KR20010100285A - Heat Compression Mat Processing Method Using Waste Matters - Google Patents

Abstract

The present invention is a method of manufacturing a thermal compression mat using waste fibers having heat resistance and strength that can be used for industrial use of various types of waste fibers embedded or incinerated as wastes, including adhesive fibers, general chemical fibers, and natural fibers. Collecting the waste fibers and classifying them by type and color; cutting the sorted waste fibers into a predetermined size suitable for blending; blending the cut waste fibers by color and type; Shaping the fibers with a masking machine, carding the mixed cotton with a carding machine, shaping the carded cotton into the fiberboard body to a desired width and thickness with a molding machine, and needlening the molded fiberboard body with a punching machine. And heating the oven with a heat-sealable fiber in the plurality of fibrous plate bodies produced through the process to melt and bond with other fibers. The fiber board made of a material of the various layers of the heat to the step of pressing using a plurality of rollers.

Therefore, in the manufacture of the mat using waste fibers, the heating and pressurizing process is performed, and the functional material such as natural jade is added between the two sheets of fiber boards, so that the tensile strength and the bursting strength are excellent, and the fire resistance is remarkable. By showing the numerical value, as well as the fire protection material, it can be widely used as various industrial mats, and the addition of various functional materials can provide a mat with far-infrared rays.

Description

Heat Compression Mat Processing Method Using Waste Matters

The present invention relates to a method for manufacturing a thermally compressed mat using waste fibers, and more particularly, to manufacturing a recycled thermally compressed mat having heat resistance and strength that can be utilized for industrial use of waste fibers embedded or incinerated as waste. It is about a method.

Conventionally, reprocessed into cotton using sweaters, T-shirts, cotton, waste of the textile factory, etc. has been used as a greenhouse thermal cover on the market.

That is, various kinds of waste fibers are cut into cotton with a cotton wool machine, and the cotton that is recycled from waste fibers is uniformly thickened on the upper and lower sides of polypropylene flat yarn (polypropylene mesh), and the front cotton is needles on the upper and lower sides of polypropylene yarn. It is manufactured by ring.

The mat is thus manufactured is used for agricultural vinyl house insulation or concrete curing cloth.

The heat-resistant molding-coated nonwoven fabric is a resin processed web of a wholly aromatic polyamide staple fibers into a heat-resistant resin, for example, a phenol resin or a polyamide resin, and a pigment or heat-resistant staple fiber and an unstretched fiber. It is known to produce by mixing with each other by water flow action to form a mixed web and then fusion of the mixed fibers of the web with each other by a heat compression process (Japanese Patent Laid-Open No. 63-28,962).

When a conventional heat resistant nonwoven fabric is used for heat resistant molding-coating, the heat resistant nonwoven fabric is resin-processed with a resin mixed with an organic or inorganic pigment to improve the concealability of the heat resistant heat insulating material to be coated.

However, such a conventional manufacturing method has been inconvenient that the use itself is fixed only by one thing and cannot be used in many ways.

In addition, these bolts are easily disassembled by direct sunlight and generate dust or debris on their own, even in small impacts. They were not good for health and hygiene, and workers had to wear masks during work or use. For example, there is a problem that the top of the mat is easily damaged when exposed to rain or snow, and the mat which has been reprocessed using various fiber wastes and the like has not been diversified in its use.

Particularly, these products have always had the risk of fire because they are simply needle-punched above and below the polypropylene network, and are extremely degraded in terms of tensile strength, bursting strength, air permeability, and their industrial degree is extremely limited. It became.

And since most of the fiber crossing points are fixed as a result of the resin processing, the elongation of the obtained resin-processed heat resistant molding coating nonwoven fabric is undesirably lowered. If elongation is degraded, wrinkles occur in the molding-coating procedure. In addition, when stretched, a low density portion is formed in the nonwoven fabric, and this portion unevenly hides the nonwoven fabric. Resin processing also increases production costs. In addition, the resin-processed nonwoven fabrics have the disadvantage that they are rough in touch, low in flexibility, high in surface smoothness, strong in light reflection and low in color.

