Method for manufacturing recycled board and recycled board

Abstract

The method for manufacturing a recycled board of the present invention comprises: a fiber material generating step, in which a fiber material is generated by crushing a recycled product containing fibers into a fiber shape; an adhesive coating step, in which a thermosetting adhesive is coated on the fiber material generated in the fiber material generating step; a molding step, in which the fiber material coated with the adhesive in the adhesive coating step is molded into a board shape; and a pressurizing and heating step, in which the fiber material molded into the board shape in the molding step is pressurized and heated.

Description

Technical Field

[0001] The technology of the present invention relates to a method for manufacturing a recycled board and the recycled board. Background Art

[0002] Japanese Patent Application Publication No. 2004-25857 discloses a method for producing a wood substitute material, wherein waste clothing is fed into a shredder to generate a fiber material, the fiber material is entangled with thermoplastic resin fibers, and then heated and compressed to produce a wood substitute material. Summary of the invention

[0003] Problem that the invention aims to solve

[0004] In the production method of Japanese Patent Application Laid-Open No. 2004-25857, a thermoplastic resin (for example, polypropylene) is used as a binder, so that glossiness is likely to appear on the surface of the produced wood substitute material.

[0005] In addition, in the manufacturing method of Japanese Patent Application Laid-Open No. 2004-25857, a rag shredder is used to generate fiber material from clothing. In the rag shredder, needle-shaped members are used to disassemble clothing, so the average fiber length of the generated fiber material tends to be long. When a fiber material with a long average fiber length is used, a coarse-grained wood substitute material is produced.

[0006] The technique of the present invention takes the above-mentioned facts into consideration, and an object of the present invention is to obtain a recycled board having excellent design properties.

[0007] Solutions for solving problems

[0008] The method for manufacturing a recycled board of the present invention comprises: a fiber material generating step, in which a fiber material is generated by crushing a recycled product containing fibers into a fiber shape; an adhesive coating step, in which a thermosetting adhesive is coated on the fiber material generated in the fiber material generating step; a molding step, in which the fiber material coated with the adhesive in the adhesive coating step is molded into a board shape; and a pressurizing and heating step, in which the fiber material molded into the board shape in the molding step is pressurized and heated.

[0009] The regenerated board of the present invention is formed to include leather fibers having an average fiber length of 10 mm or less and a thermosetting binder.

[0010] The regenerated board of the present invention is formed to include natural fibers with an average fiber length of 10 mm or less, synthetic fibers with an average fiber length of 10 mm or less, and a thermosetting binder.

[0011] Effects of the Invention

[0012] According to the technique of the present invention, a recycled board having excellent design properties can be obtained. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a block diagram showing the method for manufacturing a regenerated board according to the present embodiment.

[0014] Figure 2 This is a perspective view showing an example of a produced regenerated board.

[0015] Figure 3 This is a perspective view showing an example of a table made of recycled wood.

[0016] Figure 4 This is a perspective view showing an example of a hanger made of recycled board.

[0017] Figure 5 This is a perspective view showing an example of a human torso-shaped hanger made of recycled board.

[0018] Figure 6 This is a perspective view showing an example of a display stand made of recycled board.

[0019] Figure 7 This is a perspective view showing an example of a display stand made of recycled board.

[0020] Figure 8 This is a perspective view showing an example of a display stand made of recycled board.

[0021] Fig. 9 This is a perspective view showing an example of a plate-shaped daily-use appliance produced using a recycled board.

[0022] Fig.10 This is a perspective view showing an example of a partition made of recycled board.

[0023] Fig.11 This is a three-dimensional diagram showing an example of a cubic display stand made of recycled boards.

[0024] Fig.12 This is a perspective view showing an example of a signboard made of recycled board.

[0025] Fig.13 This is a perspective view showing an example of a screen made of recycled board. DETAILED DESCRIPTION

[0026] An example of a method for producing a regenerated board according to the present embodiment will be described with reference to the drawings.

[0027] The method for producing a regenerated board according to the present embodiment (see Figure 1) is an example of a method for manufacturing a regenerated board B (i.e., a reused board B) using a recycled product A having fibers. As an example, Figure 1 As shown, the present manufacturing method comprises a foreign matter removal step 21, a fiber material generation step 22, a mixing step 23, an adhesive coating step 24, a molding step 25, a pressurizing and heating step 26, and a polishing step 27. The recovered product A and each step of the present manufacturing method will be described below.

