Method for manufacturing home paving material from recycled waste textile fibers

Abstract

The application discloses a manufacturing method of household paving materials recycled from waste and old textile fibers, and is based on a physical recycling method, in which waste and old textile fibers, industrial waste nylon filaments and a small amount of low-melting-point polyester fibers are used as raw materials, and processes such as carding, web laying, needling and heat treatment are adopted to design and construct a non-woven fabric base cloth recycled from waste and old textile fibers, a loose thermal forming mechanism of the non-woven base cloth is disclosed, a relationship between the structure and the performance is established, a surface modification forming of the non-woven base cloth by a nylon waste filament adhesive and a nylon waste filament pulp is created, and finally, indoor and outdoor household paving materials recycled from textile fibers are obtained, and the effective hiding property, the loose characteristics and the soft performance of the coating material of the original background of the waste and old textile fibers are improved.

Description

Technical Field

[0001] This invention belongs to the field of recycling waste textile fibers, and specifically relates to a method for manufacturing home furnishing materials that utilize recycled waste textile fibers. Background Technology

[0002] With the development of textile technology, the improvement of people's living standards, and changes in aesthetic tastes, the frequency of textile product obsolescence is accelerating, leading to two main problems in the textile industry: firstly, the huge consumption of textile raw materials results in resource shortages and tight supply; secondly, the low effective utilization rate of waste textile products leads to the generation of large amounts of textile waste, causing significant resource waste and environmental harm. Therefore, the recycling of waste textile fibers is particularly important, and many countries around the world are currently paying close attention to developing methods for recycling waste textile fibers.

[0003] Currently, the recycling and reuse of waste textiles is limited to certain enterprises in the domestic textile industry, resulting in a small-scale industry and a low effective recycling rate. Therefore, the resource recovery and reuse of waste textile fibers is an urgent problem to be solved.

[0004] Home furnishing materials, including carpets, wall coverings, and other specialty textiles, have specific performance requirements due to their special uses. Among these, the effective coverage, fluffiness, and softness of the original base color of waste textile fibers are important indicators for evaluating their quality. Existing recycling technologies for waste textile fibers cannot change or control the structure and properties of nonwoven base fabrics made from waste textile fibers, and the home furnishing materials prepared from them cannot meet the basic requirements of effective coverage and softness. Summary of the Invention

[0005] The purpose of this invention is to provide a method for manufacturing home furnishing materials that utilize recycled waste textile fibers. Addressing the shortcomings of existing technologies, this method is based on physical recycling and uses loose fibers from waste textiles, industrial waste nylon filaments, and a small amount of low-melting-point polyester fibers as raw materials. It employs processes such as carding, web laying, needle punching, and heat treatment to design and construct a nonwoven fabric base for recycled waste textile fibers. The invention reveals the bulky thermoforming mechanism of the nonwoven fabric base, establishes the relationship between its structure and properties, and creates a method for surface modification and shaping of the nonwoven fabric using nylon waste filament adhesive and nylon waste filament paste. Ultimately, this method produces indoor and outdoor home furnishing materials that utilize recycled textile fibers, improving the effective coverage of the original base color of the waste textile fibers, enhancing the bulkiness, and improving the softness of the coating material.

[0006] To solve the above technical problems, the following technical solution is adopted:

[0007] A method for manufacturing home furnishing flooring materials using recycled waste textile fibers, characterized by the following steps:

[0008] (1) Processing of waste textile fibers:

[0009] Step 1: Feed waste carpets and blankets into an opening machine, and after opening, waste textile fibers are obtained.

[0010] Step 2: Prepare low-melting-point polyester fibers and incorporate them into the above-mentioned waste textile fibers;

[0011] (2) Nonwoven base fabric construction:

[0012] Waste textile fibers are processed through a needle punching device using coarse combing, fine combing, web stacking, and needle punching processes to produce a nonwoven base fabric of waste textile fibers. After pretreatment, a nonwoven base fabric of waste textile fibers suitable for coating processing is obtained.

[0013] (3) Surface finishing and molding of waste textile fiber nonwoven base fabric:

[0014] Prepare a nylon waste filament adhesive, and impregnate the waste textile fiber nonwoven base fabric from step (2) into the nylon waste filament adhesive. Control the impregnation temperature to be 40-50℃ and the impregnation time to be 20-30min. After impregnation, uniformly coat the nylon waste filament coating paste onto the waste textile fiber nonwoven base fabric. After coating, the waste textile fiber nonwoven base fabric is ionized and cured at 140-150℃ for 50-80s. After curing, it is calendered and shaped to obtain the modified and shaped waste textile fiber nonwoven base fabric.

[0015] (4) Preparation of home furnishing materials:

[0016] Select recycled polyester fibers to prepare the surface layer of the flooring material, and then combine it with the waste textile fiber nonwoven base fabric from step (3) using hot melt adhesive to obtain the home flooring material.

[0017] After optimization, the preparation process of low-melting-point polyester fiber in step (1) is as follows:

[0018] a. Mix ethylene glycol, adipic acid, propylene glycol, and terephthalic acid, and add catalyst, heat stabilizer, and anti-ether agent during the stirring process. Stir until uniform to obtain a slurry.

[0019] b. Add the slurry to the reactor and react under a nitrogen atmosphere. First, react at 180-200℃ for 15-20 minutes; then raise the temperature to 60℃ at a rate of 5℃ / min and hold the temperature for 5-10 minutes; after holding the temperature, purge nitrogen into the reactor until the pressure inside the reactor is 1 standard atmosphere and react for 10-15 minutes.

[0020] c. First, polycondense under low vacuum conditions for 30-45 minutes, then polycondense under high vacuum conditions of 60 Pa and 280 °C for 20-30 minutes to obtain low melting point polyester.

