LU102758B1 - The process of manufacturing new insulating materials from which hard or soft boards, bulk granules and modeled products can be made - Google Patents

Abstract

The method of manufacturing granules (l.G) from bulk material, manufacturing various soft and hard fiberboards for different purposes and modeled products, especially for heat and sound insulation of different rooms. We have placed the machines in a line for the manufacture of insulation material by wet or dry processes, consisting of several independent, interconnected and synchronized machines and devices. These are the coarse grinder (2), the additive dispenser (3) as dry matter, the fan V1 (4) for transporting the coarsely ground mass (1), the supply pipe (5) connecting the two grinders, the injector (6) for Adding additives (3.G) in liquid or solid state, the fan V2 (8) to transport the finely ground substance to the silo with a cyclone (10) connected to the outlet (11) for extracting warm air from the cyclone and the device (12) for dosing the granulate into the package (EM).

Description

PROCESS FOR THE MANUFACTURE OF NEW INSULATION MATERIALS, FROM ns | WHERE HARD OR SOFT PLATES, BULK GRANULATE | AND MODELED PRODUCTS CAN BE MADE | The present invention relates to a new method for recycling the unusable polyurethane foam and textile residues obtained in the textile industry in the production of various fillers, which are produced in the automotive industry or in a similar industry. This creates a new thermally and acoustically insulating material suitable for installation in residential buildings, industrial facilities or buildings that require a high level of thermal and acoustic insulation.

According to the previously known solutions for the production of insulating materials, regardless of their raw material basis, the technical problem of the invention is how to solve the environmental protection problem of significantly large amounts of polyurethane and textile residues in our industry with a unified technical process.

In the search for solutions to this new challenge, we came to a unique solution to the problem of recycling similar residues in technological processes in the textile industry, further in the process of decommissioning old cars and similar vehicles and refrigerators, sofas and products from the textile and polyurethane industries.

Thus, with regard to the present invention and the related claims, we have invented a process for the manufacture of a new insulating material from residues of the above-mentioned materials, which find their use in the form of various panels, walls, models or bulk material suitable for laying as heat or sound insulation, both in the horizontal plane and as a filling for the construction of walls, ceilings, etc.

This means that the insulation material produced by the present method has found versatile application in the construction industry as hard or bulk material and which is used in the furniture industry in soft form as material for various fillers for sofas, sofas, beds and the like.

On the other hand, there are various ways to remove polyurethane or textile residues.

Most of these are incinerated in landfills or buried | buried.

Burying is an inherent risk, which is also quite expensive as synthetic materials are known to degrade very slowly.

Exposed to the sun is best, but this requires additional space and protection against the influence of external factors such as wind, birds and self-ignition, which incurs additional costs for the manufacturer who produces these residues.

In addition, the incineration of these residues in the open air is ecologically very controversial due to the formation of toxic gases.

However, incineration in certified incinerators involves high financial investments by the manufacturer of the residues.

When developing the process of recycling polyurethane residues, we started from the well-known technical solutions of individual devices that were previously used for early stages of preparation, such as:

B.

Cutting, tearing, drying, adding various additives and defects in the systems of today's manufacturers of various insulating materials from other residues such as: paper, cellulose, plastic, etc.

According to our invention and through preliminary investigations, we have found that the purpose of our invention is to provide another recycling process of polyurethane and textile residues by using devices already known and putting them in the right order of our process, ultimately achieving the desired result , the subject of which is the grant of a patent.

In this context, it should be emphasized that we have really developed a new insulation material that, on the one hand, meets all the prescribed quality standards and, on the other hand, offers versatility in its application.

In general, with the present invention, we have overcome a major cost and environmental problem in our country, and we have already dealt with the initial disposal of textile residues from other manufacturers who have faced similar problems, i.e. how to plan and manage disposal and recycling • Process large quantities of textile residues with minimal investment of money.

We have noticed that there are various patent applications dealing with the recycling of individual waste and various residual materials.

In essence, all of these patent applications are aimed at finding solutions to a useful application of paper and cellulose, rubber and plastic residues.

However, none of the applications addressed the issue of polyurethane recycling or textiles, or a combination of these two materials, or defined products made from this recycled blend.

By examining the inventions already registered, we found that there are different technical solutions for the recycling lines of other residues already mentioned.

In our case i.e.

However, we have not found any similar reported solutions for recycling textiles and polyurethane using our process.

