JPS6337683B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for producing a composite composition using scrap materials consisting of a facing material and a corrugated cardboard base material, and more specifically, the present invention relates to a method for manufacturing a composite material composition using scrap materials consisting of a facing material and a corrugated cardboard base material, and more specifically, it relates to a method for manufacturing a composite material composition using a scrap material made of a facing material and a corrugated cardboard base material. The present invention relates to a method for producing a composite material composition using scraps generated during the production of products. Conventionally, when manufacturing vehicle interior parts, a large amount of scrap materials are generated, and when these scraps are disposed of, the disposal costs increase, causing an increase in product costs. In addition, waste materials are recycled and used to help conserve resources, but in the case of conventional corrugated ceilings, many of the covering materials are made of laminated products such as vinyl chloride resin and urethane foam.
Vinyl chloride resin thermally decomposes during recycling and generates decomposed gas, and urethane foam also generates gas through thermal decomposition, so these decomposed gases including chlorine gas corrode the cylinders of molding machines, etc. At the same time, there was a risk that the working environment would deteriorate and decomposition gas would mix into the composition, causing deterioration of physical properties. Therefore, for interior products such as corrugated ceilings, the facing material and the corrugated base material are separated and only the corrugated base material is recycled. Separating the scraps greatly increases the number of man-hours, which impairs cost benefits and must be disposed of. Naturally, this went against the grain of resource conservation. The object of the present invention is to be able to simultaneously recycle and reuse waste material consisting of a facing material and a corrugated board base material without having to separate them into the facing material and the corrugated board base material in advance. A surface material that is extremely economical because various decomposed gases do not corrode molding machines, etc. or worsen the working environment, and it has excellent physical properties and can reduce the amount of added thermoplastic resin used. The present invention also provides a method for producing a composite composition using scrap material made of a corrugated cardboard base material. An embodiment of the manufacturing method according to the present invention will be described in detail below. The facing material used in the present invention is composed of a laminate of a thermoplastic resin such as polypropylene resin PP or polyethylene resin PE, an olefin elastomer, and foamed PP or foamed PE foam. It does not contain vinyl resin. The corrugated board base material on which the facing material is laminated may be a normal corrugated board base material or one coated with a thermoplastic resin. The scrap material consisting of the facing material and the corrugated cardboard base material having the above structure is crushed to form coarse pieces. A thermoplastic resin and water are added to the coarsely crushed pieces, and the mixture is placed in a heating mixer and stirred in a closed state.The cardboard component of the coarsely crushed pieces is defibrated by steam pressure and stirring, and the thermoplastic resin component is plasticized. . Next, the generated gas containing water vapor in the heating mixer is gradually discharged from the mixer, and stirring is continued to raise the temperature to melt the thermoplastic resin component and uniformly impregnate the defibrated pulp fibers with the thermoplastic resin. to form a molten mixture. Next, the molten mixture is transferred into a mixer at room temperature to adjust the amount of thermoplastic resin to form uniform granules, and the granules are molded to produce a composite composition. Example A scrap material containing approximately 35% by weight of the facing material and 65% by weight of the corrugated board base material is crushed into pieces of 1 to 8 mm to form coarse pieces.
The covering material is made of PP resin and olefin elastomer. 30 to 50 parts by weight of thermoplastic resin and 3 to 10 parts by weight of water are added to 100 parts by weight of the crushed pieces, and the mixture is stored in a heating mixer. The thermoplastic resin added does not contain chlorinated vinyl resin. The heating mixer is also equipped with a blower device for removing generated gas. The crushed pieces, thermoplastic resin, and water are placed in a heating mixer, and the heating mixer is rotated in a closed state. When the heating mixer is driven to rotate at 500 to 800 rpm, the raw materials are stirred at high speed, the temperature of the raw materials increases due to frictional heat, and the temperature inside the mixer increases to 120 to 150 rpm.
rises to ℃. When maintained in this temperature range for 12 to 18 minutes, the water added in advance as a raw material turns into steam, and since the mixer is rotating in a closed state, the cardboard components of the coarse pieces are heated to a vapor pressure of 2 to 18 minutes.
3Kg/cm ² ) and is defibrated by beating with stirring to become pulp fibers. Further, as the lignin in the pulp fibers is eluted, the facing material components, that is, the thermoplastic resin and the added thermoplastic resin are plasticized. Next, the attached blower device is operated to gradually remove water vapor and generated gas to the outside. As generated gases such as water vapor are removed, the temperature inside the mixer rises due to frictional heat, and the temperature rises to 150 - 150 in 3 to 5 minutes.
The temperature rises to 200℃. When the temperature inside the mixer reaches 150°C or higher, the PP resin begins to melt and the thermoplastic resin uniformly surrounds the pulp fibers defibrated by beating, generally becoming wet with the resin. When the generated gas is completely removed, the temperature inside the mixer will be
The temperature is 200-205℃. A molten mixture of pulp fibers and molten thermoplastic resin is thus obtained. Next, the molten mixture is taken out from the heating mixer and placed in a mixer at room temperature, and the amount of thermoplastic resin is adjusted. If the amount of thermoplastic resin is small, add an appropriate amount.
For example, add 15 to 30 parts by weight of PP resin or PE resin to a mixer and form uniform granules while stirring at 200 to 500 rpm. The resulting granules are preferably molded using an extruder or injection machine equipped with a degassing device to produce a composite composition. Table 1 shows the physical property test results of the recycled compressed board manufactured by the method for manufacturing the composite composition described above, in comparison with the conventional recycled compressed board.

[Table] In Table 1, Comparative Example 1 is a recycled compressed board manufactured by a conventional method using the same crushed pieces as in Example 1, and Comparative Example 2 is a board that contains vinyl chloride resin as a facing material component. , Comparative Example 3 is a commercially available general recycled compression board. It is clear that the physical properties mentioned above are good, such as the impact resistance and the stickiness of the resin of the molded board, and the reason for the improvement in physical properties is that the beating and defibration of the cardboard is sufficiently promoted by the steam generated over a certain period of time when water is added. It can be seen that the particles are dispersed uniformly in the resin. Table 2 shows the state of recycling of scrap materials along with comparative examples.
Shown below.

[Table] As shown in Table 2, according to the method of the present invention, the amount of resin added is the smallest at 30 to 40 parts, and the cost of raw materials can be greatly reduced, resulting in excellent economic efficiency.

Claims (1)

[Claims] 1. Crushed scraps consisting of a facing material made of a thermoplastic resin that does not contain chlorinated vinyl resin and a corrugated cardboard base material joined to the facing material are crushed to form coarse pieces, and then put into a heating mixer equipped with a blower device. 30 to 50 parts by weight of the coarsely crushed pieces and 100 parts by weight of the coarsely crushed pieces
Parts by weight of thermoplastic resin and 3 to 10 parts by weight of water are added and stirred in a sealed state at a temperature range of 120 to 150°C, and the cardboard components of the coarsely crushed pieces are dissolved by the steam pressure and stirring caused by the added water. fiber, plasticize the facing material components, and then operate the blower device to gradually discharge the generated gas containing water vapor from the mixer,
Continue stirring to melt the thermoplastic resin component to form a molten mixture in which the defibrated pulp fibers are uniformly impregnated with the thermoplastic resin, and then transfer the molten mixture into a mixer at room temperature to melt the thermoplastic resin. Using scrap material consisting of a facing material and a corrugated cardboard base material, which is characterized by forming uniform granules with controlled amounts and molding the granules to produce a composite composition. Method of manufacturing a composite composition.