[0021] d. Dry the low-melting-point polyester in an oven at 85°C, and spin the low-melting-point polyester at 220°C with a stretching speed of 800 m / min and a stretching ratio of 4 times to obtain low-melting-point polyester fiber.

[0022] After optimization, the catalyst is antimony glycolate, the heat stabilizer is trimethyl phosphate, and the ether inhibitor is anhydrous sodium acetate.

[0023] After optimization, step (2) preprocessing includes:

[0024] a. Pre-drying: Pre-dry the waste textile fiber nonwoven base fabric at 90-150℃ for 5-10 minutes;

[0025] b. Hot pressing: The pre-dried waste textile fiber nonwoven base fabric is subjected to hot pressing treatment. The hot pressing temperature is 100-200℃, the hot pressing pressure is 5-8Mpa, and the hot pressing time is 60-240s.

[0026] After optimization, the preparation process of the nylon waste filament adhesive in step (3) is as follows: 1-50 parts of anhydrous calcium chloride and 20-100 parts of anhydrous methanol are thoroughly stirred and mixed at a temperature of 65°C. After the reaction is completed, 8-12 parts of nylon 6 waste filaments are added for dissolution. The mixture is stirred at high speed until the waste filaments are completely dissolved to obtain the nylon waste filament adhesive.

[0027] After optimization, the nylon waste filament pulp preparation process in step (3) is as follows: 1-50 parts of anhydrous calcium chloride and 20-100 parts of anhydrous methanol are thoroughly stirred and mixed at a temperature of 65°C. After the reaction is completed, 1-20 parts of nylon 6 waste filaments are added to dissolve them. After the waste filaments are completely dissolved, 2-50 parts of kaolin filler are added under high-speed stirring. After high-speed stirring and uniform mixing, it is ready for use.

[0028] After optimization, step (4) hot melt adhesive bonding: the bonding temperature is 130-140℃, the bonding pressure is 2Mpa, and the bonding time is 90-120s.

[0029] Further, step (3): Impregnation is completed in a rotary impregnation device, which includes a machine body and a fabric inlet, a fabric outlet, and a rotary clamping mechanism. Waste textile fiber nonwoven base fabric is fed into the fabric inlet, and the rotary clamping mechanism clamps the nonwoven base fabric in sequence and drives it to rotate. During the rotation, it passes through the impregnation tank of the machine body, which is filled with adhesive. The impregnation time of the nonwoven base fabric is adjusted to 20-30 minutes by controlling the rotation speed of the rotary clamping mechanism. After impregnation, it is rotated to the fabric outlet and the nonwoven base fabric is sent out from the fabric outlet. This impregnation device drives the nonwoven base fabric to continuously feed, impregnate, and exit in a rotary manner to achieve the purpose of continuous impregnation. During the impregnation process, the rotary clamping mechanism grabs and limits the travel path of the nonwoven base fabric, which can ensure that the impregnation process is stable and orderly. By controlling the rotation speed of the rotary clamping mechanism, the impregnation time of the nonwoven base fabric can be adjusted to meet different process requirements.

[0030] Furthermore, the rotating fabric clamping mechanism includes a drive assembly, a rotating frame, and fabric clamping assemblies mounted on the rotating frame. The drive assembly includes a motor unit and a transmission component. The motor unit is connected to the transmission component, which in turn connects to the rotating frame. Four sets of fabric clamping assemblies are connected to the rotating frame. Every 90° rotation, one set of fabric clamping assemblies clamps the nonwoven base fabric. Through a cyclical rotation-clamping-rotation-releasing action, the nonwoven base fabric is continuously impregnated. The fabric clamping assembly includes a rotating base connected to the rotating frame, clamping arms, and a clamping mechanism mounted on the rotating frame. The clamping arm cylinder has clamping arms on both sides of the rotating seat. The ends of the clamping arms have fixed clamping surfaces, and movable clamping plates are connected to the fixed clamping surfaces. The movable clamping plates can be folded down. When folded down, they cooperate with the fixed clamping surfaces to clamp the nonwoven base fabric. When folded up, they release the nonwoven base fabric. The piston rod of the clamping arm cylinder is connected to a connecting rod. The end of the connecting rod has a hinge joint one. A movable rod is hinged to the hinge joint one. The other end of the movable rod is hinged to the hinge joint two. The hinge joint two is connected to the movable clamping plate. The folding of the movable clamping plate is controlled by the clamping arm cylinder. This rotary fabric clamping mechanism is used to clamp nonwoven base fabric and drive it to be impregnated along a predetermined path. It consists of a drive assembly, a rotating frame, and four sets of fabric clamping assemblies. The working principle is as follows: when the fabric clamping assembly rotates to the fabric outlet end and the fixed clamping surface reaches the clamping position, the clamping arm cylinder is activated, driving the connecting rod to push the movable rod forward. Under the action of hinge joint one and hinge joint two, the movable clamping plate folds downward and cooperates with the fixed clamping surface to clamp the nonwoven base fabric. At this time, the clamping arms on both sides clamp the two sides of the nonwoven base fabric respectively. The rotary fabric clamping mechanism continues to rotate, driving the nonwoven base fabric to be conveyed earlier and impregnated in the nylon waste filament adhesive. The rotating fabric clamping mechanism can operate in an intermittent rotation mode, such as rotating 10° every 5 minutes; or in a constant speed rotation mode, rotating at a constant speed. The process is repeated as the next clamping assembly rotates to the fabric exit end, thus achieving continuous impregnation of the nonwoven base fabric. Compared to existing impregnation methods, this process allows the nonwoven base fabric to fully contact the nylon waste filament adhesive, significantly improving the impregnation effect. The continuous impregnation method offers high efficiency, and the nonwoven fabric can be immediately used in the next process after impregnation, indirectly improving the manufacturing efficiency of this invention. In this invention's impregnation method, the nonwoven base fabric moves along a fixed trajectory and does not contact other components during impregnation, resulting in excellent impregnation effects.