Therefore, we will indicate at least some of the patent solutions already pending, which show positive dimension and innovation of our solution and serve as a supporting element in demonstrating our innovation: IT BL92A000019 offers a solution for the manufacture of hard disks from waste paper, cellulose residues and similar materials.

SI 20267 A also offers a solution for the application of cellulose residues in connection with cement.

AT 1318/85 and AT 2896/85 deal with formwork walls filled with glass wool, which while showing similarities to one of the forms used by our insulating material, the dosing of our material into an existing formwork or opening is a novelty in construction and is likely to become so be a subject of the second patent application.

EP 08429667 A2 deals with composite materials in the manufacture of glass mineral fibers from glass wool and as such has nothing in common with our patent.

According to the information known to us so far, no manufacturer of such devices that have been proposed in the present invention has connected such or a similar device into a unified system to date, so that a quick and easy system expansion in the event of a

Capacity increase due to the increase in production would be possible. The search for a technical solution required many tests with individual devices, since we set ourselves the goal of obtaining, at the end of the product line, very volumetric granules, suitable for dry or wet dosing in the manufacture of various panels or when dosing the granules in Formwork walls that have already been erected and their consolidation at the same location is suitable. | On the other hand, by examining known technical solutions of similar processes on a global scale, we have found that our solution to the problem is unique and represents a novelty in the field, which is reflected in this patent application and its patent claims.

| The novelty lies mainly in the individual solutions to technical problems that arose in the design process, since the goal was set high. However, this is the most important property of the process itself, which allows the production of a product from waste and which, besides, is a widespread and highly commercial product that has found wide application thanks to unexpected results and usability and quality characteristics. The present invention innovatively solves the problem of the uniform and high-quality addition of additives after the pre-grinding phase of cut textile or polyurethane residues or the mass of both materials, which can be mixed with one another in a ratio of 0:100 or 100:0. However, the optimal ratio is reached at about half the ratio of both substances.

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| Also part of the process of manufacturing new insulating material from polyurethane and textile residues is the fact that the mill is where the crucial phase of the whole process takes place, namely the process of flocculation of granules, during which fine, short threads are extracted from the granules.

The basic function of the threads is to hold back the finest grains of the additives that coat the granulate grain.

The third technical solution solved by this invention is mass volumization in dry or wet form depending on the final purpose of the product.

On the basis of the established state of technology and the tests carried out in production, we have confirmed certain advantages of the process, which are reflected in particular in the simplicity of the entire process and in the cheaper and faster implementation of the acquired technologies and the introduction into automated production.

This simplicity is also reflected in the high-quality and fast exchange of material, in the way of dosing additives with regard to the requirements of the imported product.

This simple targeted exchange of the input materials and differences in the dosage of additives for different end products, both dry and wet, gives our invention a special innovative weight.

The problem of textile and polyurethane waste is solved by a line for the production of insulation material, composed of several independent, interconnected and synchronized machines and devices, presented below in text and pictures, operating according to the method described above in several versions.

The present invention is further illustrated by the following figures.

Figure 1 Longitudinal section of a line for the production of new insulation material using a wet or dry process.

Figure 2 Irregular round shaped granule or flake with additive grains trapped in the granule strands produced by the flocculation process.

Figure 3 Granulate grain or flakes of irregular oblong, cylindrical or conical shape with additive grains trapped in granular fides produced by the flocculation process.

Figure 4 Granulate flake as a possible body shape, which is even more undefined than in Figure 3, the threads are mostly polarized in the same direction. | Figure 5 Star-shaped flake or granule.

Figure 6 shows the combination of ground materials with a binder and additives.

Figure 7 shows the bonding of ground materials and irregularly shaped polyurethane flakes with binders and additives.

Figure 8 shows a cross-section of a modeled or formed product in a solid, soft, or loose state of aggregation that includes all of the components of Figures 2 through 7.

The line for the production of new insulation material by wet or dry processes consists of several independent, interconnected, synchronized machines and devices (see Figure 1). These are a coarse mill 2, an additive dispenser 3 for dry matter, fan V1 4 for the transport of coarsely ground mass or pre-ground material 1, discharge line 5 connecting both mills, injector 6 for adding additives (with or without air supply) in liquid or solid state, fine mill 7, fan V2 8, for transporting finely ground material 1.G to the silo with a cyclone 10, duct 9 for transport to the silo with cyclone 10 to which an outlet 11 is connected to extract warm air from the cyclone to remove, and a device for dosing the granules 12 in the package EM.

