TWI883471B - Regenerated fabric fiber masterbatch, composite material containing regenerated fabric fiber masterbatch, and manufacturing method thereof - Google Patents

Abstract

The present application provides a regenerated fabric fiber masterbatch, composite material containing regenerated fabric fiber masterbatch, and manufacturing method thereof containing recycled fabric fibers involves uniformly mixing fabric fiber raw materials with resin materials, interface compatibilizers, and additives in appropriate proportions and conditions to form a mixture. The mixture is then kneaded to form agglomerates. The agglomerates are further extruded and cut into pellets to create the regenerated fabric fiber masterbatch material. The regenerated fabric fiber masterbatch material is then mixed with virgin or recycled plastic pellets, antioxidants, and processing aids in appropriate proportions and conditions to form a blend. The blend is subjected to mixing, elongation, and cutting to obtain composite material particles containing recycled fabric fibers.

Description

Recycled textile fiber masterbatch, composite material particles containing recycled textile fiber and manufacturing method thereof

The present invention relates to the field of material manufacturing, and in particular to the use of recycled waste fabrics to make recycled fabric fiber masterbatches or composite material particles containing fabric fibers, so that downstream industries can use the composite material particles to further manufacture suitable processed products.

Every year, a large amount of old clothes are discarded all over the world, and there are mechanisms for recycling them. It is known that recycled clothing and other fabrics need to be classified according to materials such as cotton, linen, and polyester fibers before further processing. For example, the fabrics can be crushed and made into yarn, soundproof panels, carpets, blended with other fibers into non-woven products, or made into cleaning fabrics. Therefore, in addition to being very time-consuming and labor-intensive to classify materials, the range of products that can be processed later cannot be further expanded.

The object of the present invention is to provide a recycled textile fiber masterbatch and a method for producing the same, wherein the recycled waste textile can be crushed and granulated without being classified to form a textile fiber masterbatch material for further processing into other products.

In addition, another object of the present invention is to provide a composite material particle containing recycled textile fiber and a manufacturing method thereof, wherein the composite material particle containing high textile fiber content is completed by further combining the selection and design of plastic or recycled plastic formula with the textile fiber masterbatch material and melt mixing technology, and the composite material particle can be directly processed and formed, or the composite material particle containing textile fiber can be blended with recycled polyolefin polymer and then extruded to manufacture environmentally friendly laminate products, or hangers, glasses and other products can be manufactured by injection molding.

The invention provides a method for manufacturing a recycled fabric fiber masterbatch, comprising: crushing recycled fabric into fabric fiber raw materials; uniformly mixing the fabric fiber raw materials with a resin material, an interfacial compatibility agent and an auxiliary agent in a mixer to form a mixture, wherein the weight percentage of the fabric fiber raw materials in the mixture is 30-70%; extruding the mixture in an extruder to form a mixture agglomerate; and extruding and pelletizing the mixture agglomerate in a granulator in combination with a die head to form the recycled fabric fiber masterbatch material.

Preferably, the weight percentages of the interfacial compatibilizer and the auxiliary agent in the mixture are 2-10% and 0.2-5.0%, respectively.

Preferably, the fabric fiber raw material, the resin material, the interfacial compatibilizer and the auxiliary agent are uniformly mixed in the mixer at a rotation speed of 400 to 800 rpm for 3 to 5 minutes.

Preferably, the extruder extrudes the mixture at a screw temperature of 140-180° C., a rotation speed of 20-100 rpm, and an extrusion time of 10-30 minutes.

Preferably, the interfacial compatibilizer is one or a combination of epoxy resin, maleic anhydride copolymer, and silane compound.

Preferably, the additive is a flow promoter, comprising one or a combination of processing oil and plasticizer.

The present invention also provides a method for manufacturing composite material particles containing recycled textile fibers, comprising: a recycled textile fiber masterbatch material as described in any one of claims 1 to 6; blending the recycled textile fiber masterbatch material with virgin or recycled plastic pellets, an antioxidant and a processing aid, and drying the mixture at a temperature of 80° C. for 3 to 4 hours to form a blend; and mixing, stretching and pelletizing the mixture with a mixing extruder to obtain composite material particles containing recycled textile fibers, and drying the composite material particles at a temperature of 80° C. for 3 to 6 hours. The method for producing composite material particles containing recycled textile fibers as described in claim 7, wherein the mixing extruder mixes, draws and pelletizes the blend at a screw temperature of 130-200° C. and a rotation speed of 100-300 rpm.

