TWI523897B - The use of waste foam material recovery made of a renewable foam material - Google Patents

Description

Recycled foamed material made from recycled foam

The present invention relates to a regenerated foamed material produced by recycling waste material of a foamed material.

Existing foam materials such as styrene-butadiene rubber (SBR), nitrile rubber (NBR), neoprene (CR), thermoplastic rubber (TPE), ethylene-vinyl acetate copolymer (EVA) or the like are currently In the mainstream of the market, the steps of bridging or vulcanization, foaming, etc. must be carried out in the manufacturing process to make the final foamed material. The raw material forms a three-dimensional space-like polymer polymer due to bridging or vulcanization steps, wherein the mixture of SBR, NBR, CR, TPE or above has a higher bridging or vulcanization density due to the properties of the rubber itself. It can't be recycled and reused. It can only be disposed of by incineration or landfill. However, the foamed material such as EVA itself has a relatively low polymer structure and bridging density, so that it can be recycled and reused by other processing methods. EVA foam material has the advantages of low price, easy forming, easy manufacturing and light foaming density, and is suitable for use in shoes, bags, etc., but its disadvantages are poor gas permeability, poor elasticity, and production process. A waste material is produced in which a plurality of foam materials are used, and the waste material of the foamed material includes scraps, skin materials, residual zero-size sheets, formed or cut scraps, and the like. At present, the waste material treatment methods for EVA foam materials are known as direct burial method, direct incineration method, high temperature melt granulation recovery method, grinding into powder for use as a filling material or hot rolling wheel melt recovery method. After most of the waste materials in Taiwan are recycled, the direct incineration method is used to treat the waste materials of EVA foam materials. Only a very small number of manufacturers use the waste materials as powder or plastic fillers. Seek to reduce costs, but only add a small amount and can not add too much amount, otherwise it will seriously affect the physical properties. In the mainland, some waste materials for recycling EVA foam materials are recycled and reused by high-energy high-temperature melt granulation recovery method. It is well known that the waste material is first pulverized and then the granulator is used in super high. The pulverized material is melted at a high temperature and then granulated to form a recycled plastic granule raw material of the secondary product. Then, a small amount of new regular plastic granules are mixed, and then re-expanded into an EVA foaming material according to the well-known EVA foaming production process.

The main principle of the above recycling and utilization method is to use the ultra-high temperature and large pressure of the granulator to forcibly melt the bridged three-dimensional structure or the ultra-high molecular weight polymer and extrude the gas in the foam. It is restored to a plastic state, and the large particles of impurities or non-melts are removed by filtration. Although such a recycling method can remove large particles of impurities or infusible substances, it is impossible to break the bridged three-dimensional structure or the ultrahigh molecular weight polymer into a normal molecular weight or molecular weight distribution. And with the different sources of waste foaming materials, the quality is also very different, so this method can not control the stable melt index value of recycled plastic pellets, can not be used as a regular product, can only be used as a secondary product Recycled plastic pellets to use. At the same time, a large amount of heat energy must be consumed in the production process, which is a very energy-saving method. However, when the EVA foamed material produced by using the recycled plastic granules is filled with visible small pores, it is dispersed in a non-uniform pattern in the normal dense and invisible microporous bubbles, forming a significant appearance. Disadvantages, can not meet the requirements of most products, and generally can only be used for less demanding purposes. Because there is no demanding market in Taiwan, there is no high-temperature melt granulation recovery method in Taiwan to recycle the waste material of EVA foam material. It can only be disposed of by incineration or landfill. It causes a lot of pollution to the environment.

In view of the above, the present invention provides a regenerative method for recycling and recycling waste materials of a conventional SBR, NBR, CR, TPE, EVA or the like. The main purpose of the foam material is to use a waste material of a mixture of SBR, NBR, CR, TPE, EVA or the like, and to select a superior elastic elastomer adhesive and a matching curing agent or treating agent thereof. Hybrid adhesion, and the use of low-energy and low-investment equipment production processes to produce large-sized regenerated foaming materials, and the regenerative foaming material has excellent physical properties such as breathability and elasticity. .

1‧‧‧ trim

2‧‧‧Independent bubbles

3‧‧‧Small foamed granules

4‧‧‧ Elastomer Adhesive

5‧‧‧Recycled foaming material

6‧‧‧ gap

Figure 1 is a perspective view of the scrap material of the waste foam of the present invention.

Figure 2 is a schematic cross-sectional view showing irregular small foamed particles after pulverization of the waste foam of the present invention.

Figure 3 is a schematic cross-sectional view showing the surface-coated elastomer adhesive of the small foamed granules of the present invention

Figure 4 is a schematic cross-sectional view showing a regenerated foamed material formed into a large block shape after pressure bonding according to the present invention.

