JP7620448B2 - Fusion material manufacturing method, fusion material manufacturing device, and fusion material - Google Patents

Description

The present invention relates to a method for producing a fusion material, an apparatus for producing a fusion material, and the fusion material.

In recent years, the concentration of carbon dioxide in the atmosphere has increased, and climate change such as global warming has become a problem. In order to suppress environmental abnormalities such as global warming and reduce the use of fossil resources that are at risk of depletion, the use of biomass, a renewable resource that effectively utilizes biotechnology, is being promoted. Regarding the production of biomass materials, a technology has been disclosed for forming a wood-based composite resin material from a wood-based filler material, a lubricant, a thermoplastic resin raw material, and an oxygen modifier (see Patent Document 1).

JP 2018-83876 A Patent No. 4489017

Conventionally, additives have been necessary to promote the fusion of biomass materials and thermoplastic resin raw materials, as in the production of biomass materials described in Patent Document 1, but the use of additives has a negative impact on the environment. In addition, the ratio of biomass materials mixed with thermoplastic resin raw materials is generally 50% or less, which imposes a high environmental burden and raw material cost. Furthermore, there is no mention of the fusion of inorganic materials and thermoplastic resin raw materials.

In view of the above-mentioned problems, the present invention aims to provide a method for producing a fusion material that does not require additives and has a higher ratio of inorganic materials and biomass materials compared to plastic materials, a production device for a fusion material, and the fusion material.

A method for producing a fusion material according to one embodiment of the present invention includes the steps of:
A motor;
A mixing vessel;
A control unit for controlling the rotation speed or torque of the motor;
A rotating shaft rotated by the motor;
A plurality of blades formed on the outer periphery of the rotating shaft in the mixing vessel;
a helical screw formed on the outer periphery of the rotating shaft in the mixing vessel;
A pressure sensor for detecting the pressure in the mixing vessel;
A temperature sensor for detecting a temperature inside the mixing vessel;
A rotation speed sensor that detects the rotation speed of the motor;
A torque sensor that detects the torque of the motor;
Equipped with
The control unit feedback-controls the motor in accordance with values from the pressure sensor, the temperature sensor, the rotation speed sensor, and the torque sensor.
A method for producing a fusion material using a fusion material production device, comprising:
A mixing step of rotating the blade and the screw in the mixing vessel by the motor to mix at least one of the pulverized inorganic material and the pulverized biomass material and at least one of the pulverized plastic material;
a melting step of rotating the blade and the screw at a rotation speed higher than the rotation speed in the mixing step;
A fusion process is then performed by driving the motor to rotate the rotating shaft, the blade, and the screw to promote the reaction of the materials.
having
The mixing step, the melting step, and the fusing step are carried out as a single continuous step.

In addition, the manufacturing apparatus for the fusion material according to the embodiment of the present invention includes:
A motor;
A mixing vessel;
A control unit for controlling the rotation speed or torque of the motor;
A rotating shaft rotated by the motor;
A plurality of blades formed on the outer periphery of the rotating shaft in the mixing vessel;
a helical screw formed on the outer periphery of the rotating shaft in the mixing vessel;
A pressure sensor for detecting the pressure in the mixing vessel;
A temperature sensor for detecting a temperature inside the mixing vessel;
A rotation speed sensor that detects the rotation speed of the motor;
A torque sensor that detects the torque of the motor 2;
Equipped with
The control unit feedback controls the motor in accordance with values from the pressure sensor, the temperature sensor, the rotation speed sensor, and the torque sensor.

The fusion material manufacturing method, fusion material manufacturing device, and fusion material of the present invention can produce environmentally friendly materials with a uniform composition without the need for additives, with a high ratio of biomass materials, thereby reducing the environmental burden and raw material costs.

An example of a method for producing the fusion material according to this embodiment will be described. 1 shows an example of an apparatus for producing a fusion material according to this embodiment. 1 shows the fusion material of Example 1 manufactured by the fusion material manufacturing method of this embodiment. 1 shows the fusion material of Example 2 manufactured by the fusion material manufacturing method of this embodiment. The fusion material of Example 3 manufactured by the fusion material manufacturing method of this embodiment is shown.

Figure 1 shows an example of a method for producing a fusion material according to this embodiment. Figure 2 shows an example of a portion of an apparatus 1 for producing a fusion material according to this embodiment.

The method for producing the fusion material of this embodiment includes a grinding process for grinding the material, a mixing process for mixing the ground material, a melting process for melting the mixed material, and a fusion process for fusing the molten material.