Preferably, the weight percentages of the recycled textile fiber masterbatch material, the virgin or recycled plastic pellets, the antioxidant and the processing aid in the blend are 20-60%, 40-79.4%, 0.1-0.5% and 0.5-10%, respectively.

Preferably, the antioxidant is one or a combination of hindered phenols, thioesters, and phosphites.

Preferably, the processing aid is one or a combination of a flow aid, a flame retardant, a UV absorber, and a wear and scratch resistant agent.

The present invention also provides a regenerated fabric fiber masterbatch, which is formed into a granular fabric fiber masterbatch by using the aforementioned regenerated fabric fiber masterbatch manufacturing method. The fabric fiber masterbatch comprises the following components: a regenerated fiber material having a weight percentage of 30 to 70%; an interface compatibilizer having a weight percentage of 2 to 10%; an auxiliary agent having a weight percentage of 0.2 to 5.0%; and a resin material having the remaining weight percentage.

The present invention also provides a composite material particle containing recycled textile fibers, which is obtained by making waste textile fibers into granular textile fiber masterbatches, and then further processing the textile fiber masterbatches into granular composite material particles containing recycled textile fibers. The composite material particles containing recycled textile fibers include the following components: the components of the recycled textile fiber masterbatch as described in claim 12, The recycled textile fiber masterbatch has a weight percentage of 20-60% in the composite material particles; the original or recycled plastic particles have a weight percentage of 40-79.4% in the composite material particles; the antioxidant has a weight percentage of 0.1-0.5% in the composite material particles; and the processing aid has a weight percentage of 0.5-10% in the composite material particles.

In order to facilitate the understanding of the present invention, the present invention is described in detail below in conjunction with the accompanying drawings and embodiments. The accompanying drawings show some embodiments of the present invention, but not all of them. The present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the understanding of the disclosure of the present invention more thorough and comprehensive. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making progressive efforts are within the scope of protection of the present invention.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art belonging to the technical field of the present invention. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

FIG1 is a flow chart showing the manufacturing process of recycled textile fiber masterbatch according to the present invention, comprising the following steps: S1: providing textile fiber raw material; S2: forming a mixture containing textile fiber; S3: forming a mixture mass containing textile fiber; and S4: forming recycled textile fiber masterbatch material.

Specifically, in step S1, the recycled fabric is broken into fabric fiber raw materials. The recycled fabric refers to general waste clothing or items containing any fabric fiber recovered from old clothing recycling sites, etc. After the fabric is recycled, it is broken into fabric fiber raw materials using mechanical equipment such as shears and crushers, waiting for step 2.

In step S2, the fabric fiber raw material is uniformly mixed with the resin material, the interfacial compatibilizer and the auxiliary agent by a mixer to form a mixture, wherein the weight percentage of the fabric fiber raw material in the mixture is preferably 30-70%; the weight percentage of the interfacial compatibilizer and the auxiliary agent in the mixture is preferably 2-10% and 0.2-5.0% respectively. The mixer preferably stirs the fabric fiber raw material, the resin material, the interfacial compatibilizer and the auxiliary agent placed in the mixer at a rotation speed of 400-800 rpm for 3-5 minutes to obtain a uniform mixture. The interfacial compatibilizer can be one or a combination of epoxy resin, maleic anhydride copolymer and silane compound. The additive is a flow promoter and may include one or a combination of processing oil and plasticizer.

In step S3, the mixture containing textile fibers is extruded by an extruder to form a mixture mass; wherein the extruder is provided with a screw for extruding and conveying the mixture, and the mixture is extruded at a screw temperature of preferably 140-180° C., a rotation speed of preferably 20-100 rpm, and an extrusion time of preferably 10-30 minutes to form a mixture mass containing textile fibers. Specifically, when the screw temperature is 140-180°C, the mixture can maintain good hardness and be suitable for stirring and mixing; when the screw speed is 20-100 rpm and the kneading time is 10-30 minutes, the mixture can obtain better mixing uniformity.