The coarse mill 2 shown in Fig. 1 is used for coarse grinding of the input raw material VS, which is cut here into smaller flakes or strips or pre-ground material 1 with a size of 1 to 20 cm3.

Thus, the cut and pre-ground material 1 fig. 1 is transported through the duct 5 in fig. 1 by means of a fan VI, indicated with n. 4 fig.

An additive dispenser 3 is connected to the pipeline 5 shown in Fig. 1, which adds various additives in the form of dry matter. Wet additives can also be used depending on the required condition of the insulating material. Before entering the mill 7 Fig. 1, in which the incoming mass or the pre-ground material 1 Fig. 1 is further finely ground into the final granulate 1.G or into a finely ground mass, additives 3.G in dry - or wet form added, for which a | Injector 6 is used to add additives 3.G Fig. 1.

The milling process in the mill 7, Fig. 1 depends on the desired purpose of the granulate 1.G, whether it is to be in a wet or dry state, or whether it is intended as a filler in the loose state or as hard/soft sheets.

The grain size depends on the basic dimensions of the screen perforation in the mill 7, Fig. 1 and varies from 1 to 20 millimeters.

The granules usually have an irregular geometric shape, which are impregnated with 3.G additives and are usually added in the form of a finely divided mist.

The fan V2 marked in Fig. 1 with No. 8 transports finely ground mass or granules 1.G through the pipeline 9, Fig. 1 to the silo with cyclone 10, in which various additives 3.G and binders 4 .G can be added and where the bulking and drying process of the granulate 1.G takes place. The granules

1.G is finally collected via the dosing device 12 in the prescribed packaging EM.

Excess heat is dissipated via the outlet device 11, Fig. 1.

In the case of start-up, when producing various insulating boards or molded products, wet-glued granules 1.G can be fed to the presses and dryers (which are not a subject of the present invention).

If we are talking about the manufacture of slabs or modeled products, granules 1.G can be covered with binders 4.G just before entering the compression phase.

The method shown in Fig. 1 is simple and self-explanatory in that it is understandable for anyone familiar with such technical problems, however, this gives rise to certain new innovative discoveries which have led to this patent application of the invention.

In fact, while testing the technology and searching for optimal solutions, we came to the conclusion that in the process of grinding polyurethane waste and/or textile residues or input material VS, which is marked with in Fig. 1 No. 7, this is also the task of the calibrated Grinding has, for a certain time, as long as the grinding phase lasts, these residues also tear, knead and cut and homogenize the components together. This also causes the so-called Flocculation process of granules 1.G shown in Figures 2, 3, 4 and 5. This produces short fine threads 2.G illustrated in Figures 2, 3, 4 and 5 and having a length of 1 to 5 millimeters , drawn from the granules 1.G shown in figs. 2, 3, 4 and 5.

| Each granule grain 1.G shown in Fig. 2, 3, 4 and 5 is full of these threads 2.G shown in Fig. 2, 3, 4 and 5, which have the property of containing the finest particles of the added in the spaces between the threads Additives 3.G shown in figs. 2, 3, 4 and 5 and the binder 4.G shown in fig. In the friction and kneading phase in the mill 7 shown in Fig. 1, fine granulate particles of the additive 3.G shown in Fig. 2, 3, 4 and 5 and the binder 4.G shown in Fig.1 are incorporated into the granulate 1.G Figs. 2, 3, 4 and 5, and coat the entire grain with a coat of pressed additive grains 3.G, Figs. 2, 3, 4 and 5 and the binder 4.G in Fig. 3. Adding a fine Dispersed water mist into the mill 7 shown in fig. 1 enables the additive grains 3.G, fig. 2, 3, 4 and 5 and the binder 4.G, fig. 3 to penetrate deeper into the center of the granulate 1.G fig. 2, 3 , 4 and 5. During the calibration of the granules 1.G Fig. 2, 3, 4 and 5 through a mill sieve, the material is intensively kneaded. Due to the internal friction in the granules 1.G Fig. 2, 3, 4 and the local temperature above 100% C, most of the added moisture evaporates. Fig. 2 shows schematically a granule 1.G with an irregular round shape with glued additive granules 3.G, on the threads 2.G, which were produced by the flocculation process.

