KR20060092738A - The method of making plartic board with waste syrthetic fiber - Google Patents

Abstract

The present invention relates to a method for manufacturing a fiber sheet using waste filament fiber yarn, which is opened to a high-melting point filament filament fiber yarn of 210 ° C. or higher to form a non-woven fabric, and a low melting point waste synthetic resin melt of 180 ° C. or less with an additive added to the mat. To form a unit molding mat by penetrating and bonding the binder, and then densifying the structure of the sheet with a high pressure in one step in a mold maintained at a temperature of 180 ° C. to 205 ° C. and foaming it at a low pressure in two steps to obtain a foam molding mat. The present invention relates to a method for manufacturing a fiber sheet using waste fiber fibers which is injected into a flame retardant material while injecting a solution-type flame retardant in a state of being loaded in a pressure-reduced closed tank.

Description

The manufacturing method of the fiber sheet using waste fiber fiber yarn {THE METHOD OF MAKING PLARTIC BOARD WITH WASTE SYRTHETIC FIBER}

1 is a three-step process diagram of the present invention.

Figure 2 is a perspective view of the foam molding mat mold of the present invention four-step process.

Figure 3 is a cross-sectional view of the foam molding mat mold of the four step process of the present invention.

The present invention relates to a method for manufacturing a fiber sheet using waste fiber fibers, and more particularly, a mat formed by using a carding machine to form waste fiber fibers such as polyester fiber yarn and polyamide fiber yarn having a high melting point in a carding machine. Sunggle is a non-woven fabric) mats in which waste mixed resins such as acrylic resin, polypuroprene resin, and high-density polyethylene are added at room temperature. By cooling and cutting to a certain standard, a molding mat is obtained and foamed at the same time in a heated mold (template) and foamed and quenched to obtain a foam molding mat, which is placed in a pressure-reduced closed tank to penetrate the solution type flame retardant. The present invention relates to a manufacturing method of a fiber sheet using fiber yarn.

It is a synthetic polymer compound artificially manufactured to be not easily decomposed by sunlight or microorganisms in the natural state as waste which is produced in large quantities in accordance with industrial development and is produced in large quantities according to industrial development with excellent physical properties replacing conventional natural fiber materials. As a result of incineration of harmful gases due to incineration, excessive air pollution and waste disposal costs are incurred, and they do not decay even when landfilled and are not biodegradable, so they are not reduced to nature, resulting in soil pollution and deterioration. As a method of recycling waste synthetic fiber, there is an urgent need for a method that can recycle as a productive resource while improving price competitiveness and minimizing environmental pollution by overcoming factors such as high processing cost and low quality. A recent study has been constantly developing technologies to recycle waste synthetic fibers in order to conserve resources and address the prevention of environmental pollution and scarce resources issues.

Conventional wastes of chemical fiber represented by acrylic, nylon, polyester, polyproplen, etc. Waste synthetic fiber is a textile product in various textile product manufacturing plants such as textile companies and garment manufacturers. Loss and scrap scraps and chemical fibers that are discarded after use.They are light and strong due to the characteristics of chemical fibers, and have excellent tensile strength and processability. Although the amount of waste is rapidly increasing in proportion to the amount of waste, conventional waste synthetic fiber is incinerated in most cases, and only a part of it is used as a thermal insulation material and a building material for vinyl houses by making nonwoven fabrics such as cotton wool with a simple processing method. In order to replace this, we use waste synthetic fibers to replace wood plywood. However, a method of manufacturing a fiber board material by mixing, adding other binders, and then pressing, molding, and rapid cooling at high temperature and high pressure has been proposed, but it is satisfactory due to inadequate quality in strength, processability, and flame retardancy in fire. It has not achieved commercialization.