[0028] (Recyclables A)

[0029] The recycled product A is an item collected from a recycling target such as a consumer or a business. Specifically, the recycled product A is, for example, an item that is no longer needed by the recycling target and is collected for the purpose of reuse. Examples of the recycled product A include clothing.

[0030] The clothing materials as the recycled product A include not only clothes but also products such as towels, sheets, and curtains, as well as cloth and thread that are the materials of these products and clothes. Therefore, the clothing materials may be cloth and thread, or articles formed of cloth and thread.

[0031] The type of fiber of the clothing material is not particularly limited, and various types can be used. Examples of the fiber type include natural fibers and chemical fibers. Natural fibers include plant fibers such as cotton and linen, and animal fibers such as silk, wool, and cashmere. Chemical fibers include synthetic fibers such as nylon, polyester fibers, acrylic fibers, and polyurethane fibers, regenerated fibers such as rayon, and semi-synthetic fibers such as acetate fibers.

[0032] The collected product A may include, in addition to the clothes, at least one paper product selected from the group consisting of wrapping paper for wrapping the clothes, corrugated paper for housing the clothes, and a paper tube in which cloth as the clothes is wound.

[0033] The recycled product A may include, in addition to clothing, leather such as natural leather such as cowhide, synthetic leather, and artificial leather. Examples of products using leather include wallets, bags, baseball gloves, and jackets.

[0034] (Foreign matter removal process 21)

[0035] This step is a step of removing foreign matter from the recycled product A. Examples of foreign matter include accessories such as buttons and zippers provided on the recycled product A. In addition, examples of foreign matter include objects made of materials without fibers (such as metal and resin). If there are no foreign matter in the recycled product A, this step does not need to be performed.

[0036] (Fiber material production step 22)

[0037] In this process, the recycled product A from which foreign matter has been removed is crushed into a fiber state to generate the fiber material A1. Specifically, in this process, the recycled product A is crushed into a fiber state using a crusher to generate the fiber material A1. In addition, "crushed into a fiber state" means that the recycled product A is crushed in a manner that at least the state as a cloth (e.g., a woven state or a braided state) or the state as a thread (e.g., a twisted state) is eliminated.

[0038] Specifically, “crushing” means crushing the recyclables A by cutting with a cutter or the like, for example, and is different from disassembling the recyclables A with a device having a needle-like member (for example, a shredder).

[0039] Furthermore, when any of the above-mentioned clothing, leather, and paper products are used as the recyclables A, the fiber material A1 can be generated by pulverizing them together.

[0040] In addition, this step may include a step of crushing the collected product A. Therefore, in this step, for example, the collected product A may be crushed after being disassembled by a shredder.

[0041] In this step, it is preferred that the recovered product A is pulverized until the average fiber length becomes 10 mm or less to generate the fiber material A1.

[0042] When the average fiber length of the fiber material A1 produced by this step is long (for example, when the average fiber length exceeds 10 mm), the following (1) to (4) may occur.

[0043] (1) The degree of mixing of the fiber material A1 and the binder is reduced.

[0044] (2) The degree of mixing between the fiber material A1 and other fibers F described later is reduced.

[0045] (3) When the fiber material A1 includes a plurality of types of fibers, the degree of mixing of the plurality of types of fibers is reduced.

[0046] (4) The surface texture of the recycled board B becomes rough, and the designability is reduced.

[0047] In this step, for example, the recycled product A may be pulverized so that the average fiber length of the fiber material A1 is greater than 10 mm and less than 20 mm. That is, in the method for producing a recycled board of this embodiment, pulverizing the recycled product A so that the average fiber length of the fiber material A1 is greater than 10 mm is not excluded.

[0048] Furthermore, based on the viewpoints of (1) to (4) above, the average fiber length of the fiber material A1 produced in this step is preferably 8 mm or less, and more preferably 3 mm or less.

[0049] In addition, the size of the pattern on the surface of the regenerated board B can be adjusted by the average fiber length of the fiber material A1. Therefore, when a larger pattern is desired to be expressed on the surface of the regenerated board B, the average fiber length of the fiber material A1 can be set to about 7 to 8 mm, for example, and when a smaller pattern is desired to be expressed, the average fiber length of the fiber material A1 can be set to about 2 to 3 mm, for example.

