WO2023108246A1 - Method for producing pellets from recycled synthetic textile waste and natural textile waste for injection-moulding - Google Patents

Method for producing pellets from recycled synthetic textile waste and natural textile waste for injection-moulding Download PDF

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WO2023108246A1
WO2023108246A1 PCT/BR2022/050504 BR2022050504W WO2023108246A1 WO 2023108246 A1 WO2023108246 A1 WO 2023108246A1 BR 2022050504 W BR2022050504 W BR 2022050504W WO 2023108246 A1 WO2023108246 A1 WO 2023108246A1
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textile waste
polyester
waste
textile
natural
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PCT/BR2022/050504
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French (fr)
Portuguese (pt)
Inventor
André Luis Dos Santos DA SILVA
João Carlos Oleksinski DE ANDRADES
Treudi Feldens DE ANDRADES
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Indústria E Comércio De Confecções Bella Moda Ltda.
Serviço Nacional De Aprendizagem Industrial - Departamento Regional Do Rio Grande Do Sul - Senai/Rs
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Publication of WO2023108246A1 publication Critical patent/WO2023108246A1/en

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    • 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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L35/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical, and containing at least one other carboxyl radical in the molecule, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L35/06—Copolymers with vinyl aromatic monomers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L75/00—Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
    • C08L75/04—Polyurethanes
    • 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
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2367/00—Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2467/00—Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2207/00—Properties characterising the ingredient of the composition
    • C08L2207/20—Recycled plastic
    • 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 present invention is part of the field of application of textiles, more specifically, the reuse of synthetic and natural textile waste, arising from the processes of cutting and layering fabrics, aiming at the formation of pellets for use in injection molding for manufacturing of technical parts and artifacts.
  • the textile industry is one of the largest economic engines in the world, valued at around 2.4 trillion dollars of wealth generated in the year and responsible for generating more than 75 million jobs worldwide .
  • the Brazilian textile industry is responsible for the production of 1.8 million tons of textile products, making the country the fourth largest producer of clothing items worldwide.
  • the production process is divided into several stages, from planning and construction of the mold, selection of trims, cutting, spreading and sewing, generating significant waste of raw material in the form of trimmings, scraps and rejected parts. These residues are of no value to the sector, as they have become small pieces of fabric that are impossible to cut continuously in a garment part.
  • polyester the material is one of the most versatile in the world, with high added value, and can be reused for the production of new raw materials from the recycling of polyester waste generated in the post-industrial and post-consumer phases.
  • the present invention presents a technological challenge for the reuse and recycling of synthetic textile waste, aiming at the production of new raw materials with added value for use in injection molding, contributing to the reduction of the environmental impact and increasing sustainability.
  • Recycling processes have economic advantages, allowing the reduction of production costs, where pellets produced from textile waste can replace virgin raw material, leading to the conservation of natural resources and reducing energy consumption, and, consequently, reducing environmental impacts.
  • the present invention relates to the field of mechanical recycling of synthetic textile waste and natural textile waste and, in particular, the process for obtaining pellets from synthetic textile waste and thermoplastic composites reinforced with natural textile waste.
  • Document JP2004042385 (Fuji Heavy. 2002) describes a method for recycling polyester textile waste.
  • the shavings Textiles are previously pulverized into smaller pieces for mixing in a twin-screw extruder with virgin polyester and/or polypropylene for subsequent granulation.
  • the pellets obtained in a twin-screw extruder can be reused for the production of parts by injection.
  • Document CN105199138 (Elite Color. 2015) describes a process for recycling polyester and polyurethane composition fabrics, where the shavings are initially crushed into smaller pieces, washed and dried under vacuum, and subsequently mixed with grafted styrene copolymer with maleic anhydride, antioxidants and other ingredients in an extruder to produce pellets. These pellets are transformed into artifacts by injection molding.
  • Document CN1 10093018 (Fujian Normal. 2019) describes a method of recycling polyester textile scraps for the production of blends with polyolefins.
  • the blends are prepared by extrusion, resulting in pellets.
  • a compatibilizing agent, impact modifier, antioxidants and extrusion lubricants are added to the textile polyester residue.
  • Document WO2020252523 (Blocktexx. 2020) describes a system and process for separating and recycling mixed fabrics of polyester and cotton.
  • the first stage is related to the cutting and crushing of textile shavings.
  • the crushed material is added to an aqueous solution of hot sulfuric acid, where the material undergoes different chemical processes to separate cotton and polyester.
  • the polyester fraction is extruded, with the addition of chain extenders and thermal stabilizers, and subsequently pelletized.
  • Document CN103304839 (Jiangsu. 2013) also describes methods of separating cotton from polyester in mixed fabric compositions. Polyester and cotton are solubilized in appropriate solvents. The polyester solution is evaporated, extruded and granulated.
  • Document CN1 10272608 (Plastic Union. 2019) describes a method for chemically recycling textile polyester.
  • the polyester is depolymerized to obtain monomers and again polymerized into polyester, and then mixed with ABS, plasticizers and impact modifiers in a twin-screw extruder to obtain pellets from the PET/ABS blend.
  • the PET/ABS blend and other components can be used to produce injection molding artifacts.
  • Document CN1 10256822 (Plastic Union. 2019) describes a method for chemical recycling of textile polyester. As in document CN1 10272608A, polyester is depolymerized to obtain monomers and polymerized into polyester to produce blends with Polyamide 6 and compatibilizing agents. The PA6/PET blend with compatibilizing agents is used for the production of injection molding artifacts.
  • Document CN1 10256821 (Plastic Union. 2019) is similar to documents CN1 10272608 and CN1 10272608, with the difference being the use of Polyamide 6.6 as base raw material for PA66/PET blends and compatibilizing agents.
  • Document CN1 10092925 (Plastic Union. 2019) describes a method for chemically recycling textile polyester. Polyester is depolymerized to obtain monomers and again polymerized into polyester, and then mixed with Polypropylene, carbon black and compatibilizing agents for preparing PP/PET blends for use in injection molding, film extrusion and as a color concentrate (masterbatch) for injection molding.
  • thermoplastic composite pellets reinforced with cotton fabric and mixed fabric It is an objective of the present invention to describe the preparation step of thermoplastic composite pellets reinforced with cotton fabric and mixed fabric. [028] It is an objective of the present invention to describe the injection step of test specimens for characterization and injection of functional prototypes.
  • Figure 1 illustrates the textile trimmings of polyester synthetic textile waste, after being cut in the cutter to standardize the size.
  • Figure 2 shows the synthetic polyester textile waste after the defibration process in a thermoplastic binder.
  • Figure 3 shows natural cotton textile waste after the defibration process in a thermoplastic binder.
  • Figure 4 shows the masterbatches of synthetic polyester textile waste after processing in a mixing chamber.
  • Figure 5 shows the mixing chamber of the thermokinetic mixer used.
  • Figure 6 shows the masterbatches of synthetic polyester textile waste after processing in a thermokinetic mixer.
  • Figure 7 illustrates the flakes of synthetic polyester textile waste obtained after granulating the samples in a knife mill.
  • Figure 8 shows the high-density polyethylene masterbatches and natural textile waste prepared in a thermokinetic mixer.
  • Figure 9 shows the polypropylene masterbatch and natural textile waste prepared in a thermokinetic mixer.
  • Figure 10 shows the screw profile used for extrusion of thermoplastic composites of polyolefins reinforced with natural textile waste and textile waste of mixed composition.
  • Figure 1 1 shows pellets of thermoplastic composites of polypropylene and natural textile waste, prepared by twin-screw extrusion, in the 70/30 ratio by mass.
  • Figure 12 shows the pellets of high density polyethylene thermoplastic composites and natural textile waste, prepared by twin-screw extrusion, in the ratio 90/10 by mass.
  • Figure 13 shows the pellets of polypropylene thermoplastic composites and textile waste of mixed composition, prepared by twin-screw extrusion, in the ratio 70/30 by mass.
  • Figure 14 shows the pellets of thermoplastic composites of high density polyethylene and textile waste of mixed composition, prepared by twin screw extrusion, in the ratio 90/10 by mass.
  • Figure 15 illustrates the thermoplastic composite pellets of polypropylene and natural textile waste, with the addition of a compatibilizing agent, prepared in a twin-screw extruder, in the ratio 87/10/3.
  • Figure 16 shows the pellets of thermoplastic composites of high density polyethylene and natural textile waste, with the addition of a compatibilizing agent, prepared in a twin-screw extruder, in the ratio 87/10/3.
  • Figure 17 shows pellets of polypropylene thermoplastic composites and textile waste of mixed composition, with the addition of a compatibilizing agent, prepared in a twin-screw extruder, in the ratio 87/10/3.
  • Figure 18 shows the pellets of thermoplastic composites of high density polyethylene and textile waste of mixed composition, with the addition of a compatibilizing agent, prepared in a twin-screw extruder, in the ratio 87/10/3.
  • Figure 19 illustrates the prototypes prepared by injection molding for thermoplastic composites of high density polyethylene reinforced with natural textile waste, in the ratio 90/10.
  • Figure 20 shows the prototypes prepared by injection molding for thermoplastic composites of polypropylene reinforced with natural textile waste, in the ratio 90/10.
  • Figure 21 shows the prototypes prepared by injection molding for high-density polyethylene thermoplastic composites reinforced with textile waste of mixed composition, in the ratio 90/10.
  • Figure 22 shows the prototypes prepared by injection molding for thermoplastic composites of polypropylene reinforced with textile waste of mixed composition, in the ratio 90/10.
  • Figure 23 shows the prototypes prepared by injection molding for synthetic polyester textile waste.
  • Figure 24 illustrates the prototypes prepared by injection molding for synthetic polyester textile waste, with the addition of impact modifiers, in the ratio 90/10.
  • Figure 25 shows the prototypes prepared by injection molding for synthetic textile waste of polyester + polyurethane, with the addition of impact modifiers, in the ratio 70/30.
  • the first stage of the initial treatment of textile waste refers to a sorting stage, where waste is separated by composition. After sorting, the material is added to a cutter, where the textile trimmings are cut into sizes between 1 and 30cm 2 , as shown in Figure 1.
  • the cut chips are added to a binder mill, where the material is shredded until it is completely uncharacterized, turning into a disaggregated fiber ( Figures 2 and 3).
  • the binder mill is typically used for plastic film recycling.
  • the agglutinator is also known as an agglomerator mill, being generically composed of a steel container, with fixed blades positioned on the mill walls and rotating blades coupled to an electric motor. The fixed and rotating knives cut and rub the textile shavings against the equipment walls, raising the process temperature until the shavings are shredded.
  • the defibration time in a binder mill can be controlled through an ammeter present in the mill motor, where the ammeter shows low and constant values when the textile shavings are defibrated.
  • the agglutination time is shown in the
  • thermokinetic mixer Processing of synthetic textile waste in thermokinetic mixer
  • thermokinetic mixer model MH-600 from the manufacturer MH Equipamentos
  • waste compositions of polyester and/or polyester + polyurethane were prepared, and their respective blends with virgin PBT, in the mass proportions of 100/0 to 25/75 of synthetic textile waste and virgin PBT.
  • the thermokinetic mixer ( Figure 5) is also known as a Drais mixer, Dryser mixer or K-mixer. Its main application is the production of pigment concentrates (masterbatches, composites, blends, PVC compounds and WPG (wood plastic composite).
  • thermokinetic mixer consists of a horizontal mixer, without a heating source, where the melting of the material is carried out by shearing the sample with the rotor and the mixing chamber of the equipment. Processing parameters are shown in Error! Reference source not found. The filling factor used for the thermokinetic mixer chamber was 50 to 70%. The result of this processing is shown in Figure 6. [066] Table 2 - Processing parameters of polyester and polyester + elastane textile waste and their blends with PBT in a thermokinetic mixer.
  • thermokinetic mixer Processing of synthetic textile waste with impact modifiers in a thermokinetic mixer
  • thermokinetic mixer model MH-600 from the manufacturer MH Equipamentos, waste compositions of polyester and/or polyester + polyurethane were prepared, with the addition of impact modifiers of the "core-shell" type, where its core (core ) is a cross-linked butyl polyacrylate and its shell is polymethyl methacrylate (PMMA).
