JP3210813B2 - Granular composite material, secondary processed product thereof, and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a granular composite material obtained by recycling material from shredder dust (including dust shredded to the size of a shredder dust even if it is not shredded). The present invention relates to a material and a secondary processed body thereof (a solid body obtained by solidifying a granular composite material) and a method for producing the same.

[0002]

2. Description of the Related Art The recycling of waste materials has been proposed, for example, in Japanese Utility Model Laid-Open No. 5-85629. Conventionally, as shown in FIG. 12, the main purpose of waste materials, particularly waste materials containing various types of materials, such as shredder dust of scrap cars, is to collect iron and non-ferrous metals, and the remaining plastic, rubber, urethane, and fiber are used. It was considered impossible to recycle the materials because of the variety of materials, and they were exclusively landfilled or incinerated.

[0003]

The weight ratio of scrap car shredder dust having a size of 20 mm or more is shown in FIG.
0, and the volume ratio of those having a size of 20 mm or more is as shown in FIG. Therefore, even if metals occupy 10% by weight, they are less than 1% by volume, and almost all are plastics, rubber, urethane, and fibers. The annual amount of scrap car shredder dust generated is 165 kg per vehicle, which is 825,000 tons / year assuming that 5 million vehicles are scrapped annually. _Two
And the like occurs in large quantities. SUMMARY OF THE INVENTION An object of the present invention is to provide a granular composite material obtained by recycling a shredder dust excluding metals, that is, a material containing plastic, rubber, urethane, and fibers, so that it can be used for other materials, and a secondary processing thereof. It is an object of the present invention to provide bodies and methods for their production.

[0004]

The present invention for achieving the above object is as follows. (1) The metal component is selectively removed from shredder dust. It is mainly composed of urethane, fiber, plastic, and rubber, and is crushed into various sizes of 10 to 20 mm or less. Is 0.3g / cm
^The base material controlled to ³ or less is sieved through a sieve having a predetermined amount larger than the size of the crusher in crushing of various sizes, so that urethane, a material A containing fibers as a main component, and plastic and rubber as main components. And a granular composite material roughly classified into: (2) Shredder dust having a size of 10 to 20 mm or more is selected as a raw material of the composite material, and iron, non-ferrous metal, and wire harness are selectively removed from the shredder dust, and urethane, fiber, plastic, and rubber are mainly used. screened a mixture of light material to a bulk density by the various sizes of less than or equal to the size of the previous SL 1 0 to 20 mm was triturated with a mixture a pulverizer of the lighter material is 0.3 g / c
with the m ³ or less of the substrate, by applying a predetermined amount larger eye sieve than eye crusher said substrate in milling of various sizes, materials A and sieve the urethane on the sieve, the fibers as a main component A method for producing a granular composite material, comprising the steps of roughly classifying into a material B containing plastic and rubber as main components. (3) The method for producing a granular composite material according to (2), wherein the material A is lighter than the material. (4) The metal component is selectively removed from the shredder dust. It is mainly composed of urethane, fiber, plastic, and rubber, and is crushed into various sizes having a size of 10 to 20 mm or less. Is 0.3g / cm
^The base material controlled to ³ or less is sieved through a sieve having a predetermined amount larger than the size of the crusher in crushing of various sizes, so that urethane, a material A containing fibers as a main component, and plastic and rubber as main components. A material B to be divided into a granular composite material, a fibrous resin material obtained by solidifying the material A or the material B of the granular composite material into a solid body having a predetermined shape,
A secondary material formed of a composite material comprising: (5) The secondary material for a composite material according to (4), wherein the resin material is a thermoplastic resin material. (6) The composite material secondary work according to (4), wherein the resin material is composed of a granular composite material and a binder. (7) The post-processed composite material according to (4), wherein the resin material is a composite fiber. (8) The secondary processed composite material according to (4), wherein the resin material is a composite fiber, and the solid body is an automobile soundproofing material. (9) The secondary worked composite material according to (4), wherein the resin material is a urethane-based adhesive, and the solid body is a U-shaped groove. (10) Shredder dust having a size of 10 to 20 mm or more is selected as a raw material of the composite material, and iron, non-ferrous metal and wire harness are selectively removed from the shredder dust, and urethane, fiber, plastic, and rubber are used as main components. screened a mixture of light material to a bulk density by the various sizes of less than or equal to the size of the previous SL 1 0 to 20 mm was triturated with a mixture a pulverizer of the lighter material is 0.3 g /
cm ³ or less, and in crushing of various sizes, the base material is sieved through a sieve having a predetermined size larger than that of the crusher, thereby urethane on the sieve, a material A containing fibers as a main component, and a sieve. roughly a plastic that has passed, to the material B composed mainly of rubber, to produce a particulate composite material, mixing the material a or material B and a fibrous resin material of the <br/> particulate composite material, Heating the mixture of the granular composite material and the resin material,
A method for manufacturing a secondary processed composite material comprising a step of solidifying to form a solid body having a predetermined shape. (11) The method for producing a secondary processed composite material according to (10), wherein the solid body is further subjected to hot press molding into a target shape.

