Rigid color material for buildings and furniture

Abstract

The invention relates to a rigid material 1 for buildings or furniture, comprising fibrous particles bound together by a binding agent, and to a method for the production thereof. The fiber particles are textile fibers, and the binder belongs to the thermoplastic or thermoset family, such as epoxy resins. The proportion of the binder in the total weight is between 10% and 50%. The rigid material can be produced in the form of a panel 2 or a furniture component.

Description

Technical Field

[0001] The present invention generally relates to the technical field of rigid granular materials, such as media intended for obtaining rigid flat panels of predetermined dimensions or for producing furniture components, such as chair backs or seats.

[0002] The present invention more particularly relates to a rigid colored material with low or negative environmental impact obtained from recycled components and a process for its manufacture. Background Art

[0003] Panels made from wood fibers are commonly used in construction and furniture manufacturing. Among the most well-known wood fiber panels, MDF (Medium Density Fiberboard) is highly valued for its strength, low cost, and versatility.

[0004] The media is obtained from ordinary wood particles that have been defibrated by steam. After defibration, the wood fibers are aggregated with a urea-formaldehyde or melamine-formaldehyde binder and the resulting mixture is hot pressed to form panels, which are cut into various standard sizes. Despite the many advantages of the media, the media can be harmful to the health of those who use it because it contains formaldehyde.

[0005] Furthermore, as raw materials become increasingly scarce, there is a growing need to produce materials from recycled sources. Therefore, from an environmental and economic point of view, there is a need for a strong, healthy material that can be used both in construction and in furniture, which is obtained from recycled materials. Since the approval of the Waste Directive by the European Parliament in 2018, this need has become a legal obligation, as textiles will have to be collected separately in EU countries by 2025.

[0006] Patent application WO 98 / 36114 describes an insulating felt made of textile fibers and an epoxy binder, which may be in powder form. Summary of the invention

[0007] The object of the present invention is to remedy all or part of the disadvantages of the prior art and to meet the above mentioned environmental and economic needs, in particular by providing a strong and rigid material having properties similar to those of the medium, obtained by recycling materials from old clothes and paint powders destined for landfill or incineration.

[0008] To this end, according to a first aspect of the invention, a strong material for construction or furniture is proposed, which comprises fiber particles bonded together by a binder belonging to the family of thermoplastic or thermosetting materials (e.g. powdered epoxy resin), wherein the fiber particles are textile fibers and the binder consists of paint powder from unheated paint waste. The proportion of the binder in the total weight is between 10% and 50%. The proportion of the binder in the total weight is preferably 20%, 30% or 40%.

[0009] Preferably, the textile fibers are obtained by wearing textile scraps, at least some of which are from old clothing.

[0010] Advantageously, the textile fibres comprise a mixture of natural and synthetic textile fibres, such as cotton or polyester fibres, and / or the rigid material is overall coloured by the colour of the textile fibres used.

[0011] Preferably, the coating powder used as a binder consists mainly of epoxy resin, polyester, polyurethane or acrylic resin, and / or the coating powder used as a binder comprises paint, primer or varnish powder, or a mixture of these powders.

[0012] Advantageously, the rigid material also comprises at least one additive, such as an antifungal agent, a water-repellent agent and / or a flame retardant.

[0013] Preferably, the rigid material is obtained by hot pressing of textile fibers and binders and / or by sanding, calendering or cold pressing to its final thickness.

[0014] According to a second aspect of the invention, a method for manufacturing a rigid material for construction or furniture is proposed, comprising the following steps: collecting paint powder in a paint room to obtain a thermoplastic or thermosetting powder binder; mixing the thermoplastic or thermosetting powder binder with textile fibers, the proportion of the binder being 20% ​​to 30% of the total weight; spreading the textile fibers mixed with the binder to form a mat; and hot pressing the mat at a temperature depending on the properties of the binder, wherein, preferably, after hot pressing, the material undergoes a cooling step while maintaining the pressure.