[0050] Furthermore, the average fiber length of the fiber material A1 produced in this step is, for example, 0.5 mm or more.

[0051] When the average fiber length of the fiber material A1 produced by this step is less than 0.5 mm, the entanglement between the fibers becomes smaller, and the mechanical strength of the regenerated board B may be reduced. In addition, even if the average fiber length of the fiber material A1 is less than 0.5 mm, the mechanical strength of the regenerated board B can be improved by adjusting the binder and its amount used in the binder coating step 24, or adjusting the pressure and heating in the pressure and heating step 26. Therefore, the average fiber length of the fiber material A1 produced by this step can be, for example, less than 0.5 mm.

[0052] In addition, the average fiber length can be measured, for example, by a method according to JISP8226 (optical automatic analysis method). Specifically, the average fiber length is a numerical average fiber length. In addition, as the average fiber length, it can also be a length-weighted average fiber length.

[0053] (Mixing process 23)

[0054] In this step, other fibers F are mixed with the fiber material A1 produced in the fiber material production step 22. Examples of other fibers F include wood fibers and the like. Hereinafter, fibers obtained by mixing fibers F with the fiber material A1 are referred to as mixed fibers A2. The average fiber length of the other fibers F is, for example, the same as the average fiber length of the fiber material A1.

[0055] The higher the mass ratio of fiber material A1 to other fibers F, the higher the recycling efficiency. For example, depending on the fibers used as fiber material A1 and other fibers F, the higher the mass ratio of other fibers F to fiber material A1, the higher the strength of the regenerated board B can be.

[0056] Therefore, in the regenerated board B, the mass ratio of the fiber material A1 in the regenerated board B can be set based on the required recycling efficiency and the strength of the regenerated board B. Specifically, the mass ratio of the fiber material A1 in the regenerated board B (here, the mass ratio excluding the binder) can be set in a range of, for example, 50% or more and 99% or less. In addition, as long as the regenerated board B contains the fiber material A1, the mass ratio of the fiber material A1 in the regenerated board B (here, the mass ratio excluding the binder) can also be set in a range of, for example, 1% or more and less than 50%.

[0057] Alternatively, the mass ratio of the fiber material A1 (here, the mass ratio excluding the binder) in the regenerated board B may be set to 100%. In this case, since other fibers F are not mixed, the mixing step 23 is not performed. Therefore, the mixing step 23 may not be performed in this manufacturing method.

[0058] (Adhesive coating process 24)

[0059] In this step, a thermosetting adhesive is applied to the mixed fiber A2. In this step, an adhesive that has been cured by the pressurizing and heating step 26 is used. In addition, in this step, when the mixing step 23 is not performed, a thermosetting adhesive is applied to the fiber material A1.

[0060] As the adhesive, for example, an adhesive containing an organic isocyanate compound is used. Examples of the organic isocyanate compound include 4,4'-diphenylmethane diisocyanate, polymethylene polyphenylene polyisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, xylene-1,4-diisocyanate, xylene-1,3-diisocyanate, 2,4'-diphenylmethane diisocyanate, 2,2'-diphenylmethane diisocyanate, and 4,4'-diphenyl ether diisocyanate.

[0061] As the adhesive, any known adhesive including urea resin, melamine resin, phenol resin, epoxy resin, etc. can be used. As the adhesive, for example, an adhesive made of 100% natural raw materials can be used.

[0062] For example, the binder is applied to the mixed fiber A2 in a liquid state by a coating method such as spraying. Specifically, in this step, for example, the binder is applied by spraying while the mixed fiber A2 is mixed in a mixer.

[0063] For example, when the mass of the mixed fiber A2 (the fiber material A1 when the mixing step 23 is not performed) is 100 parts by mass, the amount of the binder applied is preferably 2 parts by mass or more and 15 parts by mass or less.

[0064] When the amount of the binder applied is less than 2 parts by mass, based on 100 parts by mass of the mixed fiber A2 (the fiber material A1 when the mixing step 23 is not performed), the mechanical strength of the regenerated board B may be reduced.

[0065] On the other hand, when the mass of the mixed fiber A2 (fiber material A1 when the mixing process 23 is not performed) is set to 100 parts by mass, when the coating amount of the adhesive is greater than 15 parts by mass, the mass ratio of the mixed fiber A2 in the recycled board B is reduced, and thus the recycling efficiency is reduced.