In nonwoven fabrics produced by intersecting fibers with each other by the action of water flow (spraying), the impact effect of water jet and the action of the net receiving water jet cause uneven crossover of fibers, especially the weakly intersected nonwoven fabric portion. It is thinner than other parts and shows a low concealment effect.

In addition, since the strongly intersected nonwoven portion has a reduced elongation, the nonwoven fabric exhibits a reduced elongation in its entirety and also reduces the formability of the nonwoven fabric. In addition, the nonwoven fabric obtained by mutually crossing the fibers by water jet action and heat-compressing the fibers with each other exhibits very low elongation and formability.

Nonwoven fabrics produced by the wet method have high density and low elongation, which results in poor formability and easily wrinkles on the nonwoven fabric. Needle punched and spun-bonded nonwovens also have similar drawbacks as wet nonwovens and exhibit a hard, rough feel and low flexibility.

The use of the present invention is widely utilized in the mattress interior materials, building interior / exterior materials and sound-absorbing materials, insulation, automotive interior materials, etc., and also has advantages in terms of environmental protection.

The present invention has been invented to solve this problem in view of the above-described problems, and provides a method for producing a regenerative thermal compression mat having heat resistance and strength that can be utilized for industrial use of waste fibers embedded or incinerated as waste. Is in.

1 is a process chart showing a method for manufacturing a thermal compression mat using waste fibers of the present invention.

2 is a process chart showing a method of manufacturing a thermal compression mat to which a functional material is added using waste fibers of the present invention.

Figure 3 is a graph measuring the far-infrared emissivity and radiation energy of the natural jade addition mat of Example 2 of the present invention

Figure 4 is a graph measuring the far-infrared emissivity and the radiation energy of the elvan rock addition mat of Example 2 of the present invention

5a to 5c are photographs taken of the infrared ray emissivity and radiation energy for each mat of Example 2 of the present invention with an infrared thermal imager,

5a is a general mat,

5b is a ganguerite attachment mat,

5c is a natural jade attachment mat.

Method for producing a thermal compression mat using the waste fiber of the present invention for achieving the above object,

Collecting and classifying waste fibers composed of fused fibers, general chemical fibers, and natural fibers by type and color;

Cutting the sorted waste fibers into a predetermined size suitable for blending;

Blending the cut waste fibers by color and type;

Making the blended waste fiber into cotton wool with another cotton wool,

Carding the mixed cotton with a carding machine,

Molding the carded cotton into a fiber board body in a desired width and thickness with a molding machine,

Needled the molded fiberboard body with a punching machine,

Heating the oven with a heat-sealable fiber in the plurality of fibrous plate bodies produced through the process to melt and bond with other fibers;

Pressing the heated several layers of fiberboard body using a plurality of rollers, characterized in that consisting of.

In this manufacturing method, the blending ratio of the waste fibers cut in the blending step is preferably 20 to 50% of the heat-sealable fibers, 25 to 40% of the general chemical fibers, 25 to 40% of the natural fibers, the heating step It is preferable that the heating temperature of the oven is 190 to 250 ° C.

In addition, the manufacturing method of the functional material addition mat of the present invention,

Collecting and classifying waste fibers composed of fused fibers, general chemical fibers, and natural fibers by type and color;

Cutting the sorted waste fibers into a predetermined size suitable for blending;

Blending the cut waste fibers by color and type;

Making the blended waste fiber into cotton wool with another cotton wool,

Carding the mixed cotton with a carding machine,

Molding the carded cotton into a fiber board body in a desired width and thickness with a molding machine,

Needled the molded fiberboard body with a punching machine,

Spraying the functional material on the powder between the plurality of fiber boards produced through the process;

Heating the oven with a heat-sealable fiber in the plurality of fibrous plate bodies to which the functional material has been sprayed to combine with other fibers;

Pressing the heated several layers of fiberboard body using a plurality of rollers, characterized in that consisting of.