[0015] Advantageously, in order to prepare textile fibers, the method also includes the following steps: sorting the color of the textile parts to be recycled; a sorting step for removing unworn textiles; a depilation step; a fiber separation step of the sorted textile parts by mechanical wearing; and / or a step of separating the textile fibers by blowing.

[0016] Preferably, the manufacturing method further comprises the step of collecting old non-reusable clothes to obtain at least part of the textile fibers or other textiles to be recycled.

[0017] Advantageously, the manufacturing method further comprises: a step of spraying at least one additive, and / or a step of calendering and / or grinding after the hot pressing or cooling step.

[0018] Preferably, the method further comprises: a step of cutting the rigid material into panels of a desired size, or a step of hot pressing in a mould to form a furniture component.

[0019] Advantageously, hot pressing is carried out at a temperature between 160°C and 200°C, for example at a temperature of 180°C, for a time of 6 to 10 minutes, for example 8 minutes, and / or at a pressure between 10kg / cm2 and 40kg / cm2, for example 20kg / cm2 or 30kg / cm2; and / or the step of mixing the powder binder with the textile fibers is carried out while hot.

[0020] Other features and advantages of the invention are highlighted by the following description of non-limiting examples of various aspects of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] This description refers to the accompanying drawings, which are also given as non-limiting embodiments of the invention:

[0022] Figure 1 A panel obtained using the material of the invention is shown;

[0023] Figure 2 A chair made from the material of the present invention is shown;

[0024] Figure 3 The different states of the material of the present invention during the manufacturing process are shown;

[0025] Figure 4 A method for preparing textile fibers intended for use in making the material of the present invention is shown;

[0026] Figure 5 A method for preparing a coating powder for use as a textile fiber binder is shown; and

[0027] Figure 6 A method for producing a material plate according to the invention is shown.

[0028] For enhanced clarity, the same reference symbols will be used throughout the drawings to identify the same or similar elements. DETAILED DESCRIPTION

[0029] In Europe, 5.8 million tons of textile waste are discarded every year, of which only 1.5 million tons are sorted for recycling. In 2019, operators in the French used clothing recycling industry sorted 196,054 tons of textiles and footwear. In 2020, this amount was 156,202 tons, a 20% drop in collections, mainly due to the COVID 19 pandemic. 56.5% of the used clothing collected and sorted is reused as second-hand clothing. Another 33.3% of textiles are exported to countries with low labor costs for other non-clothing industrial uses, and 9.1% are recycled to produce fuel for French cement plants. In addition, there are currently 400,000 tons of uncollected textiles in France and 5 million tons in Europe, which could be mobilized if new industrial recycling channels were implemented. The present invention exploits the large recycling volume represented by this textile to produce a rigid material based on recycled textile fibers, suitable for use as a substitute for media. Manufacturing the material described below from this low-cost, bulky, non-reusable textile meets environmental needs, particularly as textile materials that are no longer exported will reduce the current carbon footprint of the textile recycling industry and the limitations of the process for industrially producing this material.

[0030] Another major component of the rigid material described below is a binder, which enables the textile fibers to be held together to form a panel or furniture component with mechanical and operating characteristics similar to the medium. Epoxy powder lost in the electrostatic coating room is used as a binder in the manufacture of this rigid material.

[0031] Epoxy powders are increasingly used for surface coatings due to their physical and chemical properties. Coating powders consist of 4 main ingredients: coating binder, pigments, fillers and various additives. Coating binder is the main component of coating powder. It provides a connection between all coating ingredients and ensures that the coating adheres to the surface to be painted. The coating binder is in powder form and can be based on epoxy resins (also called epoxy-based resins), epoxy polyesters, polyester resins cured with triglycidyl isocyanurate, acrylic polyurethanes or polyester polyurethanes. Although epoxy-based resins are mentioned as binders in the rest of the specification, any binder used in coating powders can be used to make the rigid material of the present invention, such as those mentioned above.