[0005]

The granular composite material of the above (1) has a bulk density of 0.
Since it is controlled to be ³ g / cm ³ or less, the specific gravity is almost constant irrespective of the variety of materials of each grain, and it can be easily used as a raw material for other materials such as a soundproofing material and a U-shaped groove. Will be able to Therefore, what was previously buried and incinerated as being unusable because it contains many types of materials is managed as a raw material for other things by treating it as a single material by managing it based on bulk density standards. Will be available. The method for producing a granular composite material according to the above (2) is a method for obtaining the granular composite material according to the above (1), wherein metal is removed from shredder dust and then pulverized into various sizes of about 10 to 20 mm or less. A granular composite material having a bulk density of 0.3 g / cm ³ or less can be obtained automatically. In the above method (3), the bulk density is 0.
By sifting a substrate having a size of ³ g / cm ³ or less through a sieve having a predetermined amount (for example, +3 mm) larger than the mesh of the pulverizer, and dividing the material into a material above the sieve and a material below the sieve (the material having passed through the mesh). , Can be automatically divided into light (urethane, fiber, etc.) and slightly heavy (plastic, rubber, etc.)
For example, a light material can be used as a raw material for a soundproofing material, and a slightly heavy material can be used as a raw material for a U-shaped groove, depending on the application. In the above (4), since the composite material is solidified with a resin material and subjected to secondary processing (solidification), handling is easy,
If the shape to be solidified is the final product shape, it will be the final product as it is. In the above (5), since the resin material for hardening is fibrous, the strength of the solid body is high. When the final product is a plate-like sound-insulating material, it can be directly used as a sound-insulating material at the stage of solidification. In the above (6), since the resin material for solidification is composed of the granular composite material and the connecting material (such as coarse hair, cotton, hemp, and synthetic fiber), the strength of the solid body is further increased. In the above (7), since the resin material is a composite fiber, the strength of the solid body is high. In the above (8), since the automobile soundproofing material is a final product in use, when the scrap car dust is used as the shredder dust, the material is recycled from car to car. In the above (9), since the resin material is a urethane-based adhesive, the solid body has high hardness and strength and can be used as a U-shaped groove. In the above (10), the mixture is mixed with a resin material and heated to be solidified into a solid body having a predetermined shape. In the above (11), it is further processed into a desired final product shape by a hot press.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows a granular composite material 1 according to a first embodiment of the present invention. The granular composite material 1 is made of shredder dust, for example, scrap car shredder dust, and is made of urethane 2, fiber 3, plastic 4, rubber 5
Each particle as a main component, the size of each particle is about 10-20 mm
Below (a size of 10 to 20 mm passed through a sieve) and a bulk density of 0.3 g / cm ³ or less (for example,
Consisting ^{0.3g / cm 3 ~0.05g / cm 3} ) to those managed. Here, the bulk density is determined as a value obtained by fully filling the granular composite material 1 without pressing it into a container having a predetermined volume, and dividing the mass of the granular composite material 1 at that time by the container volume.