In this manufacturing method, the functional material may be selected from natural jade, elvan, loess powder, charcoal powder.

Therefore, in addition to the conventional nonwoven fabric manufacturing process, it is subjected to the molding, heating and pressurization process, and is produced by adding a functional material such as natural jade between two sheets of fibrous plate, excellent tensile strength, burst strength, especially of the present invention The degree of fire protection is a very useful invention such as providing not only fireproof materials but also various industrial mats by showing remarkable numerical values, and providing mats in which the wires are radiated due to the addition of various functional materials.

Hereinafter, a method of manufacturing a thermal compression mat using waste fibers of the present invention will be described in more detail with reference to the accompanying drawings.

(Example 1)

1 is a process chart showing a method of manufacturing a thermal compression mat using waste fibers of the present invention.

First, waste fibers made of natural fibers such as fusible fibers, general chemical fibers, cotton, wool, etc. are collected through various paths and classified by type and color.

The sorted waste fiber is cut into a size of approximately 100 mm x 100 mm, and then blended by color and type, and then made into a cotton ball through a screening machine. The blending ratio of the cut waste fibers in the blending depends on the use of the product to be manufactured, but usually 20 to 50% of the heat-sealable fibers (waste polypropylene, etc.) and general chemical fibers (waste polyester, acryl) Etc.) 25 to 40% and natural fibers 25 to 40%.

The mixed cotton is carded (combed) once again through a carding machine to make uniform, neatly arranged and connected cotton, and then the cotton is formed into a desired width and thickness according to the type of product through a molding machine, and the punching machine Needled through to make a fiber board with tensile force.

The thickness of the fibrous board produced through the above process is about 12-18 mm and the weight is about 1.2 kg / 1 m 2.

Subsequently, the fiber board body completed through the above process may be produced by stacking one or two or three or more layers.

Subsequently, heat is passed through an oven to impart strength as the heat sealable fiber melts and bonds with other fibers, and then passes through rollers to undergo a pressing process to complete the manufacture of a heat meltable press mat. At this time, the heating temperature of the oven is preferably 190 to 235 ° C.

As a result of the first characteristic test of the thermally compressed mat using the waste fiber of the present invention thus produced, the following results were obtained (see each table to be described later).

(Comparative Example)

After cutting various waste fibers into cotton with a cotton wool machine, the cotton is recycled from waste fibers on the upper and lower sides of polypropylene flat yarn (polypropylene net) with a constant thickness, and the front cotton is needled on the upper and lower sides of polypropylene yarn. Prepared.

Since this comparative example is a mat made of an unregular material, various test results can be derived, and samples 1, 2, and 3 were cut and tested.

Various test results comparing Comparative Examples 1, 2 and 3 with Examples of the present invention are shown in the following tables. This test was conducted by Korea Yarn Textile Testing Institute, a nationally recognized testing and research institute.

Mixed use rate (KS K 0210) (Unit%) sample Example 1 Sample 1 Sample 2 Sample 3 Other materials 84.9 74.9 73.3 71.8 mother 15.1 25.1 26.7 28.2

Tensile Strength (KS K 0220, C.R.E.Grav Method) (Unit ㎏f) sample Example 1 Sample 1 Sample 2 Sample 3 Length 201.3 28.6 37.0 28.6 width 133.7 25.5 30.8 26.1

Burst Strength (KS K 0350, C.R.E, Ball Bursting Method) (Unit kg kg) sample Example 1 Sample 1 Sample 2 Sample 3 284.9 53.1 80.7 90.5

Air permeability (KS K 0570, Frazier method) (unit cc / ㎠ / sec.) sample Example 1 Sample 1 Sample 2 Sample 3 19.6 6.4 6.9 6.0

Thermal insulation (KS K 0466, KS K 0560, constant temperature method) (Unit%) sample Example 1 Sample 1 Sample 2 Sample 3 68.4 71.0 64.6 61.8

Compression Ratio (KS K 0817) (Unit%) sample Example 1 Sample 1 Sample 2 Sample 3 8.7 27.5 27.4 24.2

(Note 1) In the case of Example 1, the applied load is 5 kg, the area of the test piece is 225 cm 2, and the measurement point is 10 seconds after the application of the load.