[0066] (Molding process 25)

[0067] In this step, the mixed fiber A2 coated with the binder in the binder coating step 24 is formed into a plate shape (ie, a mat shape). In this step, for example, a plurality of sheets of mixed fiber A2 coated with the binder and formed into a plate shape may be stacked.

[0068] In this step, for example, by housing the mixed fibers A2 in a box-shaped container having an open top surface, the mixed fibers A2 coated with a binder can be formed into a plate shape.

[0069] In this step, for example, a dry method in which the mixed fiber A2 is formed into a sheet shape by air flow may be used, or a wet method in which the mixed fiber A2 is formed into a sheet shape by using water as a medium may be used.

[0070] In addition, when the mixing step 23 is not performed, in this step, the fiber material A1 coated with the binder is formed into a plate shape (that is, a mat shape).

[0071] (Pressure and Heating Step 26)

[0072] In this process, the mixed fiber A2 formed into a plate shape in the forming process 25 is pressurized and heated. Specifically, in this process, heating is performed while pressurizing. In addition, in this process, for example, heating can also be performed after pressurizing. In addition, in this process, for example, heating can also be performed while pressurizing after pressurizing.

[0073] Through this process, the adhesive is cured. As a result, the fibers are bonded to each other to form a plate A3. The thickness of the plate A3 is controlled to be the thickness of the regenerated plate B as the final product plus the margin required for polishing.

[0074] In addition, when the mixing step 23 is not performed, the fiber material A1 formed into a plate shape is pressurized and heated.

[0075] (Polishing process 27)

[0076] In this process, the surface of the plate A3 formed in the pressurizing and heating process 26 is polished. Thus, a regenerated plate B as a final product is manufactured. Figure 2 As shown, the regenerated board B is a rectangular board with a maximum board thickness of about 30 mm and a board area that can efficiently cut out daily utensil parts. In addition, the board thickness, board area, and board shape of the regenerated board B can be determined according to the application. In addition, as this manufacturing method, the polishing step 27 may not be performed.

[0077] In addition, in each of the above steps, the recycled board B can be manufactured using a method according to a manufacturing method for manufacturing a medium density fiberboard (MDF). In addition, in each of the above steps, the recycled board B can be manufactured using a method according to a manufacturing method for manufacturing a particle board, a cardboard (hard fiberboard), and an insulation board (soft fiberboard).

[0078] (Application of recycled board B)

[0079] As described below, daily utensil can be manufactured using the recycled board B. Specifically, the recycled board B is cut into a material of a predetermined shape as a daily utensil component, and the daily utensil component is used alone or combined with other components to manufacture daily utensil used in homes and shops. Here, daily utensil refers to a general term for furniture, tools, utensils, etc. used in homes and shops.

[0080] As daily necessities, there is table F1 ( Figure 3 )、Clothes hanger F2( Figure 4 )、Human trunk hanger F3( Figure 5 )、Display Stand F41( Figure 6 )、Display Stand F42( Figure 7 )、Display Stand F43( Figure 8 ), plate-shaped daily utensils F5 ( Fig. 9 )、Partition F6( Fig.10 )、Cube Display Stand F7( Fig.11 )、Signature F8( Fig.12 ), and screen F9( Fig.13 ) etc. Furthermore, as daily utensil, it can also be a tray and chair for displaying goods.

[0081] like Figure 3 As shown, in the table F1, the top plate as the table top and the legs on one side (the left side in the figure) are made of recycled board B, and the legs on the other side (the right side in the figure) are made of acrylic resin material.

[0082] like Figure 4 As shown, the hanger F2 is made of individual household utensil parts cut from the recycled board B.

[0083] like Figure 5As shown, in the human torso type hanger F3, the base and the support are made of acrylic resin material, and the main body (trunk) for display is made of recycled board B. Here, the main body is made by arranging a plurality of daily utensil parts cut from recycled board B with gradually changed shapes in layers (multi-layers) relative to the support.

[0084] like Figure 6 As shown, in the display stand F41, the stand and frame are made of metal materials, and the shelf and back plate are made of recycled board B. Figure 7 As shown, the display frame F42 is made by combining recycled boards B of the same width in both directions. Figure 8 As shown, in the display rack F43, the rack frame is made of metal material and the rack board is made of recycled board B.

