CN101405318A - 地毯废料复合物 - Google Patents

地毯废料复合物 Download PDF

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CN101405318A
CN101405318A CNA2007800100154A CN200780010015A CN101405318A CN 101405318 A CN101405318 A CN 101405318A CN A2007800100154 A CNA2007800100154 A CN A2007800100154A CN 200780010015 A CN200780010015 A CN 200780010015A CN 101405318 A CN101405318 A CN 101405318A
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matrix material
carpet waste
carpet
tackiness agent
waste
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道格拉斯·曼考什
詹姆斯·普兹拜林斯基
大卫·E·莫道克
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Materials Innovation Inc
MATERIAL INNOVATIONS LLC
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Abstract

本发明公开一种由紧密结合的地毯废料和粘合剂组成的复合材料，所述材料包括25％－99％的所述地毯废料和1％－25％的所述粘合剂。本发明还公开了用于制造上述复合材料的方法。

Description

地毯废料复合物
相关申请的交叉引用
本申请是2006年8月31日递交的美国申请11/514,303的部分继续申请并要求该申请的优先权，美国申请11/514,303是2006年8月21日递交的美国申请11/507,366的继续部分申请并要求该申请的优先权，美国申请11/507,366要求2006年1月20日递交的美国申请60/760,500的优先权，上述专利申请通过引用插入本文。
背景技术
本发明所涉及的技术领域是被用在各种工业和消费应用中的天然和人造纤维复合物。
天然和人造纤维复合物可用在建筑物、工业应用、生活消费品、汽车产品和其它需要具有各种耐潮或耐热物理性质(诸如低吸湿率和低热变形)的工业中。上述天然和人造纤维复合物能够制造具有上述性质的复合物同时能够控制诸如强度、刚度、延展性、抗冲击性和硬度的物理性质，因而具有广阔的应用领域。
而且，对于再生数量巨大但降解性低的废料流的呼声也越来越高。具体地，地面覆盖产品尤其是地毯的制造、安装、使用和(最终)替换会产生大量废旧产品。由生产新地毯而产生的地毯废料、消费后垃圾或其它用过地毯应用是一项每年耗资数亿英镑的问题。工业通常使用术语“下脚料”(selvedge)表示在制造过程中产生的废料，而其它形式的制造和安装废料通常被称为“碎料”(scrap)。我们使用的术语地毯废料涵盖在地面覆盖产品的制造、安装、使用和替换而产生的所有类型的废料。通常，地毯废料不能回收，而是通过垃圾掩埋或焚烧来处理。
发明内容
我们发现了一种由地毯废料和粘合剂制成的复合材料。
第一方面，本发明涉及一种用于制造复合材料的方法，所述方法将具有或不具有附加的纤维和/或填料的地毯废料进行转化，并将其与粘合剂组合，以制备复合材料。更具体地，本发明涉及一种包括紧密结合的地毯废料和粘合剂的复合材料，其中，所述复合材料包括25％至99％的地毯废料和1-25％的粘合剂。