(Note 2) In the case of samples 1,2 and 3 of the comparative example, the thickness change rate at the time of 5 kg load was a test piece area: 15 * 15 cm <2>, a measurement time point: 10 second later.

Fire protection degree (KS K 0582, horizontal method) sample Example 1 Carbonization distance (cm) 25.4 Burning time (sec) 718.4 Burning speed (cm / min) B2.1

(Note 1) B_ = Burn Rate of _Centimeter per Minute

In addition, the immersion absorption rate was 201.3% as measured by the plumage test method.

As described above, when the samples 1, 2, and 3 of the comparative example were compared with each other, the tensile strength was about 201.3 kgf / 133.7 kgf and the highest sample among the comparative examples. In the case of 2, 37.0kgf / 30.8kgf was tested to prove that the tensile strength of the present invention is about 5.4 times superior, the invention also in the burst strength 284.9kgf, 90.5 for Comparative Example 3, about 3 times Proved high.

In addition, the air permeability, compression ratio, etc. were also very good. In particular, in the case of the present invention, when the immersion absorption rate and the degree of fire protection were separately measured, very high test results were obtained, thereby providing a thermally compressed mat using a waste fiber of a new concept according to the present invention. Could.

(Example 2)

Next, a second embodiment of the present invention will be described.

2 is a process chart showing a method of manufacturing a thermal compression mat to which a functional material using waste fibers of the present invention is added. In the second embodiment, the process is substantially the same as in the first embodiment, except that various functional material addition steps are added after the punching process. This functional material is finished by spraying between mats to be manufactured. That is, when the natural jade of the powder is sprayed between the two-layered fiber board (mat) to be manufactured and heated through an oven, the hot melt fibers and the natural jade are fused and bonded to the fiber board to press the mat to produce the effect of the natural jade. will be.

Instead of the natural jade functional material, it is possible to select functional materials such as powdered agglomite loess, powdered charcoal (especially oak charcoal) or powdered ceramic material.

Since the general action and efficacy of these additional functional materials are well known, only the charcoal case is outlined as an example.

Since ancient times, ancestors floated charcoal on soy poisons to purify water, inhibit bacteria propagation, and sprinkle ashes on rice paddies without chemical fertilizers.

In addition, it has the effect of removing electromagnetic waves, anti-static and air purifying, and the charcoal pillow can take a good night's sleep and prevent snoring. Charcoal is said to purify water and make your skin shine.

Granular powder is used for the absorption of poisonous gases and purification of gas species. Fine grains are used as decolorizing deodorants and medicinal preparations.

The medical efficacy of charcoal has long been proven and used in folk medicine and herbal medicine. For example, oils such as fat milk, hyunggae, baekbaek, etc., in some cases completely burned and made into charcoal or ash, which is still practiced in Chinese medicine. The general composition of charcoal is 85% carbon, 10% moisture, 4% minerals and about 2% volatiles.

The present inventors have come to complete the present invention by contemplating that there is an invention in incorporating the effects of such charcoal on the mat.

3 is a graph measuring far-infrared emissivity and radiation energy of the natural jade addition mat of Example 2 of the present invention, Figure 4 is a graph measuring far-infrared emissivity and radiation energy of the ganban stone addition mat of Example 2 of the present invention. The test condition is a result of measuring black body (Black Body) using a FT-IR Spectrometer at 40 ℃. These tests were conducted at the Far Infrared Ray Evaluation Center, Korea Institute of Construction Materials, an accredited testing laboratory.