In order to make the present invention more familiar with the present invention, a preferred embodiment and a drawing will be described in detail as follows: Referring to Figures 1 to 4, the present invention provides a reconstituted foamed material. The method comprises the following steps: (a) pulverizing the recovered waste foaming material into irregular irregular small foamed particles 3 using a pulverizer; (b) adding the irregular small foamed granules 3 to a suitable surface treating agent (c) adding the elastomer adhesive 4 and stirring uniformly to uniformly adhere the surface of the small foamed particles 3 to the elastomer adhesive 4 and the matching curing agent; (d) allowing irregular small foaming with appropriate pressure The particles 3 are bonded to each other to form a bulk-shaped regenerated foamed material 5. By the above steps, the recycled scrap material 5 of the foamed material is recovered and reused to form a large-sized regenerated foamed material 5, thereby achieving the environmental protection effect of resource recycling.

The details of the composition of the present invention are as follows: Please refer to Figures 1 to 4 for the scrap 1 of one of the waste materials of the recovered SBR, NBR, CR, TPE, EVA, etc. (as shown in Fig. 1). After being cleaned and sorted, it is pulverized into small irregular foamed particles 3 of about 1 to 100 mm in size by a pulverizer (as shown in Fig. 2), which is used in the pulverization process because of the use of many cuts. The high-speed operation of the knife produces a strong pulling force, a cutting force, and a cutting force, etc., simultaneously cutting into small irregular small foamed particles 3 in such a large pulling force and cutting force. Under the action of the foam, the foam is appropriately stretched and then cut into irregular small foamed particles 3, and when the foam is properly extended, the bubble structure in most of the foamed materials is destroyed. The surface of the irregular small foamed particles 3 is originally in the form of the closed cells 2 and becomes the connected bubbles, but the inside thereof is not destroyed, and the original closed bubble 2 type is still retained. Therefore, the irregular small foamed beads 3 after the pulverization step not only have a large surface area but also a structure which can provide a better adhesion and retain the original foam characteristics. The small foaming The granule 3 is added to a suitable surface treatment agent, which is a "bridge" between the viscous material and the adhesive, and the effect is that one end is anchored in the adherend material and the other end is anchored in the adhesive layer. Inside, it plays a role in increasing the bonding strength. In addition to the above functions, there are two functions: 1. A plasticizer that removes the surface of the foamed material. 2. Increase the roughness of the surface of the foamed material by chemical corrosion to increase the effective bonding area. These foamed materials generally require a special surface treatment agent to be adhered firmly. It is improved to have a better adhesion to the elastomer adhesive 4. When the elastomer adhesive 4 which is specially matched with the foam is added, it may be sprayed or directly poured, and the surface of the small foamed particles 3 may be uniformly adhered to the elastomer. The adhesive 4 has an outer layer forming an elastic film layer having superior elasticity, and the relative ratio of the elastomer adhesive 4 to the small foamed particles 3 is preferably between 10% and 45% to 90% to 55%. Wherein, the greater the ratio of the elastomer adhesive 4, the more elastic the recycled foamed material 5 is, and the larger the ratio of the small foamed particles 3 is, the higher the hardness of the recycled foamed material 5 is; After the small foamed granules 3 pulverized material is placed in a mold, pressurized and placed in a mature state, and each irregular small foamed granule 3 is subjected to a certain pressure and then deformed by a proper pressure to be attached to the surface. The elastomer adhesive 4 will naturally diffuse and can easily bond each of the small foamed particles 3 and the particles to each other. After a period of ripening, the mold is opened and the whole block is obtained. Recycled foam material 5. At this stage, since the elastomer adhesive 4 is attached to the surface of the irregular small foamed particles 3 rather than inside, when the elastomer adhesive 4 is cured and dried, it is naturally in each irregularity. A fine elastomeric film layer having a certain thickness is formed on the surface of the small foamed beads 3, which provides a stronger toughness of each of the irregular small foamed particles 3, so each of them is stronger. The irregular small foamed beads 3 have a function of more excellent elasticity when they are bonded to form a large-sized recycled foamed material 5. At the same time, in the process of pressure bonding, since the irregular small foamed particles 3 and the voids 6 between the particles are deformed by the pressure, there are still a lot of fine voids 6 which are densely connected with each other. This void 6 provides a very good gas permeability of the bulk-like regenerated foam material 5. In other words, the structure of the regenerated foamed material 5 which is obtained by the pressure bonding method is a kind of small foamed particles 3 which are bonded by a large number of irregularities, and the surface thereof is covered with an elastic layer and exists. A mixture of dense voids 6 is densely packed. With such a physical structural foam having good gas permeability and elasticity, the present invention is a recycled foamed material 5 which is completely recovered by recycling waste foam which is originally incinerated or buried. Such superior conditions are sufficient to provide the recycled foamed material 5 in the use of the finished product, creating a very good functional and commercial value.

Furthermore, the above-mentioned regenerated foamed material 5 may be different depending on the physical properties of the use. Different elastomeric adhesives 4, such as polyurethane elastomeric adhesive 4, or neoprene elastomeric adhesive 4, or thermoplastic elastomeric adhesive 4, or natural, synthetic rubber emulsion Or an acrylic elastomer adhesive 4, or a mixture of the above elastomer adhesives 4, and the like, and a suitable curing agent, hardener, treatment agent or the like of various elastomer adhesives 4 The accelerator is used together, and the small foamed particles 3 can be pressure-bonded by heating or without heating throughout the production process, and the pressure of the pressurization used is not large enough to make the small hair The foam particles 3 adhere well, and are a production method which is quite energy-saving and low equipment investment. It is also possible to provide the regenerated foamed material 5 of the present invention, which is more capable of meeting the economical production conditions of low cost, due to such manufacturing process characteristics. Alternatively, an aqueous or 100% solids polyurethane adhesive and its associated curing agent and accelerator may be used; of course, the above examples may also use a solvent-based thermoplastic adhesive and a matching curing agent. To use.