In step S4, the mixture agglomerate is extruded and pelletized by a granulator in combination with a die to form the recycled textile fiber masterbatch material. More specifically, the mixture agglomerate with a certain softness and hardness is extruded by a piston in the granulator through a die with a specific aperture to produce continuous long and thin strip agglomerates, which are then cut at the exit hole of the die to form pellets of a specific length, i.e., the recycled textile fiber masterbatch material.

The recycled textile fiber masterbatch material is used as a raw material for further processing, and can be directly used in manufacturing products, or further processed into composite material particles containing recycled textile fibers.

Accordingly, the prepared recycled textile fiber masterbatch comprises the following components: recycled fiber material, having a weight percentage of 30-70%; interfacial compatibilizer, having a weight percentage of 2-10%; auxiliary agent, having a weight percentage of 0.2-5.0%; and resin material, having the remaining weight percentage.

FIG2 is a flow chart showing the process of manufacturing composite material particles containing recycled textile fibers according to the present invention, comprising the following steps: Step S5: providing recycled textile fiber masterbatch material; Step S6: forming a blend containing textile fibers; and Step S7: forming composite material particles containing recycled textile fibers.

Specifically, the recycled textile fiber masterbatch material provided in step S5 refers to the recycled textile fiber masterbatch material manufactured by steps S1 to S4.

In step 6, the recycled fabric fiber masterbatch material is blended with virgin or recycled plastic pellets, an antioxidant and a processing aid, and dried in a dryer at a temperature preferably of 80° C. for 3 to 4 hours to form a blend. The weight percentages of the recycled fabric fiber masterbatch material, the virgin or recycled plastic pellets, the antioxidant and the processing aid in the blend are 20 to 60%, 40 to 79.4%, 0.1 to 0.5% and 0.5 to 10%, respectively. The antioxidant can be one or a combination of hindered phenols, thioesters, and phosphite antioxidants. The processing aid can be one or a combination of a flow aid, a flame retardant, a UV absorber, and a wear-resistant and scratch-resistant agent.

In step 7, the blend is mixed, stretched and pelletized by a mixing extruder to obtain composite material particles containing recycled textile fibers, and the composite material particles are dried in a dryer at a temperature preferably of 80° C. for 3 to 6 hours. The mixing extruder is equipped with a screw for conveying and extruding the blend, and the blend is preferably mixed, stretched and pelletized at a screw temperature of 130 to 200° C. and a screw speed of 100 to 300 rpm. More specifically, a blend having a certain softness and hardness is extruded by a screw in a mixer and passes through a die with a specific aperture to produce a continuous long and thin strip of the blend, which is then cross-sectioned at the exit hole of the die to form particles of a specific length, i.e., composite particles containing recycled textile fibers.

Accordingly, the composite material particles containing recycled textile fibers prepared include: the aforementioned recycled textile fiber masterbatch component, the recycled textile fiber masterbatch has a weight percentage of 20-60% in the composite material; virgin or recycled plastic particles, having a weight percentage of 40-79.4% in the composite material particles; antioxidants, having a weight percentage of 0.1-0.5% in the composite material particles; and processing aids, having a weight percentage of 0.5-10% in the composite material particles.

FIG3 is a data comparison table showing various embodiments and comparative embodiments of the present invention for producing composite material particles containing recycled textile fibers. Among them, the comparative embodiment does not add an interfacial compatibilizer component, resulting in a large difference in polarity between cotton fiber and PP/PE, which in turn leads to poor compatibility between the two. Therefore, during the granulation process, the fiber and the plastic will be separated, and ultimately granulation will not be possible. In embodiments 1 to 6 of the present invention, an interfacial compatibilizer is added to form a layer of a third substance on the surface of the natural fiber, which helps to significantly improve the bonding force between the two, thereby improving the granulation process problem.

The composite material particles with high textile fiber content of the present invention can be blended with recycled polyolefin polymer materials and then extruded to produce products such as environmentally friendly laminates and floor mats, or hangers, glasses, stationery and other products by injection molding. The applications are very wide and the conventional problem of consuming a lot of time and manpower to classify materials after recycling discarded clothing is overcome, and the range of products that can be processed subsequently cannot be further expanded.

The above-mentioned embodiments only represent the preferred embodiments of the present invention, and the description is relatively specific and detailed, but it should not be understood as limiting the patent scope of the present invention. It should be pointed out that for ordinary technicians in this field, they can make several changes and improvements without departing from the concept of the present invention, which all belong to the protection scope of the present invention.

