WO2023285891A1 - A process for manufacturing waste textile fiber reinforced polymer composites and composites produced therewith - Google Patents

A process for manufacturing waste textile fiber reinforced polymer composites and composites produced therewith Download PDF

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Publication number
WO2023285891A1
WO2023285891A1 PCT/IB2022/055628 IB2022055628W WO2023285891A1 WO 2023285891 A1 WO2023285891 A1 WO 2023285891A1 IB 2022055628 W IB2022055628 W IB 2022055628W WO 2023285891 A1 WO2023285891 A1 WO 2023285891A1
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WO
WIPO (PCT)
Prior art keywords
waste
crushed
recycled
fiber reinforced
impact polystyrene
Prior art date
Application number
PCT/IB2022/055628
Other languages
French (fr)
Inventor
Arosh Sandeepa WIJESINGHE
Original Assignee
Wijesinghe Arosh Sandeepa
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Filing date
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Application filed by Wijesinghe Arosh Sandeepa filed Critical Wijesinghe Arosh Sandeepa
Publication of WO2023285891A1 publication Critical patent/WO2023285891A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • B29B17/0042—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B29B17/0404—Disintegrating plastics, e.g. by milling to powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B29B2017/042—Mixing disintegrated particles or powders with other materials, e.g. with virgin materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B29B2017/0424—Specific disintegrating techniques; devices therefor
    • B29B2017/0484—Grinding tools, roller mills or disc mills
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
    • B29K2025/04—Polymers of styrene
    • B29K2025/06—PS, i.e. polystyrene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B29K2075/02—Polyureas
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