  • core core
  • PMMA polymethyl methacrylate
  • thermokinetic mixer chamber [068] Table 3. The filling factor used for the thermokinetic mixer chamber was 50 to 70%.
  • thermokinetic mixer and/or mixing chamber were granulated in a SEIBT MGHS 200LR knife mill, with a sieve opening of 5.6 MESH and a speed between 200 and 400rpm to produce pellets at a production rate between 10 and 50 kg/h.
  • the flakes obtained are shown in Figure 7.
  • Table 4 Processing parameters of masterbatches of thermoplastic composites of polyolefins reinforced with natural textile waste and/or mixed composition prepared in thermokinetic mixer.
  • thermoplastic composites of polyolefins polypropylene or high density polyethylene reinforced with natural textile waste (cotton) and/or reinforced with textile waste of mixed composition (polyester + polyurethane + cotton) were granulated in a knife mill MGHS 200LR, from the manufacturer SEIBT, with a sieve opening of 5.6 MESH and a speed between 200 and 400rpm for the production of flakes at a production rate between 10 and 50kg/h.
  • Thermoplastic composites of polyolefins (polypropylene and high-density polyethylene) reinforced with synthetic textile waste and/or reinforced with textile waste of mixed composition (polyester + polyurethane + cotton) were prepared in ratios between 90/10 and 70/30 in a Brabender Lab-Station Plasti-Corder TSE 20/40 twin screw extruder.
  • thermoplastic composite components were performed using two gravimetric dosers. The masterbatches were dried and dehumidified under the same conditions described above.
  • thermoplastic composite pellets obtained by extrusion are shown in Figures 1 1 to 14.
  • thermoplastic polyolefin composites reinforced with synthetic textile waste and/or reinforced with textile waste of mixed composition and compatibilizing agent.
  • Thermoplastic composites of polyolefins (polypropylene and high density polyethylene) reinforced with synthetic textile waste and/or reinforced with textile waste of mixed composition (polyester + polyurethane + cotton) and with the addition of compatibilizing agents were prepared in ratios between 90/10 and 70/30 in a Brabender Lab-Station Plasti-Corder TSE 20/40 twin screw extruder.
  • thermoplastic composites The thread profile used is shown in Figure 10.
  • the dosing of the thermoplastic composite components was performed using two gravimetric dosers.
  • the screw speed used for the extrusion of thermoplastic composites was between 10 and 400rpm.
  • To the samples were granulated in a pelletizer, generating pellets with an average particle size between 1 and 3 mm.
  • the process temperatures are shown in Table 6.
  • Pellets of thermoplastic composites with the addition of a compatibilizing agent processed by extrusion are shown in Figures 15 to 18.
  • the functional prototypes were prepared by injection molding using a Sandretto Lógica 370/70 injection molding machine, in a geometry as shown in Figures 19 to 25. Prototypes of all the compositions developed were prepared. The injection temperatures for the prototypes were the same used for the injection of the test specimens, as described in Table 7. The other injection parameters of the prototypes are presented in Table 9.
  • IZOD impact resistance tests as determined by the ASTM D 256 standard, were carried out in a CEAST impact resistance equipment, using a 1J hammer and hammer speed of 3.460 m/s. The notches on the specimens were made with the aid of a Notch Vis notch. The samples were conditioned for 48 hours before carrying out the notches and tests in a laboratory conditioned at 23°C and 50% relative humidity.
  • Flow index tests were carried out according to ASTM D1238-A standard to evaluate the processability of materials with 2.16kg of applied load, 10 min of test, and at a temperature of 285°C, for samples of polyester base, 230°C for polypropylene matrix samples and 190°C for polyethylene matrix samples. The equipment used was a DSM plastomer. The samples were dried in an oven with air circulation, for 24 hours, at a temperature of 70°C, before carrying out the tests.
  • thermoplastic polypropylene composites reinforced with natural textile waste and of mixed composition prepared in a twin-screw extruder with and without the addition of compatibilizing agents
  • Table 13 Results of tensile strength tests for thermoplastic polypropylene composites reinforced with textile waste natural and/or of mixed composition, prepared by extrusion, with and without the addition of compatibilizing agents.
  • thermokinetic mixer Synthetic textile waste formulations with impact modifiers in thermokinetic mixer
  • thermoplastic polypropylene composites reinforced with natural textile waste and of mixed composition prepared in a twin-screw extruder with and without the addition of compatibilizing agents [099] Table 18 - Results of impact resistance tests for thermoplastic polypropylene composites reinforced with textile waste natural and of mixed composition prepared in a twin screw extruder with and without the addition of impact modifiers.
  • Formulations of high density polyethylene thermoplastic composites reinforced with natural and mixed composition textile residues prepared in a twin-screw extruder with and without the addition of compatibilizing agents are provided.
  • Table 20 - Flow index results for formulations prepared from synthetic textile waste in a mixing chamber.
  • thermokinetic mixer Synthetic textile waste formulations with impact modifiers in thermokinetic mixer
  • thermoplastic composites of Dolypropylene reinforced with natural textile residues and of mixed composition prepared in a twin screw extruder with and without the addition of compatibilizing agents [0104] Table 23 - Results of impact resistance tests for thermoplastic composites of polypropylene reinforced with textile residues natural and of mixed composition prepared in a twin screw extruder with and without the addition of impact modifiers. Flow Index ASTM D1238-A
  • Formulations of high density polyethylene thermoplastic composites reinforced with natural and mixed composition textile residues prepared in a twin-screw extruder with and without the addition of compatibilizing agents are provided.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Environmental & Geological Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

The present invention relates to recycling technology for synthetic polyester and polyester + polyurethane textile waste, natural cotton textile waste and textile waste having a mixed composition (cotton + polyester + polyurethane) produced during garment manufacturing processes. In this technology, a piece of equipment known as an agglutinator is used to shred the waste, which is then processed in a thermokinetic blender to produce polymer pellets, and the synthetic textile waste is then used as raw material in thermoplastic injection-moulding processes, and the natural textile waste and textile waste of mixed composition are used as reinforcing fillers for extruded thermoplastic composites with a polyolefin-based matrix. These thermoplastic composites are also used as raw material for injection-moulding.

Description

PROCESSO DE OBTENÇÃO DE PELLETS A PARTIR DA RECICLAGEM RESÍDUOS TÊXTEIS SINTÉTICOS E RESÍDUOS TÊXTEIS NATURAIS PARA MOLDAGEM POR INJEÇÃO CAMPO DA APLICAÇÃO PROCESS OF OBTAINING PELLETS FROM RECYCLING SYNTHETIC TEXTILE WASTE AND NATURAL TEXTILE WASTE FOR INJECTION MOLDING FIELD OF APPLICATION
[01] A presente invenção se insere no campo de aplicação de têxteis, mais concretamente, no reaproveitamento de resíduos têxteis sintéticos e naturais, oriundos dos processos de corte e enfesto de tecidos, visando a formação de pellets para uso em moldagem por injeção para fabricação de peças técnicas e artefatos. [01] The present invention is part of the field of application of textiles, more specifically, the reuse of synthetic and natural textile waste, arising from the processes of cutting and layering fabrics, aiming at the formation of pellets for use in injection molding for manufacturing of technical parts and artifacts.
[02] ANTECEDENTES DA INVENÇÃO [02] BACKGROUND OF THE INVENTION
[03] Segundo dados da ONU Meio Ambiente, a indústria têxtil é um dos maiores motores econômicos do mundo, avaliado em cerca de 2,4 trilhões de dólares de riquezas gerados no ano e responsável por gerar mais de 75 milhões de empregos em todo mundo. No Brasil, a indústria têxtil brasileira é responsável pela produção de 1 ,8 milhões de toneladas de produtos têxteis, tornando o país o quarto maior produtor mundial de itens de vestuário em todo mundo. No Brasil, existem cerca de 30 mil empresas de confecções, onde estas empregam 75% dos trabalhadores do setor têxtil nacional. [03] According to data from the UN Environment, the textile industry is one of the largest economic engines in the world, valued at around 2.4 trillion dollars of wealth generated in the year and responsible for generating more than 75 million jobs worldwide . In Brazil, the Brazilian textile industry is responsible for the production of 1.8 million tons of textile products, making the country the fourth largest producer of clothing items worldwide. In Brazil, there are around 30,000 clothing companies, where they employ 75% of workers in the national textile sector.
[04] A indústria da moda também se destaca por ser uma das mais poluentes do mundo, sendo responsável pela emissão de 10% de gás carbônico na atmosfera. Os processos industriais dos setores da moda também são bastante intensivos em relação à utilização de recursos e consumo de energia. No setor, atualmente existe uma crescente conscientização dos impactos globais do atual sistema linear de produção, que resulta em um grande volume de resíduos gerados que acabam sendo descartados incorretamente. [05] No cenário atual, a consciência sobre a importância da sustentabilidade é cada vez maior, onde o reuso e a reciclagem de descartes torna-se uma tendência mundial como uma alternativa ao desperdício dos recursos naturais. No setor têxtil, durante a produção de uma peça de vestuário, o processo produtivo é dividido em várias etapas, desde o planejamento e construção do molde, seleção de aviamentos, corte, enfesto e costura, gerando desperdícios significativos de matéria-prima na forma de aparas, retalhos e peças rejeitadas. Estes resíduos não apresentam valor para o setor, pois se tornaram pequenos pedaços de tecidos nos quais são impossíveis de cortar de forma contínua em uma parte de peça de vestuário. [04] The fashion industry also stands out for being one of the most polluting in the world, being responsible for the emission of 10% of carbon dioxide in the atmosphere. Industrial processes in the fashion sectors are also quite intensive in terms of resource use and energy consumption. In the sector, there is currently a growing awareness of the global impacts of the current linear production system, which results in a large volume of waste generated that ends up being disposed of incorrectly. [05] In the current scenario, awareness of the importance of sustainability is increasing, where the reuse and recycling of discards becomes a worldwide trend as an alternative to the waste of natural resources. In the textile sector, during the production of a garment, the production process is divided into several stages, from planning and construction of the mold, selection of trims, cutting, spreading and sewing, generating significant waste of raw material in the form of trimmings, scraps and rejected parts. These residues are of no value to the sector, as they have become small pieces of fabric that are impossible to cut continuously in a garment part.
[06] De acordo com o Sindicato da Indústria Têxtil do Estado de São Paulo (SINDITÊXTIL/SP), em 2018, foram produzidas 140.000 toneladas de aparas de tecidos sintéticos, como o poliéster, poliamida e composições mistas. Deste volume produzido de rejeitos, estima-se que mais de 70% tenham sido destinados a aterros sanitários ou descarte ambientalmente incorreto. No Brasil, estima-se que diariamente são geradas cerca de 45 toneladas de resíduos têxteis. Além das aparas, sabe-se que mais de 150 milhões de peças de confecção não tem destinação definidas e acabam estocadas e posteriormente são destruídas. [06] According to the Textile Industry Union of the State of São Paulo (SINDITÊXTIL/SP), in 2018, 140,000 tons of synthetic fabric shavings were produced, such as polyester, polyamide and mixed compositions. Of this produced volume of waste, it is estimated that more than 70% have been destined for landfills or environmentally incorrect disposal. In Brazil, it is estimated that around 45 tons of textile waste are generated daily. In addition to shavings, it is known that more than 150 million garments have no defined destination and end up being stored and later destroyed.
[07] Dentre os resíduos têxteis sintéticos, destaca-se o poliéster, a poliamida e blendas destes materiais com poliuretano (elastano). No caso do poliéster, o material é um dos mais versáteis do mundo, com alto valor agregado, podendo ser reaproveitados para produção de novas matérias primas a partir da reciclagem dos resíduos de poliéster gerados nas fases pós-industrial e pós-consumo. [08] Diante desta problemática, existe uma tendência mundial em buscar novas alternativas de economia circular para a indústria têxtil. Deste modo, a presente invenção apresenta um desafio tecnológico para o reaproveitamento e reciclagem de resíduos têxteis sintéticos, visando a produção de novas matérias-primas de valor agregado para uso em moldagem por injeção, contribuindo com a redução do impacto ambiental e aumentando a sustentabilidade. [07] Among the synthetic textile waste, polyester, polyamide and blends of these materials with polyurethane (elastane) stand out. In the case of polyester, the material is one of the most versatile in the world, with high added value, and can be reused for the production of new raw materials from the recycling of polyester waste generated in the post-industrial and post-consumer phases. [08] Faced with this problem, there is a worldwide tendency to seek new circular economy alternatives for the textile industry. Thus, the present invention presents a technological challenge for the reuse and recycling of synthetic textile waste, aiming at the production of new raw materials with added value for use in injection molding, contributing to the reduction of the environmental impact and increasing sustainability.
