CN101392418A - 从地毯背衬中分离和清洗用后地毯面纱的方法以及由其生产的纱产品 - Google Patents
从地毯背衬中分离和清洗用后地毯面纱的方法以及由其生产的纱产品 Download PDFInfo
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Abstract
本发明涉及一种用回收的用后地毯纱生产合成纤维组合物的方法,其中所述面纱用刮削装置从用后地毯中刮削以提供刮削的面纱,刮削的面纱被粉碎,用机械筛去除污染物,熔体过滤刮削的面纱,而后进行纤维纺丝。
Description
相关申请的交叉参考
本申请基于2007年9月20日提交的美国临时申请序列60/960,211,在此要求其优先权。
技术领域
本发明涉及一种回收和重复利用用后地毯的方法。更具体而言,其涉及一种回收和重复利用用后地毯的面纱的方法。回收和重复利用的面纱可用于进一步生产用于织物和地板覆盖应用的纱。回收和重复利用的面纱也可用于生产用于其它与纱无关的应用的制品如注塑制品。
背景技术
在过去的二十年间,家庭用地毯和机构用地毯已经越来越多地由合成聚合物材料制成,但当这些地毯覆盖物达到其使用寿命的终点时,产生如何处理这些地板覆盖物的问题。此废物的处理可以若干方式完成。有两种方式是或者通过在垃圾掩埋点填埋或者通过在焚化装置中焚烧。在美国,预计50亿磅的废地毯被倒入垃圾填埋点。垃圾填埋点的使用变得越来越稀有和昂贵。最近的研究也已经表明位于接近市区的垃圾填埋点对当地居民的健康问题造成影响。废物的焚化在环境上也是为公众和一些学术圈所不容的目标。同时,从废塑料的焚化中再生的能量很低,特别考虑到此废料的量。
制作地毯的大部分成分是潜在可回收或可再利用的。因此,可代替倒入垃圾填埋点或焚化的选择,和用于处理废塑料的最有利的选择,是将这些重复利用到其它原料和/或产品中。然而,这不是如当初可能想象的那么简单的选择。公众对“塑料”的理解是描述实质上都一样的材料的单一术语,然而本领域内众所周知并不是这样的,不同类型的塑料并不容易混合在一起形成一致的单一材料。对混合的塑料废物流的再加工,而不对其分类,或添加其它材料,总是导致材料低的最终值。在许多情况下,所涉及的设备的成本和消耗的能量,不能在产品的销售中获得补偿。为了由回收原料生产工业上有价值的材料,不得不应用大量的专门技术,具有已知的和一致的含量的特定废物流必须是可用的。
现代地毯通常由以下三种主要成分构成。首先是面纱,其可以是许多不同的纤维类型或其混合物。其次是基底背衬(纱被固定于其上,或编织于其中),其最通常是聚酯或聚烯烃的纺织布或非织布。第三是次级背衬层。所述次级背衬趋于形成构造体的大部分重量,并且通常层压到簇状地毯。该次级背衬可以是片材或泡沫材料,通常含有高水平的粗粒无机矿物填料。用于次级背衬的基料的实例为聚烯烃、聚氨酯、PVC、沥青和乳胶。
已经进行了各种尝试以在不事先对组分进行分离的情况下重复利用地毯废料。Ikeda Bussan的JP 60 206 868描述了粉碎废地毯,以约50:50的比率与乙烯-乙酸乙烯酯混合,并压延以形成地毯用的背衬片。压延在低温下进行,以使纤维成分不熔融,而是仅分散到产品中。Collins和Aikman的美国专利5,728,741主张了一种类似的方法,不过在此情况下,在压延前,将废料在高温下挤压,使得所有成分熔融并在熔融态下混合。其它专利提供未分离的地毯废料的重复利用,但是用马来化聚烯烃和/或乙烯-乙酸乙烯酯作为增容剂。参见,例如,Teijin的JP 05 287 139、Toyota/Mitsubishi的JP05 293 828、和Lear Corporation的美国专利5,719,198。Georgia Tech.的美国专利5,626,939采取一种低能量的方法,通过将充分破碎的地毯废料与热固性树脂前体混合,并将得到的混合物成型和交联为“合成木材”。上述方法都得不到适于制造纤维或纱线的可熔纺产品。
其他发明人已经寻求在重复利用废料地毯的成分作为独立的产品流之前先分离废料地毯的成分。这些主要包括地毯的切碎、撕碎、和粒化,而后通过旋风分离器、旋液分离器、或不同的密度液体浮选池分离各种聚合物成分。见于,例如,Hagguist和Hume的美国专利5,230,473、JPS Automotive的美国专利5,518,188、BASF Corporation的美国专利5,535,945、Zimmer A.G.的美国专利5,598,980、和AlliedSignal/DSM的美国专利5,722,603。溶解法也已经被建议;例如,Georgia Tech.的美国专利5,233,021描述了超临界流体方法的应用,其中利用温度和压力的变化来相继溶废料地毯的不同成分。