JPH0144498B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention provides a method for manufacturing a heat insulating material using waste material of hard polyurethane foam, and in particular, a method for manufacturing a heat insulating material using waste material of hard polyurethane foam, and in particular, a method for manufacturing a heat insulating material using waste material of hard polyurethane foam. The present invention relates to a method for manufacturing a heat insulating material using waste hard polyurethane foam, which uses a mixture of n=0 or an integer of 1 or more as a binder and is cured by reaction through thermal compression in the presence of a catalyst. (However, n = 0 or n = an integer greater than or equal to 1) In recent years, rigid polyurethane foam has been used as a heat insulating material in a wider range of industrial fields, compared to styrofoam, glass wool, gypsum board, etc. due to its excellent heat insulating properties. . However, when molding rigid polyurethane foam into products that can be used for various purposes as heat insulating materials, the process is performed step by step, including foaming processes such as block foaming and mold foaming. However, at this time, a large amount of waste materials such as cut wood and broken wood are generated. However, since these waste materials are originally extremely stable synthetic resin bodies with a low density, if they are disposed of as they are by landfilling, incineration, etc., there is a risk of causing a major pollution problem. On the other hand, these waste materials essentially have the excellent thermal insulation properties of rigid polyurethane foam. Therefore, it is required to use these waste materials as heat insulating materials, not only to eliminate the risk of causing pollution problems, but also from the viewpoint of resource conservation through effective recycling of waste materials. Conventionally, similar waste materials of soft polyurethane foam have been used to manufacture ribbon foam that can be used as cushioning materials for furniture such as sofas and beds. However, it is said that twice as much waste material as soft polyurethane foam is generated, and the amount of waste material from hard polyurethane foam is expected to increase further in the future. do not have. In view of the above circumstances, and in order to meet the above-mentioned demands, the present invention provides a method for manufacturing a heat insulating material using waste materials of rigid polyurethane foam. The purpose of the present invention is to produce a heat insulating material that has excellent heat insulating properties comparable to that of a general heat insulating material made of conventional rigid polyurethane foam, and has physical properties such as strength that can be used as a heat insulating material for buildings. At the same time, it eliminates the risk of causing pollution problems and saves resources by recycling and effectively using waste materials. The present invention achieves these objects by: (a) crushing or cutting waste material of rigid polyurethane foam; (b) using a binder represented by the above general formula (1); and (c) according to the above (a). and (b) are reacted and cured by thermal compression in a mold in the presence of a catalyst; If the product obtained by crushing or cutting is 20 mmφ or less including powder, use a water-soluble tertiary amine catalyst with a catalyst/water ratio of 1/10 to 1/50 as a catalyst. This includes cases where an aqueous solution is used and cases where the degree of thermal compression is within the range of 1/2 to 1/10. Hereinafter, the structure of the present invention will be explained in detail based on the drawings, which are schematic process diagrams. Here, hard polyurethane foam means hard polyurethane foam in a broad sense. These include those with intervening fibers and similar hard polyisocyanurates. First, as a raw material, waste hard polyurethane foam is crushed or cut into chips. In this case, according to the inventors' tests based on various combinations, the degree of crushing or cutting of the waste material of rigid polyurethane foam is related to the amount of binder used and the degree of thermal compression, etc., which will be described later. It affects the heat insulation properties and strength of the heat insulating material that is the product, and in general, if the raw material is made from large particles and made into chips, the heat insulation properties will be better, but the strength will be inferior.
On the other hand, if the raw material is formed into chips with a small particle size, the heat insulation properties will be poor, but the strength will tend to be improved. In order to improve insulation properties and strength, powdered material is used to ensure that each part of the insulation product is filled with hard polyurethane foam chips without leaking. It is best to use irregularly chipped materials with a diameter of 20 mm or less.
However, these can be arbitrarily changed depending on the properties required of the heat insulating material product. Then, a binder represented by the general formula (1) is prepared. In this case, when n=0, it is diphenylmethane diisocyanate (abbreviated as MDI), and n
A mixture where n = 0 or n = an integer of 1 or more is commonly called crude MDI. These binders are
Its viscosity is low, and when manufacturing a heat insulating material with a face material as described later, it is possible to apply only this material to the chip-shaped material, making it easy to work and economical. When using a prepolymer as a binder, it is necessary to prepare the prepolymer in advance, and it must be diluted with an expensive solvent before use. Furthermore, if a two-component coating consisting of a prepolymer and a catalyst is applied, there will be time constraints and there will be less flexibility in terms of equipment and production. On the other hand, separately prepare a catalyst. Various types of catalysts commonly used in the production of rigid polyurethane foam can be used for this catalyst, but in order to provide better heat insulation properties, strength, etc. to the heat insulating material product while taking workability into consideration, the catalyst It is preferable to use an aqueous solution of a water-soluble tertiary amine catalyst in the range of /water = 1/10 to 1/50. As the water-soluble tertiary amine catalyst in this case, triethylene diamine, triethylamine, tetramethylpropylene diamine, diethylaminoethanol, and tertiary amine compounds having chemical structures similar to these can be used. Next, the above-mentioned binder and catalyst aqueous solution is spray-coated onto the measured amount of the above-mentioned chip-shaped hard polyurethane foam waste and mixed for about 30 seconds to 5 minutes. In this case, for the same reason as above, the amount of binder applied is in the form of chips.