[0085] like Fig. 9 As shown, the plate-like daily necessities F5 is made by combining a large recycled board B and a small recycled board B. A plurality of holes are opened in the large recycled board B, and metal parts are installed in the holes to install and display books, brochures, etc.

[0086] like Fig.10 As shown, in the partition F6, the partition frame and frame legs are formed of metal materials, and the partition is made of recycled board B.

[0087] like Fig.11 As shown, in the cube display stand F7, cubes of different sizes are made of recycled board B, and a plurality of cubes are arranged to display merchandise (shoes, etc.).

[0088] like Fig.12 As shown, in the sign F8, the material of the sign installed on the storefront is made of recycled board B instead of wooden board material.

[0089] like Fig.13 As shown, in the screen F9, the screen panels except the hinges connected in a foldable manner are made of recycled board B.

[0090] In addition, the example of manufacturing daily appliances used in homes and shops using the recycled board B is shown, but the invention is not limited thereto. For example, the recycled board B can also be used for various purposes such as building boards, interior boards, and interior trim boards for vehicles.

[0091] (Fiber material A1 contained in recycled board B)

[0092] The fiber material A1 and the like included in the regenerated board B produced by the present production method will be described.

[0093] Examples of the fiber material A1 include natural fibers and chemical fibers. Natural fibers include plant fibers such as cotton and linen, and animal fibers such as silk, wool, and cashmere. Chemical fibers include synthetic fibers such as nylon, polyester, acrylic, and polyurethane, regenerated fibers such as rayon, and semi-synthetic fibers such as acetate.

[0094] As described above, when the recycled products A include at least one paper product of packaging paper, corrugated paper, and paper tubes in addition to clothing, the fiber material A1 includes fibers of the paper product.

[0095] Furthermore, as described above, when leather is included as the recycled product A in addition to clothing, fibers of the leather are included in the fiber material A1.

[0096] Moreover, in this embodiment, the regenerated board B contains a plurality of fibers generated from clothing as the fiber material A1. Specifically, the regenerated board B contains natural fibers (e.g., cotton fibers) and synthetic fibers (e.g., polyester fibers) as the fiber material A1, and the content of the synthetic fibers is greater than the content of the natural fibers. Furthermore, specifically, the regenerated board B contains plant fibers and animal fibers as natural fibers, and the content of the animal fibers is less than the content of the plant fibers. In addition, the content of the fibers refers to the mass of the fibers contained in the regenerated board B.

[0097] Furthermore, in the present embodiment, the recycled board B includes fibers of multiple colors generated from clothing as the fiber material A1. Specifically, the recycled board B includes: a first fiber (e.g., cotton fiber) colored in a first color (e.g., red); a second fiber (e.g., polyester fiber) different from the first fiber and colored in a second color (e.g., blue) different from the first color; and a third fiber (e.g., cotton fiber) the same as the first fiber and colored in a third color (e.g., green) different from the first color.

[0098] (Effects of this embodiment)

[0099] The effects of the present embodiment will be described by comparison with the production method disclosed in Japanese Patent Application Laid-Open No. 2004-25857 (hereinafter referred to as production method 100 ).

[0100] In the manufacturing method 100, a thermoplastic resin (for example, polypropylene) is used as a binder. In contrast, in the manufacturing method of this embodiment, a thermosetting adhesive is used as a binder.

[0101] As described above, in the manufacturing method 100, a thermoplastic resin (such as polypropylene) is used as a binder, so that the surface of the manufactured wood substitute material is easily glossy. In addition, the thermoplastic resin is re-melted by reheating, so the manufactured wood substitute material is easily thermally deformed.

[0102] In contrast, the manufacturing method of this embodiment uses a thermosetting adhesive as a binder, so that glossiness is not easily produced on the surface of the regenerated board B, and the design is excellent. In addition, the adhesive is not easily melted even when reheated, so the manufactured regenerated board B is not easily deformed by heat.

[0103] In the manufacturing method 100, the thermoplastic resin fiber as a binder is wound around the fiber obtained from the clothing material. In contrast, the manufacturing method of this embodiment applies a binder to the mixed fiber A2 (the fiber material A1 when the mixing step 23 is not performed). Therefore, in the manufacturing method of this embodiment, the mixed fiber A2 and the binder as a binder are more easily mixed uniformly than in the manufacturing method 100.