[0032] In the powder coating process, epoxy powder is applied electrostatically: the powder is electrostatically sprayed onto the part to be painted, usually a metal part, using an electrostatic gun. The plastic is then melted onto the part and then dried in an oven or under UV light. Powder coating is carried out in paint booths designed specifically for this purpose. These paint booths have an integrated powder vacuum recovery system that collects particles that escape the electrostatic attraction of the surface to be painted during the spraying process so that they can be recycled. Waste from the epoxy spraying process accounts for 40% of the sprayed powder during the painting process and ends up in powder form (60% of collected spray waste) on the floor of the paint booth and in the filters of the suction system. This recyclable waste powder cannot be reused for painting because it is a mixture of different sprayed products, such as differently colored paints, primers or clearcoats. However, the recovered powder can be used as a binding agent to make the rigid materials described below.

[0033] Besides their mechanical properties which make them a highly sought after product in industry, the main advantage of epoxy powders is that, unlike liquid coatings, they contain no solvents. This surface coating process therefore does not release any VOCs (volatile organic compounds) and, once applied, is very healthy for the user. However, it does generate large amounts of hazardous waste which is not currently recycled in industry and which must therefore be disposed of by incineration or, worse still, landfill. It is estimated that the amount of epoxy powder used in France is 27,000 tonnes per year, with ten times this amount in Europe. Therefore, developing recycling facilities for this hazardous industrial waste, as proposed here, is a major environmental challenge. For producers, the cost of disposing of epoxy waste is €400 per tonne, making it a negative cost material for those who can reuse it.

[0034] The present invention relates to a rigid material 1, such as Figure 3 [ Figure 3 ] As shown in the figure, the material is mainly composed of textile fibers 5, but not only of textile fibers 5, and the textile fibers 5 can come from old clothes, unused textiles (such as production scraps, discontinued products or unsold inventory) or a mixture of the two. The rigid material 1 of the present invention also includes a powder binder 6 made from paint powder waste as described above. The textile fibers 5 and the powder binder 6 are mixed to form a pad 7, which includes a weight proportion of 60% to 80%, preferably 70% of textile fibers 5 and a weight proportion of 10% to 50%, preferably 20%, 30% or 40% of powder binder 6. As described in the introduction of this specification, the rigid material 1 is mainly (but not limited to) used in construction, for example in the form of panels 2 cut into predetermined sizes (such as the size of commercially available medium-sized panels) (such as Figure 1 [ Figure 1 ]), and for furniture, such as Figure 2 [ Figure 2] as shown in the chair seat 3 or chair back 4. It can be used for other purposes, such as all uses of media similar to it in terms of mechanical properties and processing methods. Rigid material 1 is the first particle board with a low (even negative) impact on the environment. The panels 2 of rigid material 1 have different thicknesses, such as 6mm, 10mm, 16mm, 19mm, 22mm, 25mm, 30mm or 40mm, and different widths and lengths, such as 1220x2440mm, 2070x2800mm, 2070x3700mm. It is also a healthy material, because the inertness of the epoxy resin allows the material to obtain an A+ rating in VOC measurements after manufacturing. For a standardized test sample with a cross-sectional area of ​​10x3mm and a length of 100mm, the flexural strength of rigid material 1 is 25.68MPa and the tensile strength is 28.94MPa.

[0035] The density of the rigid material 1 used to make the panel 2 or the furniture components 3 and 4 is 700 kg / m 3 Up to 1000kg / m 3 Between, preferably 850kg / m 3 .

[0036] The composition of the garments used (from which all or part of the textile fibres 5 used may come) is completely faithful to the composition available on the market, i.e. a mixture of natural and synthetic textile fibres, such as cotton and polyester, since the properties of the fibres do not have an impact on the mechanical properties of the material and the proportions of other fibres present on the market are too small to affect the performance. In this way, the usable old clothes collected do not need to be sorted according to their composition, which is a major economic advantage, but also an environmental advantage, since the usable clothes constitute part of the “all waste” at the end of the sorting line. However, the manufacture of the rigid material 1 requires the use of garments that can be worn, so no leggings, oilcloths, etc. are used. As described below, the wear required for the production of the rigid material 1 is the traditional end-of-line wear, which can accommodate the small amounts of residual hard points and metal objects contained in the wear material. The sorting is almost systematically carried out in the old clothes sorting and collection centres to remove non-friable materials.