[09] Os processos de reciclagem apresentam vantagens econômicas, permitindo a redução de custos de produção, onde os pellets produzidos a partir de resíduos têxteis podem substituir a matéria-prima virgem, levando à conservação dos recursos naturais e reduzindo o consumo energético, e, por consequência, reduzindo os impactos ambientais. [09] Recycling processes have economic advantages, allowing the reduction of production costs, where pellets produced from textile waste can replace virgin raw material, leading to the conservation of natural resources and reducing energy consumption, and, consequently, reducing environmental impacts.
[010] A presente invenção se refere ao campo da reciclagem mecânica de resíduos têxteis sintéticos e resíduos têxteis naturais e, em particular, o processo para obtenção de pellets a partir dos resíduos têxteis sintéticos e de compósitos termoplásticos reforçados com resíduos têxteis naturais. [010] The present invention relates to the field of mechanical recycling of synthetic textile waste and natural textile waste and, in particular, the process for obtaining pellets from synthetic textile waste and thermoplastic composites reinforced with natural textile waste.
[011] Os processos de reciclagem de fibras e resíduos têxteis são praticados por algumas grandes empresas. Grande parte destes processos envolve a reciclagem química dos resíduos e a reciclagem mecânica sem o processamento dos resíduos em estado fundido. [011] The fiber and textile waste recycling processes are practiced by some large companies. Most of these processes involve chemical recycling of waste and mechanical recycling without processing the waste in a molten state.
[012] E m pesquisa realizada junto ao estado da técnica identificamos alguns processos para reaproveitamento e reciclagem de resíduos têxteis para produção de produtos de maior valor agregado, onde podemos os seguintes documentos: [012] In research carried out with the state of the art, we identified some processes for the reuse and recycling of textile waste for the production of products with greater added value, where we can see the following documents:
[013] O documento JP2004042385 (Fuji Heavy. 2002) descreve um método para reciclagem de resíduos têxteis de poliéster. As aparas têxteis são previamente pulverizadas em menores pedaços para mistura em extrusora dupla rosca com poliéster virgem e/ou polipropileno para posterior granulação. Os pellets obtidos em extrusora dupla rosca pode ser reutilizados para produção de peças por injeção. [013] Document JP2004042385 (Fuji Heavy. 2002) describes a method for recycling polyester textile waste. the shavings Textiles are previously pulverized into smaller pieces for mixing in a twin-screw extruder with virgin polyester and/or polypropylene for subsequent granulation. The pellets obtained in a twin-screw extruder can be reused for the production of parts by injection.
[014] O documento CN105199138 (Elite Color. 2015) descreve um processo de reciclagem de tecidos de composição de poliéster e poliuretano, onde as aparas são inicialmente trituradas em pedaços menores, lavadas e secas à vácuo, e posteriormente misturadas com copolímero de estireno graftizado com anidrido maleico, antioxidantes e outros ingredientes em extrusora para produção de pellets. Esses pellets são transformados em artefatos por moldagem por injeção. [014] Document CN105199138 (Elite Color. 2015) describes a process for recycling polyester and polyurethane composition fabrics, where the shavings are initially crushed into smaller pieces, washed and dried under vacuum, and subsequently mixed with grafted styrene copolymer with maleic anhydride, antioxidants and other ingredients in an extruder to produce pellets. These pellets are transformed into artifacts by injection molding.
[015] O documento CN1 10093018 (Fujian Normal. 2019) descreve um método de reciclagem de aparas têxteis de poliéster para produção de blendas com poliolefinas. As blendas são preparadas por extrusão, originando pellets. São adicionados ao resíduo de poliéster têxtil, agente compatibilizante, modificador de impacto, antioxidantes e lubrificantes por extrusão. [015] Document CN1 10093018 (Fujian Normal. 2019) describes a method of recycling polyester textile scraps for the production of blends with polyolefins. The blends are prepared by extrusion, resulting in pellets. A compatibilizing agent, impact modifier, antioxidants and extrusion lubricants are added to the textile polyester residue.
[016] O documento WO2020252523 (Blocktexx. 2020) descreve um sistema e um processo para separação e reciclagem de tecidos mistos de poliéster e algodão. A primeira etapa é relacionada ao corte e trituração das aparas têxteis. O material triturado é adicionado em uma solução aquosa de ácido sulfúrico a quente, onde o material passa por diferentes processos químicos para que ocorra a separação do algodão e do poliéster. A fração de poliéster é extrusada, com a adição de extensores de cadeia e estabilizantes térmicos, e posteriormente peletizada. [017] O documento CN103304839 (Jiangsu. 2013) também descreve métodos de separação de algodão do poliéster em composições mistas de tecidos. O poliéster e o algodão são solubilizados em solventes apropriados. A solução de poliéster é evaporada, extrudada e granulada. [016] Document WO2020252523 (Blocktexx. 2020) describes a system and process for separating and recycling mixed fabrics of polyester and cotton. The first stage is related to the cutting and crushing of textile shavings. The crushed material is added to an aqueous solution of hot sulfuric acid, where the material undergoes different chemical processes to separate cotton and polyester. The polyester fraction is extruded, with the addition of chain extenders and thermal stabilizers, and subsequently pelletized. [017] Document CN103304839 (Jiangsu. 2013) also describes methods of separating cotton from polyester in mixed fabric compositions. Polyester and cotton are solubilized in appropriate solvents. The polyester solution is evaporated, extruded and granulated.
[018] O documento CN1 10272608 (Plastic Union. 2019) descreve um método para reciclagem química de poliéster têxtil. O poliéster é despolimerizado, para obtenção de monômeros e novamente polimerizado em poliéster, e depois é misturado com ABS, plastificantes, modificadores de impacto em extrusora dupla rosca para obtenção de pellets da blenda PET/ABS. A blenda de PET/ABS e demais componentes pode ser utilizado para produção de artefatos por moldagem por injeção. [018] Document CN1 10272608 (Plastic Union. 2019) describes a method for chemically recycling textile polyester. The polyester is depolymerized to obtain monomers and again polymerized into polyester, and then mixed with ABS, plasticizers and impact modifiers in a twin-screw extruder to obtain pellets from the PET/ABS blend. The PET/ABS blend and other components can be used to produce injection molding artifacts.
[019] O documento CN1 10256822 (Plastic Union. 2019) descreve um método para reciclagem química de poliéster têxtil. Assim como no documento CN1 10272608A, o poliéster é despolimerizado para obtenção de monômeros e polimerizado em poliéster para produção de blendas com Poliamida 6 e agentes compatibilizantes. A blenda PA6/PET com agentes compatibilizantes é utilizado para produção de artefatos por moldagem por injeção. [019] Document CN1 10256822 (Plastic Union. 2019) describes a method for chemical recycling of textile polyester. As in document CN1 10272608A, polyester is depolymerized to obtain monomers and polymerized into polyester to produce blends with Polyamide 6 and compatibilizing agents. The PA6/PET blend with compatibilizing agents is used for the production of injection molding artifacts.
[020] O documento CN1 10256821 (Plastic Union. 2019) é similar aos documentos CN1 10272608 e CN1 10272608, tendo como diferença o uso de Poliamida 6.6 como matéria-prima base para as blendas de PA66/PET e agentes compatibilizantes. [020] Document CN1 10256821 (Plastic Union. 2019) is similar to documents CN1 10272608 and CN1 10272608, with the difference being the use of Polyamide 6.6 as base raw material for PA66/PET blends and compatibilizing agents.
[021] O documento CN1 10092925 (Plastic Union. 2019) descreve um método para reciclagem química de poliéster têxtil. O poliéster é despolimerizado, para obtenção de monômeros e novamente polimerizado em poliéster, e depois é misturado com Polipropileno, negro de fumo e agentes compatibilizantes para preparação de blendas de PP/PET para uso em moldagem por injeção, extrusão de filmes e como concentrado de cor (masterbatch) para moldagem por injeção. [021] Document CN1 10092925 (Plastic Union. 2019) describes a method for chemically recycling textile polyester. Polyester is depolymerized to obtain monomers and again polymerized into polyester, and then mixed with Polypropylene, carbon black and compatibilizing agents for preparing PP/PET blends for use in injection molding, film extrusion and as a color concentrate (masterbatch) for injection molding.
[022] Estes documentos citados no estado da técnica apresentam processos de reaproveitamento e reciclagem resíduos têxteis, sendo que cada documento descreve um processo próprio. Porém, nenhum destes documentos descreve e reivindica um processo de reciclagem mecânica dos resíduos têxteis sintéticos no estado fundido, sem a necessidade da realização de nenhum processo ou tratamento químico. [022] These documents cited in the state of the art present processes for the reuse and recycling of textile waste, with each document describing its own process. However, none of these documents describes and claims a mechanical recycling process for synthetic textile waste in the molten state, without the need to carry out any process or chemical treatment.
[023] SUMÁRIO E OBJETIVOS DA INVENÇÃO [023] SUMMARY AND OBJECTIVES OF THE INVENTION
[024] É um objetivo da presente invenção descrever um processo para obtenção de pellets de poliéster e poliéster com poliuretano (elastano) a partir do processo de reciclagem mecânica dos resíduos têxteis para uso em moldagem por injeção e o processo de obtenção de pellets de compósitos termoplásticos reforçados com resíduos têxteis de algodão e resíduos têxteis de composição mista (poliéster + poliuretano + algodão). [024] It is an objective of the present invention to describe a process for obtaining pellets of polyester and polyester with polyurethane (elastane) from the mechanical recycling process of textile waste for use in injection molding and the process for obtaining composite pellets thermoplastics reinforced with cotton textile waste and mixed composition textile waste (polyester + polyurethane + cotton).
[025] É um objetivo da presente invenção descrever a etapa de processamento a seco dos resíduos têxteis sintéticos e naturais, realizado em um moinho aglutinador de filmes plásticos e/ou aglomerador de filmes plásticos e/ou densificador. [025] It is an objective of the present invention to describe the dry processing step of synthetic and natural textile waste, carried out in a plastic film binder mill and/or plastic film agglomerator and/or densifier.
[026] É um objetivo da presente invenção descrever a etapa de preparo de pellets de resíduos têxteis sintéticos. [026] It is an objective of the present invention to describe the preparation step of synthetic textile waste pellets.
[027] É um objetivo da presente invenção descrever a etapa de preparo de pellets de compósitos termoplásticos reforçados com tecido de algodão e tecido misto. [028] É um objetivo da presente invenção descrever a etapa de injeção de corpos de prova para caracterização e injeção de protótipos funcionais. [027] It is an objective of the present invention to describe the preparation step of thermoplastic composite pellets reinforced with cotton fabric and mixed fabric. [028] It is an objective of the present invention to describe the injection step of test specimens for characterization and injection of functional prototypes.
[029] BREVE DESCRIÇÃO DAS FIGURAS [029] BRIEF DESCRIPTION OF THE FIGURES
[030] A Figura 1 ilustra as aparas têxteis de resíduos têxteis sintéticos de poliéster, após serem cortadas na cortadeira para uniformizar o tamanho. [030] Figure 1 illustrates the textile trimmings of polyester synthetic textile waste, after being cut in the cutter to standardize the size.
[031] A Figura 2 apresenta os resíduos têxteis sintéticos de poliéster após o processo de desfibragem em aglutinador de termoplásticos. [031] Figure 2 shows the synthetic polyester textile waste after the defibration process in a thermoplastic binder.
[032] A Figura 3 mostra os resíduos têxteis naturais de algodão após o processo de desfibragem em aglutinador de termoplásticos. [032] Figure 3 shows natural cotton textile waste after the defibration process in a thermoplastic binder.