[0104] In the manufacturing method 100, a rag shredder is used to generate fiber material from clothing. In the rag shredder, needle-shaped members are used to disassemble clothing, so the average fiber length of the generated fiber material tends to be longer. In contrast, the manufacturing method of this embodiment generates fiber material A1 by pulverizing clothing. Therefore, in the manufacturing method of this embodiment, the average fiber length of fiber material A1 tends to be shorter than that of manufacturing method 100. As a result, the following effects (1) to (4) can be obtained.

[0105] (1) The fiber material A1 and the binder can be easily and uniformly mixed.

[0106] (2) The fiber material A1 and other fibers F can be easily mixed uniformly.

[0107] (3) When the fiber material A1 includes a plurality of types of fibers, the plurality of types of fibers are easily uniformly mixed with each other.

[0108] (4) The surface texture of the recycled board B is fine, and the design property is excellent.

[0109] Furthermore, in the production method of the present embodiment, when the recovered product A is pulverized to an average fiber length of 10 mm or less, the above-mentioned effects (1) to (4) can be further exerted.

[0110] In the manufacturing method 100, the average fiber length of the fibers is preferably 30 mm or more in order to entangle the fibers obtained from the clothing and the thermoplastic resin fibers. Therefore, in the manufacturing method 100, a method using a rag shredder is adopted instead of a method of pulverizing the clothing.

[0111] Furthermore, the manufacturing method of this embodiment has the following effects.

[0112] In this embodiment, the recycled product A may include at least one of wrapping paper for wrapping clothes, corrugated paper for accommodating clothes, and paper tubes for winding cloth as clothes, in addition to clothes. In this case, in the fiber material generating step 22, the clothes and the paper product are pulverized into fibers together to generate the fiber material A1.

[0113] In this way, since it is not necessary to distinguish between the clothing and the paper product by processing the clothing and the paper product together, it is not necessary to perform the distinguishing work, and the number of steps in the manufacturing process of manufacturing the recycled board B can be reduced.

[0114] Furthermore, since the regenerated board B contains the fiber material A1 derived from clothing, it has excellent sound absorption and heat insulation properties compared to a normal wooden board formed only of wooden fibers.

[0115] Furthermore, the regenerated board B contains natural fibers and synthetic fibers as the fiber material A1, and the content mass of the synthetic fibers is larger than the content mass of the natural fibers.

[0116] Here, natural fibers are usually twisted, whereas synthetic fibers are usually straight compared to natural fibers. Therefore, by making the regenerated board B contain natural fibers and synthetic fibers, the surface where the natural fibers are exposed and the surface where the synthetic fibers are exposed in the regenerated board B have different textures at a microscopic level. Then, by combining parts with different textures at a microscopic level, the regenerated board B has excellent design properties compared to the case where only a single type of fiber is included.

[0117] Furthermore, since the content of synthetic fibers in the regenerated board B is greater than the content of natural fibers, the characteristics of synthetic fibers can be further exhibited.

[0118] For example, natural fibers contain natural ingredients that serve as nutrients for fungi and insects, whereas synthetic fibers are less likely to serve as nutrients for fungi and insects than natural fibers. Synthetic fibers have lower water absorption than natural fibers.

[0119] Furthermore, as described above, in the manufacturing method of this embodiment, since natural fibers and synthetic fibers are easily mixed uniformly, the content of synthetic fibers is easily greater than the content of natural fibers in the entire regenerated board B on average. That is, the deviation of the content of synthetic fibers and the content of natural fibers in each part of the regenerated board B is suppressed. As a result, the characteristics of synthetic fibers are evenly exerted in the entire regenerated board B. That is, the deviation of the characteristics exerted in each part of the regenerated board B is suppressed.

[0120] Here, as the clothing materials generally circulated, it can be said that the clothing materials using synthetic fibers are more than the clothing materials using natural fibers. In addition, there are also industries that handle more clothing materials using synthetic fibers than clothing materials using natural fibers. Therefore, as the recycled product A, there are cases where the clothing materials using synthetic fibers are more than the clothing materials using natural fibers. In this case, since the content of synthetic fibers in the recycled board B is greater than the content of natural fibers, it is not necessary to adjust the mass of the fibers contained in the recycled board B, and it is not necessary to perform fiber classification, etc.

[0121] Furthermore, specifically, the regenerated board B contains plant fibers and animal fibers as natural fibers, and the content mass of the plant fibers is greater than the content mass of the animal fibers.