It is preferable that the amount is about 7 parts by weight or more per 100 parts by weight. However, as will be described later, when manufacturing a heat insulating material with a face material, it is not necessary to spray apply the aqueous catalyst solution at this stage. Finally, the material coated and mixed as described above is weighed, and the required amount is put into a mold for thermal compression and reaction hardening. In this case, it is best to use a mold, and by adjusting the temperature, time, and especially the degree of compression, the density, insulation properties, strength, etc. of the insulation product can be adjusted. However, the conditions related to these thermal compressions can be changed arbitrarily depending on the characteristics required of the heat insulating material product. Preferably, the temperature is 100°C or more, the time is 2 minutes or more, and the molding mold is 1/2 of what was put into
It is best to compress it to ~1/10. It is also possible to use a prepolymer as a binder to react and cure the chipped hard polyurethane foam waste with heated steam, but in this case, the reaction curing takes time and the absorbed moisture must be removed by drying. In addition, it is difficult to attach the facing material to the heat insulating material product at the same time. However, rigid polyurethane foam, which is generally used as a heat insulating material for buildings, has a facing material attached thereto, including for exterior purposes. According to the present invention, for example, when attaching face materials to both sides, the back face material is placed on the lower die of the mold, the aqueous solution of the catalyst is applied to the back face material, and the binder is applied onto the back face material. , the mixed chips are put in, and a surface material coated with the aqueous catalyst solution is placed on the side that will come into contact with the chips, or the chips are placed from above the chips. After applying a new aqueous solution of the catalyst, a surface material is placed on it, and then heat compression is applied.
The catalyst and water vaporize and permeate, reacting and hardening the chip-like material, and at the same time producing a heat insulating material with face materials attached to both sides, it is extremely efficient in this respect. In such a case, any material such as metal, paper, or wood can be used as the surface material, but it is preferable to use the side material that comes into contact with the chip-like material in terms of adhesiveness with the chip-like material. It is best to use a surface material laminated with polyethylene, for example. Incidentally, from what has been explained above, it is sufficient to carry out other detailed manufacturing procedures in the same manner as in ordinary molding. As explained above, the present invention has the following effects. (a) From the hard polyurethane foam waste that has been discarded in the past, it is possible to produce a heat insulating material with sufficient heat insulating properties, strength, etc. that can be used, for example, in construction. (b) From (a) above, it is possible to eliminate the risk of causing pollution problems and save resources by recycling and effectively using waste materials. (c) Since it uses a binder with a low viscosity that can be used as it is and is produced by thermal compression, it is easier to work with and is more economical than when a prepolymer is used as a binder. (d) At the same time, it is possible to efficiently manufacture the insulation material with a face material, and in this case, only the binder needs to be sprayed onto the chip-like material, so there is flexibility in terms of equipment and manufacturing. There is sex. ●Example 1 Waste material of glass fiber-containing hard polyisocyanurate foam, hard polyisocyanurate foam, or hard polyurethane foam with an average density of about 0.03 g/cm ² is crushed to produce chips of 20 mmφ or less, including powdered ones. They obtained something and used it as raw material.
Crude MDI (Sumidyur 44V-20, manufactured by Sumitomo Bayer Urethane) is added to this raw material as a binder.
was spray-coated in an amount of 10 parts by weight to 100 parts by weight of the raw material, and mixed for 3 minutes. On the other hand, a thin aluminum plate of polyethylene laminate covered with glass cloth was prepared as a face material, and an aqueous solution of triethylene diamine in a catalyst/water ratio of 1/20 was prepared as a catalyst. Using a flat mold, place the above-mentioned face material on the lower mold, and spray-coat the aqueous solution of triethylenediamine on the polyethylene laminate side,
On top of that, the above-mentioned raw materials with crude MDI applied and mixed were added. Then, after spraying the triethylene diamine aqueous solution again from above the loaded raw material, place the other surface material so that the polyethylene laminate side is in contact with it, close the upper mold, and reduce the volume to about 1/3. 2 at 120℃ so that
Heat compressed for minutes. As a result of repeating the same method, a desired heat insulating material having physical properties as shown in Table 1 below was obtained. (However, the results in Table 1 are the physical property values only for the core part from which the face material has been removed from the product insulation material.
Dimensional stability is measured at 150°C for 24 hours. In addition, test category 1 is glass fiber-filled rigid polyisocyanurate foam, test category 2 is rigid polyisocyanurate foam, test category 3 is
are each chip of rigid polyurethane foam. )