  • the invention relates to process of manufacturing fiber-reinforced polymer composite material (FRPC) using textile waste and recycled Polypropylene (PP) and recycled High Impact Polystyrene (HIPS) matrixes.
  • FRPC fiber-reinforced polymer composite material
  • PP Polypropylene
  • HIPS High Impact Polystyrene
  • the plastic industry is one of the largest consumers of organic and inorganic fillers.
  • inorganic fillers mainly calcium carbonate, talc, mica are been used and wood flour, rice hull flour and wheat chaff are the most abandon organic fillers use in plastic industry.
  • Fibrous materials such as asbestos and glass fiber, as well as graphite, cokes, blown asphalt, activated carbon use to improve physical properties of composites. All of these additives have high specific gravities and their ability to improve physical properties of the composition is limited.
  • thermoplastic matrix reinforced with fibers can be formed to overcome those deficiencies.
  • Those composites are being increasingly used in many applications especially in replacement of metallic materials as said composites are lightweight, with mechanical characteristics which are otherwise comparable in many respects.
  • the fiber material in those composites considerably influence mechanical characteristics, such as tensile and flexural strength as well as impact toughness.
  • spandex fibers have di-isocyanate origin which itself a carcinogenic material.
  • the present invention enables to blend and mix two different materials by extrusion or injection moulding processes by controlling proper ratios and proper process parameters which resulted homogeneously mixed fiber reinforced composite with improved physics-mechanical properties.
  • method for recycling of spandex is very important to local garments factories as the costs of eliminating wastage can be reduced from the garments and can be well accepted in international markets and their buyers, since the zero-environment impact shall lead for carbon credits and endorsing their products as environment friendly.
  • the final composite made using the process discloses herein can be used to produce electrical accessories and construction industry products including any other plastic products which are produced mainly with both virgin polypropylene and high impact polystyrene or with recycled polypropylene and high impact polystyrene materials.
  • the invention disclosed herein is a process for manufacturing waste textile fiber reinforced polymer composites, using spandex or polyspandex fabric waste blending together with crushed and/or recycled and/or virgin polypropylene or high impact polystyrene.
  • the waste textile fiber is firstly crushed and grind in to particles of size lOOgm - 700gm through a crusher or a grinding unit having multiple adjustable blades. Then the crushed and grind particles are cleaned through a high-pressure air circulation unit which is having an air circulation spinner barrel. Then the cleaned, crushed and grind fabric particles are blend together with crushed and/or recycled and/or virgin polypropylene or high impact polystyrene in accordance with predetermined ratios.
  • the waste particles are mixed at a ratio ranging from 15% to 50% of the weight with crushed and/or recycled and/or virgin polypropylene or high impact polystyrene, depending on the final product requirement, in an industrial mixing/ blending machine at least for 30 minutes to ensure the proper blending of the materials.
  • the mixture is further blended together with adhesive modifiers and/or plasticizers for at least 15 minutes in the mixer/ blender, as per the final product requirement. Thereafter, the blended mixture is pre-heated up to a temperature of 70°C - 90°C to take off the moisture in the mixture, if any.
  • the said moisture free mixture is subject to extrusion via a twin-screw extruder while controlling the barrel temperature between 160°C-220°C and the nozzle temperature increased to 2% to 10% of the moulding machine to achieve waste textile fiber reinforced polymer composite pallets.
  • the moisture free mixture of waste textile fiber reinforced composite is also exposed to extrusion and injection molding via single screw extruder to produce desired plastic products such as industrial and domestic Electrical Accessories and products and industrial, commercial and domestic construction industry products and or any plastic product produced via extrusion process and/or injection moulding process using required moulds.
  • the waste textile fiber reinforced polymer composite is having the characteristics of melt flow index as similar to recycled/ virgin polypropylene and high impact polystyrene. It also possesses mechanical properties similar to recycled or virgin polypropylene or high impact polystyrene and has a higher izod impact strength compared to virgin material. The composite is also having similar distribution of colour masterbatches low percentages compared with virgin polymer.
  • the present invention relates to waste textile fiber reinforced thermoplastic composite products and a method for producing the same. More particularly the invention relates to synthetic fiber reinforced thermoplastic composite products made mainly from spandex and polyspandex.
  • the thermoplastic materials are recycled and/or virgin Polypropylene and/or High Impact Polystyrene.
  • the final products are adapted to be used as electrical accessories such as sunk boxes, white goods produced by Polypropylene and High Impact Polystyrene, flower pots, Plastic Furniture and other plastics products by Polypropylene and High Impact Polystyrene which are manufactured by extrusion or injection moulding processes.
  • the method of processing is mainly by extrusion or injection moulding.