[0122] Here, animal fibers are twisted and have a complex shape compared to plant fibers. Therefore, since the regenerated board B contains plant fibers and animal fibers as natural fibers in addition to synthetic fibers, the surface where the animal fibers are exposed, the surface where the plant fibers are exposed, and the surface where the synthetic fibers are exposed in the regenerated board B have different textures at a microscopic level. Then, by combining the parts with different textures at a microscopic level, the regenerated board B has excellent design properties.

[0123] Furthermore, animal fibers are more susceptible to deterioration than plant fibers, and discoloration may occur due to deterioration. Therefore, in the regenerated board B, since the content of animal fibers is less than that of plant fibers, deterioration and discoloration of the regenerated board B can be suppressed compared to a case where the content of animal fibers is greater than that of plant fibers.

[0124] In addition, the recycled board B includes: a first fiber (e.g., cotton fiber) colored in a first color (e.g., red); a second fiber (e.g., polyester fiber) different from the first fiber and colored in a second color (e.g., blue) different from the first color; and a third fiber (e.g., cotton fiber) the same as the first fiber and colored in a third color (e.g., green) different from the first color.

[0125] According to this composition, the second fiber, which is different in both fiber type and color from the first fiber, shows a part with different texture and color microscopically on the surface of the regenerated board B, and the third fiber, which is the same fiber type as the first fiber but different in color, shows a part with the same texture but different color microscopically on the surface of the regenerated board B. In this way, the texture and color are varied, so the design is excellent. In addition, the third color can be different from the first color, and can be a color different from the second color or the same color as the second color.

[0126] In addition, the surface of the regenerated board B is preferably not coated with a resin material or the like. Since the surface of the regenerated board B is not coated and the fibers are exposed, the texture of the fibers on the surface of the regenerated board B is easily discernible.

[0127] (Variation of Recovered Product A)

[0128] As the recycled product A, natural leather such as cowhide, synthetic leather, and artificial leather may be used instead of clothing. Therefore, only leather may be used as the recycled product A. In this case, a regenerated board containing leather fibers as the fiber material A1 can be manufactured.

[0129] Leather is not suitable for producing fiber material A1 using a shredder because its fibers are difficult to disassemble and difficult to turn into cotton. In contrast, in the manufacturing method of this embodiment, fiber material A1 is produced by pulverizing recycled product A. Therefore, fiber material A1 can be produced even if recycled product A is leather. Therefore, by adopting the manufacturing method of this embodiment, a regenerated board B can be produced from leather.

[0130] As the recycled product A, an article having plant-derived fibers such as cocoa bean shells, coffee grounds, and paper (articles having pulp) may be used instead of clothing. Therefore, as the recycled product A, only one of cocoa bean shells, coffee grounds, and paper (articles having pulp) may be used. The paper includes the aforementioned paper products, paper samples for clothing manufacturing, and other papers.

[0131] As the recycled product A, for example, an article containing carbon fiber may be used. In addition, as the recycled product A, for example, any one or more of the aforementioned clothing, leather, paper products, articles containing fiber from plants, and articles containing carbon fiber may be used. As long as it is an article containing fiber, it can be used as the recycled product A.

[0132] (Other Modifications)

[0133] The regenerated board B has a first fiber, a second fiber, and a third fiber, but is not limited thereto. The regenerated board B may be a composition having the first fiber and the third fiber without the second fiber, or a composition having the first fiber and the second fiber without the third fiber. In addition, in the regenerated board B, instead of or in addition to the third fiber, a fourth fiber (e.g., rayon fiber) colored in the same color as the first color (e.g., red) or in the same color series (e.g., orange), i.e., a fourth color, and different from the first fiber, may be included. In addition, the fourth fiber may be a fiber different from the second fiber or the same fiber as the second fiber, as long as it is different from the first fiber. In addition, the same color series can be defined as a color having the following color: for example, a color that is closer to the first color than the color of the second color.

[0134] In addition, the regenerated board B contains plant fibers and animal fibers as natural fibers, and the content of the animal fibers is less than the content of the plant fibers, but is not limited thereto. The content of the animal fibers in the regenerated board B may be greater than the content of the plant fibers. The content of the animal fibers in the regenerated board B may be the same as the content of the plant fibers. In addition, the regenerated board B may have a composition having one of the plant fibers and the animal fibers as natural fibers but not the other.