[033] A Figura 4 mostra os masterbatches de resíduos têxteis sintéticos de poliéster após processamento em câmara de misturas. [033] Figure 4 shows the masterbatches of synthetic polyester textile waste after processing in a mixing chamber.
[034] A Figura 5 apresenta a câmara de misturas do misturador termocinético utilizado. [034] Figure 5 shows the mixing chamber of the thermokinetic mixer used.
[035] A Figura 6 apresenta os masterbatches de resíduos têxteis sintéticos de poliéster após processamento em misturador termocinético. [035] Figure 6 shows the masterbatches of synthetic polyester textile waste after processing in a thermokinetic mixer.
[036] A Figura 7 ilustra os flakes de resíduos têxteis sintéticos de poliéster obtidos após a granulação das amostras em moinho de facas. [037] A Figura 8 apresenta os masterbatches de polietileno de alta densidade e resíduos têxteis naturais preparados em misturador termocinético. [036] Figure 7 illustrates the flakes of synthetic polyester textile waste obtained after granulating the samples in a knife mill. [037] Figure 8 shows the high-density polyethylene masterbatches and natural textile waste prepared in a thermokinetic mixer.
[038] A Figura 9 apresenta os masterbacthes de polipropileno e resíduos têxteis naturais preparados em misturador termocinético. [038] Figure 9 shows the polypropylene masterbatch and natural textile waste prepared in a thermokinetic mixer.
[039] A Figura 10 apresenta o perfil de rosca utilizado para extrusão dos compósitos termoplásticos de poliolefinas reforçados com resíduos têxteis naturais e resíduos têxteis de composição mista. [040] A Figura 1 1 mostra os pellets de compósitos termoplásticos de polipropileno e resíduos têxteis naturais, preparados por extrusão dupla rosca, na razão 70/30 em massa. [039] Figure 10 shows the screw profile used for extrusion of thermoplastic composites of polyolefins reinforced with natural textile waste and textile waste of mixed composition. [040] Figure 1 1 shows pellets of thermoplastic composites of polypropylene and natural textile waste, prepared by twin-screw extrusion, in the 70/30 ratio by mass.
[041] A Figura 12 mostra os pellets de compósitos termoplásticos de polietileno de alta densidade e resíduos têxteis naturais, preparados por extrusão dupla rosca, na razão 90/10 em massa. [041] Figure 12 shows the pellets of high density polyethylene thermoplastic composites and natural textile waste, prepared by twin-screw extrusion, in the ratio 90/10 by mass.
[042] A Figura 13 apresenta os pellets de compósitos termoplásticos de polipropileno e resíduos têxteis de composição mista, preparados por extrusão dupla rosca, na razão 70/30 em massa. [042] Figure 13 shows the pellets of polypropylene thermoplastic composites and textile waste of mixed composition, prepared by twin-screw extrusion, in the ratio 70/30 by mass.
[043] A Figura 14 mostra os pellets de compósitos termoplásticos de polietileno de alta densidade e resíduos têxteis de composição mista, preparados por extrusão dupla rosca, na razão 90/10 em massa. [043] Figure 14 shows the pellets of thermoplastic composites of high density polyethylene and textile waste of mixed composition, prepared by twin screw extrusion, in the ratio 90/10 by mass.
[044] A Figura 15 ilustra os pellets de compósitos termoplásticos de polipropileno e resíduos têxteis naturais, com a adição de agente compatibilizante, preparados em extrusora dupla rosca, na razão 87/10/3. [044] Figure 15 illustrates the thermoplastic composite pellets of polypropylene and natural textile waste, with the addition of a compatibilizing agent, prepared in a twin-screw extruder, in the ratio 87/10/3.
[045] A Figura 16 apresenta os pellets de compósitos termoplásticos de polietileno de alta densidade e resíduos têxteis naturais, com a adição de agente compatibilizante, preparados em extrusora dupla rosca, na razão 87/10/3. [045] Figure 16 shows the pellets of thermoplastic composites of high density polyethylene and natural textile waste, with the addition of a compatibilizing agent, prepared in a twin-screw extruder, in the ratio 87/10/3.
[046] A Figura 17 mostra os pellets de compósitos termoplásticos de polipropileno e resíduos têxteis de composição mista, com a adição de agente compatibilizante, preparados em extrusora dupla rosca, na razão 87/10/3. [046] Figure 17 shows pellets of polypropylene thermoplastic composites and textile waste of mixed composition, with the addition of a compatibilizing agent, prepared in a twin-screw extruder, in the ratio 87/10/3.
[047] A Figura 18 apresenta os pellets de compósitos termoplásticos de polietileno de alta densidade e resíduos têxteis de composição mista, com a adição de agente compatibilizante, preparados em extrusora dupla rosca, na razão 87/10/3. [048] A Figura 19 ilustra os protótipos preparados por moldagem por injeção para os compósitos termoplásticos de polietileno de alta densidade reforçados com resíduos têxteis naturais, na razão 90/10. [047] Figure 18 shows the pellets of thermoplastic composites of high density polyethylene and textile waste of mixed composition, with the addition of a compatibilizing agent, prepared in a twin-screw extruder, in the ratio 87/10/3. [048] Figure 19 illustrates the prototypes prepared by injection molding for thermoplastic composites of high density polyethylene reinforced with natural textile waste, in the ratio 90/10.
[049] A Figura 20 mostra os protótipos preparados por moldagem por injeção para os compósitos termoplásticos de polipropileno reforçados com resíduos têxteis naturais, na razão 90/10. [049] Figure 20 shows the prototypes prepared by injection molding for thermoplastic composites of polypropylene reinforced with natural textile waste, in the ratio 90/10.
[050] A Figura 21 apresenta os protótipos preparados por moldagem por injeção para os compósitos termoplásticos de polietileno de alta densidade reforçados com resíduos têxteis de composição mista, na razão 90/10. [050] Figure 21 shows the prototypes prepared by injection molding for high-density polyethylene thermoplastic composites reinforced with textile waste of mixed composition, in the ratio 90/10.
[051] A Figura 22 apresenta os protótipos preparados por moldagem por injeção para os compósitos termoplásticos de polipropileno reforçados com resíduos têxteis de composição mista, na razão 90/10. [052] A Figura 23 mostra os protótipos preparados por moldagem por injeção para os resíduos têxteis sintéticos de poliéster. [051] Figure 22 shows the prototypes prepared by injection molding for thermoplastic composites of polypropylene reinforced with textile waste of mixed composition, in the ratio 90/10. [052] Figure 23 shows the prototypes prepared by injection molding for synthetic polyester textile waste.
[053] A Figura 24 ilustra os protótipos preparados por moldagem por injeção para os resíduos têxteis sintéticos de poliéster, com adição de modificadores de impacto, na razão 90/10. [053] Figure 24 illustrates the prototypes prepared by injection molding for synthetic polyester textile waste, with the addition of impact modifiers, in the ratio 90/10.
[054] A Figura 25 apresenta os protótipos preparados por moldagem por injeção para os resíduos têxteis sintéticos de poliéster + poliuretano, com adição de modificadores de impacto, na razão 70/30. [054] Figure 25 shows the prototypes prepared by injection molding for synthetic textile waste of polyester + polyurethane, with the addition of impact modifiers, in the ratio 70/30.
[055] DESCRIÇÃO DETALHADA DA INVENÇÃO [055] DETAILED DESCRIPTION OF THE INVENTION
[056] O processo de obtenção de pellets a partir da reciclagem resíduos têxteis sintéticos e resíduos têxteis naturais para moldagem por injeção, objeto da presente invenção, descreve detalhadamente todos os processos para obtenção de pellets a partir de resíduos têxteis sintéticos de poliéster e/ou poliéster com poliuretano e a obtenção de pellets de compósitos termoplásticos de poliolefinas reforçados com tecido de algodão ou de composição mista, são mostradas imagens e tabelas e uma discussão detalhada referentes a modalidades preferidas com o intuito que a presente descrição possa ser considerada como uma exemplificação dos princípios da invenção, não limitando a presente invenção ao que foi ilustrado e descrito neste texto. As etapas do processo são detalhadas como na sequência: [056] The process of obtaining pellets from recycling synthetic textile waste and natural textile waste for injection molding, object of the present invention, describes in detail all the processes for obtaining pellets from synthetic textile waste of polyester and/or polyester with polyurethane and obtaining pellets of thermoplastic composites of polyolefins reinforced with cotton fabric or of mixed composition, images and tables are shown and a detailed discussion referring to preferred embodiments with the intention that the present description can be considered as an exemplification of the principles of the invention, not limiting the present invention to what has been illustrated and described in this text. The process steps are detailed as follows:
[057] Tratamento inicial dos resíduos têxteis sintéticos e resíduos têxteis naturais e processamento a seco [057] Initial treatment of synthetic textile waste and natural textile waste and dry processing
[058] A primeira etapa do tratamento inicial dos resíduos têxteis refere- se a uma etapa de triagem, onde os resíduos são separados por composição. Após a triagem, o material é adicionado em uma cortadeira, onde as aparas têxteis são cortadas em tamanhos entre 1 e 30cm2, tal como demonstrado na Figura 1 . [058] The first stage of the initial treatment of textile waste refers to a sorting stage, where waste is separated by composition. After sorting, the material is added to a cutter, where the textile trimmings are cut into sizes between 1 and 30cm 2 , as shown in Figure 1.
[059] As aparas cortadas são adicionadas em um moinho aglutinador, onde o material é desfibrado até que esteja completamente descaracterizado, se transformando em uma fibra desagregada (Figuras 2 e 3). O moinho aglutinador é tipicamente utilizado para reciclagem de filmes plásticos. O aglutinador também é conhecido como moinho aglomerador, sendo composto de maneira genérica de um recipiente de aço, com navalhas fixas posicionadas nas paredes do moinho e navalhas rotativas acopladas a um motor elétrico. As navalhas fixas e rotativas cortam e atritam as aparas têxteis contra as paredes do equipamento, elevando a temperatura do processo até fazer com que as aparas sejam desfibradas. [059] The cut chips are added to a binder mill, where the material is shredded until it is completely uncharacterized, turning into a disaggregated fiber (Figures 2 and 3). The binder mill is typically used for plastic film recycling. The agglutinator is also known as an agglomerator mill, being generically composed of a steel container, with fixed blades positioned on the mill walls and rotating blades coupled to an electric motor. The fixed and rotating knives cut and rub the textile shavings against the equipment walls, raising the process temperature until the shavings are shredded.
[060] O tempo de desfibragem em moinho aglutinador pode ser controlado através de um amperímetro presente no motor do moinho, onde o amperímetro mostra valores baixos e constantes quando as aparas têxteis são desfibradas. Para a desfibragem dos tecidos, utilizou-se um moinho aglutinador de termoplásticos Premiata, modelo PRM 30A. O tempo de aglutinação é apresentado na [060] The defibration time in a binder mill can be controlled through an ammeter present in the mill motor, where the ammeter shows low and constant values when the textile shavings are defibrated. For fabric defibration, A Premiata thermoplastic binder mill, model PRM 30A, was used. The agglutination time is shown in the
[061] Tabela 1. [061] Table 1.
Tabela 1 - Tempo de desfibragem dos resíduos têxteis em moinho aglutinador
Figure imgf000013_0001
Table 1 - Defibration time of textile waste in agglutinating mill
Figure imgf000013_0001
Secagem e desumidicacão dos materiais Drying and dehumidification of materials
[062] Após a desfibragem dos tecidos em moinho aglutinador, para todos os processos conseguintes, os resíduos têxteis sintéticos e naturais foram secos em uma estufa com circulação de ar em tempos de 1 h a 4h, em temperaturas de 70°C a 1 10°C, de modo a remover a umidade presente nos materiais. [062] After defibration of the fabrics in a binder mill, for all subsequent processes, the synthetic and natural textile waste was dried in an oven with air circulation in times of 1 h to 4 h, at temperatures from 70°C to 110° C, in order to remove the moisture present in the materials.