As shown in FIG. 2, the fusion material manufacturing device 1 of this embodiment includes a motor 2, a mixing vessel 3, a control unit 4 that controls the rotation speed or torque of the motor 2, a rotating shaft 5 rotated by the motor 2, a plurality of blades 10 formed on the outer periphery of the rotating shaft 5 in the mixing vessel 3, a helical screw 12 formed on the outer periphery of the rotating shaft 5 in the mixing vessel 3, a pressure sensor 6 that detects the pressure in the mixing vessel 3, a temperature sensor 7 that detects the temperature in the mixing vessel 3, a rotation speed sensor 8 that detects the rotation speed of the motor 2, and a torque sensor 9 that detects the torque of the motor 2.

It is preferable that the control unit 4 feedback-controls the motor 2 according to the values from the pressure sensor 6, the temperature sensor 7, the rotation speed sensor 8, and the torque sensor 9. For example, when the actual load is large and the rotation speed of the motor 2 is lower than the set value, feedback control can be used to control it to an appropriate value.

It is not necessary to use the pressure sensor 6, temperature sensor 7, rotation speed sensor 8, and torque sensor 9. The rotation speed and torque of the motor 2 from the grinding process to the fusion process may be set in advance in the control unit 4. As the manufacturing device 1 of the fusion material of this embodiment, for example, the mixing and grinding device described in Patent Document 2 may be used.

The materials used to produce the fusion material are at least one of inorganic materials or biomass materials, and at least one plastic material. No additives may be used when producing the fusion material of this embodiment.

Inorganic materials are inorganic substances, and include carbon fiber reinforced plastics (CFRP), gypsum, carbonic acid, calcium oxide, shells, glass, metal films, vapor-deposited metals, metal powders, etc.

Biomass materials are renewable organic resources derived from living organisms that can be utilized, including waste materials such as food, construction waste, and waste paper, as well as resource crops such as plants. Examples include food waste, wood, paper, and seaweed.

Plastic materials include polypropylene, polyethylene, polyethylene terephthalate, polytrimethylene terephthalate, polyvinyl chloride, polystyrene, PLA resin, ABS resin, polycarbonate, polyamide, polyurethane, or nylon, etc.

As shown in Figure 1, the manufacturing method of the fusion material in this embodiment is carried out in the order of a crushing process, a mixing process, a melting process, and a fusion process. Although each process may be switched manually, it is preferable to automatically change the rotation speed etc. according to time and carry out the processes as if they were one process.

In the manufacturing method of the fusion material of this embodiment, first, in step 1, a crushing process is performed. In the crushing process, materials are put into the mixing container 3 of the fusion device shown in FIG. 2 through an opening (not shown), and the motor 2 is driven to rotate the rotating shaft 5, the blades 10, and the screw 12 to finely crush the inorganic or biomass materials and the plastic materials. The size of the crushed particles is preferably about 2 to 7 mm. Note that the crushing process is not performed when materials that have been crushed in advance in another device are simply put in.

Next, in step 2, a mixing process is performed. In the mixing process, the motor 2 continues to be driven to rotate the rotating shaft 5, the blades 10, and the screw 12 to mix the crushed inorganic material or biomass material and the plastic material. In conventional manufacturing methods, only one type of biomass material is mixed, and the ratio of the biomass material mixed into the plastic material is generally less than 50%. In this embodiment, multiple biomass materials can be mixed at 50% or more and up to 97%. By increasing the mixing ratio of biomass materials, the environmental burden and raw material costs can be reduced.

In addition, in the production of the fusion material of this embodiment, it is not necessary to use additives for compatibility. Not using additives improves environmental friendliness. Furthermore, it is preferable that the mixing process of this embodiment includes the incorporation of moisture. By including moisture, the internal pressure can be increased in a later process.

Next, in step 3, the melting process is carried out. In the melting process, the motor 2 continues to be driven to rotate the rotating shaft 5, the blades 10, and the screw 12. The rotation speed of the blades in the melting process is set to be higher than that in the mixing process. When the blades 10 are rotated at high speed, the temperature inside the mixing vessel 3 becomes high due to the movement of the materials themselves and the friction caused by the materials colliding with each other. After that, steam is generated from the moisture, the pressure inside the mixing vessel 3 increases, and each material melts. Then, decomposition and separation of the biomass begins in the mixing vessel 3, and the torque decreases while the rotation speed remains constant.