As a prior art for the recycled synthetic fiber board recycled waste fiber, Korean Patent Office Publication (Publication No .: 1998-0068123, published date: 1998.10.15) "A method for forming and forming the fiber board material" waste acrylic fiber, Grinding process to primaryly crush raw materials such as waste nylon fiber, waste polyester fiber, waste polypropylene fiber, waste glass fiber, waste cotton fiber, waste synthetic resin into 10mm ~ 20mm and open them into cotton-like shape, The mixing process of conveying the raw material opened by the grinding process to adjust the thickness and mixing the coagulant to form the mat form, and injecting the mixed mat-type material at a high temperature and high pressure of 100 ° C to 300 ° C to obtain a predetermined thickness. Through the compression process to have the material, the cooling process to cool the material formed to a predetermined thickness to smooth the surface of the product, and the cutting process to cut the productized fiber board material to the desired size. It relates to a molding method for making a plate, first of all, such a composite sheet can not expect a tensile strength due to the short fiber length, since the short fibers of the waste fiber fibers except the cotton fibers or glass fibers are melted by using a high temperature up to 300 ℃ As long as the tensile strength cannot be expected and the fibrillated fibrous fiber is not present in the fibrous fiber, it does not need to go through the complicated and costly opening process.

In addition, waste glass fiber is a material that is strictly regulated due to environmental problems. Therefore, such fiber boards are heavy and flammable, which is dangerous when used as building materials.

In another prior art, the Korean Patent Application Publication (Publication No .: 1996-0010239, publication date: April 20, 1996) filed with "Method of manufacturing a fine fiber", the technical composition of the fine fiber fiber and the fine fiber waste snow In the filament plate formed by mixing and melting, waste snow such as polyester fiber, acrylic fiber and nylon fiber having high melting point and polypropylene fiber, x-ray fiber, pyrene fiber, etc. The mixture is compressed to 50 to 50 volume ratio, and then pressurized at 500 ~ 800 ton for 5-8 minutes at 190 ~ 210 ℃, the melting point of low melting group, and melting point of low melting group is not melted. Wrapping and embedding the closed snow of this high fiber group, transfer the integrally formed primary intermediate to the cold press, heat-pressurized for 2-7 minutes at a pressure of 300-500 tons Although it is made of fiber sheet material mainly using fiber waste snow, synthetic resins generally have 10 ~ 15 ℃ melting point lower than their inherent melting point when pressurized at high pressure at each melting point, and pressure of 500 ~ 800 tons at 190 ~ 210 ℃. When heat-treated under pressure for 5 to 8 minutes, only polyester fiber (melting point 250 ° C) remains, and polyamide fiber (melting point 210 ~ 220 ° C), acrylic fiber (melting point 180 ° C), polypuroprene fiber (melting point 168 ~ 171 ° C), Since pyrene fibers (melting point 156 ℃) are melted, reinforcement by waste fibers cannot be expected. Furthermore, when cutting snow melt and mixing it as it is, it is extremely difficult to mix, so it is not homogeneous in the structure of the fiber. Local aggregates of these particles occur, so the overall physical properties of the fiber sheet are greatly reduced. In addition, such a fibrous sheet material also has high flammability when used as an alternative building material, causing problems.

In addition, acrylic fiber, nylon fiber, and polyester fiber snow cotton fibers are cut into 50 ~ 100mm lengths and uniformly mixed, and then opened with a cotton wool machine, as in the method of manufacturing a fibrous sheet material of Korean Patent Publication No. (Specific 1990-0009273). In the manufacturing method of the fiber board material obtained by obtaining the mat in the web (web) state and pressing for 3 to 10 minutes in a hard press of 650 to 700 tons pressure at 200 ~ 250 ℃ temperature and cooling for 2 to 7 minutes at a pressure of 300 tons in a cooling press Also, under the conditions of temperature, pressure, and time, all plastic fibers except cotton fibers are melted, and therefore, the fiber board having strong physical properties by fiber reinforcement cannot be expected, and the most complicated process is There is no need to refurbish fiber wastes with cost-effective cotton machines.