另一个可选择的方法,用于含有尼龙6的地毯,是从地毯废料中直接回收己内酰胺,如BASF Corporation的美国专利5,169,870、和DSM的美国专利5,668,277所描述。对于从尼龙66和尼龙混合物中回收单体也做过类似的努力,例如E.I.DuPont de Nemours and Company的美国专利5,536,694和美国专利5,468,900。由这些方法回收的单体而后能被再聚合以产生用于进一步纤维纺丝的聚合物。上述分离方法在许多情况下是复杂的,包括许多阶段,并且在实施中显然需要资金花费。还需注意的是,在许多这些方法中,从分离方法中仅得到一种可用的产品,而仍然存在生产方法中的其它残余物的处理问题。
对用后地毯面纱的分析已经表明,在其寿命期间,依据地毯的处境,可能存在多种污染物。可能需要去除以使回收的面纱能被再用于纤维纺丝过程中的不期望的污染物包括,但不限于,沙、纤维素(例如以木材或纸的形式)、乳胶、橡胶、地毯背衬材料、石膏和其它建筑材料。其它可能的污染物包括来自宠物、人和织物的动物毛发、以及植物物质。所有的这些污染物与单个地毯纱线长丝相比通常是非常大的“颗粒”尺寸的固体。这些污染物需要在回收的材料适于纤维纺丝之前被去除,特别是那些在被重新利用的聚合物的纤维挤出温度下不熔融的污染物,或与被重新利用的聚合物不相容的污染物。熔融挤出纤维纺丝法通常包括精细过滤作为该方法一部分使得大颗粒污染物不包括在形成的纤维中。大颗粒污染物的存在降低了形成的纤维的强度,使其不适于大多数地毯和织物应用。另外,高水平的污染物,特别是大粒径的污染物,导致短的挤出机过滤器寿命,使得纤维纺丝方法由于需要非常频繁的更换过滤筛而不经济。
在本发明之前,尚没有适于回收和再利用地毯面纱的方法以适用于熔融挤出纤维纺丝来生产地毯或织物纱线而无需应用不期望的解聚和再聚合方法。
已经发现生产用后地毯纱回收料的方法,所述回收料具有充分清洁度使得回收的产品而后能经济地进一步用于地毯纱产品而没有有害损失所生产的纱的物理性质。
发明内容
本发明的方法首先是对面纱的化学属性的鉴别。面纱可以是若干不同的种类,包括但不限于,聚丙烯、聚酯例如聚对苯二甲酸乙二醇酯和聚对苯二甲酸丙二醇酯、聚乳酸、聚酰胺例如尼龙6和尼龙66、或天然纤维如羊毛。
能用各种实验室分析技术,包括湿化学法和仪器技术,来提取和分析样品。更优选的是,使用便携的或手持的鉴别装置,和最优选的是,使用特别为本领域内的塑料废料的鉴别设计的近红外(NIR)分光计。
一旦确定面纱类型并通过化学属性分类使得面纱类型主要是一种类型,下一步就是从地毯背衬中分离面纱以使分离的面纱含有少于5%的背衬材料,优选少于2%的背衬材料。分离的面纱最优选含有少于0.5%的背衬材料。此分离能通过刮削、***或修剪方法完成,所述方法能刮掉面纱而不会与面纱一起去掉大量的地毯背衬材料。可商购的地毯剪毛机可用于此目的或可潜在地进行适当的修改以最适合应用。其它地毯加工设备的修改也能被用于此目的,其包括,但不限于,用于双层绒头织物织造或熔融粘接的***设备(参考:“Carpet Manufacture”,G.H.Crawshaw,Chaucer PressLtd,2002)。可选择的并优选的方法是使用通常用于皮革制革工业中将天然或合成皮革分割成期望的厚度的片皮机。片皮机通常由两个相互对立的辊子组成。皮革通过这两个辊子,传至安装在两个辊子之间的区域内的分离刀片。可以改变辊子相对于***刀片的位置以得到特定厚度的皮革。每张地毯的堆积高度和背衬的厚度可以依据地毯设计和构造而变化。因此,当“***”或“刮削”地毯的面纱时,适当地调整辊子相对于***刀片的位置以使最大量的面纱被除去而不刮掉任何的地毯背衬。
而后刮削和分离的面纱在再挤压回纤维中之前被清洗。优选的方法包括首先使用机械筛选装置。分离的面纱的粉碎有利于随后污染物的去除;在粉碎过程中面纱的机械搅动将污染物从面纱中排出,从而有助于污染物的去除。粉碎过程也开发了能使可能陷在加捻纱结构中的污染物释放的加捻纱、并捻纱或barber-pole纱。一种高速度、低强度研磨机是优选的,以使在粉碎过程中的摩擦热最小化,使得聚合物不显著受机械退化或热退化的影响。研磨机安装有孔径为1/8-3/4英寸,为优选3/16-7/16英寸的筛。
粉碎的面纱通过旋风分离器供入机械筛选装置中。在此运送过程中,气载灰尘能通过旋风分离器从进料流中去除。优选的筛的类型是最适合处理轻质材料或膨体材料的那些,例如,但不限于,转筒筛、往复筛、旋转往复筛。也可以使用振动筛。其它选择是对转筒筛类型的改造,其中筛是固定的,而材料经过旋转螺旋钻通过多孔转筒筛。筛的开口或孔径的最小尺寸为1/8-3/4英寸,优选为3/16-7/16英寸。孔尺寸的选择由研磨机筛上的孔径决定。污染物通过筛上的孔被去除。筛过的面纱从圆柱的末端排出。减压流或真空可施加于筛的外侧以改善污染物从面纱中去除的效率。