[0037] If the garments used to produce the textile fibres 5 are colour sorted, different shades of rigid material 1 can be obtained. Unlike material sorting, colour sorting is easy to perform. By colour sorting, the rigid material 1 can be naturally dyed in a mass using textile fibres 5 from old garments of the same colour, which provides aesthetic added value through a controlled colour range and avoids the need for surface treatment or finishing, thereby avoiding the use of polluting additives. If colour sorting is not required, the rigid material 1 will have a heterogeneous colour due to the colour mix of the textile fibres 5 used. In addition to obtaining a unique aesthetic appearance, the absence of colour sorting can also provide a cheaper rigid material 1.

[0038] As mentioned above, the powder binder 6 used to make the rigid material 1 also comes from waste to be recycled. When an object is painted using powder coating, that is, by applying hot glazing powder to an object that is mainly metal, most of the spray powder is not captured by the part. These lost paint powders will eventually fall on the floor of the paint room or be captured by the suction of the paint room. These lost paint powders collected in the paint room are mainly composed of epoxy resins and polyesters, and more rarely polyurethanes. Since they have not undergone any heating process, they are completely usable except for painting, because they present a mixture of colors and properties between primers, paints and varnishes. Although the properties of these paint powders vary and the colors are mixed, their main components make it possible to obtain polymers with sufficient mechanical properties to be used as binders 6 in rigid materials 1. This new outlet for these toxic paint powders makes it possible to reduce or avoid their incineration or worse, landfill.

[0039] As shown above, if Figure 3 [ Figure 3 ] As shown in the figure, the rigid material 1 is obtained by mixing a powder binder 6 and a textile fiber 5 to form a pad 7, which is arranged in a mold 8 or a continuous conveyor belt. The pad 7 is then hot pressed by a hot pressing device 8 (which can be a mold upper part 9). The proportion of binder powder in the resulting mixture is 10% to 50% by weight of the mixture, preferably 20%, 30% or 40%. The proportion of powder binder 6 depends on the manufacturing process used and the mechanical properties required for the rigid material 1 to be produced, which may vary according to its different outlets. Since the powder binder 6 is in a different state and is much thinner than the textile fiber 5, it tends to move down along the pad 7 and naturally falls to the bottom of the mold 8 or the continuous conveyor belt of the pad 7. In order to alleviate this problem, the powder binder 6 is hot mixed with the textile fiber 5. To this end, the powder binder 6 is heated to its sticky powder transition temperature, which enables the powder binder 6 to permanently adhere to the textile fiber and remain evenly dispersed in the pad 7. Other processes can be used to prevent the powder binder 6 from migrating to the bottom of the mold 8, such as an electrostatic mixing process or mixing after wetting the textile fiber.

[0040] Once this hot mixing has taken place, the resulting mat 7 is stable and can be used for a long time after manufacture without time restrictions, which is a great advantage for production management. The mat 7 is then placed between the mold 8 and the mold upper part 9 and heated and pressed simultaneously, the temperature depending on the composition of the powder binder 6 used. For example, using a powder binder 6 consisting of epoxy polyester powder, the mat 7 is hot pressed at a temperature of about 180°C for 8 minutes. Pressing is carried out under high pressure to achieve a high density and a smooth, homogeneous surface. The pressure is between 10kg / cm 2 Up to 40kg / cm 2Between, preferably between 30kg / cm 2 The hot pressed mat is then kept under cold pressing in order to control the shape of the rigid material thus obtained during its cooling, thus preventing it from bending or thickening due to spring-back effects. This cooling phase is carried out by passing through another cold die of similar shape to the cold die used for the hot pressing or by cooling the hot pressing die 8.