Preparação de pellets para moldagem por injeção a partir de resíduos têxteis sintéticos Preparation of pellets for injection molding from synthetic textile waste
Processamento dos resíduos têxteis sintéticos em câmara de misturas [063] Em um reômetro de torque Haake, acoplado a uma câmara de misturas Rheomex 3000p, utilizando rotores do tipo roller foram preparadas composições de resíduos de poliéster e/ou poliéster + poliuretano, e suas respectivas blendas com PBT virgem, nas proporções em massa de 100/0 a 25/75 de resíduo têxtil sintético e PBT virgem. Normalmente, a câmara de misturas é utilizada para preparar misturas e compostos em escala piloto para termoplásticos, elastômeros e compósitos. O processamento em câmara de misturas foi realizado em temperaturas a partir de 150°C até 300°C, com velocidade dos rotores entre 60 e 150rpm. A ordem de adição em câmara de mistura é 100% do polímero virgem e o resíduo têxtil é adicionado em até 3 etapas, controlando o torque do equipamento para garantia da eficácia do processo de mistura. O fator de enchimento da câmara de misturas foi de 70%. O resultado desse processamento é apresentado na Figura 4. Processing of synthetic textile waste in a mixing chamber [063] In a Haake torque rheometer, coupled to a Rheomex 3000p mixing chamber, using roller-type rotors, compositions of polyester and/or polyester + polyurethane waste were prepared, and their respective blends with virgin PBT, in mass proportions from 100/0 to 25/75 of synthetic textile waste and virgin PBT. Typically, the mixing chamber is used to prepare pilot scale blends and compounds for thermoplastics, elastomers and composites. Processing in a mixing chamber was carried out at temperatures from 150°C to 300°C, with rotor speeds between 60 and 150rpm. The order of addition in the mixing chamber is 100% of the virgin polymer and the textile residue is added in up to 3 stages, controlling the torque of the equipment to guarantee the effectiveness of the mixing process. The mixing chamber filling factor was 70%. The result of this processing is shown in Figure 4.
Processamento dos resíduos têxteis sintéticos em misturador termocinético Processing of synthetic textile waste in thermokinetic mixer
[064] Em um misturador termocinético modelo MH-600 do fabricante MH Equipamentos, foram preparadas composições de resíduos de poliéster e/ou poliéster + poliuretano, e suas respectivas blendas com PBT virgem, nas proporções em massa de 100/0 a 25/75 de resíduo têxtil sintético e PBT virgem. O misturador termocinético (Figura 5) também é conhecido por misturador Drais, Dryser ou K-mixer. Sua principal aplicação é a produção de concentrados de pigmentos (masterbatches, compósitos, blendas, compostos de PVC e WPG (wood plastic composite). [064] In a thermokinetic mixer model MH-600 from the manufacturer MH Equipamentos, waste compositions of polyester and/or polyester + polyurethane were prepared, and their respective blends with virgin PBT, in the mass proportions of 100/0 to 25/75 of synthetic textile waste and virgin PBT. The thermokinetic mixer (Figure 5) is also known as a Drais mixer, Dryser mixer or K-mixer. Its main application is the production of pigment concentrates (masterbatches, composites, blends, PVC compounds and WPG (wood plastic composite).
[065] O misturador termocinético consiste em um misturador horizontal, sem fonte de aquecimento, onde a fusão do material é realizada através do cisalhamento da amostra com o rotor e a câmara de misturas do equipamento. Os parâmetros de processamento são apresentados na Erro! Fonte de referência não encontrada.. O fator de enchimento utilizado para a câmara do misturador termocinético foi de 50 a 70%. O resultado deste processamento é apresentado na Figura 6. [066] Tabela 2 - Parâmetros de processamento dos resíduos têxteis de poliéster e poliéster + elastano e de suas blendas com PBT em misturador termocinético. [065] The thermokinetic mixer consists of a horizontal mixer, without a heating source, where the melting of the material is carried out by shearing the sample with the rotor and the mixing chamber of the equipment. Processing parameters are shown in Error! Reference source not found. The filling factor used for the thermokinetic mixer chamber was 50 to 70%. The result of this processing is shown in Figure 6. [066] Table 2 - Processing parameters of polyester and polyester + elastane textile waste and their blends with PBT in a thermokinetic mixer.
Parâmetros de processamento
Figure imgf000015_0001
Processamento dos resíduos têxteis sintéticos com modificadores de impacto em misturador termocinético processing parameters
Figure imgf000015_0001
Processing of synthetic textile waste with impact modifiers in a thermokinetic mixer
[067] E m um misturador termocinético modelo MH-600 do fabricante MH Equipamentos, foram preparadas composições de resíduos de poliéster e/ou poliéster + poliuretano, com adição de modificadores de impacto do tipo “core-shell”, onde seu núcleo (core) é um poliacrilato de butila reticulado e sua casca (shell) é um polimetacrilato de metila (PMMA). Para os resíduos têxteis de poliéster e de poliéster + poliuretano foram adicionados um modificador de impacto de base acrílico. Os parâmetros de processamento são apresentados na[067] In a thermokinetic mixer model MH-600 from the manufacturer MH Equipamentos, waste compositions of polyester and/or polyester + polyurethane were prepared, with the addition of impact modifiers of the "core-shell" type, where its core (core ) is a cross-linked butyl polyacrylate and its shell is polymethyl methacrylate (PMMA). For polyester and polyester + polyurethane textile waste, an acrylic-based impact modifier was added. The processing parameters are shown in the
[068] Tabela 3. O fator de enchimento utilizado para a câmara do misturador termocinético foi de 50 a 70%. [068] Table 3. The filling factor used for the thermokinetic mixer chamber was 50 to 70%.
[069] Tabela 3 - Parâmetros de processamento dos resíduos têxteis de poliéster e poliéster + elastano com modificadores de impacto base acrílico em misturador termocinético. [069] Table 3 - Processing parameters of polyester and polyester + elastane textile waste with acrylic-based impact modifiers in a thermokinetic mixer.
Parâmetros de processamento
Figure imgf000016_0001
Figure imgf000017_0001
processing parameters
Figure imgf000016_0001
Figure imgf000017_0001
Granulação das amostras preparadas em misturador termocinético ou em câmara de misturas Granulation of samples prepared in a thermokinetic mixer or in a mixing chamber
[070] As composições obtidas em misturador termocinético e/ou câmara de misturas foram granuladas em um moinho de facas SEIBT MGHS 200LR, com abertura de peneira de 5,6 MESH e velocidade entre 200 e 400rpm para produção de pellets em uma taxa de produção entre 10 e 50kg/h. Os flakes obtidos são apresentados na Figura 7.[070] The compositions obtained in a thermokinetic mixer and/or mixing chamber were granulated in a SEIBT MGHS 200LR knife mill, with a sieve opening of 5.6 MESH and a speed between 200 and 400rpm to produce pellets at a production rate between 10 and 50 kg/h. The flakes obtained are shown in Figure 7.
Preparação de pellets para moldagem por injeção a partir de compósitos termoplásticos de poliolefinas reforçados com resíduos têxteis naturais e/ou reforçados com resíduos têxteis de composição mista Preparation of pellets for injection molding from thermoplastic polyolefin composites reinforced with natural textile waste and/or reinforced with textile waste of mixed composition
Preparação de masterbatches de compósitos termoplásticos de poliolefinas reforçados com resíduos têxteis naturais e/ou reforçados com resíduos têxteis de composição mista Preparation of masterbatches of thermoplastic composites of polyolefins reinforced with natural textile waste and/or reinforced with textile waste of mixed composition
[071] Os masterbatches de compósitos termoplásticos de poliolefinas (polipropileno ou polietileno de alta densidade) reforçados com resíduos têxteis naturais (algodão) e/ou reforçados com resíduos têxteis de composição mista (poliéster + poliuretano + algodão) foram preparados a partir de amostras de tecidos previamente desfibrados em um moinho aglutinador, em um misturador termocinético, modelo MH- 600, do fabricante MH Equipamentos. [071] Masterbatches of thermoplastic composites of polyolefins (polypropylene or high density polyethylene) reinforced with natural textile waste (cotton) and/or reinforced with waste textiles of mixed composition (polyester + polyurethane + cotton) were prepared from samples of fabrics previously defibered in a binder mill, in a thermokinetic mixer, model MH-600, from the manufacturer MH Equipamentos.
[072] As amostras de resíduos têxteis desagregados foram secas e desumidificadas nas condições descritas anteriormente. Os masterbatches foram preparados em uma razão 70/30 (poliolefinas / resíduos têxteis). O fator de enchimento utilizado na câmara do misturador ficou entre 50 e 70% e as condições de processamento são descritas na Tabela 4. As amostras foram granuladas conforme condições informadas anteriormente. Os masterbacthes são apresentados nas Figuras 8 e 9. [072] The disaggregated textile waste samples were dried and dehumidified under the conditions described above. Masterbatches were prepared in a 70/30 ratio (polyolefins / textile waste). The filling factor used in the mixer chamber was between 50 and 70% and the processing conditions are described in Table 4. The samples were granulated according to previously informed conditions. Masterbaches are shown in Figures 8 and 9.
[073] Tabela 4 - Parâmetros de processamento dos masterbatches de compósitos termoplásticos de poliolefinas reforçados com resíduos têxteis naturais e/ou de composição mista preparados em misturador termocinético. [073] Table 4 - Processing parameters of masterbatches of thermoplastic composites of polyolefins reinforced with natural textile waste and/or mixed composition prepared in thermokinetic mixer.
Parâmetros de processamento
Figure imgf000018_0001
Moagem dos masterbatches de compósitos termoplásticos de poliolefinas reforçados com resíduos têxteis sintéticos e/ou reforçados com resíduos têxteis de composição mista processing parameters
Figure imgf000018_0001
Grinding of masterbatches of thermoplastic polyolefin composites reinforced with synthetic textile waste and/or reinforced with textile waste of mixed composition
[074] Os masterbatches de compósitos termoplásticos de poliolefinas (polipropileno ou polietileno de alta densidade) reforçados com resíduos têxteis naturais (algodão) e/ou reforçados com resíduos têxteis de composição mista (poliéster + poliuretano + algodão) foram granulados em um moinho de facas MGHS 200LR, do fabricante SEIBT, com abertura de peneira de 5,6 MESH e velocidade entre 200 e 400rpm para produção de flakes em uma taxa de produção entre 10 e 50kg/h. [074] The masterbatches of thermoplastic composites of polyolefins (polypropylene or high density polyethylene) reinforced with natural textile waste (cotton) and/or reinforced with textile waste of mixed composition (polyester + polyurethane + cotton) were granulated in a knife mill MGHS 200LR, from the manufacturer SEIBT, with a sieve opening of 5.6 MESH and a speed between 200 and 400rpm for the production of flakes at a production rate between 10 and 50kg/h.
Extrusão de compósitos termoplásticos de poliolefinas reforçados com resíduos têxteis sintéticos e/ou reforçados com resíduos têxteis de composição mista Extrusion of thermoplastic polyolefin composites reinforced with synthetic textile waste and/or reinforced with textile waste of mixed composition
[075] Os compósitos termoplásticos de poliolefinas (polipropileno e polietileno de alta densidade) reforçados com resíduos têxteis sintéticos e/ou reforçados com resíduos têxteis de composição mista (poliéster + poliuretano + algodão) foram preparadas em razões entre 90/10 e 70/30 em uma extrusora dupla rosca Brabender Lab-Station Plasti-Corder TSE 20/40. [075] Thermoplastic composites of polyolefins (polypropylene and high-density polyethylene) reinforced with synthetic textile waste and/or reinforced with textile waste of mixed composition (polyester + polyurethane + cotton) were prepared in ratios between 90/10 and 70/30 in a Brabender Lab-Station Plasti-Corder TSE 20/40 twin screw extruder.
[076] O perfil de rosca utilizado é apresentado na Figura 10. A dosagem dos componentes do compósito termoplástico foi realizada utilizando dois dosadores gravimétricos. Os masterbatches foram secos de desumidificados nas mesmas condições descritas anteriormente. [076] The thread profile used is shown in Figure 10. The dosing of the thermoplastic composite components was performed using two gravimetric dosers. The masterbatches were dried and dehumidified under the same conditions described above.