优选地，地毯废料和粘合剂的总和占全部材料的50-99％，复合材料还包括0-50％的天然纤维或人造纤维(诸如定向玻璃纤维)或人造和天然纤维的组合。复合材料还可以包括至少一种无机填料，诸如碳酸钙或硅石。而且，复合材料还可以包括会导致有利物理性质的添加剂。阻燃剂和/或抑霉剂(mold inhibitor)的添加量占全部材料的0-25％(优选为0-10％)。可以使用的阻燃剂包括，但并不局限于，Occidental的DechloranePlus、Ferro的Pyrochek 68PB和Great Lakes PO-64P。阻燃剂可以需要或者可以不需要Sb3O2协效剂(synergizer)。可以以相同水平使用的抑霉剂包括，但不限于，硼酸锌和Rohm&Haas的Vinyzene抑霉剂。明显地，地毯废料包括所有基本上不会彼此分离的地毯组分。例如，地毯废料包括用量至少等于复合材料的10重量％的地毯衬料，并且/或者包括地毯面料聚合物，诸如尼龙、聚酯、烯丙稀和羊毛。
优选地，粘合剂包括二苯基甲烷二异氰酸酯(MDI)、脲醛(UF)、三聚氰胺脲醛(MUF)和酚醛(PF)中的一种或多种。
还优选的是，通过ASTM测试D790测定的复合材料的弹性模量为至少55000PSI，更优选为至少100000PSI。优选地，通过ASTM D790测定的复合材料的破裂模量为至少600PSI，更优选为1000-2500PSI。优选地，复合材料的密度为至少30磅每ft3，更优选为40-80磅每ft3。
第二方面，本发明通常涉及一种制造复合材料的方法，所述方法包括：提供地毯废料；通过将地毯废料进行尺寸-缩小处理来准备地毯废料；将尺寸缩小的地毯废料与粘合剂组合；将粘合剂/地毯废料组合物在受限几何形状内进行加压和升温处理，从而制成包含紧密结合的地毯废料与粘合剂的复合结构。由此制成的材料优选包括25％-99％的地毯废料和1-25％的粘合剂。优选地，尺寸缩小步骤包括如下工艺中的一个或多个：剁碎、切碎、磨碎、分离污染物、造粒、成块、粉碎、细磨和/或纤维化地毯废料。例如，使地毯废料颗粒旋转并且在压力下迫使其通过具有一定尺寸和构型的孔从而使所述材料的密度增加。
将尺寸缩小的地毯废料与粘合剂在鼓式容器(drum)中组合从而使废料被粘合剂包覆。在连续的带式传动压机或固定压机上对粘合剂/地毯废料组合物进行加热和加压处理。
可选地，将另一层施加到由此制造的复合片材的表面上。例如，所述另一层是层压层或箔转印层，或者所述另一层是涂料、着色剂或聚合化合物。可以对所述另一层进行模塑或轧花，从而在复合材料上形成图案化表面。可选地，所述另一层可以是胶合板、合成板和/或聚合物片材。通过机械或化学方法来准备复合材料的表面，接着箔或薄膜层压所述另一层。另一层可以包括热冲压层。
由此形成的复合材料可被热成形成所需形状。所述另一层可以是箔或薄膜层压板。
可以打磨所述复合材料的至少一层。
以下附图和描述阐述了本发明的一个或多个实施方式的细节。显然由所述说明书、附图以及权利要求得到本发明的其它特征、目的和优点。
附图说明
图1是描述各种类型的尺寸缩小设备和各种尺寸缩小工序的流程图，所述设备和过程依赖于加工设备所需要的最终地毯废料的形式。
图2描述了采用粘合剂包覆地毯废料和随后的形成工艺的步骤。
图3描述了用于整理复合板产品的步骤。
详细描述
由本发明制成的地毯废料产品的一般性组成如下：
原料描述                    组合物中的原料百分率
地毯废料                    25％-99％
粘合剂                            1％-25％
木材或天然纤维、合成纤维、无机    0％-50％
填料、增强填料
阻燃剂                            0％-25％
抑霉剂                            0％-25％
由地毯废料制造复合材料的过程包括两个基本步骤。图1示出了各种类型的设备和各种工序，所述设备和工序依赖于加工设备所需要的最终形式。最终形式还可以依赖于本方法所获得的所需复合成品以及物理性质。
首先，如下所述加工地毯废料以缩小其尺寸。然后，将尺寸缩小的地毯废料与粘合剂混合以制成原料，通过面板/片材/板材工艺对所述原料进行加温和/或加压处理从而得到复合材料。