[0031] Furthermore, an infrared sensor is installed at the fixed clamping surface. When the clamping arm rotates to the nonwoven base fabric, the fixed clamping surface faces the nonwoven base fabric, and the infrared sensor identifies the nonwoven base fabric, activating the clamping arm cylinder to control the moving clamp plate to fold and clamp the nonwoven base fabric. The cross-section of the impregnation tank is semi-circular, matching the rotation path of the fabric clamping assembly. Spray assemblies are located at the front and rear ends of the bottom of the impregnation tank, rinsing the clamping arm through the spray assemblies. The spray assemblies include three spray heads arranged from top to bottom, which rinse different positions of the clamping arm. During rinsing, the spray assemblies and the rotating fabric clamping mechanism are turned on, and the rotation speed of the rotating fabric clamping mechanism is adjusted to one revolution every 5 minutes. The clamping arm is rinsed when it passes the spray assemblies, and the impregnation tank is rinsed for the rest of the time, for 10 or 15 minutes. When the clamping surface rotates to the fabric clamping position, it aligns with the nonwoven base fabric. The light signal emitted by the infrared sensor is blocked by the fabric, thus identifying the fabric and enabling automated control of the clamping arm cylinder. The ingenious structural design achieves automatic fabric clamping. The bottom of the impregnation tank is arc-shaped, matching the rotation path of the fabric clamping assembly. Compared with a rectangular impregnation tank, less nylon waste filament adhesive is required to fill the same height. The spray assembly, in conjunction with the rotation of the rotating fabric clamping mechanism, achieves comprehensive rinsing of the clamping arm and the impregnation tank. The cleaning structure is simple, and the cleaning effect is good.

[0032] The above technical solution has the following beneficial effects:

[0033] This invention relates to a method for manufacturing home furnishing materials based on the recycling of waste textile fibers. Based on physical recycling, it uses loose fibers from waste textiles, industrial waste nylon filaments, and a small amount of low-melting-point polyester fibers as raw materials. Through processes such as carding, web laying, needle punching, and heat treatment, a nonwoven fabric base material for recycling waste textile fibers is designed and constructed. The invention reveals the bulky thermoforming mechanism of the nonwoven fabric base material, establishes the relationship between its structure and properties, and creates a method for surface modification and shaping of the nonwoven fabric using nylon waste filament adhesive and nylon waste filament paste. Finally, indoor and outdoor home furnishing materials made from recycled textile fibers are obtained, improving the effective coverage of the original base color of the waste textile fibers, the bulkiness, and the softness of the coating material.

[0034] 1. The raw materials used in this invention are all scraps, offcuts, waste silk, etc. from the production process of waste carpets, blankets, wall coverings, etc., as well as waste textiles generated in daily life. Therefore, using waste textiles to prepare home furnishing materials can not only meet the raw material needs of industrial production and reduce environmental pollution, but also save energy and achieve the strategic goal of sustainable development.

[0035] 2. Step (2) adopts pre-drying and hot-pressing pretreatment process, and controls the hot-pressing pressure within 5-8 MPa. The nonwoven base fabric after molding has a fluffy characteristic. The nonwoven base fabric of untreated waste textile fiber recycling has relatively poor strength and loose surface structure, which is not conducive to further coating. The internal structure of the nonwoven base fabric is constructed by the fluffy thermoforming process of pre-drying and hot pressing, and the surface state, porosity and thickness are controlled. At the same time, the hot pressing pressure is reduced so that the nonwoven base fabric is not compacted, and the fluffy construction requirements are met.

[0036] 3. Incorporating low-melting-point polyester fibers can change the defects of relatively poor strength and loose surface structure of nonwoven base fabric, control its surface condition, porosity and thickness, and improve its physical and mechanical properties and hand feel.

[0037] 4. In step (3), the nonwoven base fabric is successively modified by nylon waste filament adhesive and nylon waste filament slurry. This not only changes the surface structure of the waste textile fiber nonwoven base fabric and obtains a unique appearance style, but also covers the original color of the waste textile fiber and improves the adhesion and fluffiness retention of different surface layers of the paving material.

[0038] 5. This impregnation equipment uses a rotating mechanism to continuously feed, impregnate, and discharge the nonwoven base fabric, achieving continuous impregnation. During the impregnation process, a rotating clamping mechanism grips and limits the travel path of the nonwoven base fabric, ensuring a stable and orderly impregnation process. By controlling the rotation speed of the rotating clamping mechanism, the impregnation time of the nonwoven base fabric can be adjusted to meet different process requirements. Attached Figure Description

[0039] The present invention will be further described below with reference to the accompanying drawings:

[0040] Figure 1 This is a schematic diagram of the impregnation equipment of the present invention;

[0041] Figure 2 This is a schematic diagram of the organism's structure;

[0042] Figure 3 This is a schematic diagram of the rotating fabric clamping mechanism;

[0043] Figure 4 This is a schematic diagram of the fabric clamping assembly.

[0044] Figure 5 This is a schematic diagram of the clamping arm.

[0045] The components are denoted as follows: machine body 1, impregnation tank 11, spray assembly 12, spray head 121, connector 13, fabric inlet end 2, tension roller 21, fabric outlet end 3, rotating fabric clamping mechanism 4, motor unit 41, transmission component 42, rotating frame 43, fabric clamping assembly 44, rotating seat 441, clamping arm 442, clamping arm cylinder 443, moving clamping plate 444, fixed clamping surface 445, connecting rod 4431, hinge joint one 4432, movable rod 4433, hinge joint two 4434, infrared sensor 446. Detailed Implementation

[0046] This invention aims to provide a method for manufacturing home furnishing materials that utilize recycled waste textile fibers. Based on physical recycling, it uses loose fibers from waste textiles, industrial waste nylon filaments, and a small amount of low-melting-point polyester fibers as raw materials. It employs processes such as carding, web laying, needle punching, and heat treatment to design and construct a nonwoven fabric base for recycled waste textile fibers. The invention reveals the bulky thermoforming mechanism of the nonwoven fabric base, establishes the relationship between its structure and properties, and creates a method for surface modification and shaping of the nonwoven fabric using nylon waste filament adhesive and nylon waste filament paste. Ultimately, it produces indoor and outdoor home furnishing materials that utilize recycled textile fibers, improving the effective coverage of the original base color of the waste textile fibers, enhancing the bulkiness, and improving the softness of the coating material.