[077] A velocidade de rosca utilizada para extrusão dos compósitos termoplásticos foi entre 10 e 400rpm. As temperaturas de processo são apresentadas na Tabela 5. As amostras foram granuladas em um pelletizador, gerando pellets com tamanho médio de partícula entre 1 e 3mm. Os pellets de compósitos termoplásticos obtidos por extrusão são apresentados nas Figuras 1 1 a 14. [077] The screw speed used for extrusion of thermoplastic composites was between 10 and 400rpm. The process temperatures are presented in Table 5. The samples were granulated in a pelletizer, generating pellets with an average particle size between 1 and 3mm. The thermoplastic composite pellets obtained by extrusion are shown in Figures 1 1 to 14.
[078] Tabela 5 - Perfil de temperatura utilizado na extrusora dupla rosca para preparação dos compósitos termoplásticos. [078] Table 5 - Temperature profile used in the twin-screw extruder for the preparation of thermoplastic composites.
Temperaturas de Extrusão
Figure imgf000020_0001
Extrusion Temperatures
Figure imgf000020_0001
Extrusão de compósitos termoplásticos de poliolefinas reforçados com resíduos têxteis sintéticos e/ou reforçados com resíduos têxteis de composição mista e agente compatibilizantes. Extrusion of thermoplastic polyolefin composites reinforced with synthetic textile waste and/or reinforced with textile waste of mixed composition and compatibilizing agent.
[079] Os compósitos termoplásticos de poliolefinas (polipropileno e polietileno de alta densidade) reforçados com resíduos têxteis sintéticos e/ou reforçados com resíduos têxteis de composição mista (poliéster + poliuretano + algodão) e com a adição de agentes compatibilizantes foram preparadas em razões entre 90/10 e 70/30 em uma extrusora dupla rosca Brabender Lab-Station Plasti-Corder TSE 20/40. [079] Thermoplastic composites of polyolefins (polypropylene and high density polyethylene) reinforced with synthetic textile waste and/or reinforced with textile waste of mixed composition (polyester + polyurethane + cotton) and with the addition of compatibilizing agents were prepared in ratios between 90/10 and 70/30 in a Brabender Lab-Station Plasti-Corder TSE 20/40 twin screw extruder.
[080] A fração de agente compatibilizante adicionada nas formulações de compósitos termoplásticos foram descontadas da fração de poliolefina. Foi utilizado agentes compatibilizantes de base poliolefinas graftizados com anidrido maleico. Os masterbatches foram secos e desumidificados nas condições já descritas neste texto antes do processo de extrusão. [080] The fraction of compatibilizing agent added in the formulations of thermoplastic composites were deducted from the polyolefin fraction. Compatibilizing agents based on polyolefins grafted with maleic anhydride were used. The masterbatches were dried and dehumidified under the conditions already described in this text before the extrusion process.
[081] O perfil de rosca utilizado é apresentado na Figura 10. A dosagem dos componentes do compósito termoplástico foi realizada utilizando dois dosadores gravimétricos. A velocidade de rosca utilizada para extrusão dos compósitos termoplásticos foi entre 10 e 400rpm. As amostras foram granuladas em um pelletizador, gerando pellets com tamanho médio de partícula entre 1 e 3mm. As temperaturas de processo são apresentadas na Tabela 6. Os pellets de compósitos termoplásticos com adição de agente compatibilizante processados por extrusão são apresentados nas Figuras 15 a 18. [081] The thread profile used is shown in Figure 10. The dosing of the thermoplastic composite components was performed using two gravimetric dosers. The screw speed used for the extrusion of thermoplastic composites was between 10 and 400rpm. To the samples were granulated in a pelletizer, generating pellets with an average particle size between 1 and 3 mm. The process temperatures are shown in Table 6. Pellets of thermoplastic composites with the addition of a compatibilizing agent processed by extrusion are shown in Figures 15 to 18.
[082] Tabela 6 - Perfil de temperatura utilizado na extrusora dupla rosca na preparação dos compósitos termoplásticos [082] Table 6 - Temperature profile used in the twin screw extruder in the preparation of thermoplastic composites
Temperaturas de Extrusão
Figure imgf000021_0001
Extrusion Temperatures
Figure imgf000021_0001
Injeção de corpos de prova para caracterização e injeção de protótipos Injection of specimens for characterization and prototype injection
[083] Os pellets obtidos a partir das composições de resíduos têxteis sintéticos, com e sem a adição de modificadores de impacto e dos compósitos termoplásticos de poliolefinas reforçados com resíduos têxteis naturais e resíduos têxteis de composição mista foram moldados por injeção para obtenção de corpos de prova para a realização de ensaios de resistência ao impacto Izod (ASTM D256) e de tração (ASTM D638, tipo V) em uma injetora Babyplast 6/12. Os pellets foram desumidificados antes do processo de moldagem por injeção em um desumidificador Moretto XDO TX durante 4h a 70°C. O perfil de temperatura utilizado para injeção dos corpos de prova é apresentado na Tabela 7. [083] The pellets obtained from the compositions of synthetic textile waste, with and without the addition of impact modifiers and thermoplastic composites of polyolefins reinforced with natural textile waste and textile waste of mixed composition, were injection molded to obtain bodies of proof for carrying out Izod (ASTM D256) and tensile (ASTM D638, type V) impact strength tests on a Babyplast 6/12 injection molding machine. The pellets were dehumidified before the injection molding process in a Moretto XDO TX dehumidifier for 4h at 70°C. The temperature profile used for injection of the test specimens is shown in Table 7.
[084] Tabela 7 - Perfil de temperatura utilizado no processo de moldagem por injeção para as diferentes composições desenvolvidas. Injeção de corpos de prova [084] Table 7 - Temperature profile used in the injection molding process for the different compositions developed. Injection of specimens
Temperaturas de Processo (°C)
Figure imgf000022_0001
Process Temperatures (°C)
Figure imgf000022_0001
[085] Os demais parâmetros utilizados na injeção de corpos de prova são apresentados na Tabela 8. Demais condições de processamento utilizadas foram velocidade de plastificação de 50% e tempo de resfriamento de 20s. Tabela 8 - Parâmetros de moldagem de corpos de prova por injeção
Figure imgf000023_0001
[085] The other parameters used in the injection of specimens are shown in Table 8. Other processing conditions used were plastification speed of 50% and cooling time of 20s. Table 8 - Injection molding parameters for specimens
Figure imgf000023_0001
[086] Os protótipos funcionais foram preparados por moldagem por injeção utilizando uma injetora Sandretto Lógica 370/70, em uma geometria conforme mostra as Figuras 19 a 25. Foram preparados protótipos de todas as composições desenvolvidas. As temperaturas de injeção para os protótipos foram as mesmas utilizadas para injeção dos corpos de prova, conforme descrito na Tabela 7. Os demais parâmetros de injeção dos protótipos são apresentados na Tabela 9. [086] The functional prototypes were prepared by injection molding using a Sandretto Lógica 370/70 injection molding machine, in a geometry as shown in Figures 19 to 25. Prototypes of all the compositions developed were prepared. The injection temperatures for the prototypes were the same used for the injection of the test specimens, as described in Table 7. The other injection parameters of the prototypes are presented in Table 9.
Tabela 9 - Parâmetros de moldagem dos protótipos por injeção
Figure imgf000023_0002
Figure imgf000024_0001
Table 9 - Injection molding parameters of prototypes
Figure imgf000023_0002
Figure imgf000024_0001
CARACTERIZAÇÃO DAS AMOSTRAS CHARACTERIZATION OF SAMPLES
[087] Os corpos de prova obtidos por injeção a partir das composições de resíduos têxteis sintéticos, com e sem a adição de modificadores de impacto e dos compósitos termoplásticos de poliolefinas reforçados com resíduos têxteis naturais e resíduos têxteis de composição mista foram caracterizados mecanicamente em relação a sua resistência à tração, resistência ao impacto Izod e reologicamente, através de ensaio de índice de fluidez. [087] The specimens obtained by injection from the compositions of synthetic textile waste, with and without the addition of impact modifiers and thermoplastic composites of polyolefins reinforced with natural textile waste and textile waste of mixed composition were mechanically characterized in relation to its tensile strength, Izod impact resistance and rheologically, through flow rate testing.
[088] Os ensaios mecânicos de resistência à tração foram realizados conforme norma ASTM D 638, utilizando uma máquina universal de ensaios mecânicos EMIC DL 2000, com célula de carga de 5 kN, microextensômetro e velocidade de afastamento de 50 mm/min. No ensaio de resistência à tração, foram obtidas as propriedades de tensão máxima, tensão na ruptura, módulo de elasticidade e deformação na ruptura. A avaliação foi realizada conforme o tipo de tecido e a matriz utilizada na preparação das amostras. [088] The mechanical tests of tensile strength were performed according to ASTM D 638 standard, using a universal machine for mechanical tests EMIC DL 2000, with a 5 kN load cell, microextensometer and spacing speed of 50 mm/min. In the tensile strength test, the properties of maximum stress, stress at break, modulus of elasticity and deformation at break were obtained. The evaluation was carried out according to the type of tissue and the matrix used in the preparation of the samples.
[089] Os ensaios de resistência ao impacto IZOD, conforme determina a norma ASTM D 256, foram realizados em um equipamento de resistência ao impacto CEAST, utilizando um martelo de 1J e velocidade do martelo de 3,460 m/s. Os entalhes nos corpos de prova foram realizados com auxílio de um entalhador Notch Vis. As amostras foram acondicionadas por 48h antes da realização dos entalhes e dos ensaios em laboratório condicionado a 23°C e 50% de umidade relativa do ar. [090] Foram realizados ensaios de índice de fluidez (MFI) conforme norma ASTM D1238-A para avaliar a processabilidades dos materiais com 2,16kg de carga aplicada, 10 min de ensaio, e à temperatura de 285°C, para as amostras de base poliéster, 230°C para as amostras de matriz polipropileno e 190°C para as amostras de matriz polietileno. O equipamento utilizado foi um plastômero DSM. As amostras foram secas em estufa com circulação de ar, por 24 horas, a uma temperatura de 70°C, antes da realização dos ensaios. [089] The IZOD impact resistance tests, as determined by the ASTM D 256 standard, were carried out in a CEAST impact resistance equipment, using a 1J hammer and hammer speed of 3.460 m/s. The notches on the specimens were made with the aid of a Notch Vis notch. The samples were conditioned for 48 hours before carrying out the notches and tests in a laboratory conditioned at 23°C and 50% relative humidity. [090] Flow index tests (MFI) were carried out according to ASTM D1238-A standard to evaluate the processability of materials with 2.16kg of applied load, 10 min of test, and at a temperature of 285°C, for samples of polyester base, 230°C for polypropylene matrix samples and 190°C for polyethylene matrix samples. The equipment used was a DSM plastomer. The samples were dried in an oven with air circulation, for 24 hours, at a temperature of 70°C, before carrying out the tests.
Resistência à tração conforme norma ASTM D638Tensile strength as per ASTM D638
Formulações de resíduos têxteis sintéticos preparados em câmara de misturas e suas blendas com PBT Formulations of synthetic textile waste prepared in a mixing chamber and their blends with PBT
[091] Tabela 10 - Resultados dos ensaios de resistência à tração para as formulações preparadas a partir de resíduos têxteis sintéticos em câmara de misturas Resistência à tração ASTM D 638
Figure imgf000025_0001
Formulações de resíduos têxteis sintéticos preparados em misturador termocinético e suas blendas com PBT [091] Table 10 - Results of tensile strength tests for formulations prepared from synthetic textile waste in a mixing chamber Tensile strength ASTM D 638
Figure imgf000025_0001
Formulations of synthetic textile waste prepared in a thermokinetic mixer and their blends with PBT
[092] Tabela 11 - Resultados dos ensaios de resistência à tração para as formulações preparadas a partir de resíduos têxteis sintéticos em misturador termocinético Resistência à tração ASTM D 638
Figure imgf000026_0001
[092] Table 11 - Results of tensile strength tests for formulations prepared from synthetic textile waste in thermokinetic mixer Tensile Strength ASTM D 638
Figure imgf000026_0001
Formulações de resíduos têxteis sintéticos preparados em misturador termocinético com e sem adiçào de modificadores de impactoFormulations of synthetic textile waste prepared in a thermokinetic mixer with and without the addition of impact modifiers
[093] Tabela 12 - Resultados dos ensaios de resistência à tração para as formulações preparadas a partir de resíduos têxteis sintéticos em misturador termocinético com e sem a adição de modificadores de impacto base acrílico. [093] Table 12 - Results of tensile strength tests for formulations prepared from synthetic textile waste in a thermokinetic mixer with and without the addition of acrylic-based impact modifiers.
