton surface is reduced. When the content of the cotton is less than 20% by weight, it is difficult to sufficiently exhibit the functions of soundproofing, insulation and insulation. When the content exceeds 40% by weight, the content of the polyester fiber is reduced and the heat bonding becomes poor. When 20 to 40% by weight of the cotton is contained in the inner panel 13 at the time of manufacturing the inner panel 13, it is possible to exhibit the function of heat insulation, soundproofing, insulation and shock absorption. 3 shows a photograph of one of the inner panels 13 obtained in the following embodiment.

[Various Embodiments of Inner Panel]

 polyester          if       Other Textiles      Example 1         60          30         10      Example 2         70          20         10      Example 3         40          40         10

In Table 1, the unit is wt%.

Then, it has a forming step S14. It is made to have a certain width and thickness through a well-known card and face machine, and then, through a pressure roller of a known molding machine, a soft and flat formed felt is formed. At this time, the temperature of the pressure roller may be 50 ° C to 70 ° C and the pressure of 100 kg / cm 2.

In the forming step S14, nanoceramic powders, elvanite powders, zeolite powders, bentonites, antibacterial ceramic powders, and the like are added to increase the mutual bonding of porous crystals between molecular materials. , Montmorillonite (MONTMORILLONITE), and the like may be further applied.

In the forming step S14, polyester is mixed with a high density, medium density, and low density to be mixed with each other at the time of working the well-known counterface (interfacer), and then the mixed yarn (cotton) Powder can be applied. Charcoal powder has numerous honeycomb-shaped porous forms that adsorb odor, moisture and harmful substances, has proper temperature keeping warmth, adsorbs moisture, releases moisture in dry places, and can control humidity. It has an energy synergistic function and has an air purifying function to remove formaldehyde, odor and odor. In this case, a natural fiber surface can be interposed in the middle of the mixing.

Then, a needle punching step S15 is carried out. This is because the felt 2 formed as shown in Fig. 4 is crossed by the upper and lower long needles 101a and 102a using the needle punching machine 100 as shown in Fig. 5 so that the release fiber constituting the felt 2 is 1.18 g / So that it becomes a network structure having a high density. That is, the needle plates 101 and 102 having the long needles 101a and 102a are repeatedly moved up and down to couple a part of a two-dimensional random fiber arrangement into a three-dimensional structure. In this case, the volume is reduced to 70% of the molding step.

The outer panels 11 and 12 and the inner panel 13 are primarily fabricated through such a sequential manufacturing process.

Then, it has a heat compression step (S16). That is, a plurality of unit panels, that is, the outer panels 11 and 12 and the inner panel 13 are stacked and laminated, and the temperature is 150 ° C. to 220 ° C. and the pressure 100 kg / Cm < 2 >. In this case, the upper and lower layers are cured and the volume is reduced by 15%.

On the other hand, at this stage, the bonding surfaces of the outer panels 11, 12 and the inner panel 13 include 2 to 4 parts by weight of non-slip relative to 100 parts by weight of the outer panels 11, 12 or the inner panel 13 . The non-slip agent is selected from one or a mixture of non-metal powders, ceramic powders, aluminum oxide powders and iron oxide powders, and the particle size is preferably 200 mesh or less. The non-metallic powder may be a powder of titanium oxide, and the ceramic powder may be powder of silicon carbide or silicon nitride.

When an appropriate amount of the non-slip agent is applied to the joining surfaces of the outer panels 11 and 12 and the inner panel 13, it is possible to suppress the slip on the joining surfaces and further improve the joining properties between the panels.

As another embodiment, at this stage, the joining surfaces of the outer panels 11 and 12 and the inner panel 13 include second to fourth grains of non-slip relative to 100 weight parts of the outer panels 11 and 12 or the inner panel 13 And the non-slip agent may be irregularly shaped and formed of a non-metal powder, a ceramic powder, an aluminum oxide powder, an iron oxide powder, or a mixture of these species, and formed into a cylindrical rod shape having different lengths.

Then, it has a cooling compression step (S17). This means that the heat-compressed panel 10 is cooled and compressed with a temperature of 5 ° C to 15 ° C and a pressure of 300 kg / cm 2 through the cooling press 300 of FIG. 7 to harden the panel 10 to a high density. This results in a pre-cut functional panel 10 whose volume is reduced by 7%.

Thereafter, the functional panel 10 of a desired size is manufactured through a step S18 of cutting the functional panel 10 cured to a desired size using a well-known laser or water jet. Here, the laser cutting is changed to a black color by the heat, and the water jet cutting can have an advantage that there is no color change.

At this time, the density of the functional panel 10 according to each product is 1.18 g / cm3 for a high density fiber panel, 0.35 to 0.85 g / cm3 for a MDF, 0.5 to 0.8 g / cm3 for a partition board, 0.4 to 0.65 g / Can have a high density fiber panel of 76.3 N / mm 2, an MDF of 20 to 40 N / mm 2, a partition board of 8 to 18 N / mm 2, a plywood of 16 to 30 N / mm 2 and a gypsum board of 5 to 10 N / mm 2.

Since the functional panel 10 using the waste fiber has a uniform density and high strength, it can be used as MDF, plywood, partition board, and gypsum board which are basic building materials, and other applicable products such as a sidewalk block, a deck, , Furniture, interior / exterior finishes.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the above teachings. will be. The invention is not limited by these variations and modifications, but is limited only by the claims appended hereto.