[0047] The present invention will be further described below with reference to specific embodiments:

[0048] Example 1

[0049] (1) Processing of waste textile fibers:

[0050] Step 1: After disinfection, waste carpets and blankets are sent into an opening machine to obtain waste textile fibers after opening treatment.

[0051] Step 2: Preparation of low-melting-point polyester fibers: a) Mix ethylene glycol, adipic acid, propylene glycol, and terephthalic acid. During stirring, add antimony glycolate catalyst, trimethyl phosphate heat stabilizer, and anhydrous sodium acetate ether inhibitor. Stir until a uniform slurry is obtained. b) Add the slurry to a reactor and react under a nitrogen atmosphere. First, react at 180-200℃ for 15-20 minutes; then raise the temperature to 60℃ at a rate of 5℃ / min and hold for 5-10 minutes. After the reaction, nitrogen gas is introduced into the reactor until the pressure inside the reactor is 1 standard atmosphere, and the reaction is carried out for 10-15 minutes; c) Polycondensation is first carried out under low vacuum conditions for 30-45 minutes, and then under high vacuum conditions of 60 Pa and 280℃ for 20-30 minutes to obtain low melting point polyester; d) The low melting point polyester is dried in an oven at 85℃, and then spun at 220℃ with a stretching speed of 800 m / min and a stretching ratio of 4 times to obtain low melting point polyester fiber.

[0052] 3% low-melting-point polyester fiber is added to waste textile fibers.

[0053] (2) Nonwoven base fabric construction:

[0054] Waste textile fibers are processed through a needle punching device using coarse combing, fine combing, web stacking, and needle punching processes to produce a waste textile fiber nonwoven base fabric. After pretreatment, a waste textile fiber nonwoven base fabric suitable for coating processing is obtained. The pretreatment includes: a) pre-drying: pre-drying the waste textile fiber nonwoven base fabric at 100℃ for 8 minutes; b) hot pressing: hot pressing the pre-dried waste textile fiber nonwoven base fabric at 150℃, 5 MPa, and 100 seconds.

[0055] (3) Surface finishing and molding of waste textile fiber nonwoven base fabric:

[0056] Preparation of nylon waste filament adhesive: 30 parts of anhydrous calcium chloride and 80 parts of anhydrous methanol are thoroughly mixed and reacted at a temperature of 65°C. After the reaction is completed, 10 parts of nylon 6 waste filaments are added to dissolve them. The mixture is stirred at high speed until the waste filaments are completely dissolved to obtain nylon waste filament adhesive.

[0057] The waste textile fiber nonwoven base fabric from step (2) is impregnated in nylon waste filament adhesive, and the impregnation temperature is controlled at 40°C and the impregnation time is 30 min.

[0058] Preparation of nylon waste filament pulp: Mix 30 parts of anhydrous calcium chloride and 80 parts of anhydrous methanol thoroughly at a temperature of 65°C. After the reaction is complete, add 20 parts of nylon 6 waste filament to dissolve it. After the waste filament is completely dissolved, add 20 parts of kaolin filler under high-speed stirring and stir evenly for later use.

[0059] Nylon waste filament coating paste is uniformly coated onto the impregnated waste textile fiber nonwoven base fabric. The coated waste textile fiber nonwoven base fabric is then ionized and cured at 140℃ for 60s. After curing, it is calendered and shaped to obtain the modified waste textile fiber nonwoven base fabric.

[0060] (4) Preparation of home furnishing materials:

[0061] Select recycled polyester fiber to prepare the surface layer of the paving material, and then combine it with the waste textile fiber nonwoven base fabric from step (3) using hot melt adhesive. The composite temperature is 130℃, the composite pressure is 2Mpa, and the composite time is 100s to obtain the home paving material.

[0062] Example 2

[0063] (1) Processing of waste textile fibers:

[0064] Step 1: After disinfection, waste carpets and blankets are sent into an opening machine to obtain waste textile fibers after opening treatment.

[0065] Step 2: Preparation of low-melting-point polyester fibers: a) Mix ethylene glycol, adipic acid, propylene glycol, and terephthalic acid. During stirring, add antimony glycolate catalyst, trimethyl phosphate heat stabilizer, and anhydrous sodium acetate ether inhibitor. Stir until a uniform slurry is obtained. b) Add the slurry to a reactor and react under a nitrogen atmosphere. First, react at 180-200℃ for 15-20 minutes; then raise the temperature to 60℃ at a rate of 5℃ / min and hold for 5-10 minutes. After the reaction, nitrogen gas is introduced into the reactor until the pressure inside the reactor is 1 standard atmosphere, and the reaction is carried out for 10-15 minutes; c) Polycondensation is first carried out under low vacuum conditions for 30-45 minutes, and then under high vacuum conditions of 60 Pa and 280℃ for 20-30 minutes to obtain low melting point polyester; d) The low melting point polyester is dried in an oven at 85℃, and then spun at 220℃ with a stretching speed of 800 m / min and a stretching ratio of 4 times to obtain low melting point polyester fiber.

[0066] 4% low-melting-point polyester fiber is added to waste textile fibers.