Resistência à tração ASTM D 638
Figure imgf000026_0002
Figure imgf000027_0001
ASTM D 638 tensile strength
Figure imgf000026_0002
Figure imgf000027_0001
Formulações de compósitos termoplásticos de polipropileno reforçados com resíduos têxteis naturais e de composição mista preparados em extrusora dupla rosca com e sem adição de agentes compatibilizantes [094] Tabela 13 - Resultados dos ensaios de resistência à tração para os compósitos termoplásticos de polipropileno reforçados com resíduos têxteis naturais e/ou de composição mista, preparados por extrusão, com e sem a adição de agentes compatibilizantes. Formulations of thermoplastic polypropylene composites reinforced with natural textile waste and of mixed composition prepared in a twin-screw extruder with and without the addition of compatibilizing agents [094] Table 13 - Results of tensile strength tests for thermoplastic polypropylene composites reinforced with textile waste natural and/or of mixed composition, prepared by extrusion, with and without the addition of compatibilizing agents.
Resistência à tração ASTM D 638
Figure imgf000027_0002
Figure imgf000028_0001
ASTM D 638 tensile strength
Figure imgf000027_0002
Figure imgf000028_0001
Formulações de compósitos termoplásticos de polietileno de alta densidade reforçados com resíduos têxteis naturais e de composição mista preparados em extrusora dupla rosca com e sem adição de agentes compatibilizantes High-density polyethylene thermoplastic composite formulations reinforced with natural and composite textile waste mixture prepared in a twin-screw extruder with and without the addition of compatibilizing agents
[095] Tabela 14 - Resultados dos ensaios de resistência à tração para os compósitos termoplásticos de polietileno de alta densidade reforçados com resíduos têxteis naturais e/ou de composição mista, preparados por extrusão, com e sem a adição de agentes compatibilizantes [095] Table 14 - Results of tensile strength tests for high-density polyethylene thermoplastic composites reinforced with natural textile waste and/or mixed composition, prepared by extrusion, with and without the addition of compatibilizing agents
Resistência à tração ASTM D 638
Figure imgf000029_0001
Figure imgf000030_0001
ASTM D 638 tensile strength
Figure imgf000029_0001
Figure imgf000030_0001
Resistência ao Impacto IZOD conforme norma ASTM D256IZOD Impact Resistance according to ASTM D256
Formulações de resíduos têxteis sintéticos preparados em câmara de misturas e suas blendas com PBT Formulations of synthetic textile waste prepared in a mixing chamber and their blends with PBT
[096] Tabela 15 - Resultados dos ensaios de resistência ao impacto para as formulações preparadas a partir de resíduos têxteis sintéticos em câmara de misturas. Resistência ao Impacto IZOD ASTM D256
Figure imgf000031_0001
[096] Table 15 - Results of impact resistance tests for formulations prepared from synthetic textile waste in a mixing chamber. Impact Resistance IZOD ASTM D256
Figure imgf000031_0001
Formulações de resíduos têxteis sintéticos preparados em misturador termocinético e suas blendas com PBT Formulations of synthetic textile waste prepared in a thermokinetic mixer and their blends with PBT
[097] Tabela 16 - Resultados dos ensaios de resistência ao impacto para as formulações preparadas a partir de resíduos têxteis sintéticos em misturador termocinético. [097] Table 16 - Results of impact resistance tests for formulations prepared from synthetic textile waste in a thermokinetic mixer.
Resistência ao Impacto IZOD ASTM D256
Figure imgf000031_0002
Impact Resistance IZOD ASTM D256
Figure imgf000031_0002
Formulações de resíduos têxteis sintéticos com modificadores de impacto em misturador termocinético Synthetic textile waste formulations with impact modifiers in thermokinetic mixer
[098] Tabela 17 - Resultados dos ensaios de resistência ao impacto para as formulações preparadas em misturador termocinético a partir de resíduos têxteis sintéticos com e sem modificadores de impacto Resistência ao Impacto IZOD ASTM D256
Figure imgf000032_0001
[098] Table 17 - Results of impact resistance tests for formulations prepared in a thermokinetic mixer from synthetic textile waste with and without impact modifiers Impact Resistance IZOD ASTM D256
Figure imgf000032_0001
Formulações de compósitos termoplásticos de polipropileno reforçados com resíduos têxteis naturais e de composição mista preparados em extrusora dupla rosca com e sem adição de agentes compatibilizantes [099] Tabela 18 - Resultados dos ensaios de resistência ao impacto para os compósitos termoplásticos de polipropileno reforçados com resíduos têxteis naturais e de composição mista preparados em extrusora dupla rosca com e sem a adição de modificadores de impacto. Formulations of thermoplastic polypropylene composites reinforced with natural textile waste and of mixed composition prepared in a twin-screw extruder with and without the addition of compatibilizing agents [099] Table 18 - Results of impact resistance tests for thermoplastic polypropylene composites reinforced with textile waste natural and of mixed composition prepared in a twin screw extruder with and without the addition of impact modifiers.
Resistência ao Impacto IZOD ASTM D256
Figure imgf000032_0002
Figure imgf000033_0001
Impact Resistance IZOD ASTM D256
Figure imgf000032_0002
Figure imgf000033_0001
Formulações de compósitos termoplásticos de polietileno de alta densidade reforçados com resíduos têxteis naturais e de composição mista preparados em extrusora dupla rosca com e sem adição de agentes compatibilizantes. Formulations of high density polyethylene thermoplastic composites reinforced with natural and mixed composition textile residues prepared in a twin-screw extruder with and without the addition of compatibilizing agents.
[0100] Tabela 19 - Resultados dos ensaios de resistência ao impacto para os compósitos termoplásticos de polietileno de alta densidade reforçados com resíduos têxteis naturais e de composição mista preparados em extrusora dupla rosca com e sem a adição de modificadores de impacto. [0100] Table 19 - Results of impact resistance tests for high-density polyethylene thermoplastic composites reinforced with natural textile waste and mixed composition prepared in a twin-screw extruder with and without the addition of impact modifiers.
Resistência ao impacto IZOD ASTM D256
Figure imgf000033_0002
Figure imgf000034_0002
índice de Fluidez conforme norma ASTM D1238A Impact resistance IZOD ASTM D256
Figure imgf000033_0002
Figure imgf000034_0002
Fluidity Index according to ASTM D1238A
Formulações de resíduos têxteis sintéticos preparados em câmara de misturas e suas blendas com PBT Formulations of synthetic textile waste prepared in a mixing chamber and their blends with PBT
[0101] Tabela 20 - Resultados de índice de fluidez para as formulações preparadas a partir de resíduos têxteis sintéticos em câmara de misturas.
Figure imgf000034_0001
[0101] Table 20 - Flow index results for formulations prepared from synthetic textile waste in a mixing chamber.
Figure imgf000034_0001
Indice de Fluidez ASTM D1238-A
Figure imgf000034_0003
Formulações de resíduos têxteis sintéticos preparados em misturador termocinético e suas blendas com PBT Flow Index ASTM D1238-A
Figure imgf000034_0003
Formulations of synthetic textile waste prepared in a thermokinetic mixer and their blends with PBT
[0102] Tabela 21 - Resultados dos ensaios de resistência ao impacto para as formulações preparadas a partir de resíduos têxteis sintéticos em misturador termocinético. índice de Fluidez ASTM D1238-A
Figure imgf000035_0001
[0102] Table 21 - Results of impact resistance tests for formulations prepared from synthetic textile waste in thermokinetic mixer. Flow Index ASTM D1238-A
Figure imgf000035_0001
Formulações de resíduos têxteis sintéticos com modificadores de impacto em misturador termocinético Synthetic textile waste formulations with impact modifiers in thermokinetic mixer
[0103] Tabela 22 - Resultados dos ensaios de resistência ao impacto para as formulações preparadas em misturador termocinético a partir de resíduos têxteis sintéticos com e sem modificadores de impacto. índice de Fluidez ASTM D1238-A
Figure imgf000035_0002
Figure imgf000036_0001
[0103] Table 22 - Results of impact resistance tests for formulations prepared in thermokinetic mixer from synthetic textile waste with and without impact modifiers. Flow Index ASTM D1238-A
Figure imgf000035_0002
Figure imgf000036_0001
Formulações de compósitos termoplásticos de Dolipropileno reforçados com resíduos têxteis naturais e de composição mista preparados em extrusora dupla rosca com e sem adição de agentes compatibilizantes [0104] Tabela 23 - Resultados dos ensaios de resistência ao impacto para os compósitos termoplásticos de polipropileno reforçados com resíduos têxteis naturais e de composição mista preparados em extrusora dupla rosca com e sem a adição de modificadores de impacto. índice de Fluidez ASTM D1238-A
Figure imgf000036_0002
Figure imgf000037_0001
Formulations of thermoplastic composites of Dolypropylene reinforced with natural textile residues and of mixed composition prepared in a twin screw extruder with and without the addition of compatibilizing agents [0104] Table 23 - Results of impact resistance tests for thermoplastic composites of polypropylene reinforced with textile residues natural and of mixed composition prepared in a twin screw extruder with and without the addition of impact modifiers. Flow Index ASTM D1238-A
Figure imgf000036_0002
Figure imgf000037_0001
Formulações de compósitos termoplásticos de polietileno de alta densidade reforçados com resíduos têxteis naturais e de composição mista preparados em extrusora dupla rosca com e sem adição de agentes compatibilizantes. Formulations of high density polyethylene thermoplastic composites reinforced with natural and mixed composition textile residues prepared in a twin-screw extruder with and without the addition of compatibilizing agents.
[0105] Tabela 24 - Resultados dos ensaios de resistência ao impacto para os compósitos termoplásticos de polietileno de alta densidade reforçados com resíduos têxteis naturais e de composição mista preparados em extrusora dupla rosca com e sem a adição de modificadores de impacto. índice de Fluidez ASTM D1238-A
Figure imgf000037_0002
Figure imgf000038_0001
[0105] Table 24 - Results of impact resistance tests for high-density polyethylene thermoplastic composites reinforced with natural textile waste and mixed composition prepared in a twin-screw extruder with and without the addition of impact modifiers. Flow Index ASTM D1238-A
Figure imgf000037_0002
Figure imgf000038_0001

Claims

37 REINVINDICAÇÕES: 37 CLAIMS:
1 . PROCESSO PARA OBTENÇÃO DE PELLETS de resíduos têxteis sintéticos de poliéster e poliéster mais poliuretano, caracterizado pelo fato de que compreende as etapas de: a) desfibragem dos resíduos têxteis sintéticos de poliéster e poliéster + poliuretano em moinho do tipo aglutinador; b) preparo das formulações compreendendo as etapas de: 1 . PROCESS FOR OBTAINING PELLETS from synthetic textile waste of polyester and polyester plus polyurethane, characterized by the fact that it comprises the steps of: a) defibration of synthetic textile waste of polyester and polyester + polyurethane in a binder-type mill; b) preparation of formulations comprising the steps of:
I. preparar as composições em razão de 100/0 a 25/75 de resíduo têxtil sintético e polímero base poliéster, em uma câmara de misturas, em uma faixa de temperatura a partir de 150° até 300°C; I. prepare the compositions in a ratio of 100/0 to 25/75 of synthetic textile waste and polyester-based polymer, in a mixing chamber, in a temperature range from 150° to 300°C;
II. preparar as composições em razão de 100/0 a 25/75 de resíduo têxtil sintético e polímero base poliéster, em um misturador termocinético, em velocidades entre 1000 e 5000rpm; II. prepare the compositions in a ratio of 100/0 to 25/75 of synthetic textile waste and polyester-based polymer, in a thermokinetic mixer, at speeds between 1000 and 5000rpm;
III. preparar as composições em razão de 100/0 a 70/30 de resíduo têxtil sintético e modificador de impacto, em um misturador termocinético, em velocidades entre 1000 e 5000rpm; c) granular as amostras produzidas em um moinho de facas, gerando pellets com diâmetro inferiores a 4mm; III. prepare the compositions in a ratio of 100/0 to 70/30 of synthetic textile waste and impact modifier, in a thermokinetic mixer, at speeds between 1000 and 5000rpm; c) granulate the samples produced in a knife mill, generating pellets with a diameter of less than 4mm;
2. PROCESSO, de acordo com a reivindicação 1 , caracterizado pelo fato de que a câmara de misturas da etapa b.l pode ser acoplada a um reômetro. 2. PROCESS, according to claim 1, characterized by the fact that the mixing chamber of step b.l can be coupled to a rheometer.