The textile is usually covered with a layer of polyurethane foam. The grain size in the profile is from 1 to 200 square millimeters. For the production of panels or modeled products, binders 4.G or adhesives, which can have different chemical structures, are added to the mixer. The percentage of binder 4.G or adhesive can be 1 to 50% by weight. Fig. 3 shows, similar to Fig. 2, a granulate 1.G with a coat of added additives 3.G. The grain shape can be oblong, cylindrical or conical, irregular geometric shape. Fig. 4 shows a granulate 1.G as a possible body shape. The shape is even more undefined than in Fig. 3. The threads 2.G of the granulate grain 1.G are mostly polarized in the same direction. Fig. 5 shows a similar picture of granule grain 1.G as Fig. 3, it only has a more star-shaped contour. It bears no resemblance to the round shape of the granules. Fig. 6 shows the combination of granulate 1.G with the binder 4.G and the additives

3.G. The thickness of the threads 2.G in Fig. 6 is from 0.005 to 2 millimeters, the thread length is from 1 to 60 mm. The binder 4.G and additive 3.G Fig. 6 were added by means of a water mist during grinding in the mill 7 Fig. 1 and 2 and during subsequent stirring in the silo with cyclone 10 in Fig.1. At the thread transitions Fig. 6 there is a thickened part of the binding agent 4.G Fig.6. The part by weight of binders 4.G and additives 3.G can be between 0 and 60%. 4.G binders and 3.G additives are not used if it is a production intended exclusively for exterior wall cladding (finished formwork), because in this case granules and additives that prevent rot, insects, sedimentation, etc. prevent being injected directly into the formwork. | Fig. 7 is similar to Fig. 6 showing a structure of the mixed granules 1.G, except that polyurethane flakes PU with irregular geometric shape are added | will. Polyurethane can be made on the basis of polyester or polystyrene.

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It can be hot-laminated-laminated on textiles.

The polyurethane grain size in Fig. 7 can be from 1 to 2000 cubic millimeters.

Fig. 8 shows a cross-section of the modeled or molded product and includes compressed shapes from Figs. 2 to 7. The bulk density of the granules 1.G from Figs. 2 to 7 is from 15 to 150 kg/m3, the bulk density of the compressed granules 1.G Fig. 8 is from 100 to 1800 kg/m3. Thermoplastics or duroplastics as well as various polyurethane binders are used as binders 4.G.

Binder 4.G Fig. 8 can react with heat or moisture or with both at the same time.

The outer shape, visibly highlighted by the compressed granules 1.G and the polyurethane granules PU in Fig. 8, can be flat or shaped with negative angles.

The surface roughness (unevenness) can depend on the density, hardness and particle size of the granules 1.G and the content of polyurethane granules (PU) in Fig. 8.

As already mentioned, the ideal distribution of both materials (textile and polyurethane) in the mixture is 1:1. The proportion of adhesive is between 0% and 50%, depending on the requirements and the type of binder. Additives include any material that is added either before roughblanking or before fineblanking.

These are materials that prevent rot, burning, insect infestation, odor control, etc.

These are materials purchased in a wide trading network and used in accordance with the regulations of manufacturers.

Therefore, the state of the art is known and we will not specifically describe it.

In the following some implementation examples for the construction of a production line for the production of the new insulation material are shown.

Example 1: The use of granules 1.G as insulating material in the form of bulk material for filling cavities, to which water and other additives 3.G and binders 4.G with a specific weight of 10 to 150 kg/m3 are added to bind to allow in a full cavity. A filling device is used for filling cavities, which is not an object of the present invention, consisting of a granulate feed and a binder feed, which is fed during the filling process. The dry granulate 1.G, which already contains additives, is filled into the cavity

3.G has been mixed in an appropriate amount and according to the additive manufacturer's instructions. A cavity wall can be filled with granules 1.G without additives, which are later added in dry or wet form when filling. When filling in wet form, water with additives 3.G can be injected into the cavity through a special additional nozzle together with granules 1.G, and through another nozzle powder additives 3.G. Additives 3.G, additives and granules 1.G mix with each other due to turbulence and thus physically bind the granules 1.G. If the filling is in wet form, additives 3.G and additives are previously diluted in water and are mixed with the granules 1.G during the filling process. After the filling process is completed, the cavity is closed. Inside, the granulate 1.G slowly hardens under the influence of solidifying agents and thus prevents settling. If the granulate 1.G is added without setting additives, it does not harden but remains prestressed in the wall (spring effect). Example 2: | The use of granules for the production of duroplastic panels with a specific weight of 50 to 1800 kg/m3. Hardboards are made from prefabricated granulate 1.G with added | Additives 3.G and additives made. The granules are processed in the mill 7 Fig. 1 or later in the mixer or by manual mixing

A binder 4.G is added to 1.G, which allows the formation of a hard plate by compressing and drying the granules 1.G. The process of panel production can be individual or continuous with treated or untreated surface. There are endless design variations for the manufacture of

Plates that depend on the technical skills of the manufacturer, which are not dealt with in this application.