如下我们详细描述了两个步骤。然后我们描述了对所述复合材料进行制造后处理。
缩小地毯废料的尺寸
地毯废料由下脚料、工业后地毯废料、消费后废旧地毯或由垃圾掩埋场回收的废旧地毯组成。这些材料以大包形式开始进行加工前的尺寸缩小阶段。大包的尺寸可以发生变化，但通常为约1000lb至2000lb。
第一步是缩小废料以达到本方法的其余步骤易于处理的尺寸。使用切碎机/剁碎机和研磨机的组合或使用大容量研磨机将所述原料加工成较小尺寸。切碎机/剁碎机将下脚料或地毯废料切割成约3英寸见方(3”×3”)的大块。然后，将切碎的材料通过研磨机，从而进一步将这些大块缩小成纤维绒毛材料，这种纤维的直径与原始地毯纤维的直径类似，长度为约1/4”至1”。
所述废料可选通过充当锤式粉碎机/旋风分离器的分离机，从而除去地毯废料中的污垢。在这个步骤中，一些含有无机填料的地毯衬料也可以被除去。在锤式粉碎机的作用下，准备尺寸略微减小的材料用于下一步，即成块工艺。然后，将从大块中去除的污垢和地毯衬料进行处置。
无论是否使用分离机，纤维绒毛可选与诸如木质或天然纤维、合成纤维(例如，玻璃纤维)、无机填料、其它增强填料、阻燃剂和抑霉剂的其它材料共混。然后，将纤维绒毛材料或共混材料运送到成块步骤。
在成块机(agglomerator)中，对上述材料进行成块。这些材料进入含有旋转转子的水平鼓式容器中。转子具有一定形状，从而迫使纤维绒毛或共混物撞击鼓式容器壁。鼓式容器壁是被穿孔的，使得因为转子迫使所含材料撞击被穿孔的壁，因而所述材料被迫通过穿孔从而形成具有固定直径的绳股。鼓式容器的外面具有固定的刀子，其将绳股切割成固定长度。在这个过程中，通过摩擦力将材料加热至这样一个温度，该温度低于共混物中熔点最高材料的熔点。通过转子的速度、穿孔的直径和鼓式容器壁的厚度来控制温度。
在成块步骤中形成的颗粒是圆柱形的，其直径为约1/8英寸，长1/8至1/4英寸。可以通过改变鼓式容器壁上孔洞的直径和/或改变刀子旋转的速率来调整颗粒的直径和长度。因为颗粒在被形成时和被切割时是热的，所以一些颗粒彼此粘在一起。因此，为了达到更好的尺寸一致性，接着使颗粒通过研磨机，从而使多个颗粒彼此分开。这个研磨步骤也可用于缩小颗粒的尺寸。
可以通过粉碎机进一步缩小颗粒的尺寸。如果所需要的最终尺寸小于1/8英寸，那么使用粉碎机将粒子尺寸减小至8-16目。这相当于0.04英寸至0.10英寸。
现在可以进行最后一个可选步骤，来纤维化所述颗粒或被粉碎的粒子。纤维化是对表面进行机械粗磨，从而使表面具有“绒毛”状特征。对于在以下“工艺描述”中所述的复合产品工艺来说，这是最后一项重要的准备。现在将材料，不论是颗粒还是被粉碎的粒子，也不论纤维化与否，运送至复合物生产工艺。
开始缩小尺寸的另一种方法是使用大容量研磨机，从而将地毯废料缩小成长度为约1/4英寸至1英寸且直径为约1/32英寸至1/8英寸的纤维。准备好这些尺寸无规的纤维用于成块工艺或不需成块的其它动作。
不论工艺方向如何，下一步是使材料通过分离机。这是与上述的相同的设备并具有相同的作用。如上所述，这是在本文所述的材料准备阶段中的一个可选步骤。现在，可以使纤维以与上述完全相同的方式进行成块工艺，或者可以使纤维直接通过成纤机设备。同样，成纤机用于改变纤维的表面特征，从而使其具有表面积更大的“绒毛”表面和不同的堆密度。对于所有最终使用的复合产品来说，纤维化步骤不是必需的。
不论纤维是否已被纤维化，使其通过混合机，在混合机中，可以添加木质或天然纤维、合成纤维(例如玻璃纤维)、无机填料、矿物填料(如果需要的话)、阻燃剂和防霉剂。在纤维和所添加的材料完成了共混以后，用于复合产品工艺的混合物就准备好了。