3. PROCESSO, de acordo com a reivindicação 2, caracterizado pelo fato de que o reômetro de torque pode ser um reômetro de torque Haake. 38 PROCESSO, de acordo com a reivindicação 1 , caracterizado pelo fato de que o misturador termocinético da etapa b.ll pode ser um misturador do tipo Drais, Dryzer, K-mixer ou Kinect mixer. PROCESSO, de acordo com a reivindicação 1 , caracterizado pelo fato de que inclui adicionalmente a adição de pelo menos um modificador de impacto. PROCESSO, de acordo com a reivindicação 5, caracterizado pelo fato de que o modificador de impacto é selecionado a partir do grupo que consiste em acrilatos, metacrilatos, polímeros estirênicos, polímeros de base butadieno, polímeros base butílicos, elastômeros termoplásticos, e similares. PROCESSO, de acordo com a reivindicação 1 , caracterizado pelo fato que, antes da etapa b, compreende adicionalmente a uma etapa de secar os resíduos têxteis sintéticos desfibrados, por 1 h a 24h, em temperaturas entre 70 e 110°C. PROCESSO, de acordo com a reivindicação 1 , caracterizado pelo fato que, subsequentemente à etapa c, compreende adicionalmente uma etapa de injetar o material obtido em uma faixa de temperatura entre 220°C e 300°C; PROCESSO PARA OBTENÇÃO DE PELLETS de compósitos termoplásticos reforçados com resíduos têxteis naturais, caracterizado pelo fato que compreende as etapas de: a) desfibragem dos resíduos têxteis naturais de algodão em moinho do tipo aglutinador; b) preparo das formulações compreendendo as etapas de: 3. PROCESS, according to claim 2, characterized in that the torque rheometer can be a Haake torque rheometer. 38 PROCESS, according to claim 1, characterized in that the thermokinetic mixer of step b.ll can be a Drais, Dryzer, K-mixer or Kinect mixer. PROCESS, according to claim 1, characterized in that it additionally includes the addition of at least one impact modifier. PROCESS, according to claim 5, characterized in that the impact modifier is selected from the group consisting of acrylates, methacrylates, styrenic polymers, butadiene-based polymers, butyl-based polymers, thermoplastic elastomers, and the like. PROCESS, according to claim 1, characterized by the fact that, before step b, it additionally comprises a step of drying the shredded synthetic textile waste, for 1 h for 24 hours, at temperatures between 70 and 110°C. PROCESS, according to claim 1, characterized in that, subsequent to step c, it additionally comprises a step of injecting the material obtained in a temperature range between 220°C and 300°C; PROCESS FOR OBTAINING PELLETS from thermoplastic composites reinforced with natural textile residues, characterized by the fact that it comprises the steps of: a) defibration of natural cotton textile residues in a binder-type mill; b) preparation of formulations comprising the steps of:
I. preparar os masterbatches em razão de 70/30 de poliolefinas com resíduo têxtil natural de algodão, em um misturador termocinético, em velocidades entre 1000 e 5000rpm; I. prepare the masterbatches in a ratio of 70/30 polyolefins with natural cotton textile waste, in a thermokinetic mixer, at speeds between 1000 and 5000rpm;
II. granular as amostras produzidas em um moinho de facas;II. granulate the samples produced in a knife mill;
III. extrusar a poliolefina e a mistura produzida em uma razão de 90/10 e 70/30 de poliolefina e resíduo têxtil natural de algodão, em uma extrusora duplas rosca, com velocidades variando entre 10 e 400rpm, e temperaturas a partir de 90°C a 220°C; c) pelletização das amostras em um granulador, gerando pellets com diâmetro entre 1 e 3mm; 0. PROCESSO, de acordo com a reivindicação 9, caracterizado por a poliolefina pode ser um polipropileno, com índice de fluidez entre 10g e 80g/1 Omin/2,16kg/230°C. 1 . PROCESSO, de acordo com a reivindicação 9, caracterizado por a poliolefina pode ser um polietileno de alta densidade, com índice de fluidez entre 10g e 80g/1 Omin/2,16kg/190°C. 2. PROCESSO, de acordo com a reivindicação 2, caracterizado pelo fato de que inclui adicionalmente a adição de pelo menos um agente compatibilizante. 3. PROCESSO, de acordo com a reivindicação 12, caracterizado por o agente compatibilizante é selecionado a partir do grupo que consiste em anidrido maleico e similares. III. extrude the polyolefin and the mixture produced in a ratio of 90/10 and 70/30 of polyolefin and natural cotton textile waste, in a twin-screw extruder, with speeds varying between 10 and 400rpm, and temperatures from 90°C to 220°C; c) pelletizing the samples in a granulator, generating pellets with a diameter between 1 and 3mm; 0. Process, according to claim 9, characterized in that the polyolefin can be a polypropylene, with a melt index between 10g and 80g/1 Omin/2.16kg/230°C. 1 . PROCESS, according to claim 9, characterized in that the polyolefin can be a high density polyethylene, with a fluidity index between 10g and 80g/1 Omin/2.16kg/190°C. 2. PROCESS according to claim 2, characterized in that it additionally includes the addition of at least one compatibilizing agent. 3. Process according to claim 12, characterized in that the compatibilizing agent is selected from the group consisting of maleic anhydride and the like.
4. PROCESSO, de acordo com a reivindicação 9, caracterizado pelo fato que, antes da etapa b,l, compreende adicionalmente a uma etapa de secar os resíduos têxteis naturais desfibrados, por 1 h a 24h, em temperaturas entre 70 e 1 10°C. 4. PROCESS, according to claim 9, characterized by the fact that, before step b,l, it additionally comprises a step of drying the shredded natural textile waste, for 1 h to 24 h, at temperatures between 70 and 1 10°C .
5. PROCESSO, de acordo com a reivindicação 9, caracterizado pelo fato que, antes da etapa b, 111, compreende adicionalmente a uma etapa de secar os masterbatches, por 1 h a 24h, em temperaturas entre 70 e 1 10°C. PROCESSO, de acordo com a reivindicação 9, caracterizado pelo fato que, subsequentemente à etapa c, compreende adicionalmente uma etapa de injetar o material obtido em uma faixa de temperatura entre 90°C e 300°C; PROCESSO PARA OBTENÇÃO DE PELLETS de compósitos termoplásticos reforçados com resíduos têxteis de composição mista, com algodão, poliéster e poliuretano, caracterizado pelo fato que compreende as etapas de: a) desfibragem dos resíduos têxteis de composição mista, algodão, poliéster e poliuretano, em moinho do tipo aglutinador; b) preparo das formulações compreendendo as etapas de: 5. PROCESS, according to claim 9, characterized in that, before step b, 111, it additionally comprises the a stage of drying the masterbatches, for 1 h 24h, at temperatures between 70 and 110°C. PROCESS, according to claim 9, characterized in that, subsequent to step c, it additionally comprises a step of injecting the material obtained in a temperature range between 90°C and 300°C; PROCESS FOR OBTAINING PELLETS made of thermoplastic composites reinforced with textile waste of mixed composition, with cotton, polyester and polyurethane, characterized by the fact that it comprises the steps of: a) defibration of textile waste of mixed composition, cotton, polyester and polyurethane, in a mill agglutinating type; b) preparation of formulations comprising the steps of:
I. preparar os masterbatches em razão de 70/30 de poliolefinas com resíduo têxtil de composição mista, algodão/poliéster/poliuretano, em um misturador termocinético, em velocidades entre 1000 e 5000rpm; I. prepare the masterbatches in a ratio of 70/30 polyolefins with textile residue of mixed composition, cotton/polyester/polyurethane, in a thermokinetic mixer, at speeds between 1000 and 5000rpm;
II. granular as amostras produzidas em um moinho de facas;II. granulate the samples produced in a knife mill;
III. extrusar a poliolefina e a mistura produzida em uma razão de 90/10 e 70/30 de poliolefina e resíduo têxtil de composição mista, algodão/poliéster/poliuretano, em uma extrusora duplas rosca, com velocidades variando entre 10 e 400rpm, e temperaturas a partir de 90°C a 220°C; c) pelletização das amostras em um granulador, gerando pellets com diâmetro entre 1 e 3mm. PROCESSO, de acordo com a reivindicação 17, caracterizado por a poliolefina pode ser um polipropileno, com índice de fluidez entre 10g e 80g/10min/2,16kg/230°C. PROCESSO, de acordo com a reivindicação 17, caracterizado por a poliolefina pode ser um polietileno de alta densidade, com índice de fluidez entre 10g e 80g/1 Omin/2,16kg/190°C. PROCESSO, de acordo com a reivindicação 17, caracterizado pelo fato de que inclui adicionalmente a adição de pelo menos um agente compatibilizante; PROCESSO, de acordo com a reivindicação 20, caracterizado por o agente compatibilizante é selecionado a partir do grupo que consiste em anidrido maleico e similares. PROCESSO, de acordo com a reivindicação 17, caracterizado pelo fato que, antes da etapa b,l, compreende adicionalmente a uma etapa de secar os resíduos têxteis naturais desfibrados, por 1 h a 24h, em temperaturas entre 70 e 110°C. PROCESSO, de acordo com a reivindicação 17, caracterizado pelo fato que, antes da etapa b, 111, compreende adicionalmente a uma etapa de secar os masterbatches, por 1 h a 24h, em temperaturas entre 70 e 110°C. PROCESSO, de acordo com a reivindicação 17, caracterizado pelo fato que, subsequentemente à etapa c, compreende adicionalmente uma etapa de injetar o material obtido em uma faixa de temperatura entre 90°C e 300°C. III. extrude the polyolefin and the mixture produced in a ratio of 90/10 and 70/30 of polyolefin and textile residue of mixed composition, cotton/polyester/polyurethane, in a twin screw extruder, with speeds varying between 10 and 400rpm, and temperatures at from 90°C to 220°C; c) pelletizing the samples in a granulator, generating pellets with a diameter between 1 and 3 mm. PROCESS, according to claim 17, characterized in that the polyolefin can be a polypropylene, with a melt index between 10g and 80g/10min/2.16kg/230°C. PROCESS, according to claim 17, characterized in that the polyolefin can be a high density polyethylene, with a fluidity index between 10g and 80g/1 Omin/2.16kg/190°C. PROCESS, according to claim 17, characterized in that it additionally includes the addition of at least one compatibilizing agent; PROCESS according to claim 20, characterized in that the compatibilizing agent is selected from the group consisting of maleic anhydride and the like. PROCESS, according to claim 17, characterized by the fact that, before step b,l, it additionally comprises a step of drying the shredded natural textile waste, for 1 ha 24h, at temperatures between 70 and 110°C. PROCESS, according to claim 17, characterized in that, before step b, 111, it additionally comprises a step of drying the masterbatches, for 1 h for 24 hours, at temperatures between 70 and 110°C. PROCESS, according to claim 17, characterized in that, subsequent to step c, it additionally comprises a step of injecting the material obtained in a temperature range between 90°C and 300°C.
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WO2016151363A1 (en) * 2015-03-24 2016-09-29 Really Aps Reuse of used woven or knitted textile
WO2021250228A1 (en) * 2020-06-11 2021-12-16 Kleiderly Ug (Haftungsbeschränkt) Method for processing textile waste into recycled plastic granule

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016151363A1 (en) * 2015-03-24 2016-09-29 Really Aps Reuse of used woven or knitted textile
WO2021250228A1 (en) * 2020-06-11 2021-12-16 Kleiderly Ug (Haftungsbeschränkt) Method for processing textile waste into recycled plastic granule

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