The above granular composite material 1 is manufactured by the method shown in FIG. First, in step 11, shredder dust is prepared. Then, in step 12, the shredder dust is passed through a rotary sieving machine (having a mesh size of 10 to 20 mm) to collect dust having a size of about 10 to 20 mm or more (those remaining on the sieve, step 13). . The small powdered dust that has passed through the screen is discarded or regenerated for other uses. Next, in step 14, a shredder dust having a size of about 10 to 20 mm or more is subjected to a magnetic separator to remove an iron material. Next, in step 15, the shredder dust is passed through a non-ferrous metal sorter to remove non-ferrous metals such as aluminum and copper. The above-described magnetic separator and non-ferrous metal separator may be conventionally known ones. Next, in step 16, the wire harness is removed. The wire harness is longer than granular plastic, rubber, urethane, fiber, etc., and can be removed by passing it through a lattice comb. The product from which the wire harness has been removed is sorted and collected as a light granular mixture (Step 1).
7). The light composite is then subjected to at least one stage in a rotary pulverizer in step 18 to reduce the granular dust having a size of about 10 to 20 mm to various sizes of about 10 to 20 mm or less, for example, 1, 2, 3, 6, 8, 12
Grind to mm or the like. The substrate obtained in this step is a substrate (Step 19), and the granular material of the substrate does not contain metal,
It is composed of mixed granules mainly composed of plastic, fiber, urethane and rubber of various sizes having a size of about 10 to 20 mm or less. As shown in FIG. 3, the bulk density of the base material is between the upper limit of the base material and the lower limit of the base material, and the particle size is 1 to 20.
mm (up to 12 mm in the figure) is substantially 0.3 g / cm ³ or less (0.3 to 0.05) regardless of the particle size.
g / cm ³ ). Therefore, the particle size is crushed in step 18 to various sizes of 1 to 20 mm, so that the bulk density is automatically reduced to 0 regardless of the various materials, that is, including plastics, rubber, urethane, and fibers. 0.3 g / cm ³ or less. This makes it easier to reuse as a raw material for other things,
Landfill and incineration can be recycled.

Further, as shown in FIG. 2, a substrate (plastic, rubber, urethane, fiber granules) is prepared in step 20.
Then, the mixture is passed through a rotary sieving machine having a crushed particle size of about 3 mm and a light granule remaining on the sieve (a granule mainly composed of urethane or fiber; hereinafter, referred to as a material A) and (in step 21) Sampling), slightly heavy granular material under the sieve (plastic or rubber-based granular material, hereinafter referred to as material B) and (Step 22)
) Is roughly classified. Plastics and rubbers have a small particle size expansion due to expansion (spring back) of the crushed material, and pass through a sieve with a diameter of about 3 mm larger than the crushed particle size of the crusher. Particle size expansion due to expansion is large, it can not pass through the eyes of the sieve, thereby, urethane, granules mainly composed of fibers,
They are roughly classified into granular materials mainly composed of plastic and rubber. Above, pulverize with pulverizers with different pulverized particle sizes,
Each time, by screening with a sieve of the crushed particle size + 3 mm, the granular material is, for example, an A material having a particle size of about 12 mm, a B material having a particle size of about 12 mm, an A material having a particle size of about 8 mm, It can be classified into B material having a particle size of about 8 mm,... Material A having a particle size of about 1 mm, and B material having a particle size of about 1 mm. Then, the respective bulk densities are measured and plotted, as shown in FIG. The B material exhibits almost a single bulk density at various particle sizes (the bulk density hardly varies), while the A material varies between the upper limit and the lower limit (0.12 to 0.03). However, the variation is small, and the specific gravity of the material is about 0.06 for the A material and about 0.23 for the B material. And
This can be said irrespective of the change of the particle size and the change of the material. For this reason, various materials, 1 mm to 20 m
This shows that substrates containing various particle sizes of m can be further separated into industrial materials having a specific gravity that is almost constant and easy to handle, and material recycling becomes more appropriate and easier.