[Table] ●Example 2 Waste glass fiber-containing rigid polyisocyanurate foam with an average density of approximately 0.03 g/cm ² was pulverized.
Chips of 20 mmφ or less, including powders, were obtained and used as raw materials. To this raw material, while spraying Crude MDI (Sumidyur 44V-20, manufactured by Sumitomo Bayer Urethane) as a binder at a ratio of 10 parts by weight to 10 parts by weight of the raw material,
Mixed for a minute. Thereafter, in the same manner as in Example 1, heat compression was performed using a mold. However, in this case, the volume is 1/2,
It was thermally compressed to 1/5 or 1/10. As a result of repeating the same method, a desired heat insulating material having physical properties as shown in Table 2 below was obtained.

[Table] (However, the results in Table 2 are the physical property values only for the core part, which is obtained by removing the face material from the insulation product.) ●Example 3 Contains glass fiber with an average density of approximately 0.03 g/cm ² By crushing the waste material of hard polyisocyanurate foam,
Chips of 20 mmφ or less, including powders, were obtained and used as raw materials. Add crude MDI as a binder to this raw material at 15% by weight per 100 parts by weight of the raw material.
The mixture was mixed for 3 minutes while spraying the parts by weight. However, in this case, the crude MDI
Four types were used: Millionate MR (manufactured by Nippon Polyurethane Co., Ltd.), Isocyanate NO41 (manufactured by Nippon Polyurethane Co., Ltd.), PAPI-135 (manufactured by Kasei Upjiyon Co., Ltd.), and Sumidyur 44V-20 (manufactured by Sumitomo Bayer Urethane Co., Ltd.). Thereafter, in the same manner as in Example 1, heat compression was performed using a mold. Thus, by repeating the same method, a desired heat insulating material having physical properties as shown in Table 3 below was obtained.

【table】

[Table] (However, the results in Table 3 are the physical property values only for the core part of the heat insulating product from which the face material has been removed.
In addition, Test Category 1 uses Sumidyur 44V-20, Test Category 2 uses Millionate MR, Test Category 3 uses Isocyanate NO41, and Test Category 4 uses PAPI-135.
are used as crude MDIs. )

[Brief explanation of drawings]

The drawings are schematic process diagrams as an example of the present invention.

Claims (1)

[Scope of Claims] 1. A product obtained by crushing or cutting hard polyurethane foam waste, a single substance when n=0 in the following general formula, or a case where n=0 or an integer of 1 or more A method for producing a heat insulating material using a waste material of rigid polyurethane foam, characterized in that a mixture of the following is used as a binder and the mixture is reacted and cured by thermal compression in a mold in the presence of a catalyst. (However, n = 0 or n = an integer greater than or equal to 1) 2. Items obtained by crushing or cutting hard polyurethane foam waste, including powdered items20
A method for producing a heat insulating material using waste hard polyurethane foam according to claim 1, which has a diameter of less than mmφ. 3. The hard polyurethane foam waste material according to claim 1 or 2, which uses an aqueous solution of a water-soluble tertiary amine catalyst in a catalyst/water ratio of 1/10 to 1/50 as a catalyst. The manufacturing method of the insulation material used. 4. A method for producing a heat insulating material using waste hard polyurethane foam according to claim 1 or 2, wherein the degree of thermal compression is within the range of 1/2 to 1/10.