Example 3: Use of granules for the production of soft thermoplastic panels with a specific weight of 10 to 200 kg/m3. Soft boards are made from prepared granules 1.G with additives 3.G and additives containing thermoplastic binders 4.G.

A thermoplastic binder 4.G is added to the granules 1.G, which enables the production of a soft panel by dissolving the binder 4.G in a tunnel oven and binding the granules 1.G after the drying process or cooling.

The flow of soft board manufacture is largely continuous.

Example 4: Use of granules to produce modeled parts with a density of 10 to 1800 kg/m3. Modeled parts are made from ready-made granules 1.G with added additives 3.G and additives.

In the mill 7 fig. 1 a binder 4.G is added, which allows the production of a hard molded product by compressing the granules 1.G.

The manufacturing process of modeled parts is largely individual, but can also be continuous on an automated line.

Moulded/modelled products can have areas of different density in their volume, which is achieved by different (sectionwise) filling of the models.

Molded/modeled products can be made with 4.G thermoplastic or thermoset binders as described in Examples 2 and 3.

As we can see from the previous text and according to the present invention, the proposed process for the manufacture of insulating material from polyurethane and textile residues can be adapted to any need, resulting in a final product with potential and a wide range of applications or further finishing for a wide range presented by applications.

Claims (6)

patent claim 1. The process for the production of new insulating materials, from which hard or soft boards, bulk granular and modeled products can be made, is characterized by the fact that it is applicable both to the use of raw materials | (VS) such as polyurethane and textile residues as well as their mixture is designed, which is first coarsely ground into smaller parts or pre-ground mass (1) | and according to need with dispenser 3 at this stage add additives (3.G) required to prevent rotting, burning and odors, if necessary, other agents that prevent oxidation, disinfect, bacteria and harmful insects in the required amount combat added and pre-ground mass (1) is finally transported through the pipeline (5) with the help of fan V1 (4) to a fine mill (7), in which in the first stage of the process a sufficient amount of various additives (3.G) with can be added to the injector (6), which are necessary for volumizing and solidifying the mixture and in the second stage, this mixture can be ground again to a finely ground mass or fine granules (1.G) and be ground and kneaded during this individual granulate particles are flaked and thus attract binders (4.G), additives (3.G) and additives and the resulting mixture, which, due to friction, locally heated in the mill, is again forcibly transported by means of ventilation V2 (8) to the silo with a cyclone (10), in which excess moisture is removed through the outlet (11) and the granulate (1.G) is dried; the granules (1.G) are finally collected with a granule dosing device (12) in a packaging (EM) for this or removed for further compression treatment. 2. The process for the production of new insulation materials, from which hard or soft board, bulk granular and modeled products can be made, according to application 1, characterized in that additives (3.G) and binders (4.G ) on both levels, both wet and dry. 3. The process of making new insulating materials from which hard or soft | Slabs, bulk granular and modeled products can be manufactured | can, according to application 1, characterized in that during the grinding process in the second grinding stage the granulate (1.G) made of polyurethane and textile fiber mixture flakes and binds binder (4.G), additives (3.G) or additives, which then coat the individual granules (1.G) and thus form a compact mixture. 4. The process for the production of new insulating materials, from which hard or soft boards, bulk granular and modeled products can be made, according to proposal 1, characterized in that the granular shapes have different shapes from irregular round, conical, cylindrical, oblong or irregular star shape. 5. The method of manufacturing new insulating materials, from which hard or soft boards, bulk granular and modeled products can be made, according to proposal 1, characterized by the fact that textile and polyurethane fibers are mixed in the optimal 1:1 ratio, this Additives (3.G), binders (4.G) and additives can be added to the mixture depending on the desired final form and the state of aggregation. 6. The method for the production of new insulating materials from which hard or soft boards, bulk material in granular form and modeled products can be produced according to application 1, characterized in that the granules (1.G) as a final product can also be used for volumetric filling of cavity walls , can be used to produce hardboard of various shapes by compression processes, to produce softboard and to produce molded boards of different strengths.