  • the extremely controlled temperature and pressure parameters are applied to process the materials, as spandex fibers are having elastomer properties and matrix materials are thermoplastics.
  • the mechanical properties of recycled polypropylene and recycled high impact polystyrene are significantly improved due to high strength and elastic properties of spandex fibers.
  • This invention greatly contributes to environmental sustainability as very few research has been done on waste spandex and open up new methods and further innovative ideas to recycle waste spandex fibers.
  • the composite material and the improved process parameters thereof disclosed by the invention can recycle resources, convert waste to value addition and promote the circular economy.
  • the textile material used in this invention is spandex fiber. Due to superior physical properties such as high tensile strength, elasticity, durability and heat conductivity of spandex fibers, the prepared composite is with high physics- mechanical properties compared to the physics-mechanical properties of virgin and/or recycled PP and HIPS reinforced by any other natural or synthetic fibers.
  • the defined composites and the controlled process parameters show that the homogenous morphology with improved mechanical properties compared with separate thermoplastics such as PP and HIPS.
  • raw material costs can be reduced and wastages from the garment industries can be reused in plastic industries directly.
  • This technology helps to reduce the increasing costs related to manufacturing materials in the electrical appliances related to industry and domestic applications such as electrical accessories such as sunk boxes, white goods produced by Polypropylene and High Impact Polystyrene, flower pots and other plastics products by Polypropylene and High Impact Polystyrene which are manufactured by extrusion or injection moulding processes.
  • the high cost of incineration of Spandex fabric waste in Garments industry shall be completely illuminated while tremendously contributing to completely illuminate the related carbon emission to the environment by the said incineration process.
  • the within invention relates to a composite material comprising a product of a combination of materials and process for producing the same.
  • the combination of materials comprises a textile fiber and thermoset polymers.
  • all the materials involved within the invention are low cost and/or waste materials and the finals products are with improved physical properties compared to the known products manufactured using same thermoplastic materials in the market.
  • the present invention relates to the production of new composite material using an extruded composition of textile waste fiber and thermoplastic material.
  • the present invention is related to fiber reinforced thermoplastic products and their production process.
  • Composites of the invention provide lower density, enhance of physics-mechanical properties, such as impact resistance, tensile strength, elongation, hardness and reduced water absorption. This was proven by the test results shown in Table 01 hereto obtained for the composite made out with spandex and recycled polypropylene, and results clearly indicated that the tensile strength, elongation at break, and water absorption properties are very similar to the properties which can be resulted with virgin Polypropylene as per the literature. The significant reinforcement of the waste Polypropylene by the spandex fibers were evidence by the excellent impact strength of the prepared composite, compared to the same of the virgin Polypropylene as per the literature.
  • the invention can be used to make composites for variety of structural applications e.g. electrical accessories such as sunk boxes, white goods produced by Polypropylene and High Impact Polystyrene, flowerpots and other plastics products by Polypropylene and High Impact Polystyrene.
  • electrical accessories such as sunk boxes, white goods produced by Polypropylene and High Impact Polystyrene, flowerpots and other plastics products by Polypropylene and High Impact Polystyrene.
  • composites of the invention comprise one or more thermoplastic resins, spandex as a reinforcing fiber and other additives such as flame retardants, colorants and the like.
  • composites of the invention will comprise from about 15 to 50 weights percent of the fiber-reinforcing filler.
  • the lower amount may be used but may tent to provide insufficient adjustments of physical properties.
  • Higher amounts may be used but may tend to result in composites that are inconvenient to Products can be made with composites of the invention by injection moulding and extrusion.
  • blending of two different materials homogeneously is very crucial in the production process. Controlled of particle size of spandex is very important and particles size range from lOOgm to 700gm in the present invention. Finer the particles, better the final composite is made.
  • the mixed compound with finer particle size is fed into the hopper and let them mix evenly and travel through the barrel.
  • Heating elements maintain required temperature around 160°C-220°C throughout the barrel.
  • the nozzle temperature has to be increased around 2% to 10% of the moulding machine.
  • mould temperature, injection pressure, holding time, screw rpm and also above parameters should be adjusted.
  • the cooling time of the molding process should be decided according to the weight of the part and size of the mould.
  • Figure 01 shows a flow chart of the production process disclosed in the present invention.
  • Table 01 shows test results of the final products produced with the composite manufactured from the process disclosed in the present invention.