10: Functional Panel
11, 12:
13: Inner panel

Claims (9)

delete delete delete (a) collecting waste fibers and sorting them into polyester, cotton and other fibers;
(b) cutting polyester, cotton, and other fibers classified from waste fibers to a predetermined size through a cutter, and then loosening the fibers through a cotton machine to form a cotton pad;
(c) feeding the other side and interfacial cotton-like fibers into a mixing tank and mixing them;
(d) making the mixed fibers have a predetermined width and thickness by using a card machine and a face machine, and then forming soft and flat felt through the molding machine, respectively;
(e) crossing each felt with needle 101a, 102a up and down using a needle punching machine 100, and binding the loosened fibers to the net structure uniformly to have a density of 1.18 g / cm 2 or more;
(f) A plurality of the outer panels 11 and 12 and the inner panel 13, which have been combined through the steps (a) to (e), are stacked and laminated, A first heating and compressing step of heating and compressing the upper and lower layers with a pressure of 100 kg / cm < 2 >
(g) The heat-pressed outer panels 11 and 12 and the inner panel 13 are cooled and compressed through a cooling press 300 at a temperature of 5 ° C to 15 ° C and a pressure of 300 kg / cm 2, A second cooling and compressing step;
(h) cutting the panel 10 cured to a desired size using a laser or a water jet,
[7] The method of claim 7, wherein the step (d) further comprises the step of applying charcoal powder in the middle of the mixed yarn. 5. The method of claim 4,
Further comprising the step of interposing a natural fiber surface in the middle of mixing. delete (a) collecting waste fibers and sorting them into polyester, cotton and other fibers;
(b) cutting polyester, cotton, and other fibers classified from waste fibers to a predetermined size through a cutter, and then loosening the fibers through a cotton machine to form a cotton pad;
(c) feeding the other side and interfacial cotton-like fibers into a mixing tank and mixing them;
(d) making the mixed fibers have a predetermined width and thickness by using a card machine and a face machine, and then forming soft and flat felt through the molding machine, respectively;
(e) crossing each felt with needle 101a, 102a up and down using a needle punching machine 100, and binding the loosened fibers to the net structure uniformly to have a density of 1.18 g / cm 2 or more;
(f) A plurality of the outer panels 11 and 12 and the inner panel 13, which have been combined through the steps (a) to (e), are stacked and laminated, A first heating and compressing step of heating and compressing the upper and lower layers with a pressure of 100 kg / cm < 2 >
(g) The heat-pressed outer panels 11 and 12 and the inner panel 13 are cooled and compressed through a cooling press 300 at a temperature of 5 ° C to 15 ° C and a pressure of 300 kg / cm 2, A second cooling and compressing step;
(h) cutting the panel 10 cured to a desired size using a laser or a water jet,
In the step (f), the joining surfaces of the outer panels 11 and 12 and the inner panel 13 include second to fourth weight portions of non-slip relative to 100 weight parts of the outer panels 11 and 12 or the inner panel 13, Wherein the non-slip agent is selected from one or a mixture of non-metal powders, ceramic powders, aluminum oxide powders and iron oxide powders, and the particle size is 200 mesh or less. (a) collecting waste fibers and sorting them into polyester, cotton and other fibers;
(b) cutting polyester, cotton, and other fibers classified from waste fibers to a predetermined size through a cutter, and then loosening the fibers through a cotton machine to form a cotton pad;
(c) feeding the other side and interfacial cotton-like fibers into a mixing tank and mixing them;
(d) making the mixed fibers have a predetermined width and thickness by using a card machine and a face machine, and then forming soft and flat felt through the molding machine, respectively;
(e) crossing each felt with needle 101a, 102a up and down using a needle punching machine 100, and binding the loosened fibers to the net structure uniformly to have a density of 1.18 g / cm 2 or more;
(f) A plurality of the outer panels 11 and 12 and the inner panel 13, which have been combined through the steps (a) to (e), are stacked and laminated, A first heating and compressing step of heating and compressing the upper and lower layers with a pressure of 100 kg / cm < 2 >
(g) The heat-pressed outer panels 11 and 12 and the inner panel 13 are cooled and compressed through a cooling press 300 at a temperature of 5 ° C to 15 ° C and a pressure of 300 kg / cm 2, A second cooling and compressing step;
(h) cutting the panel 10 cured to a desired size using a laser or a water jet,
In the step (f), the joining surfaces of the outer panels 11 and 12 and the inner panel 13 include second to fourth weight portions of non-slip relative to 100 weight parts of the outer panels 11 and 12 or the inner panel 13, Characterized in that the non-slipping agent is selected from one or a mixture of non-metal powders, ceramic powders, aluminum oxide powders and iron oxide powders, and is formed in a cylindrical rod shape having a different length and is irregularly coated. ≪ / RTI > A functional panel (10) produced by the manufacturing method of any one of claims 4, 5, 7, and 8,
Outer panels 11 and 12 fabricated with 100% polyester fiber;
The outer panel 11 and 12 are fabricated to be 40 to 70% by weight of polyester fiber, 20 to 40% by weight of cotton and 10 to 20% by weight of other fiber, and then the inner panel 13 And a functional panel using the waste fiber.

Images