[0067] (2) Nonwoven base fabric construction:

[0068] Waste textile fibers are processed through a needle punching process involving coarse combing, fine combing, web stacking, and needle punching to produce a nonwoven base fabric of waste textile fibers. After pretreatment, a nonwoven base fabric of waste textile fibers suitable for coating processing is obtained. The pretreatment includes: a) pre-drying: the waste textile fiber nonwoven base fabric is pre-dried at 120℃ for 10 minutes; b) hot pressing: the pre-dried waste textile fiber nonwoven base fabric is hot-pressed at a temperature of 140℃, a pressure of 5 MPa, and a time of 120 seconds.

[0069] (3) Surface finishing and molding of waste textile fiber nonwoven base fabric:

[0070] Preparation of nylon waste filament adhesive: 20 parts of anhydrous calcium chloride and 70 parts of anhydrous methanol are thoroughly mixed and reacted at a temperature of 65°C. After the reaction is completed, 8 parts of nylon 6 waste filaments are added to dissolve them. The mixture is stirred at high speed until the waste filaments are completely dissolved to obtain nylon waste filament adhesive.

[0071] The waste textile fiber nonwoven base fabric from step (2) is impregnated in nylon waste filament adhesive, and the impregnation temperature is controlled at 50°C and the impregnation time is 30 min.

[0072] Preparation of nylon waste filament pulp: Mix 20 parts of anhydrous calcium chloride and 70 parts of anhydrous methanol thoroughly at a temperature of 65°C. After the reaction is complete, add 16 parts of nylon 6 waste filament to dissolve it. After the waste filament is completely dissolved, add 25 parts of kaolin filler under high-speed stirring and stir evenly for later use.

[0073] Nylon waste filament coating paste is uniformly coated onto the impregnated waste textile fiber nonwoven base fabric. The coated waste textile fiber nonwoven base fabric is then ionized and cured at 150℃ for 80s. After curing, it is calendered and shaped to obtain the modified waste textile fiber nonwoven base fabric.

[0074] (4) Preparation of home furnishing materials:

[0075] Recycled polyester fibers were selected to prepare the surface layer of the paving material. The surface layer of the paving material was then combined with the waste textile fiber nonwoven base fabric from step (3) using hot melt adhesive. The composite temperature was 140°C, the composite pressure was 2 MPa, and the composite time was 120 s to obtain the home paving material.

[0076] Example 3

[0077] (1) Processing of waste textile fibers:

[0078] Step 1: After disinfection, waste carpets and blankets are sent into an opening machine to obtain waste textile fibers after opening treatment.

[0079] Step 2: Preparation of low-melting-point polyester fibers: a) Mix ethylene glycol, adipic acid, propylene glycol, and terephthalic acid. During stirring, add antimony glycolate catalyst, trimethyl phosphate heat stabilizer, and anhydrous sodium acetate ether inhibitor. Stir until a uniform slurry is obtained. b) Add the slurry to a reactor and react under a nitrogen atmosphere. First, react at 180-200℃ for 15-20 minutes; then raise the temperature to 60℃ at a rate of 5℃ / min and hold for 5-10 minutes. After the reaction, nitrogen gas is introduced into the reactor until the pressure inside the reactor is 1 standard atmosphere, and the reaction is carried out for 10-15 minutes; c) Polycondensation is first carried out under low vacuum conditions for 30-45 minutes, and then under high vacuum conditions of 60 Pa and 280℃ for 20-30 minutes to obtain low melting point polyester; d) The low melting point polyester is dried in an oven at 85℃, and then spun at 220℃ with a stretching speed of 800 m / min and a stretching ratio of 4 times to obtain low melting point polyester fiber.

[0080] 3% low-melting-point polyester fiber is added to waste textile fibers.

[0081] (2) Nonwoven base fabric construction:

[0082] Waste textile fibers are processed through a needle punching process involving coarse combing, fine combing, web stacking, and needle punching to produce a nonwoven base fabric of waste textile fibers. After pretreatment, a nonwoven base fabric of waste textile fibers suitable for coating processing is obtained. The pretreatment includes: a) pre-drying: the waste textile fiber nonwoven base fabric is pre-dried at 110℃ for 10 minutes; b) hot pressing: the pre-dried waste textile fiber nonwoven base fabric is hot-pressed at a temperature of 160℃, a pressure of 8 MPa, and a time of 150 seconds.

[0083] (3) Surface finishing and molding of waste textile fiber nonwoven base fabric:

[0084] Preparation of nylon waste filament adhesive: 25 parts of anhydrous calcium chloride and 100 parts of anhydrous methanol are thoroughly mixed and reacted at a temperature of 65°C. After the reaction is completed, 9 parts of nylon 6 waste filaments are added to dissolve them. The mixture is stirred at high speed until the waste filaments are completely dissolved to obtain nylon waste filament adhesive.

[0085] The waste textile fiber nonwoven base fabric from step (2) is impregnated in nylon waste filament adhesive, and the impregnation temperature is controlled at 40-50℃ and the impregnation time is 20-30min.

[0086] Preparation of nylon waste filament pulp: Mix 25 parts of anhydrous calcium chloride and 100 parts of anhydrous methanol thoroughly at a temperature of 65°C. After the reaction is complete, add 18 parts of nylon 6 waste filament to dissolve it. After the waste filament is completely dissolved, add 30 parts of kaolin filler under high-speed stirring and stir evenly for later use.

[0087] Nylon waste filament coating paste is uniformly coated onto the impregnated waste textile fiber nonwoven base fabric. The coated waste textile fiber nonwoven base fabric is then ionized and cured at 150℃ for 80s. After curing, it is calendered and shaped to obtain the modified waste textile fiber nonwoven base fabric.

[0088] (4) Preparation of home furnishing materials:

[0089] Recycled polyester fibers were selected to prepare the surface layer of the paving material. The surface layer of the paving material was then combined with the waste textile fiber nonwoven base fabric from step (3) using hot melt adhesive. The composite temperature was 140°C, the composite pressure was 2 MPa, and the composite time was 120 s to obtain the home paving material.