FIG. 4 shows a second working body 6 according to a second embodiment of the present invention, in which a granular composite material is solidified. FIG.
Among them, 1 is a granular composite material 1 of the first embodiment, which is crushed into various sizes of about 10 to 20 mm or less, and mainly comprises urethane, fiber, plastic, and rubber having a bulk density of 0.3 g / cm ^3. It is a mixed material as a component. Also, 7
It is a resin material as a binder which solidifies the granular composite material into a solid body having a predetermined shape. The resin material 7 is made of a thermoplastic resin or a thermosetting resin. Before the resin material 7 is heated and solidified with the granular composite material 1, the resin material 7 may be a polyester composite fiber which is a fibrous thermoplastic resin, and is connected to various fiber materials such as PE powder and phenol powder. In some cases, natural fibers such as trichomes, cotton, hemp, etc. may be added as materials, and in some cases urethane-based adhesives. By mixing 5 to 10% of the fibrous thermoplastic resin, the soundproofing effect of the secondary processed body 6 (FIG. 7 shows a test example of the soundproofing effect of the vehicle soundproofing material) and the strength (FIG. 8) are increased, and the urethane type In the case of an adhesive, molding into a block body becomes easy.
In addition, the secondary processing body 6 may be, in some cases, an automobile soundproof material 8.
(For example, a dash silencer), and in some cases, a U-shaped groove 9. In the case of a soundproofing material, the granular composite material 1
Is preferably a light A material (urethane or fiber), and the resin material 7 is desirably a fibrous thermoplastic resin. In the case of a U-shaped groove, a base material (step 19) or a slightly heavy B material (plastic, rubber) is preferably used for the granular composite material 1, and a urethane-based adhesive is preferably used for the resin material 7. Can be

FIGS. 5, 6, and 9 show a method of manufacturing the secondary processing body 6 using a soundproof material and a U-shaped groove as an example. In the manufacturing method of FIG. 5, in step 31, the fibrous thermoplastic resin is supplied to the preliminary defibration step 32 by the conveyor 36. In the preliminary fibrillation step 32, the fibrous thermoplastic resin is prefibrillated by the fibrillator 37 to produce a cotton-like sheet. Next, in a waste material input step 33, a predetermined amount of a shredder dust substrate (granular composite material 1, preferably light A material) is evenly spread on a cotton sheet, and then mixed in a mixing and defibration step. Disintegrate. Next, in step 35, the cotton-like sheet that has been subjected to the mixed defibration is heated in an oven 40, compressed to a required thickness, and cooled to obtain an intended secondary processed body, for example, a soundproofing material for vehicles. Such a secondary processed body has strength while being air permeable by using the fibrous resin. In addition, the use of fibrous resin reduces the amount of harmful substances emitted from the manufacturing process, and has a good effect on environmental hygiene. FIG. 6 is a view obtained by adding a pressing step 41 to the step of FIG. 5. In this pressing step 41, hot press forming or cold press forming by heating again is performed by a press machine 42, and the secondary shape of the final shape is obtained. It is processed into a processed body, for example, a dash silencer and a floor silencer which are vehicle soundproofing materials.

FIG. 9 shows a case where the secondary processing body 6 is a U-shaped groove. In step 51, a scrap 57 is prepared by removing metal and wire harness from scrap car shredder dust having a grain size of 20 mm or more. Next, in a grinding step 52, the substrate 19 is ground by a rotary grinder 58 to various sizes of 10 to 20 mm or less. This base material 19 is subjected to the rotary sieve process 5
In 3, the material is roughly classified into a light material A and a slightly heavy material B by the rotary sieve 59. Among them, for example, the material B is sent to the adhesive mixing step 54, where it is mixed with the urethane-based adhesive by the mixer 60. This mixture is subjected to heat molding step 5
At 5, heat molding is performed using a press machine 61, and is collected as a U-shaped groove 62 in a collected solid matter collecting step 56. Conventionally, the resin content of the scrap car shredder dust has been buried and incinerated, but in the example of FIG.
This U-shaped groove has no corrosion and has excellent durability. In addition, the construction is easy because it is lighter than the conventional concrete. Unlike concrete, it can be cut with a saw, fixed with nails or bolts, bonded, and the like, facilitating actual assembly.