Next, in step 4, the fusion process is carried out. In the fusion process, the motor 2 continues to be driven to rotate the rotating shaft 5, the blades 10, and the screw 12 to advance the reaction of the materials. As the reaction progresses, the materials are refined and re-resinized, increasing their density and viscosity, sticking to the inner wall of the outer periphery, and increasing the torque. At the same time, the moisture is turned into steam and released to the outside from an outlet (not shown) of the mixing vessel 3. As a result, the inside of the mixing vessel 3 dries, and a fusion product is obtained from which moisture and other substances have been removed.

The resulting fusion product is a new material that is uniformly fused at the molecular level and can be molded by injection, extrusion, blowing, pressing, etc., making it suitable for a variety of uses.

The fusion material manufacturing method of this embodiment is also performed in less than 1800 seconds. Normally, the more heat input a plastic material receives, the more severe its degradation becomes. The fusion material manufacturing method of this embodiment applies heat to the plastic material for a short period of time. Therefore, the fusion material manufactured by the fusion material manufacturing method of this embodiment is less prone to degradation and can retain its strength. Furthermore, because the fusion material manufactured by the fusion material manufacturing method of this embodiment is less prone to degradation, the completed fusion product can be reused.

Next, an example of a fusion material produced using the fusion material production method of this embodiment is shown.

Figure 3 shows the fusion material of Example 1 produced by the fusion material production method of this embodiment. Figure 3(a) shows the surface of the fusion material of Example 1, and Figure 3(b) shows a scanning electron microscope photograph of the fusion material of Example 1.

In Example 1, 55% wood material and 45% polypropylene were fused together. Table 1 shows the surface state components of Example 1. It is estimated that oxygen was approximately 20 Atom% and polypropylene components were abundant on the surface. The wood components and polypropylene components were fused together uniformly, resulting in a uniform appearance.

Figure 4 shows the fusion material of Example 2 produced by the fusion material production method of this embodiment. Figure 4(a) shows the surface of the fusion material of Example 2, and Figure 4(b) shows a scanning electron microscope photograph of the fusion material of Example 2.

In Example 2, 50% scallop shells, 37.5% polypropylene, 12.5% polyethylene terephthalate, and 300 g of water were fused together. Table 2 shows the surface state components of Example 2. Calculations show that carbon is about 62 Atom%, oxygen is about 29 Atom%, and calcium is about 8 Atom%, and since there is a lot of carbon, it is estimated that there is a lot of polypropylene component on the surface. The calcium carbonate component, polypropylene component, and polyethylene terephthalate component of the scallop shells are fused together uniformly, resulting in a uniform appearance.

Figure 5 shows the fusion material of Example 3 produced by the fusion material production method of this embodiment. Figure 5(a) shows the surface of the fusion material of Example 3, and Figure 5(b) shows a scanning electron microscope photograph of the fusion material of Example 3.

In Example 3, 50% nylon, 50% polyethylene, and 300 g of water were fused together. Table 3 shows the surface state components of Example 3. Calculations showed that carbon was about 93 Atom % and oxygen was about 7 Atom %, and since there was a lot of carbon, it is estimated that there was a lot of polypropylene components on the surface. The nylon components and polyethylene components were fused together uniformly, resulting in a uniform appearance.

As described above, according to the present embodiment, the method for producing a fusion material uses a fusion material production device 1 equipped with a motor 2, a mixing vessel 3, a rotating shaft 5 rotated by the motor 2, a plurality of blades 10 formed on the outer periphery of the rotating shaft 5 in the mixing vessel 3, and a helical screw 12 formed on the outer periphery of the rotating shaft 5 in the mixing vessel 3. The method includes a mixing process in which the blades 10 and the screw 12 are rotated in the mixing vessel 3 by the motor 2 to mix at least one type of inorganic material or biomass material and at least one type of plastic material, a melting process in which the blades 10 and the screw 12 are rotated at a higher rotation speed than the rotation speed in the mixing process, and a fusion process in which the motor 2 is subsequently driven to rotate the rotating shaft 5, the blades 10, and the screw 12 to promote the reaction of the materials. Since the mixing process, melting process, and fusion process are performed as a single continuous process, additives are not required, the ratio of biomass material is increased, and an environmentally friendly material with uniform components can be produced, which reduces the environmental load and raw material costs.

In addition, according to the manufacturing method of the fusion material of this embodiment, a crushing process is performed before the mixing process to finely crush the materials, and the crushing process, mixing process, melting process, and fusion process are performed as a single continuous process. This means that additives are not required, the ratio of biomass material is increased, and an environmentally friendly material with uniform components can be manufactured, further reducing the environmental burden and raw material costs.

In addition, according to the manufacturing method of the fusion material of this embodiment, the mixing process causes the material to absorb moisture, which increases the internal pressure of the mixing container 3 and allows the production of a more uniform material.