通过控制以上步骤来控制复合产品的组成。显然地，通常不需将下脚料或地毯废料中所含的各种材料进行分离或分类。大部分地毯面料是尼龙、聚酯、聚丙烯或羊毛。衬料通常是聚丙烯和/或高度填充的合成乳胶。这些材料的物理性质和加工性质具有相当大的差异。不论材料的差异如何，全部废料都可以使用。然而，如果需要的话，可以根据面料纤维的类型将地毯废料进行分离并加工。例如，面板可以由100％的尼龙6面料纤维地毯废料制成。面板也可以通过如下制成：将不同类型的面料纤维地毯废料以受控比率进行共混从而制成面板。例如面板可以由50％聚酯面料纤维地毯废料和50％聚丙烯面料纤维地毯废料制成。
已被制成团块、纤维化团块、被粉碎团块或被纤维化、被粉碎团块的废旧地毯是复合产品的基础材料。废旧纤维或被纤维化的废旧纤维也可用于制造复合产品。地毯废料中的所有的材料可以是组合物的一部分。
组合物的另一个主要部分是粘合剂。粘合功能可以通过使用二苯基甲烷二异氰酸酯(MDI)、脲醛(UF)、三聚氰胺脲醛(MUF)、酚醛(PF)或其组合来实现。根据诸如相容性、成本和环境问题等因素，也可以使用其它粘合剂。粘合剂作为纤维或成块材料的胶水，从而作为复合产品的基础。粘合剂与纤维或粒子的比率对在本方法中所达到的物理性质具有决定性。而且，通过使用木质和天然纤维、合成纤维、无机填料、增强填料、阻燃剂和抑霉剂来改进物理性质。
粘合剂和地毯废料占所述组合物的至少50％，并且可以构成最终产品的100％。粘合剂的含量为1％-25％，剩余材料是地毯废料和所添加的材料。所添加的材料，即木质和天然纤维、合成纤维、无机填料、增强填料、阻燃剂和抑霉剂，可以占全部组合物的50％。然而，基础材料通常是比率为9：1的地毯废料和粘合剂，所添加的任何材料约为地毯废料/粘合剂含量的25％。
总的来说，地毯废料和粘合剂的组合物(不论是否具有添加剂)可用于制造各种复合产品。地毯废料包括所有地毯产品，包括所有不同类型的面料纤维和地毯衬料在内。
采用粘合剂包覆地毯废料
地毯废料可以是颗粒形式(小球或粒子)或纤维状废料，或者可以是被纤维化的颗粒或纤维状废料。通常将地毯废料加入大容量旋转鼓式容器中，或加入具有旋转混合叶片或树脂处理吹气管线(resination blow line)的鼓式容器。诸如天然纤维填料、无机填料、阻燃剂和抑霉剂的其它材料可以与地毯废料一起加入。如果将所述材料加入鼓式容器，那么由鼓式容器内部的顶端喷洒水和/或粘合剂从而充分包覆所述材料。在鼓式容器和/或叶片旋转并使保持在其中的材料均匀分布的时候，喷头释放水或粘合剂的细雾。这得到被充分包覆的材料。通常将水喷射到鼓式容器中，从而使材料获得所需含水量，并为所述粘合剂准备材料。通常在水以后喷射粘合剂，从而确保其反应并充分包覆鼓式容器中的材料。对于树脂处理吹气管线方法，通过其中具有水和粘合剂的管子向材料吹气。所述吹气动作使空气形成湍流，这使得水和粘合剂均匀地包覆材料。以上述方式将粘合剂以相对于颗粒加上任何其它添加剂的总重为1％至25％的浓度施加到颗粒或纤维上。(整篇说明书中，术语颗粒或纤维除包括地毯废料以外还可以包括添加剂)。粘合剂附着到颗粒和纤维上，这使得每颗颗粒或每根纤维具有粘合剂表面涂层。在环境条件下使粘合剂快速干燥，这使得颗粒或纤维可以继续流动而不会彼此粘在一起。然后，使具有粘合剂涂层的颗粒或纤维进行本方法中的下一步，即制备用于板材的地毯废料复合材料。
准备板材形成工艺
将经粘合剂包覆的复合材料运送至板坯形成场所(mat formingstation)，所述场所包括传送带、计量天平、喷洒头和控制管理系统。所述板坯形成场所采用分配设备将所述复合材料分配到成形带上，从而使散布的材料成为一个具有均匀厚度、宽度和密度的板坯。主要通过地毯废料复合粒子/纤维的形状和它们在成形板坯中的位置来确定板材的性质。由于这个原因，细微地调节分配设备，从而生成具有合适形状和尺寸的板坯。所述形成场所可以为多层板材分配一种类型以上的材料。例如，形成场所中的喷洒头可以在成形带上散布一层纤维，然后第二喷洒头可以在所述纤维顶部散布一层小球，然后第三喷洒头可以在所述小球上散布一顶层纤维。可以将各种不同组成的材料散布到成形带上，从而制成各种不同类型的板材。每块板材中各层的数量也可以变化。例如，可以制成具有CW纤维外壳和玻璃纤维芯的板材，或者可以制成具有CW小球外壳、CW纤维底层和CW小球芯的板材。