[0041] The rigid material 1 obtained by this manufacturing process can find a place in many fields due to its high resistance. For example, the rigid material 1 can be used to make panels 2 of furniture, such as Figure 1 [ Figure 1 ] as shown. These panels 2 are suitable for manufacturers who want to replace traditional particleboards (such as medium boards). Therefore, these panels 2 have the same dimensional standards, the same thickness, and have mechanical properties similar to or better than wood fiberboard. A second use example of the rigid material 1 relates to the manufacture of furniture. Figure 2 [ Figure 2 ], the rigid panel 1 can be used to directly manufacture furniture parts, such as tabletops, chair backs 4 or chair seats 3. In this case, the upper part of the mold 9 and the mold 8 will have a shape suitable for hot pressing the material 1 into the shape of the furniture part to be produced.

[0042] The manufacturing process of the rigid material 1 will be described in detail below. Figure 4 [ Figure 4 ] shows a schematic diagram of the process of obtaining textile fibers 5 for the manufacture of rigid material 1. The textiles intended for the production of rigid material 1 come from a sorting process that can be subcontracted to specialized operators. The garments intended for reuse are separated from the waste that is collected directly or by specialized operators. The process for preparing textile fibers 10 thus starts with a stage of sorting the garments 10 that are intended to be reused. The garments to be recycled, i.e. those that cannot be reused, are recycled for the manufacture of rigid material 1.

[0043] This is followed by a color sorting step 12. The rigid material 1 takes on the color of the textile fibers used, i.e. the color of the garment used to produce at least part of the textile fibers 5 from which the rigid material 1 is made. Thus, after being dyed as a whole, the rigid material 1 acquires a particular aesthetic quality which increases its added value and obviates the need to paint it when it is used on a visible support.

[0044] The color of the panel 2 depends on the textile selected. To obtain a given color, you just have to sort the old clothes and / or other collected textiles used to make the panels accordingly so that you get panels of the desired shade. In the standard range of panel 2, the textiles will be sorted into 5 colors: cyan, magenta, yellow, black and white. The color sorting of the textiles is still done manually, which represents an additional operation and additional costs. Nevertheless, automation of the color sorting of textiles is easily possible. For special orders, other colors are available. Although color sorting is mainly described in the production of panels 2, it can also be used to produce furniture components 3 and 4 in different colors. Alternatively, a neutral-colored textile can be used, such as white, which can be dyed to the desired color for the rigid material 1.

[0045] After the color sorting stage 12, the textiles go through an unpacking operation 13 and a fiber separation operation 14. The unpacking operation involves disassembling the garments to remove hard points such as buttons, rivets, zippers, patches, and the like.

[0046] The fiber separation operation involves converting old clothes or other textiles to be recycled into textile fibers 5. Fiber separation can be performed by mechanical abrasion, hot grinding or chemical extrusion. However, mechanical unraveling works best for the production of rigid materials 1. Unraveling involves passing clothing or other textiles through an unraveling machine, which converts the clothing or other textiles into textile fibers 5 of different lengths ranging in size from 1 to 5 mm. Shredding is commonly used in the automotive field for cushion filling or as insulation material. To complete the preparation of the textile fibers 5, they are passed through a blower stage 15 to loosen and loosen the textile fibers 5. This loosening will allow the textile fibers 5 to be mixed more evenly with the powder binder 6. The textile fibers 5 are then packaged into bales.