现在优选进一步通过水分离法或洗涤过程清洁或冲洗机械筛选的面纱。面纱优选在高温下用或不用表面活性剂洗涤。如果使用表面活性剂,阴离子基表面活性剂是优选的。在氧化剂还原的环境中,也可以使用高pH条件,然而,所用的条件不应使得面纱在洗涤期间被基本上降解。高pH条件可通过添加碱达到,所述碱包括但不限于,氢氧化钠、氢氧化钾、氢氧化铵、碳酸钠或碳酸钾、或磷酸钠、或它们的混合物。任选使用漂白环境可例如通过添加二氧化硫脲达到。氧化剂漂白条件可通过使用次氯酸盐、过氧化氢或亚氯酸钠来达到。商用洗涤设备能被用于此冲洗目的。另一个非限制性选择是使用压力容器,使得温度可以增加到沸点之上来改进清洁效率和减少洗涤时间。如果使用高pH条件,在干燥前,洗涤液的中和和面纱的走梭是优选的。如果非常需要,此洗涤过程也可以在研磨和机械筛选之前进行。
基本上无污染物的面纱可转化成颗粒或者小球形式。颗粒形成过程包括,但不限于,使用Netzsch-Condux Plastocompactor或California制粒机、熔融挤出、或它们结合使用。小球形成过程包括熔融挤出过程,其包括将原料送入熔融配混挤出机中,用适当的填塞或充塞装置以改进进料效率,用在线过滤***过滤熔融材料,随后形成股线,冷却而后粒化。用于特定聚合物类型的水下造粒机也可成功地应用而无需对回收材料捻股。回收的材料而后能用于进一步制备用于织物和地板应用的合成纤维。
通过在小试规模的单螺杆熔体挤出机纤维纺丝线上进行熔体过滤测试来分析纤维挤出已回收原料。将包含80×700的Dutch斜纹编织筛和粗网支承筛(coarser mesh supporting screen)的过滤筛组置于纤维喷丝头上。80×700的Dutch斜纹编织筛具有25微米的额定保留,和34-36微米的绝对保留;(参考:Woven Wire Cloth Reference Book,Haven & Boecker,1990)。压力传感器置于筛组之上。在RV=3.1的纯PA66中制备各种百分比的回收料共混物,并用此装置和监控的压力测试。
实施例1(非发明性的)
一种商业回收后工业熔融挤出线用纯尼龙6树脂冲洗。已经用片皮机刮削掉用后地毯的尼龙66地毯面纱通过运输机以额定500lbs/h送至单螺杆挤出机的进料口。尼龙熔融物通过包含325方网眼筛和粗网支承网筛的筛组进行在线过滤。325方网眼筛的口径为43微米。在线过滤器是手动过滤筛的改型。过滤器的压力上升非常迅速,以至于在回收材料还没有完全清除纯尼龙6之前,压力就超过了过滤器的操作极限。挤出线进一步用尼龙6树脂冲洗,将包含80方网眼和粗网支承筛的粗筛组安装入在线过滤器内。80方网眼过滤筛的口径为180微米。尼龙66地毯面纱再次送入挤出机。在将尼龙6冲洗出挤出机前再次超过在线过滤器的操作极限。挤出机用纯尼龙6冲洗,将包含3×20方网眼筛的粗筛组安装入在线过滤器中。20方网眼过滤器的口径为860-910微米。尼龙66面纱再一次被送入挤出机。过滤器的压力上升率约为0.03psi/g。
实施例2(非发明性的)
将实施例1的粒化产物与RV=3.1的PA66以25%∶75%的重量比混合并干燥至500ppm水分。粒料共混物在配有在线自动过滤器筛更换器的单螺杆熔融混合挤出机上被进一步加工。过滤器孔径为75微米。将过滤的熔融物捻股并粒化。污染物的水平使得孔径小于75微米的过滤器在不超过机器的操作极限下不能使用。
实施例3(本发明)
已经以类似于实施例1的方式刮削掉用后地毯的尼龙66地毯面纱在配有5/16”目筛的Cumberland造粒机中被粉碎。将粉碎的材料送至旋风分离器中。而后将面纱通过旋转阀送至多孔转筒筛中包含旋转螺旋钻的筛中。污染物通过筛在减压下被去除,面纱由螺旋钻被输送通过第二个旋转阀并收集。收集的面纱用Condux Plastocompactor压实。压实的面纱与纯尼龙66以5:95的比例在生产纤维纺丝线上混合。使用含有类似于熔体过滤测试所用的过滤器筛组的在线过滤器。得到约5小时的过滤器寿命。
实施例4(本发明)
已经以类似于实施例1的方式刮削掉用后地毯的尼龙66地毯面纱在配有5/16”目筛的Cumberland造粒机中被粉碎。面纱进一步以类似于实施例3的方式加工,不同之处是面纱生产量被降低和使用较高的真空以从筛中去除污染物。
实施例1和2的粒化材料、实施例3和4的压实回收物、以及实施例5的无污染面纱用上述熔体过滤测试评价。结果显示于表1。由实施例3、4和5回收的材料相比于实施例1和2给出显著较低的过滤压力上升,这表明地毯面纱中污染物的去除在生产可纺丝成地毯纤维的产品中是有效的。