在散布形成板坯后，成形带将所述板坯运送到预热机中或直接运送到预压机中。预热机继续运送板坯并且在所述板坯进入板材成形工艺以前，使复合材料接受微波或者为板坯注射热空气和/或热蒸汽。在进入板材成形工艺以前，板坯的温度由约65°F升高至200°F。这种将热量快速传递给地毯废料的过程通过微波或者将蒸汽/空气混合物(潮湿空气)由表面注射入板坯来实现。在这个过程中蒸汽凝结从而将热量传递给板坯。在所述材料进入板材成形工艺以前，预热机也可以预压或者压缩该材料。然后，将加热过的板坯通过中间传送带传递到连续辊压机的进给端(infeed end)中的压缩段，或者传递到作为板材成形工艺的开端的循环压机中。
如果使用循环或者固定压机替代连续辊压机，那么通常跳过板坯预热步骤，并且在循环压机中的压片工艺(sheeting process)期间使用蒸汽注射或者可以跳过注射蒸汽步骤。
板材成形工艺采用循环压机或连续辊压机。这两种类型的设备都采用压力或温度使被粘合剂包覆的地毯废料复合材料形成板材、面板或片材。
循环压机可以具有一个或多个压板间距(daylight opening)。将复合材料运送到循环压机中，在所述压机中，由顶部滚筒和底部滚筒向所述复合材料加温和加压，这将板坯压缩成预定高度，并使得粘合剂可以发生反应，从而使板坯粘合在一起形成板材。在循环压机中，可以注射蒸汽穿过板坯，从而确保充分加热并粘合所述复合材料。滚筒可以具有雕刻在其上的图案，从而使板材的表面具有结构图案。循环压机还可以使用冷却循环，从而在板材离开压机前降低其温度。
已经使用循环压机制造了地毯废料复合板材。附在本文中的表1列举了操作条件和设置。
连续辊压机是一种双带压机，其能够将板坯保持在一定范围的温度和压力下，从而允许发生粘合剂反应使板坯粘合在一起。对于连续辊压机来说，优选类型的带子由钢制成，但是也可以使用其它材料。该压机能够达到65°F至550°F的温度，从而可以将热量传递给整个板坯。类似地，可以使用不同的压力，从而将颗粒层或纤维板坯压缩至最终产品所需的厚度和密度。
连续辊压机由压力结构组成，这些结构承载由带子张紧导致的水平作用力。存在许多框架单元，这些单元的数量依赖于压机的长度和所需压力。在框架单元上以各种组合方式布置用于施加压力的圆筒，一定量的所述圆筒适于打开压机。辊杆和带子穿过顶部和底部的经加热的滚筒。所述压机具有用于引导辊杆、带子和待压板坯的进给头(infeed head)。辊杆位于经加热的滚筒和带子之间。板坯位于两条带子之间。两个鼓式容器位于压机的各个末端，传送带绕过其行进。使用鼓刮刀使板坯保持在带子之间。可以将脱模剂喷洒到带子上，从而抑制板坯对传送带的粘附性并使其离开压机。控制系统调节压机的操作，诸如传动带的速度、温度、压力、板坯的厚度等。
连续辊压机将热量传递给经粘合剂包覆的复合材料。热量使所述材料上的粘合剂涂层活化，然后通过连续移动带将所述材料压制成较小厚度。因为材料在传送带之间移动穿过进给段，因此厚度尺寸减小了并被连续加热。将经粘合剂包覆的颗粒或经粘合剂包覆的纤维的温度保持在粘合剂的活化温度以上。在被设定在预定高度下的滚筒的压力下，颗粒或纤维彼此粘在一起形成了连续的片材。这个最终厚度也决定了材料的密度。密度由进入连续压机的未经粘合板坯的初始厚度和离开压机的新形成的复合产品的最终厚度决定。
如果连续压机带或固定压力滚筒的温度升高至230℃或更高，那么可以形成具有薄且致密外壳的面板。这种外壳有助于改善面板的物理性质，诸如弹性模量(MOE)和破裂模量(MOR)。
在连续压机中将板坯加热和压制到所需高度和密度后，可以采用冷却段使面板在离开连续压机前被冷却。由于被压制的聚合物材料的性质，所以在一定压力下冷却压机中的面板有助于保持板材的平直程度并避免卷曲。在面板离开连续压机前通常将其冷却到至少120℃。固定压机也可以使用冷却循环，从而在板材离开固定压机前将其冷却。然而，这个额外的冷却时间导致生产面板的周期延长。所以可以使用第二固定压机仅用于冷却。例如，可以在第一压机中在热量和压力下形成面板，然后将其转移到第二固定压机中冷却。面板可以在任意类型的压机中形成并且在离开压机后在第二个工艺中冷却。