[0047] Figure 5 [ Figure 5] shows a schematic diagram of a method for obtaining a powder binder 16. As described above, the powder binder 6 used to manufacture the rigid material 1 is obtained from powder coating waste in industry. The method for obtaining the powder binder 16 begins with a step of collecting powder coating losses 17 in industrial coating rooms. This is followed by a step of separating the powder coating residues from the epoxy resin waste 18. The powder coating is then sorted between thermoplastic powders and thermosetting powders 19. Although thermoplastic powders or thermosetting powders can be used to manufacture the rigid material 1, thermosetting powders are preferred because they enable more rigid materials with better mechanical properties to be obtained for the manufacture of panels for buildings or furniture. Unlike thermosetting coating powders, thermoplastic powders can be recycled for the manufacture of plastic bottles. Therefore, they already have their own recycling channels. The thermosetting powders used are epoxy polyesters, TGIC, acrylic polyurethanes or polyester polyurethanes. The collected powder most often contains a mixture of several powders. The thermosetting powder is then stored in BigBags 20 and transported by ADR certified trucks and drivers 21 to a consolidation company 22 from where it is obtained as a powder binder 6 to manufacture rigid materials 1 in a production center 23.

[0048] Figure 6 [ Figure 6] shows a schematic diagram of the manufacturing process of the rigid material 24. In the following, the manufacturing process 24 for manufacturing the panel 2 is described, but it is also applicable to the manufacturing of the furniture components 3 and 4. The epoxy powder forming the powder binder 6 is mixed with the textile fibers 5 in a weight ratio of 20% to 40%. In the described embodiment, the powder binder 6 accounts for 30% of the total weight and the textile fibers 5 account for 70% of the total weight. As mentioned above, the powder binder 6 and the textile fibers 5 are, for example, hot mixed 25 to avoid the binder sinking to the bottom of the mixture. Other mixing methods can also be used to fix the powder binder 6 to the textile fibers 5, for example by wetting the textile fibers 5 or by electrostatic effects. For mixing, the textile fibers are weighed 26, for example using a belt weigher, and the weight of the textile fibers 5 determines the weight 27 of the powder binder 6 to be used. The powder binder is heated to its viscous phase temperature 28 to mix with the textile fibers 5, for example by a heated air-laid process 29 or any other pneumatic coating process. After the textile fibers 25 are sized, they are passed through a magnetic field 30 to remove any metal residues. This step is preferred but not necessary. They are then evenly distributed on a continuously running conveyor belt 31. Optionally, the mat 7 on the conveyor belt is sprayed with additives 32. This spraying step can be carried out before the hot mixing step or on the material after hot pressing. In this stage, one or more additives, such as antifungal agents, waterproofing agents and / or flame retardants, are applied by spraying. Before the hot pressing step (34), the mat 7 is checked using an X-ray weight unit area balance (33). Before pressing, this stage can check whether there are any fluctuations in the structure of the layer, the humidity and the distribution of the total density over the thickness of the mat. Foreign matter with high original density (stones, metals, etc.) can be detected and removed again to avoid damage to the press.

[0049] The hot pressing operation 34 involves applying high pressure under heat to change the density of the mat and transform it into a denser panel 2. The temperature of the hot pressing varies between 160°C and 200°C, depending on the catalytic or polymerizing temperature of the powder binder 6. For epoxy powder-based binders, the press temperature is preferably 180°C. The hot pressing is performed for a time between 6 and 10 minutes, for example 8 minutes, with a pressure of 10 kg / cm 2 Up to 40kg / cm 2 Between, for example 20 or 30 kg / cm 2 For example, the hot pressing may be performed at a temperature of 200° C. for 6 minutes, or at a temperature of 180° C. for 8 minutes, or at a temperature of 170° C. for 10 minutes.

[0050] In order to save time in the hot pressing stage, the mat 7 can be pre-pressed to expel the air contained in the mat 7. A continuous hot press is used to manufacture the panel 2. Pressurized cooling is carried out at the outlet of the hot press to prevent the panel from deforming when cooling. At this stage, it is best to perform quality control on the panel 2. The panel is then calendered (36) to accurately calibrate the required thickness of the panel and improve the smoothness of its surface. Calendering 36 can also be used to cool the panel after hot pressing. Alternatively, calendering can be replaced by grinding the surface. Grinding can also be combined with calendering 36. The panel 2 is then cut to the required size 37.