According to the present invention, in the method for producing a fiber board material by recycling waste synthetic resin fibers having a high melting point and waste synthetic resins having a low melting point, the physical properties of the high melting point synthetic resin fibers and the low melting point waste synthetic resins are accurately determined and judged to be the most efficient. By manufacturing the fiber board by the method, the fiber fiber of the high melting point waste synthetic resin is first present in the fiber state in the fiber board material, which can give a strong tensile force, and the fiber board material is added by the addition of the flame retardant material and the immersion effect of the flame retardant solution. The low melting point waste synthetic resin melt solidified material, which is a constituent binder, can also have excellent non-flammability to the fiber, and furthermore, it is a foaming agent added to the binder to provide a fiber that improves the thermal insulation, vibration resistance, and heat retention as well as the weight of the fiber. Is in.

The raw materials used in the manufacturing method of the fiber according to the present invention are waste chemical fibers of high melting point, polyester chemical fiber yarns having a melting point of 250 ° C., polyamide chemical fiber yarns having a melting point of 210 to 220 ° C., and low synthetic melting point resins of 168 ~. Polypropylene resins in the range of 171 ° C., acrylic resins in the melting point of 180 ° C. and high density polystyrene waste synthetic resins in the melting point of 110 ° C. are used as binders (adhesives) in the molten state. In addition, as an additive added to the low-melting-point synthetic resin used as a binder, a flame retardant, a foaming agent, a mineral fine powder, and the like are added, and a flame retardant is also added to the solution in which the fiber is immersed. The manufacturing method of the sump board material manufactured as the above raw material

As a first step, waste synthetic resin fiber with high melting point is collected from waste chemical fiber yarn produced by defects in spinning at textile manufacturing company or cutting scrap produced from cutting scrap sewing product produced by clothing manufacturing company, and yam, etc. The raw material, which has been sorted and washed, is cut to have a fiber length of at least 50 mm, and opened by a cotton noodle machine to obtain a mat of non-gender sex.

The low melting point waste synthetic resin used as a binder as a two-step process is scrap scraps or defective products from waste fiber yarns or sewing companies such as acrylic fiber yarns, polypuroprene fiber yarns and polystyrene fiber yarns. In addition, waste synthetic resins, such as polypropylene, woven grain straws, acrylic plates, polyethylene and polypropylene, and containers, packaging and beverage bottles, are collected and can be easily mixed through conventional treatment processes such as sorting and washing. It is cut or shredded to length or size to obtain a melt in which the mineral fine powder, the high-temperature decomposable blowing agent, the flame retardant, and the like are added while melted simultaneously with the blending in the extruder.

As a three-stage process, the nonwoven fabric mat obtained in the first step is infiltrated and bonded to the binder obtained in the second step. The pair of nonwoven mats (1, 1 ') supplied from the left and right sides as shown in FIG. The nonwoven mats 1, 1 are passed through the rotating rollers 2, 2 'which are opposed to each other, and the sheet-like melt 3', which is a binder, is fed from the extruder 3 between the intersection points where the nonwoven mats 1, 1 'meet. Molten material 6, 6 supplied from each of the extruded dies 5, 5 'on the upper side of the roller while penetrating into the tissue of') and the mat is moved to pass between the rollers 4, 4 'facing each other at a predetermined interval. ) Is impregnated into rollers 4 and 4 'on both sides of the mat, and then passed through the cooler 7 and through the rollers 8 and 8' to obtain a sheet-like molding mat 9 cut to unit specifications.

As the four-step process, as shown in FIG. 2, the mold of the mold 23 on which the hot plate 22 on which the mold 21 having the same size (horizontal length) of the molding mat 9 obtained in step 3 is formed is formed. 21) filling the molding mat (9) and in the hydraulic equipment 24 to cover the pressure plate 25 through the 200㎏ / inch pressurized ^two minutes with the pressure and by adjusting the pressure 10㎏ / inch ^2, and at the same time maintaining the pressure inside the mold temperature After holding at 180 to 205 ° C. for 2 minutes, the blowout plate 27 is pushed out with the hydraulic blower 26 to take out the foamed molding mat 28.

