Equipment and process for recycling waste carpets

Abstract

The invention belongs to the technical field of recycling and reprocessing waste carpets from terminal markets, and particularly relates to equipment for recycling waste carpets and a recycling and reprocessing technology. The recycled waste carpets are flapped and vibrated, so that sand grains, dust, particulate matters, pins, paper clips and other foreign matters mixed in the surfaces of the carpets are shaken off in advance; after a waste carpet is scraped, sucked, washed, brushed and dried, carpet fluff and non-woven fabric on the bottom back of the carpet are cut off respectively, the bottom back of the carpet without the fluff and the non-woven fabric is crushed and ground, fibers and a binder in the bottom back of the waste carpet are separated, so that colloidal calcium powder and short fluff are obtained, the fluff is directly granulated and sold, and the service life of the carpet is prolonged. The non-woven fabric is recycled to manufacture new non-woven fabric after being opened, and the colloidal calcium powder replaces part of the raw rubber and the new calcium powder to serve as raw materials to be circularly used for manufacturing new carpets, so that the problem of high recycling difficulty caused by inconvenience in recycling, processing and granulating of the waste carpets in existing equipment and a recycling method for recycling the waste carpets is solved.

Description

Technical Field

[0001] The invention belongs to the technical field of recycling and reprocessing waste carpets from terminal markets, and in particular relates to equipment for recycling waste carpets and a recycling and reprocessing process. Background Art

[0002] Carpets are floor coverings made of natural fiber materials such as cotton, linen, wool, silk, and grass yarns that are knitted, piled, or woven by hand or mechanical processes. In recent years, chemical fiber materials have been the most common. Carpets are used to cover the floors of residences, guesthouses, meeting rooms, entertainment venues, gymnasiums, exhibition halls, vehicles, ships, airports, etc. They can effectively reduce noise, provide heat insulation and decorative effects, improve foot feel, and prevent slipping. They are arts and crafts and indoor soft covering products with a long history and tradition worldwide. By deeply reprocessing recycled old carpets, the non-degradable solid waste can be transformed into new carpets, which can not only save a large amount of chemical fibers, polymer chemical materials, and mining resources such as calcium carbonate, but also minimize the generation of solid waste, which is conducive to protecting the ecological environment and realizing resource recycling.

[0003] The surface of the patchwork carpet is made of nearly a thousand straight needles that implant chemical fiber yarns into non-woven fabrics to form loop pile, loop cut pile and cut pile carpet surfaces with various patterns. After the carpet surface is treated with anti-fouling and the carpet back is pre-coated, polyolefin and calcium carbonate are melted and stirred into liquid glue, and the carpet back and non-woven fabric are bonded and then cut into patchwork carpets of different specifications by cooling. Most patchwork carpets are laid in places with dense population or large flow of people. Therefore, the surface of patchwork carpets is relatively dirty, and foreign objects are easily hidden in the pile. Most of these foreign objects are sand, dust, particles, pins and paper clips. The waste carpets have different service years and different laying environments, and the degree of pollution is different. The waste carpets recovered from the terminal market are classified and deeply processed. It is difficult to achieve the technical effect of full recycling and reuse. Summary of the invention

[0004] The technical problem to be solved by the present invention is to overcome the defects of the prior art and solve the problem that the existing equipment and method for recycling waste carpets are inconvenient for recycling and granulating the waste carpets, which makes recycling difficult.

[0005] The technical solutions adopted by the present invention to solve the cleaning, separation, reuse and regeneration of waste carpets are as follows: 1. A device and a recycling process for waste carpets, including a waste carpet regeneration workshop, wherein a 600-type tuft head shaving machine, a 1500Ⅰ-type tuft head shaving machine, a 1500Ⅱ-type tuft head shaving machine, a back tearing machine, a back low-temperature air separation grinding machine, a tuft head granulator, a non-woven fabric granulator, a scraping, washing, brushing, sucking and drying combined machine, and an opening and combing machine are sequentially installed in the waste carpet regeneration workshop, wherein a multi-layer mesh vibrating screen is installed on either side of the opening and combing machine;

[0006] The steps include:

[0007] S1: Beat and vibrate the recycled waste carpet to shake out the sand, dust, particles, pins, paper clips and other foreign objects mixed in the carpet surface in advance;

[0008] S2: Place the waste carpets flat on the scraping, washing, brushing, sucking and drying combined machine in turn, use a straight metal scraper to scrape up the fallen pile, spray high-pressure water on the carpet surface and the back of the carpet, and use a rotating wire brush to clean the stains remaining on the carpet surface and the back of the carpet. The high-pressure vacuum cleaner sucks away the particles on the carpet surface and the back of the carpet. Several groups of pressure rollers squeeze out the moisture in the carpet, and then put the cleaned waste carpet into the oven to dry it;

[0009] S3: Use 1500Ⅰ type tuft trimming machine to trim the carpet nap, and transfer the carpet backing including non-woven fabric to the next non-woven fabric trimming process. The trimmed nap is directly transferred to the granulator for processing into pellets for direct sale.

[0010] S4: The carpet backing containing non-woven fabric is shaved off by a 1500Ⅱ type tuft shaving machine. The carpet backing without tuft and non-woven fabric is transferred to a shredder to be broken into 3 mm particles. There are two recycling processes for the shaved non-woven fabric. One is to transfer the shaved non-woven fabric to a granulator to be processed into particles for sale; the other is to transfer the shaved non-woven fabric to an opening and combing machine to be processed into short fibers to make new non-woven fabrics.