[0090] Example 4

[0091] (1) Processing of waste textile fibers:

[0092] Step 1: After disinfection, waste carpets and blankets are sent into an opening machine to obtain waste textile fibers after opening treatment.

[0093] Step 2: Add 4% of low-melting-point polyester fiber purchased from the market to the waste textile fiber.

[0094] (2) Nonwoven base fabric construction:

[0095] Waste textile fibers are processed through a needle punching device using coarse combing, fine combing, web stacking, and needle punching processes to produce a waste textile fiber nonwoven base fabric. After pretreatment, a waste textile fiber nonwoven base fabric suitable for coating processing is obtained. The pretreatment includes: a) pre-drying: pre-drying the waste textile fiber nonwoven base fabric at 100℃ for 8 minutes; b) hot pressing: hot pressing the pre-dried waste textile fiber nonwoven base fabric at 150℃, 5 MPa, and 100 seconds.

[0096] (3) Surface finishing and molding of waste textile fiber nonwoven base fabric:

[0097] Preparation of nylon waste filament adhesive: 30 parts of anhydrous calcium chloride and 80 parts of anhydrous methanol are thoroughly mixed and reacted at a temperature of 65°C. After the reaction is completed, 10 parts of nylon 6 waste filaments are added to dissolve them. The mixture is stirred at high speed until the waste filaments are completely dissolved to obtain nylon waste filament adhesive.

[0098] The waste textile fiber nonwoven base fabric from step (2) is impregnated in nylon waste filament adhesive, and the impregnation temperature is controlled at 40°C and the impregnation time is 30 min.

[0099] Preparation of nylon waste filament pulp: Mix 30 parts of anhydrous calcium chloride and 80 parts of anhydrous methanol thoroughly at a temperature of 65°C. After the reaction is complete, add 20 parts of nylon 6 waste filament to dissolve it. After the waste filament is completely dissolved, add 20 parts of kaolin filler under high-speed stirring and stir evenly for later use.

[0100] Nylon waste filament coating paste is uniformly coated onto the impregnated waste textile fiber nonwoven base fabric. The coated waste textile fiber nonwoven base fabric is then ionized and cured at 140℃ for 60s. After curing, it is calendered and shaped to obtain the modified waste textile fiber nonwoven base fabric.

[0101] (4) Preparation of home furnishing materials:

[0102] Select recycled polyester fiber to prepare the surface layer of the paving material, and then combine it with the waste textile fiber nonwoven base fabric from step (3) using hot melt adhesive. The composite temperature is 130℃, the composite pressure is 2Mpa, and the composite time is 100s to obtain the home paving material.

[0103] Example 5:

[0104] The impregnation process in Examples 1-4 is completed in a rotary impregnation device, which includes a machine body 1 and a fabric inlet end 2, a fabric outlet end 3, and a rotary fabric clamping mechanism 4 disposed on the machine body 1. Waste textile fiber nonwoven base fabric is fed into the fabric inlet end 2, and the rotary fabric clamping mechanism 4 clamps the nonwoven base fabric in sequence and drives it to rotate. During the rotation, it passes through the impregnation tank 11 of the machine body 1, which is filled with nylon waste filament adhesive. The impregnation time of the nonwoven base fabric is adjusted to 20-30 minutes by controlling the rotation speed of the rotary fabric clamping mechanism 4. After impregnation, it is rotated to the fabric outlet end 3 and the nonwoven base fabric is sent out from the fabric outlet end 3.

[0105] A tension roller 21 is provided at the fabric inlet end 2, and the nonwoven base fabric is kept in a flat and unfolded state by passing through the tension roller 21;

[0106] A heater is adapted to be installed inside the body 1 to heat and keep the nylon waste filament adhesive warm.

[0107] The impregnation equipment uses a rotating mechanism to continuously feed, impregnate, and discharge the nonwoven base fabric, achieving continuous impregnation. During the impregnation process, the rotating clamping mechanism 4 grips and limits the travel path of the nonwoven base fabric, ensuring a stable and orderly impregnation process. By controlling the rotation speed of the rotating clamping mechanism 4, the impregnation time of the nonwoven base fabric can be adjusted to meet different process requirements.

[0108] The rotating fabric clamping mechanism 4 includes a drive assembly, a rotating frame 43, and fabric clamping assemblies 44 mounted on the rotating frame 43. The drive assembly includes a motor unit 41 and a transmission component 42. The motor unit 41 is connected to the transmission component 42, which in turn connects to the rotating frame 43. Four sets of fabric clamping assemblies 44 are connected to the rotating frame 43. Every 90° rotation, one set of fabric clamping assemblies 44 clamps the nonwoven base fabric. Through a cyclical rotation-clamping-rotation-releasing action, the nonwoven base fabric is continuously impregnated. The fabric clamping assembly 44 includes a rotating base 441 connected to the rotating frame 43, clamping arms 442, and clamping arm cylinders 443 mounted on the clamping arms 442. The rotating base 441 has two... Each side is provided with a clamping arm 442, and the end of the clamping arm 442 is provided with a fixed clamping surface 445. A movable clamping plate 444 is connected to the fixed clamping surface 445. The movable clamping plate 444 can be folded. When it is folded downward, it cooperates with the fixed clamping surface 445 to clamp the non-woven base fabric. When it is folded upward, it lowers the non-woven base fabric. The piston rod of the clamping arm cylinder 443 is connected to a connecting rod 4431. The end of the connecting rod 4431 is provided with a hinge joint 4432. The hinge joint 4432 is hinged to a movable rod 4433. The other end of the movable rod 4433 is hinged to a hinge joint 4434. The hinge joint 4434 is connected to the movable clamping plate 444. The folding of the movable clamping plate 444 is controlled by the clamping arm cylinder 443.