In the five-step process, dozens of foam molding mats obtained in step 4 are loaded into a cylindrical sealed tank, and a liquid flame retardant is injected through another valve while depressurizing the inside of the closed tank with a motor through a valve. The penetration of the flame retardant solution and extraction of the flame retardant plate of the present invention is completed.

More specifically, the above method will be described in detail, and the melting temperature of the melting point or foaming agent of each of the high melting point waste chemical fiber yarn (synthetic resin fiber yarn) or the low melting point waste synthetic resin which is used as a raw material of the fiber in the technical configuration of the present invention. Has great significance in achieving the present invention.

To enumerate the key points in the technical configuration of the present invention, first, the high-melting-point waste synthetic fiber yarns are present in the fine-textured sheet tissue as it is. If a nonwoven mat is not formed, the network structure of waste chemical fibers having homogeneity in the fiber structure can not be expected, and the temperature maintained in the mold by the hot plate in the four-stage foam molding mat process is extremely limited, in the range of 180 ° C to 205 ° C. can do. If the temperature is higher than 205 ℃ polyamide fibers can be melted. For this reason, the melting point of the polyamide fiber is in the range of 210 ~ 220 ℃ but the temperature of the upper limit should be extremely limited because the melting point may be slightly lower in the presence of pressure. In addition, a foaming agent is added to the melt as a binder in the process of obtaining the melt in the two-step process, but in order to obtain the melt, the foaming agent must be raised to at least 180 ° C. In the two-step or three-step molding mat molding process, the foaming agent should not be foamed. For this reason, in the blending process or the forming mat forming process by the roller, even if foamed, the foamed or decomposed gas is released to the outside, so there is no meaning of foaming. Therefore, low temperature (below 180 ° C) degradable blowing agents cannot be used, and high temperature (above 180 ° C) degradable blowing agents must be used.

In addition, polyester fiber or polyamide fiber having high melting point is not a big difference in terms of tensile strength and has a slight effect on the fibrous plate material. The binder is a waste synthetic resin, 20-30 wt% of acrylic resin, 25-30 wt% of polypropylene resin, and 35-50 wt% of high density polyethylene resin may be an ideal composition. Here, the acrylic resin is used to obtain the adhesive strength with the fiber having a high melting point, but when the amount is small, the adhesive strength with the fiber is insufficient, so there is no strong binding force between the fiber and the binder, and thus the tensile strength of the fiber is reduced. In the case of using a large amount, the impact strength is lowered and a problem occurs in foaming in the fiber board. In the case of polyfuropyrene, the use of a large amount tends to reduce the cold resistance of the fiber and the impact strength. In the case of the high density polyethylene, the impact resistance is greatly improved, but the hardness and the bearing capacity of the plate are insufficient. And poor printability during secondary processing and poor adhesion. As the additives added to the above binders, a flame retardant, a high temperature decomposable blowing agent, and an optical powder microfine powder are added. It is composed of a melt of mixed resin.

The mineral powder added here is a fine powder corresponding to a few microns of tourmaline and illite minerals, and is also a functional material such as anion generation and far-infrared radiation. The main component is composed of polyolefin resin or polystyrene resin of poor polyolefin resin, which improves the printability and adhesion of the fiber, and also serves as a foam core when foaming. However, when a lot of mineral powder is used, the overall physical properties such as tensile strength and impact strength are lowered.

In addition, the mixing ratio of chemical fiber and melt with high melting point is 30 ~ 40wt% of chemical fiber yarn and 60 ~ 70wt% binder. It is a proper mixing ratio. The strength increases, but when more than 50% is used as the starting point, the tensile strength tends to be lowered. However, when more than 40% is used to increase the tensile strength, the chemical fiber is exposed to the surface of the fiber sheet and the primary molding process of infiltrating the binder into the nonwoven fabric mat, which is a three-step process, is not smooth. As a foaming process in the fourth step there is a problem that the foam is not properly. It is known that the gas produced by the decomposition of the vesicles is released to the outside through the pores of chemical fiber yarns.