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  • Engineering & Computer Science (AREA)
  • Environmental & Geological Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)

Abstract

The invention discloses herein is a process for manufacturing waste textile fiber reinforced polymer composites, using spandex or polyspandex fabric waste blending with crushed and/or recycled and/or virgin polypropylene or high impact polystyrene. The fabric waste is crushed in to particles of size 100µm - 700µm and cleaned and blended with crushed and/or recycled and/or virgin polypropylene or high impact polystyrene and also with adhesive modifiers and/or plasticizers in accordance with predetermined ratios depending on the final product requirement. The mixture is pre-heated up to a temperature of 70°C - 90°C to take off the moisture therein and then subject to extrusion via a twin-screw extruder while controlling the barrel temperature between 160°C-220°C and the nozzle temperature increased to 2% to 10% of the moulding machine to achieve waste textile fiber reinforced polymer composite pallets.

Description

A PROCESS FOR MANUFACTURING WASTE TEXTILE FIBER REINFORCED POLYMER COMPOSITES AND COMPOSITES PRODUCED THEREWITH
DESCRIPTION
1. TECHNICAL FIELD OF THE INVENTION
The invention relates to process of manufacturing fiber-reinforced polymer composite material (FRPC) using textile waste and recycled Polypropylene (PP) and recycled High Impact Polystyrene (HIPS) matrixes.
2. BACKGROUND OF THE INVENTION
Due to the growth of the world population, improvement of living standards and changes in the consumption patterns during the past few decades, the demand for clothing has seen a significant increase. These changing demands and consumption patterns have caused severe environmental impacts in terms of resource consumption and waste generation. Post industrial waste is generated during the textile and apparel manufacturing process, which include fabrics, paper and packaging materials. Post-industrial textile waste is mainly cutting waste, excess fabrics and rejected fabrics. Among textile waste, Polyester fibers are most abandon and second is spandex fibers. Spandex has a destructive influence on the environment. This influence is not as distinct as the negative impression of other types of synthetic fibers, but it is surely present, and at this point, no possible solutions have been recommended to curb the environmental deprivation caused by waste spandex fibers.
The plastic industry is one of the largest consumers of organic and inorganic fillers. Among inorganic fillers mainly calcium carbonate, talc, mica are been used and wood flour, rice hull flour and wheat chaff are the most abandon organic fillers use in plastic industry. Fibrous materials such as asbestos and glass fiber, as well as graphite, cokes, blown asphalt, activated carbon use to improve physical properties of composites. All of these additives have high specific gravities and their ability to improve physical properties of the composition is limited. As an alternative to particulate fillers, thermoplastic matrix reinforced with fibers can be formed to overcome those deficiencies. Those composites are being increasingly used in many applications especially in replacement of metallic materials as said composites are lightweight, with mechanical characteristics which are otherwise comparable in many respects. The fiber material in those composites considerably influence mechanical characteristics, such as tensile and flexural strength as well as impact toughness.
3. TECHNICAL PROBLEM
Most of the waste fibers generated from the textile industry such as nylon, polyesters etc. have been effectively used in reuse process by blending with second polymer, most commonly with thermoplastics. The origin of the said fibers is petroleum by products, however spandex fibers made up of a long chain polyglycol combined with a short di-isocyanate and contains at least 85% polyurethane. Spandex is an elastomer which can be stretched to almost 500% of their length. Therefore, processing of spandex fibers with thermoplastic materials is not an easy process specially by extrusion and injection moulding, because of the two different behaviors of plastic and elastomer with different structures, different morphologies and different crystallinities. Therefore, recycling of spandex fibers was not given much attention and currently waste/rejects spandex fibers are used in landfilling or incineration which cause severe damage to the environment as spandex fibers have di-isocyanate origin which itself a carcinogenic material.
4. TECHNICAL SOLUTION
The present invention enables to blend and mix two different materials by extrusion or injection moulding processes by controlling proper ratios and proper process parameters which resulted homogeneously mixed fiber reinforced composite with improved physics-mechanical properties.
Further, method for recycling of spandex is very important to local garments factories as the costs of eliminating wastage can be reduced from the garments and can be well accepted in international markets and their buyers, since the zero-environment impact shall lead for carbon credits and endorsing their products as environment friendly.
The final composite made using the process discloses herein can be used to produce electrical accessories and construction industry products including any other plastic products which are produced mainly with both virgin polypropylene and high impact polystyrene or with recycled polypropylene and high impact polystyrene materials.
5. SUMMARY OF THE INVENTION
The invention disclosed herein is a process for manufacturing waste textile fiber reinforced polymer composites, using spandex or polyspandex fabric waste blending together with crushed and/or recycled and/or virgin polypropylene or high impact polystyrene. The waste textile fiber is firstly crushed and grind in to particles of size lOOgm - 700gm through a crusher or a grinding unit having multiple adjustable blades. Then the crushed and grind particles are cleaned through a high-pressure air circulation unit which is having an air circulation spinner barrel. Then the cleaned, crushed and grind fabric particles are blend together with crushed and/or recycled and/or virgin polypropylene or high impact polystyrene in accordance with predetermined ratios. Generally, the waste particles are mixed at a ratio ranging from 15% to 50% of the weight with crushed and/or recycled and/or virgin polypropylene or high impact polystyrene, depending on the final product requirement, in an industrial mixing/ blending machine at least for 30 minutes to ensure the proper blending of the materials. The mixture is further blended together with adhesive modifiers and/or plasticizers for at least 15 minutes in the mixer/ blender, as per the final product requirement. Thereafter, the blended mixture is pre-heated up to a temperature of 70°C - 90°C to take off the moisture in the mixture, if any. Then the said moisture free mixture is subject to extrusion via a twin-screw extruder while controlling the barrel temperature between 160°C-220°C and the nozzle temperature increased to 2% to 10% of the moulding machine to achieve waste textile fiber reinforced polymer composite pallets. The moisture free mixture of waste textile fiber reinforced composite is also exposed to extrusion and injection molding via single screw extruder to produce desired plastic products such as industrial and domestic Electrical Accessories and products and industrial, commercial and domestic construction industry products and or any plastic product produced via extrusion process and/or injection moulding process using required moulds.