[0012]

According to the granular composite material of the first aspect, since the bulk density is controlled and the particle size is almost uniformed to 20 mm or less, the uniformity (specific gravity, specific gravity, Size) and material recycling becomes possible. According to the method for manufacturing a granular composite material according to the second aspect, it is possible to pulverize and sieve multi-material mixed dust, which was conventionally considered to be impossible to recycle after the metal is recovered, and to control the bulk density. Thus, it becomes possible to change the material into a recyclable granular composite material. According to the method of the third aspect, since the base material is further divided into light and slightly heavy materials, a composite material more suitable for material recycling can be obtained. According to the secondary processed body of the fourth aspect, a desired secondary processed body can be obtained by mixing with the resin material. According to claim 5,
Since the fibrous resin material is used, the strength of the secondary processed body increases. According to the sixth aspect, since the resin material for solidification is composed of the granular composite material and the linking material (hair, cotton, hemp, synthetic fiber, etc.), the strength of the solid body is further increased. According to the seventh aspect, since the composite fiber is used for the resin material, the strength of the secondary processed body is increased. According to the eighth aspect, since the molded article is formed into the vehicle soundproofing material, it is possible to recycle the scrap car shredder dust into the vehicle soundproofing material in the same field. According to claim 9,
Since the U-shaped groove is recycled, a U-shaped groove that is lightweight and has good workability can be obtained. According to the method of the tenth aspect, since the mixture is mixed with the resin material and solidified by heating, a secondary processed body having a desired shape can be easily manufactured. According to the eleventh aspect, the final product can be easily formed by hot press molding.

[Brief description of the drawings]

FIG. 1 is a diagram showing an example of mixing of a granular composite material according to a first embodiment of the present invention.

FIG. 2 is a block diagram illustrating a method for producing a granular composite material of the present invention.

FIG. 3 is a graph showing the relationship between the bulk density and the size of the granular composite material of the present invention.

FIG. 4 is a view showing an example of a secondary processing body according to a second embodiment of the present invention.

FIG. 5 is a block diagram illustrating a method for manufacturing a secondary processed body according to the present invention.

FIG. 6 is a block diagram obtained by further adding a press forming step to the manufacturing method of FIG. 5;

FIG. 7 is a graph showing a relationship between transmission loss and frequency of the soundproofing material according to the present invention.

FIG. 8 is a graph showing the relationship between the tensile strength of the secondary processed product and the amount of binder when the binder resin is fibrous in the present invention.

FIG. 9 is a block diagram showing a manufacturing method in the case where the secondary processing body is a U-shaped groove in the present invention.

FIG. 10: Particle size of scrap car shredder dust is 2
It is a circle graph which shows the weight ratio of thing of 0 mm or more.

FIG. 11: The particle size of scrap car shredder dust is 2
It is a circle graph which shows the volume ratio of thing of 0 mm or more.

FIG. 12 is a block diagram showing a conventional metal resource recovery process of scrap car shredder dust.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Granular composite material 2 Urethane grain 3 Fiber grain 4 Plastic grain 5 Rubber grain 6 Secondary processed body 7 Resin material (binder)