As a result, natural jade has emissivity (5-20 μm) 0.925, emissivity (W / m 2) is 3.73 × 10 ² , and elvan has emissivity (5-20 μm) 0.926 and emissivity (W / M 2) was 3.74 × 10 ² .

5a to 5c is a photograph taken by the infrared thermal imager of the far-infrared emissivity and radiation energy for each mat of the second embodiment of the present invention, Figure 5a is a general mat, Figure 5b is a gangue stone attachment mat, Figure 5c is a natural jade attachment mat Will be taken.

Photographing conditions are room temperature of 21 ℃ and humidity of 50%, which is the result of processing the infrared radiation energy emitted from the measurement object with image and temperature data. These shots were taken at the Far Infrared Ray Applied Evaluation Center, a Korea Institute of Building Materials Testing and Research Institute.

As also revealed by these infrared photographs, in the case of the mat manufactured by the process of the present invention, infrared radiation is shown in many red colors.

When various functional materials are added to the basic mat of the present invention as clearly shown in these figures and photographs, the mat is beneficial to the human body by radiating far infrared rays.

As described above, according to the manufacturing method of the thermal compression mat using the waste fiber of the present invention, in addition to the conventional nonwoven fabric manufacturing process, it is subjected to the forming, heating and pressing process, and adding a functional material such as natural jade between two sheets of fiberboard In order to manufacture, it is excellent in tensile strength and bursting strength, and especially the fire resistance of the present invention has a remarkable value, so that it can be widely used not only for fire prevention materials but also for various industrial mats, and various functional materials are added. It is a very useful invention such as providing a mat in which the navel is radiated.

Claims (8)

Collecting and classifying waste fibers composed of fused fibers, general chemical fibers, and natural fibers by type and color; Cutting the sorted waste fibers into a predetermined size suitable for blending; Blending the cut waste fibers by color and type; Making the blended waste fiber into cotton wool with another cotton wool, Carding the mixed cotton with a carding machine, Molding the carded cotton into a fiber board body in a desired width and thickness with a molding machine, Needled the molded fiberboard body with a punching machine, Heating the oven with a heat-sealable fiber in the plurality of fibrous plate bodies produced through the process to melt and bond with other fibers; The method of manufacturing a thermal compression mat using waste fibers, characterized in that for pressing the heated multiple layers of fiber board using a plurality of rollers. According to claim 1, wherein the blending ratio of the waste fibers cut in the blending step is 20 to 50% of the heat-sealable fibers, 25 to 40% of the general chemical fibers, 25 to 40% of the natural fibers relative to the weight Method for producing a thermal compression mat using. The method of claim 1, wherein the heating temperature of the oven in the heating step is 190 to 250 ° C. 6. Collecting and classifying waste fibers composed of fused fibers, general chemical fibers, and natural fibers by type and color; Cutting the sorted waste fibers into a predetermined size suitable for blending; Blending the cut waste fibers by color and type; Making the blended waste fiber into cotton wool with another cotton wool, Carding the mixed cotton with a carding machine, Molding the carded cotton into a fiber board body in a desired width and thickness with a molding machine, Needled the molded fiberboard body with a punching machine, Spraying the functional material on the powder between the plurality of fiber boards produced through the process; Heating the oven with a heat-sealable fiber in the plurality of fibrous plate bodies to which the functional material has been sprayed to combine with other fibers; The method of manufacturing a thermal compression mat using waste fibers, characterized in that for pressing the heated multiple layers of fiber board using a plurality of rollers. The method of manufacturing a thermal compression mat using waste fibers according to claim 4, wherein the functional material is natural jade. The method of manufacturing a thermal compression mat using waste fibers according to claim 4, wherein the functional material is elvan. The method of claim 4, wherein the functional material is ocher powder. 5. The method of claim 4, wherein the functional material is charcoal powder.