The waste textile fiber reinforced polymer composite is having the characteristics of melt flow index as similar to recycled/ virgin polypropylene and high impact polystyrene. It also possesses mechanical properties similar to recycled or virgin polypropylene or high impact polystyrene and has a higher izod impact strength compared to virgin material. The composite is also having similar distribution of colour masterbatches low percentages compared with virgin polymer.
6. DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to waste textile fiber reinforced thermoplastic composite products and a method for producing the same. More particularly the invention relates to synthetic fiber reinforced thermoplastic composite products made mainly from spandex and polyspandex. The thermoplastic materials are recycled and/or virgin Polypropylene and/or High Impact Polystyrene. The final products are adapted to be used as electrical accessories such as sunk boxes, white goods produced by Polypropylene and High Impact Polystyrene, flower pots, Plastic Furniture and other plastics products by Polypropylene and High Impact Polystyrene which are manufactured by extrusion or injection moulding processes. The method of processing is mainly by extrusion or injection moulding. The extremely controlled temperature and pressure parameters are applied to process the materials, as spandex fibers are having elastomer properties and matrix materials are thermoplastics. The mechanical properties of recycled polypropylene and recycled high impact polystyrene are significantly improved due to high strength and elastic properties of spandex fibers. This invention greatly contributes to environmental sustainability as very few research has been done on waste spandex and open up new methods and further innovative ideas to recycle waste spandex fibers. The composite material and the improved process parameters thereof disclosed by the invention can recycle resources, convert waste to value addition and promote the circular economy.
The textile material used in this invention is spandex fiber. Due to superior physical properties such as high tensile strength, elasticity, durability and heat conductivity of spandex fibers, the prepared composite is with high physics- mechanical properties compared to the physics-mechanical properties of virgin and/or recycled PP and HIPS reinforced by any other natural or synthetic fibers.
The defined composites and the controlled process parameters show that the homogenous morphology with improved mechanical properties compared with separate thermoplastics such as PP and HIPS. Using this process, raw material costs can be reduced and wastages from the garment industries can be reused in plastic industries directly. This technology helps to reduce the increasing costs related to manufacturing materials in the electrical appliances related to industry and domestic applications such as electrical accessories such as sunk boxes, white goods produced by Polypropylene and High Impact Polystyrene, flower pots and other plastics products by Polypropylene and High Impact Polystyrene which are manufactured by extrusion or injection moulding processes. On the other hand, the high cost of incineration of Spandex fabric waste in Garments industry shall be completely illuminated while tremendously contributing to completely illuminate the related carbon emission to the environment by the said incineration process.
The within invention relates to a composite material comprising a product of a combination of materials and process for producing the same. The combination of materials comprises a textile fiber and thermoset polymers. Preferably all the materials involved within the invention are low cost and/or waste materials and the finals products are with improved physical properties compared to the known products manufactured using same thermoplastic materials in the market.
More particularly, in the preferred embodiment, the present invention relates to the production of new composite material using an extruded composition of textile waste fiber and thermoplastic material. The mixing of two different materials within the extruder barrel under the careful control of temperature and pressure and other relevant parameters, aided the homogeneous distribution of materials and finally several products with improved physical properties were resulted using either extrusion or injection molding techniques.
The present invention is related to fiber reinforced thermoplastic products and their production process. Composites of the invention provide lower density, enhance of physics-mechanical properties, such as impact resistance, tensile strength, elongation, hardness and reduced water absorption. This was proven by the test results shown in Table 01 hereto obtained for the composite made out with spandex and recycled polypropylene, and results clearly indicated that the tensile strength, elongation at break, and water absorption properties are very similar to the properties which can be resulted with virgin Polypropylene as per the literature. The significant reinforcement of the waste Polypropylene by the spandex fibers were evidence by the excellent impact strength of the prepared composite, compared to the same of the virgin Polypropylene as per the literature.
The invention can be used to make composites for variety of structural applications e.g. electrical accessories such as sunk boxes, white goods produced by Polypropylene and High Impact Polystyrene, flowerpots and other plastics products by Polypropylene and High Impact Polystyrene.
Briefly summarizing, composites of the invention comprise one or more thermoplastic resins, spandex as a reinforcing fiber and other additives such as flame retardants, colorants and the like.
Typically, composites of the invention will comprise from about 15 to 50 weights percent of the fiber-reinforcing filler. The lower amount may be used but may tent to provide insufficient adjustments of physical properties. Higher amounts may be used but may tend to result in composites that are inconvenient to Products can be made with composites of the invention by injection moulding and extrusion. However, blending of two different materials homogeneously is very crucial in the production process. Controlled of particle size of spandex is very important and particles size range from lOOgm to 700gm in the present invention. Finer the particles, better the final composite is made. Upto 50%w of crushed materials were mixed with the polypropylene and high impact polystyrene for different products and then mixed with one or more other additives such as coloring pigments, fillers, flame retarders, heat stabilizers, impact modifiers, plasticizers, process aids and reinforcements for improve properties accordingly. Most of the physical parameters such as melting points, glass transition temperatures and crystallinity are different in spandex and thermoplastics materials used in this invention which lead to inhomogeneous solutions. Therefore, setting of the correct barrel temperature, pressure, mixing time, and material length are crucial to control the homogeneity of the composite during extrusion and injection moulding process.
The mixed compound with finer particle size is fed into the hopper and let them mix evenly and travel through the barrel. Heating elements maintain required temperature around 160°C-220°C throughout the barrel. But the nozzle temperature has to be increased around 2% to 10% of the moulding machine. According to the item and mould design, mould temperature, injection pressure, holding time, screw rpm and also above parameters should be adjusted. The cooling time of the molding process should be decided according to the weight of the part and size of the mould.
BRIEF DESCRIPTION OF THE DRAWINGS
1. Figure 01: shows a flow chart of the production process disclosed in the present invention.
2. Table 01: shows test results of the final products produced with the composite manufactured from the process disclosed in the present invention.