S1～S4: Steps S5～S7: Steps

FIG1 is a flow chart showing the manufacturing process of recycled textile fiber masterbatch according to the present invention; FIG2 is a flow chart showing the manufacturing process of composite material particles containing recycled textile fibers according to the present invention; and FIG3 is a data comparison table showing various embodiments and comparative embodiments of the manufacturing process of composite material particles containing recycled textile fibers according to the present invention.

S5~S7: Steps

Claims (13)

A method for manufacturing a recycled fabric fiber masterbatch comprises: Crushing recycled fabric into fabric fiber raw materials; Using a mixer to uniformly mix the fabric fiber raw materials with a resin material, an interfacial compatibility agent and an additive to form a mixture, wherein the weight percentage of the fabric fiber raw materials in the mixture is 30-70%; Using an extruder to extrude the mixture to form a mixture agglomerate; and Using a granulator in combination with a die head to extrude and pelletize the mixture agglomerate to form the recycled fabric fiber masterbatch material. The method for producing a recycled textile fiber masterbatch as described in claim 1, wherein the weight percentages of the interfacial compatibility agent and the auxiliary agent in the mixture are 2-10% and 0.2-5.0%, respectively. The method for producing recycled textile fiber masterbatch as described in claim 2, wherein the textile fiber raw material, the resin material, the interfacial compatibility agent and the auxiliary agent are uniformly mixed in the mixer at a rotation speed of 400 to 800 rpm for 3 to 5 minutes. The method for producing recycled textile fiber masterbatch as described in claim 3, wherein the extruder extrudes the mixture at a screw temperature of 140 to 180° C., a rotation speed of 20 to 100 rpm, and an extrusion time of 10 to 30 minutes. The method for producing recycled textile fiber masterbatch as described in claim 2, wherein the interfacial compatibility agent is one or a combination of epoxy resin, maleic anhydride copolymer, and silane compound. A method for producing recycled textile fiber masterbatch as described in claim 2, wherein the auxiliary agent is a flow promoter, including one or a combination of processing oil and plasticizer. A method for manufacturing composite material particles containing recycled textile fibers, comprising: A recycled textile fiber masterbatch material as described in any one of claims 1 to 6; Blending the recycled textile fiber masterbatch material with virgin or recycled plastic pellets, an antioxidant and a processing aid, and drying at 80°C for 3 to 4 hours to form a blend; and Mixing, stretching and pelletizing the blend with a mixing extruder to obtain composite material particles containing recycled textile fibers, and drying the composite material particles at 80°C for 3 to 6 hours. The method for producing composite material particles containing recycled textile fibers as described in claim 7, wherein the mixing extruder mixes, draws and pelletizes the blend at a screw temperature of 130-200° C. and a rotation speed of 100-300 rpm. A method for manufacturing composite material particles containing recycled textile fibers as described in claim 7, wherein the weight percentages of the recycled textile fiber masterbatch material, the virgin or recycled plastic pellets, the antioxidant and the processing aid in the blend are 20-60%, 40-79.4%, 0.1-0.5% and 0.5-10%, respectively. The method for producing composite material particles containing recycled textile fibers as described in claim 9, wherein the antioxidant is one of hindered phenols, thioesters, and phosphite antioxidants or a combination thereof. A method for producing composite material particles containing recycled textile fibers as described in claim 9, wherein the processing aid is one of a flow aid, a flame retardant, a UV absorber, a wear and scratch resistant agent, or a combination thereof. A recycled textile fiber masterbatch is formed into a granular form and comprises the following components: Recycled fiber material, having a weight percentage of 30 to 70%; Interface compatibilizer, having a weight percentage of 2 to 10%; Auxiliary agent, having a weight percentage of 0.2 to 5.0%; and Resin material, having the remaining weight percentage. A composite material particle containing recycled textile fibers, formed into a granular form, comprising: The components of the recycled textile fiber masterbatch as described in claim 12, the recycled textile fiber masterbatch having a weight percentage of 20 to 60% in the composite material particle; Virgin or recycled plastic particles, having a weight percentage of 40 to 79.4% in the composite material particle; Antioxidant, having a weight percentage of 0.1 to 0.5% in the composite material particle; and Processing aid, having a weight percentage of 0.5 to 10% in the composite material particle.

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