[0051] As shown in the preceding description, various aspects of the invention can be implemented in different configuration variants than those described above, depending on the context. For example, for producing panels or furniture components.

[0052] Of course, the present invention has been described above by way of example only. It will be appreciated by those skilled in the art that different variations of the present invention may be implemented without departing from the scope of the present invention.

Claims

1. Rigid material for use in construction or furniture, comprising fibrous particles bonded together by a binder belonging to the family of thermoplastic or thermosetting materials such as powdered epoxy resins, characterized in that: The fiber particles are textile fibers (5); The binder (6) is composed of coating powder produced by loss of unheated coating; and The proportion of the binder (6) in the total weight is between 10% and 50%, preferably 20%, 30% or 40%.

2. The rigid material according to claim 1, characterized in that The textile fibers (5) are obtained by wearing textile scraps, at least some of which come from old clothing.

3. A rigid material according to any one of claims 1 or 2, wherein the textile fibers (5) comprise a mixture of natural and synthetic textile fibers, such as cotton or polyester fibers, and / or the rigid material (1) is solution-dyed by the color of the textile fibers (5) used.

4. A rigid material according to any one of claims 2 to 4, wherein: The coating powder (6) used as a binder is mainly composed of epoxy resin, polyester, polyurethane or acrylic resin; and / or The coating powder (6) used as a binder includes paint, primer or varnish powder, or a mixture of these powders.

5. Rigid material according to any one of the preceding claims, characterised in that The rigid material may further comprise at least one adjuvant, such as an antifungal agent, a water repellent and / or a flame retardant.

6. A rigid material according to any one of the preceding claims, characterised in that The rigid material is obtained by hot pressing textile fibers (5) and a binder (6); and / or its final thickness is obtained by grinding, calendering or cold pressing.

7. A method for producing a rigid material for construction or furniture, characterized in that The method comprises the following steps: A step of collecting coating powder (17) in a coating chamber to obtain a thermoplastic or thermosetting powder binder (6); A step (25) of mixing the powdered binder (6) with the textile fibers (5), wherein the proportion of the binder is 20% to 30% of the total weight; a step (30) of spreading said textile fibers (5) mixed with said binder (6) to form a mat (7); and a step of hot pressing (32) the mat (7) at a temperature dependent on the nature of the bonding agent (6); Preferably, after hot pressing, the material undergoes a cooling step while maintaining the pressure.

8. Method for producing a rigid material according to the preceding claim, characterized in that The method further comprises the following steps to prepare the textile fiber (5): a color sorting stage for textile components to be recycled (12); a sorting stage for removing unworn textiles; Smoothing step (13); a fiber separation stage (14) of the textile fragments sorted by mechanical abrasion; and / or A step (15) of separating the textile fibers by blowing air.

9. The method for manufacturing a rigid material according to any one of claims 7 and 8, characterized in that The method comprises the step of collecting old non-reusable clothes (11) in order to obtain at least some of the textile fibers (5), or other textile scraps to be recycled.

10. The method for manufacturing a rigid material according to any one of claims 9 to 10, characterized in that: The method comprises the following steps: a step of spraying (31) with at least one auxiliary agent; and / or A calendering (35) and / or grinding step follows the hot pressing (32) or cooling step.

11. The method for manufacturing a rigid material according to any one of claims 9 to 11, characterized in that: The method further comprises a step (36) of cutting the rigid material (1) into panels (2) of desired size, or performing the hot pressing step (32) in a mould to form furniture components (3, 4).

12. A method of manufacturing a rigid material according to any one of claims 8 to 12, wherein: The hot pressing (32) is carried out at a temperature between 160°C and 200°C, for example 180°C, for a duration of 6 to 10 minutes, for example 8 minutes, and / or at 10 kg / cm 2 Up to 40kg / cm 2 The pressure is between 20 and 30 kg / cm2. 2 ; and / or The step (25) of mixing the powder binder (6) with the textile fibers (5) is performed in a hot state.

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