Claims

CLAIMS What is claimed is:
1. A process for manufacturing waste textile fiber reinforced polymer composites, wherein the process comprising the steps of;
- providing spandex or polyspandex fabric waste;
- crushing and grinding the fabric waste into particles of size lOOgm - 700gm through a crusher or a grinding unit having multiple adjustable blades;
- cleaning the crushed and grind particles through a high-pressure air circulation unit which is having an air circulation spinner barrel;
- providing crushed and/or recycled and/or virgin polypropylene or high impact polystyrene;
- blending the cleaned, crushed and grind fabric waste particles at a ratio ranging from 15% to 50% of the weight with crushed and/or recycled and/or virgin polypropylene or high impact polystyrene, depending on the final product requirement, in an industrial mixing/ blending machine at least for 30 minutes to ensure the proper blending of the materials;
- further blending the said mixture together with adhesive modifiers and/or plasticizers for at least 15 minutes in the mixer/ blender, as per the final product requirement;
- pre-heating the blended mixture up to a temperature of 70°C - 90°C to take off the moisture in the mixture, if any;
- subjecting the said moisture free mixture to extrusion via a twin- screw extruder while controlling the barrel temperature between 160°C-220°C and the nozzle temperature increased to 2% to 10% of the moulding machine to achieve waste textile fiber reinforced polymer composite pallets.
2. The process of claim 1, wherein the moisture free mixture is exposed to extrusion and injection molding via single screw extruder to produce desired plastic products.
3. The process of claim 1, wherein the waste textile fiber reinforced polymer composite having the characteristics of melt flow index as similar to recycled/ virgin polypropylene and high impact polystyrene, having mechanical properties similar to recycled or virgin polypropylene or high impact polystyrene, having a higher izod impact strength compared to virgin material, having similar distribution of colour masterbatches low percentages compared with virgin polymer.
4. The plastic products of claim 2 are industrial and domestic electrical accessories and products and industrial, commercial and domestic construction industry products and or any plastic product produced via extrusion process and/or injection moulding process using required moulds.
PCT/IB2022/055628 2021-07-14 2022-06-17 A process for manufacturing waste textile fiber reinforced polymer composites and composites produced therewith WO2023285891A1 (en)

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Citations (5)

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US6475412B1 (en) * 2000-09-22 2002-11-05 E. I. Du Pont De Nmeours And Company Process for making polyurethaneurea powder
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