[0109] The motor assembly 41 includes a motor and a reducer. The reducer is used to control the rotation speed of the rotating frame 43. The transmission component 42 includes a drive pulley, a belt, and a driven pulley. The drive pulley is connected to the motor shaft and then the belt drives the driven pulley. The driven pulley is connected to the rotating frame 43, thereby driving it to rotate.

[0110] The rotating fabric clamping mechanism 4 is used to clamp the nonwoven base fabric and drive it to impregnate along a predetermined path. It consists of a drive assembly, a rotating frame 43, and four sets of fabric clamping assemblies 44. The working principle is as follows: when the fabric clamping assembly 44 rotates to the fabric outlet end 3 and the fixed clamping surface 445 reaches the clamping position, the clamping arm cylinder 443 is activated, driving the connecting rod 4431 to push the movable rod 4433 forward. Under the action of the first and second hinge joints, the movable clamping plate 444 folds down and cooperates with the fixed clamping surface 445 to clamp the nonwoven base fabric. At this time, the clamping arms 442 on both sides clamp the two sides of the nonwoven base fabric respectively. The rotating fabric clamping mechanism 4 continues to rotate, driving the nonwoven base fabric that was previously fed in during the rotation. The fabric is fed and impregnated in nylon waste filament adhesive. The rotating clamping mechanism 4 can rotate in an intermittent mode, such as rotating 10° every 5 minutes, or in a constant speed mode, i.e., rotating at a constant speed. The process is repeated as the clamping assembly 44 rotates to the output end 3, thus achieving continuous impregnation of the nonwoven base fabric. Compared to existing impregnation methods, this impregnation process allows the nonwoven base fabric to fully contact the nylon waste filament adhesive, significantly improving the impregnation effect. The continuous impregnation method has high impregnation efficiency, and the nonwoven fabric can be immediately used in the next process after impregnation, indirectly improving the manufacturing efficiency of this invention. In the impregnation method of this invention, the nonwoven base fabric runs along a fixed trajectory and does not contact other components during the impregnation process, resulting in excellent impregnation effects.

[0111] An infrared sensor 446 is installed at the fixed clamping surface 445. When the clamping arm 442 rotates to the nonwoven base fabric, the fixed clamping surface 445 faces the nonwoven base fabric, and the infrared sensor 446 identifies the nonwoven base fabric, activating the clamping arm cylinder 443 to control the moving clamping plate 444 to fold and clamp the nonwoven base fabric. The impregnation tank 11 has a semi-circular cross-section to match the rotation path of the fabric clamping assembly 44. Spraying assemblies 12 are provided at the front and rear ends of the bottom of the impregnation tank 11 to rinse the clamping arm 442. The spray assembly 12 includes three spray heads 121 arranged from top to bottom and a connector 13 for an external water pipe. The connector 13 is connected to the spray heads 121, and the spray heads 121 rinse different positions of the clamping arm 442. During rinsing, the spray assembly 12 and the rotating cloth clamping mechanism 4 are turned on, and the rotation speed of the rotating cloth clamping mechanism 4 is adjusted to one revolution every 5 minutes. When the clamping arm 442 passes through the spray assembly 12, it is rinsed. The remaining time is spent rinsing the immersion tank 11 for 10 or 15 minutes.

[0112] When the clamping surface 445 rotates to the clamping position, it aligns with the nonwoven base fabric. The light signal emitted by the infrared sensor 446 is blocked by the fabric, thus identifying the fabric and enabling automated control of the clamping arm cylinder 443. The ingenious structural design achieves automatic fabric clamping. The bottom of the impregnation tank 11 is arc-shaped, matching the rotation path of the fabric clamping assembly 44. Compared with the rectangular impregnation tank 11, less nylon waste filament adhesive is required to fill the same height. The spray assembly 12, in conjunction with the rotation of the rotating fabric clamping mechanism 4, achieves comprehensive rinsing of the clamping arm 442 and the impregnation tank 11. The cleaning structure is simple and the cleaning effect is good.

[0113] The above are merely specific embodiments of the present invention, but the technical features of the present invention are not limited thereto. Any simple changes, equivalent substitutions, or modifications made based on the present invention to solve essentially the same technical problems and achieve essentially the same technical effects are all covered within the protection scope of the present invention.