The production process as described above can be selected without heating or micro heating and pressurization The manufacturing method of the pressure and the mold for molding do not require special requirements, and generally ordinary or cheap materials can be selected and used as long as they are applicable, and the equipment cost is low. It is also easy to make different specifications of products, special specifications or very thick regenerated foamed materials 5 according to the different uses required, which is also a great advantage of this manufacturing method, commonly used SBR, NBR, A foamed material of a mixture of CR, TPE, EVA or the like is incapable of making a very thick foam.

The present invention is to make SBR, NBR, CR, TPE, EVA originally discarded. The foaming material waste material of the above mixture or the like can be recycled and reused as a valuable commodity, and the foamed material waste material is discarded and buried in the soil to contaminate the land or burned to pollute the air, so the research is painstakingly studied. The present invention solves the above serious problems. The practice of the present invention is to retain the advantages of the waste material of the foamed material itself, including: not removing the independent air bubbles in the foam body and taking its own characteristics of light density and elasticity, and first pulverizing into small irregular foamed particles 3 Adding the elastomer adhesive 4 and its matching curing agent or treatment agent to the irregular small On the surface of the foamed granule 3, the adhesive function of the elastic adhesive 4 can well bond each of the irregular small foamed granules 3, and the selected elastomer adhesive 4 is cured and dried. Then, a layer of a high-elastic polymer film having a certain thickness and a three-dimensional structure is formed on the surface of each of the irregular small foamed particles 3 to form a continuous film layer, and this has a high thickness of a continuous three-dimensional structure. The polymer film layer itself is an excellent elastomer which is rapidly deformed by compression and rapidly deformed after the force is applied, and the superior elasticity of the recycled foam material 5 is created. In addition, by using the pressure at the time of controlling the adhesive pressure, a fine void 6 having a large number of connectivity is retained between each of the irregular small foamed particles 3 to achieve very good gas permeability. Reusing the elastomeric adhesive 4 and its matching curing agent or treatment agent characteristics, in a very energy-saving manner with or without heating, and a low-cost economic condition using a small pressure of pressurization The regenerated foamed material 5 of the present invention is produced.

In summary, the regenerated foamed material 5 of the present invention is indeed a foamed material having excellent physical properties and a good product for environmentally friendly recycling which meets low-cost economic production conditions. At present, there is no product of the regenerated foaming material described in the present invention on the market, and it has excellent progress and practicality in the same kind of products. Therefore, the present invention has already possessed the invention patent element, and the application is filed according to law.

2‧‧‧Independent bubbles

4‧‧‧ Elastomer Adhesive

3‧‧‧Small foamed granules

5‧‧‧Recycled foaming material

6‧‧‧ gap

Claims (7)

A regenerated foaming material, which comprises the steps of: (a) pulverizing the recovered waste foaming material into irregular irregular small foaming particles using a pulverizer; (b) arranging the irregular small foaming granules Adding a suitable surface treatment agent; (c) adding an elastomeric adhesive and stirring uniformly to uniformly adhere the surface of the small foamed particles to the elastomeric adhesive; (d) allowing the small foamed particles to interact with each other with an appropriate pressure The bonded foam is formed into a large-sized regenerated foaming material; by the above steps, the waste material of the foamed material is recovered and recycled to achieve the environmental protection effect of resource recycling. The regenerated foaming material according to claim 1, wherein the waste foaming material is styrene-butadiene rubber (SBR), nitrile rubber (NBR), neoprene rubber (CR), thermoplastic rubber (TPE). a foamed material of ethylene-vinyl acetate copolymer (EVA) or a mixture of the above. The regenerated foamed material according to claim 1, wherein the small expanded beads are pulverized into particles having a size of from 1 to 100 mm. The regenerated foamed material according to claim 3, wherein the small foamed particles have interconnected voids. The regenerated foaming material according to claim 1, wherein the relative ratio of the elastomer adhesive to the small foamed particles is between 10% and 45% and between 90% and 55%. The regenerated foaming material according to claim 1, wherein the elastomer adhesive may be solvent-based or solvent-free, water-based or 100% solid content-containing, two-component polyurethane adhesive, Two-component polyurethane raw material, foamed polyurethane foaming material, solvent-based or 100% solids moisture-curing polyurethane, solvent-based or water-based neoprene adhesive, solvent-based thermoplastic adhesive One of the agents, natural or synthetic rubber emulsions, acrylic emulsions or acrylate series adhesives or mixtures thereof. The regenerated foamed material according to claim 1 or 6, wherein the elastomer adhesive further comprises a suitable curing agent, hardener, treating agent or accelerator.