──────────────────────────────────────────────────続 き Continuing on the front page (72) Osamu Yamase 1st Toyota Town, Toyota City, Aichi Prefecture Inside Toyota Automobile Co., Ltd. (72) Toru Naruse 5-21-11 Chiyoda, Naka-ku, Nagoya City, Aichi Prefecture Co., Ltd. Chugai (72) Inventor Shinji Matsuhiro 5-21-11 Chiyoda, Naka-ku, Nagoya City, Aichi Prefecture Chugai Co., Ltd. (72) Inventor Gotsugu Sugiguchi 5-21-11 Chiyoda, Naka-ku, Nagoya City, Aichi Prefecture Shares Chugai Inside Company (72) Inventor Hiroshi Sarai 5-21-11 Chiyoda, Naka-ku, Nagoya-shi, Aichi Chugai Co., Ltd. (56) References JP-A-6-254859 (JP, A) JP-A 63-12390 ( JP, A) JP-A-6-254530 (JP, A) JP-A-6-39834 (JP, A) JP-A-56-142032 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B09B 3/00 301 B09B 5/00 B29B 17 / 00-17/02

Claims (11)

(57) [Claims] 1. A metal component is selectively removed from shredder dust, which is mainly composed of urethane, fiber, plastic and rubber, and is pulverized into various sizes of 10 to 20 mm or less. Bulk density is 0.3g
/ Cm ³ or less is sieved through a sieve having a predetermined size larger than the size of the crusher in the crushing of various sizes, so that the material A mainly composed of urethane and fibers, and plastic and rubber are mainly used. And a granular composite material roughly classified into a material B as a component. 2. A shredder dust having a size of 10 to 20 mm or more is selected as a raw material of a composite material, and iron, non-ferrous metal, and a wire harness are selectively removed from the shredder dust to remove urethane, fiber, plastic, and rubber. It screened a mixture of lighter material mainly, 0 pre Symbol 1 was pulverized by a pulverizer mixture of the light material
By setting the base material to have a bulk density of 0.3 g / cm ³ or less by using various sizes of up to 20 mm, a sieve having a predetermined amount larger than that of a pulverizer is used in pulverization of various sizes. A material A mainly composed of urethane and fibers on the sieve and a material B mainly composed of plastic and rubber passed through the sieve. 3. The material A is lighter than the material.
A method for producing the granular composite material as described above. 4. A metal component is selectively removed from shredder dust, which is mainly composed of urethane, fiber, plastic, and rubber, and is pulverized into various sizes of 10 to 20 mm or less. Bulk density is 0.3g
/ Cm ³ or less is sieved through a sieve having a predetermined size larger than the size of the crusher in the crushing of various sizes, so that the material A mainly composed of urethane and fibers, and plastic and rubber are mainly used. A granular composite material roughly classified into a material B as a component, and a fibrous resin material obtained by solidifying the material A or the material B of the granular composite material into a solid body having a predetermined shape. Secondary processed body. 5. The composite material secondary work according to claim 4, wherein the resin material is a thermoplastic resin material. 6. The secondary processed composite material according to claim 4, wherein the resin material comprises a granular composite material and a binder. 7. The post-processed composite material according to claim 4, wherein the resin material is a composite fiber. 8. The post-processed composite material according to claim 4, wherein the resin material is a composite fiber, and the solid body is an automobile soundproofing material. 9. The resin material is a urethane-based adhesive,
The composite material secondary processing body according to claim 4, wherein the solid body is a U-shaped groove. 10. A shredder dust having a size of 10 to 20 mm or more is selected as a raw material of a composite material, and iron, non-ferrous metal, and a wire harness are selectively removed from the shredder dust to remove urethane, fiber, plastic, and rubber. It screened a mixture of lighter material mainly, 0 pre Symbol 1 was pulverized by a pulverizer mixture of the light material
By setting the base material to have a bulk density of 0.3 g / cm ³ or less by using various sizes of up to 20 mm, a sieve having a predetermined amount larger than that of a pulverizer is used in pulverization of various sizes. To produce a granular composite material roughly divided into urethane on the sieve, a material A mainly composed of fibers, and a material B mainly composed of plastic and rubber passed through the sieve. Mixing the material A or the material B with the fibrous resin material, heating and solidifying the mixture of the granular composite material and the resin material to form a solid body having a predetermined shape. Production method. 11. The method according to claim 10, wherein the solid body is hot-pressed into a desired shape.