实施例5(本发明)
将尼龙66地毯面纱以类似于实施例3的方式刮削掉用后地毯、粉碎和机械筛选。然后将纱线在商业洗衣机中用衣物清洗剂(注册商标是Proctor and Gamble)和漂白剂(注册商标是Clorox ChemicalCompany)洗涤。清洗的纱线用熔体过滤测试进行测试。压力上升显著小于实施例3和4,表明水洗过程对污染物去除效率有额外的益处。
实施例6(本发明)
将尼龙66地毯面纱以类似于实施例3的方式刮削掉用后地毯、粉碎和机械筛选。机械筛选的纱线用California制粒机压实。压实的材料被送入配有在线熔体过滤***的双螺杆熔体挤出机中。熔融物通过60目筛过滤并粒化。对粒化材料进行熔体过滤测试。结果见表1。
表1
实施例 | 在纯PA66中回收的面纱(%) | 压力上升(psi/g) |
1 | 5% | 3.20 |
2 | 5% | 1.10 |
3 | 2% | 0.60 |
3 | 10% | 1.10 |
4 | 2% | 0.08 |
5 | 2% | 0.05 |
6 | 5% | 0.09 |
Claims (13)
1.一种用回收的用后地毯纱生产合成纤维组合物的方法,其包括:
a.用刮削装置从用后地毯中刮削面纱以提供刮削的面纱,
b.粉碎所述刮削的面纱,
c.用机械筛从所述面纱中去除污染物,
d.用水洗方法进一步从所述面纱中去除污染物,
e.熔体过滤所述面纱,和
f.对熔体过滤的面纱进行纤维纺丝。
2.依据权利要求1的方法,其中所述刮削装置是片皮机。
3.依据权利要求1的方法,其中所述机械筛选自具有旋转螺旋钻的固定筛、往复筛、旋转往复筛和振动筛。
4.依据权利要求1的方法,其中所述回收的用后地毯纱选自尼龙6、尼龙66、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二醇酯、聚乳酸和聚丙烯。
5.依据权利要求1的方法,其中所述刮削的纱含有少于2%的背衬材料。
6.一种用回收的用后地毯纱生产合成纤维组合物的方法,其包括:
a.用刮削装置从用后地毯中刮削面纱以提供刮削的面纱,
b.粉碎所述刮削的面纱,
c.用机械筛从所述刮削的面纱中去除污染物,
d.熔体过滤所述刮削的面纱,和
e.对熔体过滤的刮削的面纱进行纤维纺丝。
7.依据权利要求6的方法,其中所述刮削装置是片皮机。
8.依据权利要求6的方法,其中所述机械筛选自具有旋转螺旋钻的固定筛、往复筛、旋转往复筛和振动筛。
9.依据权利要求6的方法,其中所述回收的用后地毯纱选自尼龙6、尼龙66、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二醇酯、聚乳酸和聚丙烯。
10.依据权利要求6的方法,其中所述刮削的纱含有少于5%的背衬材料。
11.一种合成纤维组合物,其包含:
a)含有少于5%的地毯背衬材料的回收的用后地毯纱,和
b)成纤热塑性树脂。
12.依据权利要求11的合成纤维组合物,其中所述回收的用后地毯纱选自尼龙6、尼龙66、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二醇酯、聚乳酸和聚丙烯。
13.依据权利要求11的合成纤维组合物,其中所述成纤热塑性树脂选自尼龙6、尼龙66、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二醇酯、聚乳酸和聚丙烯。
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2008
- 2008-05-29 US US12/155,117 patent/US8017662B2/en not_active Expired - Fee Related
- 2008-06-02 AU AU2008202425A patent/AU2008202425B2/en not_active Ceased
- 2008-06-16 JP JP2008156211A patent/JP5442219B2/ja not_active Expired - Fee Related
- 2008-06-17 TW TW97122606A patent/TWI359067B/zh not_active IP Right Cessation
- 2008-06-20 MX MX2008008143A patent/MX2008008143A/es active IP Right Grant
- 2008-06-24 EP EP20120150077 patent/EP2439035A1/en not_active Withdrawn