In addition, the foaming agent added to the melt as a binder in the invention is extremely limited as a relatively high temperature decomposable foaming agent, and the foaming decomposition starting temperature should be 180 ° C or higher and the foaming decomposition end temperature should be 205 ° C or lower as shown in Table (1).

         분해 Category Disintegrant Decomposition start temperature Decomposition end temperature Resolution Silica Gel Coprecipitated Lead 200 ℃ 205 ℃ Slowly disintegrate Barium stearate 190 ℃ 201 ℃ usually Barium laurate 186 ℃ 205 ℃ Slowly disintegrate Cd-Ba Laurate 182 ℃ 188 ℃ Explode

Other flame retardants include permeable solution flame retardants which are reactive with the flame retardants added to the melt.Anti-retardant flame retardants include antimony trioxide, zinc borate, chlorinated polychlorinated polychlorene, chlorinated polyphenyls, tetrabromethane, tetrabrombisphenol A, Toris, triphenylphosphine oxide, tricledyl phosphate, trioxyl phosphate, etc. are used, and as a solution type flame retardant, they are saturated with hept acid, tetrabromphthalic anhydride, tetracrophthalic anhydride, tetrabrombisphenol A, and the like. Used as an aqueous solution.

In the above-described additive flame retardant is a flame retardant dispersed in the binder (solidification of the melt) of the fibrous board material to impart flame retardancy to the solidified binder structure and the reactivity performed in step 5 is a fiber bundle remaining in the fiber state in the fibrous board material Instantly penetrates into the space created by continuous bubbles, etc., and reacts with synthetic resins in the space walls of continuous bubbles formed in chemical fibers or binders to have excellent flame retardancy.

In addition, when the sheet-like forming mat 9 obtained in the three bottoms is pressurized in the mold at the primary high pressure (200㎏ / inch ² ), the thickness of the forming mat is reduced to ⅔ and simultaneously pressurized to the secondary pressure (10㎏ / inch ² ). When foamed at a high temperature (180 ℃ ~ 205 ℃) it is taken out while increasing the thickness pressurized by the high pressure 50% to 100% in the above can be obtained a foamed sump board having a specific gravity of 0.5 ~ 0.7g / cc.

The fiber made by the above method is lighter than wood, and the binder of the fiber is also flame retardant to chemical fiber, and thus it is a non-flammable plate. In addition, since the pores are formed by chemical fibers and independent or continuous bubbles inside the plate, they are given warmth, impact resistance, and dust resistance, and are excellent in terms of building interior materials.

Claims (2)

3 ~ 4wt% of mineral powder of tourmaline and illite on low melting point waste synthetic resin melt of 180 ℃ or less on mat made of non-woven fabric by opening waste chemical fiber yarn having high melting point above 210 ℃ A sheet-forming molding mat was obtained by impregnating a binder of 60 to 70 wt% of a molten binder containing 2 to 3 wt% of a high temperature foaming agent and a flame retardant 1.5 to 2 wt% to which the decomposition end temperature was 205 ° C. by controlling the pressure at which the pressure plate by the hydraulic equipment maintained for 1 min at a high pressure of the primary pressure 200㎏ / inch ² densify the structure of the sheet-molding the mat and the holding temperature 180 ℃ ~ 205 ℃ the mold internal state of 10㎏ / inch ² It was characterized in that the foamed mat was blown and quenched by the second pressurized pressure for 2 minutes in a pressure-reduced closed tank and injected with a reactive solution flame retardant to penetrate into the foamed mold tissue. The method of island plates. The method of claim 1, wherein the low melting point closed synthetic resin melt is a mixed resin melt of 20 to 30 wt% of acrylic resin, 25 to 35 wt% of polypropylene resin, and 35 to 50 wt% of high density polystyrene resin.

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