板材的整理工艺
在连续辊压机中使所述材料粘合并且使板坯具有所需高度尺寸后，形成连续条带形状的板材。当所述条带离开压机后，对其进行连续边缘修整操作从而得到所需宽度，然后将其横切成预定长度。所述条带通过辊子传送带和压带辊传送通过修整和横切操作。然后，将已被切成预定宽度和长度的板材传送至冷却场所。冷却场所可以采用各种不同的机器，诸如随后具有堆集装置的星形冷却器或带堆集装置的辊式传送带。最常用的类型之一是随后具有堆集装置的星形冷却器。星形冷却器是一种大直径轮子，其中多列轮辐从所述辊子向外延伸。各个轮辐提升来自传送带的各个板材，并且允许各个板材随着轮子旋转并被空冷。如果需要的话，连续辊压机的出口附近可以具有一个冷却段。该段在板材离开压机以前将其冷却，从而消除进一步冷却的需要。然后，将板材运送至堆积操作并贮存待用。现在已准备好了将被出货或者可以进行各种装饰的板材。
在循环压机中，板材可以被制成成品尺寸或略大。如果板材略大，那么在其离开压机后切割成成品尺寸。循环压机中的滚筒可以具有图案化的表面，从而使板材具有结构化的表面，诸如仿木纹图案(wood grainpattern)。
装饰复合产品
在复合产品离开上述工艺时，其厚度可以在小于1/8英寸至2英寸之间变化。因为所述工艺中的最后一步是切割复合产品的长度，所以整理产品的第一步是切割成品的宽度。图3示出了在切割至成品宽度以后可以使用的整理和装饰步骤。
现在可以模塑复合产品以改变其轮廓，从而使成品具有所需形状。在具有不同设计的切割机上进行模塑。最常见的切割机是旋转刀设备。该机器允许设定刀片，从而调整对所需轮廓的切割。另一种常用的设备是刳刨机(router)，其在复合产品的表面上切削特定的凹槽(rout)。所述刳刨机具有与模塑机相同的作用，因为它们使来自上述工艺的初始轮廓变至成品所需轮廓。
还可以使用热成形方法来改变轮廓。在这种情况下，将复合产品置于具有所需轮廓的模中，并且施加热量和压力，结果所述产品具有模的形状。这种轮廓的变化能够进行额外的装饰，因为被置于模中的转印箔可以具有所需颜色和/或图案。在该工艺期间通过施加热量和压力，颜色和/或图案由载体箔转移到复合产品上。因此，在热成形工艺完成时，复合产品具有所需形状并且具有所需装饰。
可以在上述工艺后对复合产品进行轧花。采用轧花板或轧花辊来完成所述轧花。所述板或辊的表面上具有待转移到所述产品上的图案。将这个表面加热至将软化所述复合产品表面的温度。然后，将所述板或辊压到所述产品的表面上，从而得到所需的图案转移。当冷却所述复合产品的表面时，轧制的图案固定在所述复合产品的表面上。现在准备好了用于涂敷的轧花的复合产品，或者如果终端使用产品不需涂层，那么准备好了将进行包装的复合产品。
使所有待装饰的复合产品通过打磨机(sander)(上述设备)。这表面光滑操作为产品的涂敷、转移和层压做准备。
采用底漆、末道漆或着色剂包覆经打磨或经轧花的复合产品。采用各种常规喷雾技术涂敷涂层，其中采用排气系统除去过量的喷雾和溶剂。可涂敷渗透涂层或成膜涂层，这个选择取决于所需最终产品的外观和应用。
经打磨的复合产品也可以作为芯，其上可以热冲压来自箔或薄膜的装饰层或防护层或者层压装饰层或防护层，从而使本发明具有改善的物理性质和外观。如下相关专利申请通过引用全文插入此处：2005年2月9日递交的美国专利申请11/054,258和2005年1月4日递交的美国专利申请60/641,308。
可以采用转印箔来装饰复合产品。同样，需要对产品进行打磨从而使表面变得光滑。利用常规的涂敷技术将粘合剂层涂敷到轮廓上。在聚合基材上的转印箔具有所需颜色和/或图案。采用为了特定应用而设计的冲压设备，使所述箔与产品的表面接触。利用热量和压力，将所述颜色和图案由箔转印到产品上。转印所需热量使轮廓表面上的粘合剂层活化，从而确保装饰结合到所述轮廓上。现在复合产品具有颜色和图案，然后将用过的箔进行收集处理，成品具有所需装饰效果。