[0135] Furthermore, the regenerated board B includes natural fibers and synthetic fibers as the fiber material A1, and the content of synthetic fibers is greater than that of natural fibers, but the present invention is not limited thereto. The content of natural fibers in the regenerated board B may be greater than that of synthetic fibers.

[0136] In this case, the regenerated board B can further exert the characteristics of natural fibers. Here, natural fibers are superior in water absorption compared to synthetic fibers. Therefore, in the regenerated board B, by making the content of natural fibers greater than the content of synthetic fibers, the water absorption is superior compared to the case where the content of natural fibers is less than the content of synthetic fibers, and it can have a humidity regulating effect. That is, when the regenerated board B is used as a wall material for a room, etc., it can have a humidity regulating effect, that is, it absorbs moisture when the humidity in the room is high, and releases moisture when the humidity in the room is low. Furthermore, the content of natural fibers in the regenerated board B can also be the same as the content of synthetic fibers.

[0137] In addition, in the regenerated board B, as the fiber material A1, synthetic fibers as chemical fibers are included, and chemical fibers other than synthetic fibers may be included instead of or in addition to synthetic fibers. Chemical fibers other than synthetic fibers include regenerated fibers such as rayon, semi-synthetic fibers such as acetate fibers, and the like. Therefore, the regenerated board B may be composed as follows: it includes natural fibers (e.g., cotton fibers), synthetic fibers (e.g., polyester fibers), and regenerated fibers (rayon fibers) as the fiber material A1, and the content of natural fibers is greater than the content of regenerated fibers, and the content of synthetic fibers is greater than the content of natural fibers.

[0138] Furthermore, the regenerated board B includes fibers of multiple colors generated from the recycled product A as the fiber material A1, but is not limited thereto and may also include fibers of a single color.

[0139] The recycled board B includes multiple types of fibers generated from the recycled product A as the fiber material A1, but is not limited thereto and may include a single type of fiber. The recycled board B can be used by changing the type and amount of the fibers contained in it according to its application.

[0140] The present invention is not limited to the above-mentioned embodiments, and various modifications, changes, and improvements can be made without departing from the gist of the present invention. For example, the above-mentioned modified examples can be appropriately combined in multiple forms.

Claims

1. A method for manufacturing a recycled board, comprising: A fiber material generating step of generating a fiber material in which the plurality of fibers are mixed by pulverizing a cloth containing a plurality of fibers into a fiber shape; An adhesive coating step of coating the fiber material generated in the fiber material generating step with an adhesive having thermosetting properties; a molding step of molding the fiber material coated with the adhesive in the adhesive coating step into a plate shape; as well as The pressurizing and heating step pressurizes and heats the fiber material formed into the plate shape in the forming step.

2. The method for manufacturing a recycled board according to claim 1, wherein: In the fiber material generating step, the fiber material is generated by pulverizing the clothing material until the average fiber length becomes 10 mm or less.

3. The method for producing a recycled board according to claim 1 or 2, wherein A recycled board comprising natural fibers and synthetic fibers as the fiber material is produced.

4. The method for manufacturing a recycled board according to claim 3, wherein: A regenerated board is produced in which the content mass of the synthetic fibers is greater than the content mass of the natural fibers.

5. The method for manufacturing a recycled board according to claim 3, wherein: A recycled board is produced in which the natural fiber content is greater than the synthetic fiber content.

6. The method for producing a recycled board according to claim 1 or 2, wherein: A mixing step of mixing other fibers into the fiber material produced in the fiber material producing step is provided, In the binder coating step, a thermosetting binder is coated on the fiber material mixed with other fibers in the mixing step.

7. The method for manufacturing a recycled board according to claim 3, wherein: A mixing step of mixing other fibers into the fiber material produced in the fiber material producing step is provided, In the binder coating step, a thermosetting binder is coated on the fiber material mixed with other fibers in the mixing step.

8. The method for manufacturing a recycled board according to claim 4, wherein: A mixing step of mixing other fibers into the fiber material produced in the fiber material producing step is provided, In the binder coating step, a thermosetting binder is coated on the fiber material mixed with other fibers in the mixing step.

9. The method for manufacturing a recycled board according to claim 5, wherein: A mixing step of mixing other fibers into the fiber material produced in the fiber material producing step is provided, In the binder coating step, a thermosetting binder is coated on the fiber material mixed with other fibers in the mixing step.

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