Claims

1. A method of manufacturing a home flooring material from recycled waste textile fibers, characterized by It comprises the following steps: (1) waste textile fiber finishing: Step one, the waste carpet, blanket into the opener, after opening treatment, the waste textile fiber is prepared; Step two, preparation of low melting point polyester fiber, and mixed into the above waste textile fiber; (2) non-woven fabric construction: By means of needle punching equipment, waste textile fiber is treated by carding, fine combing, lapping and needling process to prepare waste textile fiber non-woven fabric, and the waste textile fiber non-woven fabric suitable for coating processing is obtained after pretreatment; (3) surface modification and forming processing of waste textile fiber non-woven fabric: The nylon waste silk adhesive is prepared, the waste textile fiber non-woven fabric of step (2) is immersed in the nylon waste silk adhesive, the immersion temperature is controlled at 40-50℃, and the immersion time is 20-30min; After immersion, the nylon waste silk coating slurry is uniformly coated on the waste textile fiber non-woven fabric, the coated waste textile fiber non-woven fabric is pasted ion, and is cured at 140-150℃ for 50-80s; After curing, it is calendered and shaped, and the modified and shaped waste textile fiber non-woven fabric is prepared; The preparation process of nylon waste silk adhesive: 1-50 parts of anhydrous calcium chloride and 20-100 parts of anhydrous methanol are fully stirred and mixed at a temperature of 65℃, after the reaction is completed, 8-12 parts of nylon 6 waste silk is added for dissolution, and high speed stirring is carried out until the waste silk is completely dissolved, and the nylon waste silk adhesive is prepared; The preparation process of nylon waste silk slurry: 1-50 parts of anhydrous calcium chloride and 20-100 parts of anhydrous methanol are fully stirred and mixed at a temperature of 65℃, after the reaction is completed, 8-12 parts of nylon 6 waste silk is added for dissolution, and high speed stirring is carried out until the waste silk is completely dissolved, and the nylon waste silk adhesive is prepared; The preparation process of nylon waste silk slurry: 1-50 parts of anhydrous calcium chloride and 20-100 parts of anhydrous methanol are fully stirred and mixed at a temperature of 65℃, after the reaction is completed, 8-12 parts of nylon 6 waste silk is added for dissolution, and high speed stirring is carried out until the waste silk is completely dissolved, and the nylon waste silk adhesive is prepared; The impregnation is completed in a rotary impregnation device, which comprises a machine body, a cloth feeding end, a cloth discharging end and a rotary cloth clamping mechanism arranged on the machine body. The waste textile fiber non-woven base cloth is fed into the cloth feeding end, and the non-woven base cloth is clamped by the rotary cloth clamping mechanism in sequence and rotated, and passes through the impregnation tank of the machine body in the rotating process. The impregnation tank is filled with adhesive. The rotation speed of the rotary cloth clamping mechanism is controlled to adjust the impregnation time of the non-woven base cloth to 20-30 min. After impregnation is completed, the rotary cloth clamping mechanism is rotated to the cloth discharging end, and the non-woven base cloth is discharged from the cloth discharging end. The rotary cloth clamping mechanism comprises a driving assembly, a rotating frame and a cloth clamping assembly mounted on the rotating frame. The driving assembly comprises a motor set and a transmission part. The motor set is connected to the transmission part, and the transmission part is connected to the rotating frame. Four sets of the cloth clamping assembly are connected to the rotating frame. Every 90° rotation, one set of the cloth clamping assembly clamps the non-woven base cloth. Through the rotating-clamping-rotating-discharging action, the non-woven base cloth is continuously impregnated. The cloth clamping assembly comprises a rotating seat connected to the rotating frame, a clamping arm and a clamping arm cylinder mounted on the clamping arm. The two sides of the rotating seat are respectively provided with the clamping arm. The end of the clamping arm is provided with a fixed clamping surface. The fixed clamping surface is connected with a movable clamping plate. The movable clamping plate can be folded. After being folded downward, the movable clamping plate clamps the non-woven base cloth together with the fixed clamping surface. After being folded upward, the movable clamping plate releases the non-woven base cloth. The piston rod of the clamping arm cylinder is connected with a connecting rod. The end of the connecting rod is provided with a hinge joint one. The hinge joint one is hinged with a movable rod. The other end of the movable rod is hinged to a hinge joint two. The hinge joint two is connected to the movable clamping plate. The folding of the movable clamping plate is controlled by the clamping arm cylinder. (4) Preparation of a home paving material: The recycled polyester fiber is selected to prepare a paving material surface layer, which is hot melt glued with the waste textile fiber non-woven base cloth of step (3). The compounding temperature is 130-140℃, the compounding pressure is 2Mpa, and the compounding time is 90-120s. The home paving material is prepared.

2. The method of claim 1, wherein the method is a method of manufacturing a home flooring material from recycled textile fibers. The preparation process of the low-melting-point polyester fiber of step (1): a. Mix and stir ethylene glycol, adipic acid, propylene glycol and terephthalic acid. Add catalyst, heat stabilizer and anti-ether agent during stirring until the slurry is uniform. b. Add the slurry to the reaction kettle and react under a nitrogen atmosphere. First, react at 180-200℃ for 15-20 min. Then, increase the temperature by 60℃ at a rate of 5℃ / min and maintain the temperature for 5-10 min. After the heat preservation reaction, inject nitrogen into the reaction kettle until the gas pressure in the reaction kettle reaches 1 atm. React for 10-15 min. c. First, condense under low vacuum conditions for 30-45 min, then condense under high vacuum conditions of 60 pa and 280℃ for 20-30 min to obtain low-melting-point polyester. d. Dry the low-melting-point polyester in an oven at 85℃. Spin the low-melting-point polyester at 220℃, with a drawing speed of 800 m / min and a drawing ratio of 4 times. The low-melting-point polyester fiber is prepared by spinning.

3. The method of claim 2, wherein the waste textile fiber recycling home flooring material manufacturing method is characterized by: The catalyst is ethylene glycol antimony, the heat stabilizer is trimethyl phosphate, and the ether inhibitor is anhydrous sodium acetate.

4. The method of claim 1, wherein the method is a method of manufacturing a home flooring material from recycled textile fibers. The step (2) pretreatment comprises: a. pre-drying: the waste textile fiber nonwoven substrate is pre-dried at 90-150℃ for 5-10min; b. hot pressing: the pre-dried waste textile fiber nonwoven substrate is hot pressed, the hot pressing temperature is 100-200℃, the hot pressing pressure is 5-8Mpa, and the hot pressing time is 60-240s.

5. The method of claim 1, wherein the method is characterized by: The fixed clamping surface is provided with an infrared sensor, when the clamping arm rotates to the nonwoven substrate, the fixed clamping surface faces the nonwoven substrate, and the infrared sensor identifies the nonwoven substrate, starts the clamping arm cylinder, controls the folding of the movable clamping plate to clamp the nonwoven substrate; the cross section of the impregnation tank is semicircular, matched with the rotating path of the cloth clamping assembly; the bottom of the impregnation tank is provided with a spraying assembly at the front and rear ends, which washes the clamping arm through the spraying assembly; the spraying assembly comprises three spraying heads arranged from top to bottom, which wash different positions of the clamping arm respectively; when washing, open the spraying assembly and the rotating cloth clamping mechanism, adjust the rotating speed of the rotating cloth clamping mechanism to one turn per 5 minutes; when the clamping arm passes through the spraying assembly, it is washed, and the rest of the time is used to wash the impregnation tank, which is washed for 10 or 15 minutes.

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