- 2008-06-24 EP EP20080252165 patent/EP2039486A3/en not_active Withdrawn
- 2008-07-01 CN CN2008101284819A patent/CN101392418B/zh not_active Expired - Fee Related
- 2008-07-16 CA CA2637966A patent/CA2637966C/en not_active Expired - Fee Related
- 2008-08-18 BR BRPI0803390-0A patent/BRPI0803390A2/pt not_active Application Discontinuation
- 2008-09-18 KR KR20080091518A patent/KR101508115B1/ko not_active IP Right Cessation
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- 2011-06-20 US US13/163,835 patent/US20110257345A1/en not_active Abandoned
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CN101838864A (zh) * | 2010-03-02 | 2010-09-22 | 喻成进 | 一种地毯表面纤维的回收方法及其生产流水线 |
CN101845150A (zh) * | 2010-04-20 | 2010-09-29 | 沈阳八达能源环保科技发展有限公司 | 一种废旧地毯再生利用加工方法 |
CN105694094A (zh) * | 2011-11-04 | 2016-06-22 | 肖工业集团有限公司 | 回收地毯的方法以及这种方法的产品 |
CN104630916A (zh) * | 2013-11-11 | 2015-05-20 | 柯汉哲 | 废渔网回收再制方法 |
CN105386143A (zh) * | 2015-11-25 | 2016-03-09 | 吴江双杰玻璃钢设备有限公司 | 一种工业毛毯回收再生化纤丝的制作方法 |
CN111727279A (zh) * | 2018-01-19 | 2020-09-29 | 阿德勒佩尔泽控股有限公司 | 回收纤维的方法 |
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CN112981906A (zh) * | 2021-02-09 | 2021-06-18 | 吴燕军 | 一种改进的纺织机双面除尘装置 |
CN112981906B (zh) * | 2021-02-09 | 2022-05-03 | 泰安岱银新宇纺织有限公司 | 一种改进的纺织机双面除尘装置 |
Also Published As
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JP2009072569A (ja) | 2009-04-09 |
MX2008008143A (es) | 2009-04-15 |
US8017662B2 (en) | 2011-09-13 |
CA2637966A1 (en) | 2009-03-20 |
CA2637966C (en) | 2014-04-29 |
AU2008202425A1 (en) | 2009-04-09 |
AU2008202425B2 (en) | 2012-07-12 |
EP2039486A2 (en) | 2009-03-25 |
KR101508115B1 (ko) | 2015-04-03 |
CN101392418B (zh) | 2013-10-02 |
TW200930535A (en) | 2009-07-16 |
TWI359067B (en) | 2012-03-01 |
US20110257345A1 (en) | 2011-10-20 |
US20090082476A1 (en) | 2009-03-26 |
KR20090031261A (ko) | 2009-03-25 |
EP2439035A1 (en) | 2012-04-11 |
EP2039486A3 (en) | 2011-06-29 |
BRPI0803390A2 (pt) | 2011-08-02 |
JP5442219B2 (ja) | 2014-03-12 |
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