In addition, according to the manufacturing method of the fusion material of this embodiment, since the plastic material contains the fusion material, the manufactured fusion material can be reused.

In addition, according to the manufacturing method of the fusion material of this embodiment, the mixing process, melting process, and fusion process are performed in less than 1,800 seconds, so that a fusion material with a short heat input time can be manufactured in a short time, and a fusion material with uniform components can be manufactured efficiently and at low cost.

Furthermore, the fusion material manufacturing device of this embodiment includes a motor 2, a mixing vessel 3, a control unit 4 that controls the rotation speed or torque of the motor 2, a rotating shaft 5 rotated by the motor 2, a plurality of blades 10 formed on the outer periphery of the rotating shaft 5 in the mixing vessel 3, a helical screw 12 formed on the outer periphery of the rotating shaft 5 in the mixing vessel 3, a pressure sensor 6 that detects the pressure in the mixing vessel 3, a temperature sensor 7 that detects the temperature in the mixing vessel 3, a rotation speed sensor 8 that detects the rotation speed of the motor 2, and a torque sensor 9 that detects the torque of the motor 2. The control unit 4 feedback controls the motor 2 according to the values from the pressure sensor 6, the temperature sensor 7, the rotation speed sensor 8, and the torque sensor 9, so that additives are not required, the ratio of biomass material is increased, and an environmentally friendly material with uniform components can be manufactured, thereby reducing the environmental burden and raw material costs.

Furthermore, according to the fusion material manufacturing apparatus of this embodiment, since the fusion material is manufactured using the fusion material manufacturing method or the fusion material manufacturing apparatus, additives are not required, the ratio of biomass material is increased, and the material has a uniform composition of environmentally friendly components, which reduces the environmental burden and raw material costs.

The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the present invention. All such modifications are included in the technical concept of the present invention.

1...Fusion material manufacturing device, 2...Motor, 3...Mixing container, 4...Control unit, 5...Rotating shaft, 6...Pressure sensor, 7...Temperature sensor, 8...Rotational speed sensor, 9...Torque sensor, 10...Blade, 12...Screw

Claims (6)

A motor;
A mixing vessel;
A control unit for controlling the rotation speed or torque of the motor;
A rotating shaft rotated by the motor;
A plurality of blades formed on the outer periphery of the rotating shaft in the mixing vessel;
a helical screw formed on the outer periphery of the rotating shaft in the mixing vessel;
A pressure sensor that detects the pressure in the mixing vessel;
A temperature sensor for detecting a temperature inside the mixing vessel;
A rotation speed sensor that detects the rotation speed of the motor;
A torque sensor that detects the torque of the motor;
Equipped with
The control unit feedback-controls the motor in accordance with values from the pressure sensor, the temperature sensor, the rotation speed sensor, and the torque sensor.
A method for producing a fusion material using a fusion material production device, comprising:
A mixing step of rotating the blade and the screw in the mixing vessel by the motor to mix at least one of the pulverized inorganic material and the pulverized biomass material and at least one of the pulverized plastic material;
a melting step of rotating the blade and the screw at a rotation speed higher than the rotation speed in the mixing step;
A fusion process is then performed by driving the motor to rotate the rotating shaft, the blade, and the screw to promote the reaction of the materials.
having
The method for producing a fusion material, wherein the mixing step, the melting step, and the fusion step are carried out as a single continuous step. A grinding step of finely grinding the material is provided prior to the mixing step,
The method for producing a fusion material according to claim 1 , wherein the grinding step, the mixing step, the melting step, and the fusion step are carried out as a single continuous step. The method for producing a fusion material according to claim 1 or 2, wherein the mixing step includes the step of adding moisture to the material. The method for producing a fusion material according to claim 1 , wherein the plastic material comprises the fusion material. The method of claim 1 , wherein the mixing, melting and fusing steps are carried out in less than 1800 seconds. A motor;
A mixing vessel;
A control unit for controlling the rotation speed or torque of the motor;
A rotating shaft rotated by the motor;
A plurality of blades formed on the outer periphery of the rotating shaft in the mixing vessel;
a helical screw formed on the outer periphery of the rotating shaft in the mixing vessel;
A pressure sensor that detects the pressure in the mixing vessel;
A temperature sensor for detecting a temperature inside the mixing vessel;
A rotation speed sensor that detects the rotation speed of the motor;
A torque sensor that detects the torque of the motor 2;
Equipped with
The control unit feedback controls the motor according to values from the pressure sensor, the temperature sensor, the rotation speed sensor, and the torque sensor.

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