可以采用的另一种装饰方式是层压。数种材料可被用作层压表面，诸如胶合板、合成板、箔、薄膜和聚合物片材。
采用常规层压设备来施加硬质层压板，诸如胶合板。一般而言，将采用底料和粘合剂的粘合剂体系(为湿固化粘合剂体系或热熔融固化粘合剂体系)涂敷到基材上。然后，将硬质表面层压板放置在所述基材上，并加温加压。在加温加压步骤以后，然后使层压的产品固定一段时间，从而使粘合体系固化。在复合产品的情况下，所述复合产品是基材。将粘合体系(通常是热熔粘合剂)施加到复合产品上。将硬质胶合板放置在粘合层上，从而形成复合产品、粘合剂和硬质层压板的三明治结构。然后压制所述三明治结构，从而确保层压板结合到复合产品上。固化以后，准备好了将进行包装的具有所需装饰外观的层压板。
用于复合产品的另一种层压技术是箔层压(foil laminating)。这项技术也被称为封套(wrapping)，其中复合产品轮廓被封套在装饰箔中。在打磨复合产品的轮廓以后，使所述轮廓通过封套设备。该设备从卷筒上取下封套箔，然后将粘合剂(和底漆，如果需要的话)涂敷到箔上。在连续工艺中，然后使封套箔在复合材料轮廓上通过。利用一系列辊子，使封套箔在复合产品轮廓上成形。除了装饰元素以外，封套箔还可以结合必要的面漆材料用于增强物理性质。这种被结合的元素可以是聚氨酯、丙烯酸材料或其它防护材料。然后，如果所述封套箔仅结合装饰元素，那么对于某些应用，所封套的复合产品将需要面漆。
如果终端产品应用要求表面性质(诸如耐磨性)显著提高，那么可以将面漆添加到装饰工艺中。面漆可以是聚氨酯、丙烯酸材料或其它防护材料，从而赋予包装后的成品表面具有更佳的物理性质。面漆可以喷涂或者通过热熔融涂敷。如果喷涂，那么包装后的复合产品将通过喷涂机，然后可以通过或可以不通过固化设备，诸如紫外线辐射。如果面漆通过热熔融涂敷，那么将一层聚氨酯施加到经装饰复合产品的平坦表面上。这种类型材料的固化工艺耗时，可能花费数天，这依赖于对于所完成成品的特定终端应用所选择的热熔融面漆。
已经描述了本发明的大量实施方式。然而，应当理解到，可以进行各种修正而并未脱离本发明的精神和反应。因此，其它实施方式也包括在权利要求书的范围内。
Figure A20078001001500191

Claims (43)

1.一种包括紧密结合的地毯废料和粘合剂的复合材料，所述材料包括25％-99％的所述地毯废料和1-25％的所述粘合剂。
2.如权利要求1所述的复合材料，其中，所述地毯废料和所述粘合剂的总和占全部所述材料的50％-99％。
3.如权利要求1所述的复合材料，其中，所述材料包括0-50％的天然纤维。
4.如权利要求1所述的复合材料，其中，所述材料包括0-50％的人造纤维。
5.如权利要求1所述的复合材料，还包括定向的玻璃纤维。
6.如权利要求1所述的复合材料，还包括至少一种无机填料。
7.如权利要求6所述的复合材料，其中，所述无机填料包括碳酸钙、硅石或二者。
8.如权利要求1所述的复合材料，其中，所述材料包括0-25％的阻燃剂。
9.如权利要求1所述的复合材料，其中，所述材料包括0-25％的抑霉剂。
10.如权利要求1所述的复合材料，其中，所述地毯废料包括所有基本上不会彼此分离的地毯组分。
11.如权利要求8所述的复合材料，其中，所述地毯废料包括用量等于所述复合材料的至少10重量％的地毯衬料。
12.如权利要求1所述的复合材料，其中，所述地毯废料包括至少两种不同的地毯面料聚合物。
13.如权利要求10所述的复合材料，其中，所述地毯面料聚合物包括尼龙、聚酯、聚丙烯和羊毛中的一种或更多种。
14.如权利要求1所述的复合材料，其中，所述粘合剂包括二苯基甲烷二异氰酸酯(MDI)、脲醛(UF)、三聚氰胺脲醛(MUF)和酚醛(PF)中的一种或更多种。
15.如权利要求12所述的材料，其中，所述粘合剂是MDI。
16.如权利要求12所述的材料，其中，所述粘合剂是PF。
17.如权利要求1所述的复合材料，其中，所述复合材料的弹性模量通过ASTM测试D790测定为至少55000PSI。
18.如权利要求1所述的复合材料，其中，所述复合材料的弹性模量通过ASTM测试D790测定为至少100000PSI。
19.如权利要求1所述的复合材料，其中，所述复合材料的破裂模量通过ASTM测试D790测定为至少600PSI。
20.如权利要求1或权利要求15所述的复合材料，其中，所述复合材料的破裂模量通过ASTM测试D790测定为1000-2500PSI。
21.如权利要求1所述的复合材料，其中，所述复合材料的密度为至少30磅每ft3。
22.如权利要求19所述的复合材料，其中，所述复合材料的密度为至少40-80磅每ft3。
23.一种制造复合材料的方法，所述方法包括：
a)提供地毯废料；
b)通过将所述地毯废料进行尺寸缩小处理来准备所述地毯废料；
c)将所述尺寸缩小的地毯废料与粘合剂组合；
d)将粘合剂/地毯废料组合物在受限几何形状内进行加压和升温处理，从而制成包含紧密结合的地毯废料与粘合剂的复合结构，所述材料包括25％-99％的地毯废料和1-25％的粘合剂。
24.如权利要求21所述的方法，其中，步骤b)包括如下工艺的一个或多个：剁碎、切碎、碾碎、分离污染物、造粒、成块、粉碎、细磨和/或纤维化地毯废料
25.如权利要求22所述的方法，其中，使所述地毯废料颗粒旋转并且在压力下迫使所述地毯废料颗粒通过具有一定尺寸和构型的孔从而使所述材料的密度增加。
26.如权利要求21所述的方法，其中，所述地毯废料与粘合剂在鼓式容器中组合从而使所述废料被粘合剂包覆。
27.如权利要求21所述的方法，其中，所述粘合剂是MDI，所述地毯废料和MDI在鼓式容器中组合。
28.如权利要求21所述的方法，其中，所述粘合剂是PF，所述地毯废料和PF在鼓式容器中组合。
29.如权利要求21所述的方法，其中，在连续的带式传动压机或固定压机上对所述粘合剂/地毯废料组合物进行加热和加压处理。
30.如权利要求21所述的方法，其中，将所述粘合剂/地毯废料组合物加热至230℃以上，从而形成致密的外壳。
31.如权利要求21所述的方法，其中，将所述经加热并加压的粘合剂/地毯废料组合物在固定压机中冷却至120℃以下，从而保持平坦并且避免卷曲。
32.如权利要求21所述的方法，还包括将另一层施加到所述复合片材表面上的步骤e)。
33.如权利要求1所述的复合材料，还包括在所述表面上的另一层。
34.如权利要求30所述的方法或权利要求31所述的复合材料，其中，所述另一层是层压层或箔转印层。
35.如权利要求30所述的方法或权利要求31所述的复合材料，其中，所述另一层是涂料、着色剂或聚合化合物。
36.如权利要求30所述的方法或权利要求31所述的复合材料，其中，模塑或轧花所述另一层从而在所述复合材料上形成图案化的表面。
37.如权利要求30所述的方法或权利要求31所述的复合材料，其中，所述另一层是胶合板、合成板或聚合片材。
38.如权利要求30所述的方法或权利要求31所述的复合材料，其中，所述另一层是箔或薄膜层压板。
39.如权利要求30所述的方法，还包括，准备所述复合材料的表面，对所述材料的表面进行机械或化学处理，接着箔或薄膜层压所述另一层。
40.如权利要求30所述的方法或权利要求31所述的复合材料，其中，所述另一层是热冲压层。
41.如权利要求30所述的方法或权利要求31所述的复合材料，其中，将所述复合材料热成形成所需形状。
42.如权利要求30所述的方法或权利要求31所述的复合材料，其中，所述另一层是箔或薄膜层压板。
43.如权利要求30所述的方法或权利要求31所述的复合材料，其中，所述复合材料的至少一层被打磨。
CN2007800100154A 2006-01-20 2007-01-11 地毯废料复合物 Expired - Fee Related CN101405318B (zh)

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US8455558B2 (en) 2013-06-04
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