[0011] S5: The back of the waste carpet is shredded into 3 mm particles by the shredder, and then transferred to the low-temperature air separation grinder for grinding. The 3 mm particles are mainly composed of colloidal calcium carbonate and the velvet roots, i.e. short fibers, left over from the shaving process. The colloidal calcium carbonate particles are further ground into 50 mesh fine powder by the low-temperature air separation grinder. The velvet root short fibers are separated from the colloidal calcium carbonate. The fine powder and the separated velvet root short fibers are sucked away by the negative pressure fan. The colloidal calcium carbonate that does not reach 50 mesh and the particles that are not completely separated continue to be ground in the mold cavity.

[0012] S6: The micro powder and short fibers processed by the low-temperature air separation grinder are transferred to a multi-layer mesh vibrating screen to further screen and separate the micro powder and short fibers. The micro powder is added in proportion to make new carpets, and the short fibers are directly granulated and sold.

[0013] In a preferred technical solution of the present invention, the shaved carpet fluff, the carpet pile roots sorted by multi-layer mesh vibrating screens and the shaved non-woven fabrics are directly sold through granulation to form nylon particles, polyester particles and polypropylene particles.

[0014] In a preferred technical solution of the present invention, the cut carpet nonwoven fabric is processed by an opening and carding machine to form short fibers to make new nonwoven fabric.

[0015] In a preferred technical solution of the present invention, new carpets are made from colloidal calcium carbonate powder selected by vibration screening.

[0016] In a preferred technical solution of the present invention, the tufting material components of the waste carpet include chemical fibers of various materials, and the components of the base of the waste carpet include materials such as polyolefin, calcium carbonate, EVA and polyvinyl alcohol.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] The pure physical recycling method combines the waste carpets with the carpet scraps recycling process. The recycled waste carpets can go through the pre-processing process of removing foreign matter, cleaning, drying, etc. in sequence to facilitate the later processing of the waste carpets, and the carpet scraps can be processed and recycled for recycling. The waste carpets are crushed and ground to loosen the fibers of the waste carpets, comb them, and loosen the fiber yarns. The colloidal calcium powder and short fibers of the waste carpets are selected by vibrating screens. After the tufts are separated from the non-woven fabrics, the back of the large area of ​​waste carpets is torn into 3 mm granular objects and ground again. The colloidal calcium carbonate serves as a raw material cycle for processing new carpets, realizing the recycling and reuse of waste carpets to save raw materials and promote energy conservation and environmental protection. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic diagram of the present invention's processing of cleaning, separating, opening and granulating waste carpets;

[0020] Figure 2 This is a process flow chart of the automatic cleaning and drying of waste carpets according to the present invention;

[0021] Figure 3 This is a front view of the process flow of the production line for opening and combing waste carpets and processing carpet scraps according to the present invention;

[0022] In the figure: 1. Waste carpet recycling workshop; 2. 600 type pile head removal machine; 3. 1500Ⅰ type pile head removal machine; 4. 1500Ⅱ type pile head removal machine; 5. Bottom tearing machine; 6. Bottom low-temperature air flow crushing machine; 7. Pile granulating machine; 8. Non-woven polyester granulating machine; 9. Scraping, washing, brushing, suction, drying and cleaning machine; 10. Opening and combing machine; 11. Multi-layer mesh vibrating screen. DETAILED DESCRIPTION

[0023] See also Figure 1-3 The present invention provides a technical solution: a device and a recycling process for waste carpets, comprising a waste carpet recycling workshop 1, wherein the waste carpet recycling workshop 1 is sequentially equipped with a 600-type tuft head shaving machine 2, a 1500Ⅰ-type tuft head shaving machine 3, a 1500Ⅱ-type tuft head shaving machine 4, a back tearing machine 5, a back low-temperature air separation grinding machine 6, a tuft head granulating machine 7, a non-woven polyester granulating machine 8, a scraping, washing, brushing, sucking, drying and cleaning machine 9, and an opening and combing machine 10, wherein a multi-layer mesh vibrating screen 11 is installed on any side of the opening and combing machine 10, and the opening and combing machine 10 is used to adjust the 600-type tuft head shaving machine 2, the 1500Ⅰ-type tuft head shaving machine 3, the 1500Ⅱ-type tuft head shaving machine 4, a back tearing machine 5, a back low-temperature air separation grinding machine 6, a tuft head granulating machine 7, a non-woven polyester granulating machine 8, a scraping, washing, brushing, sucking, drying and cleaning machine 9, and an opening and combing machine 10. A multi-layer mesh vibrating screen 11 is installed on any side of the opening and combing machine 10, and the opening and combing machine 10 is used to adjust the 600-type tuft head shaving machine 2, the 1500Ⅰ-type tuft head shaving machine 3, the 150 0Ⅱ type pile head cutting machine 4, back tearing machine 5, back low temperature air selection grinding machine 6, pile head granulator 7, non-woven polyester granulator 8, scraping, washing, brushing, sucking, drying and cleaning machine 9 are operating normally. 600 type pile head cutting machine 2, 1500Ⅰ type pile head cutting machine 3, 1500Ⅱ type pile head cutting machine 4, back tearing machine 5, back low temperature air selection grinding machine 6 are used to physically decompose the back of the waste carpet. The pile head granulator 7 and non-woven polyester granulator 8 are used to generate granular raw materials from the waste carpet fluff after processing. The scraping, washing, brushing, sucking and drying cleaning machine 9 is used to clean the surface of the waste carpet. Foreign matter, impurities, and dirt lurking in the fluff are cleaned up;

[0024] The recycled waste carpets are laid flat on the vibration equipment and vibrated. The vibration causes the waste carpets to swing up and down to shake out foreign objects such as sand, granules, metal pins and paper clips mixed in the carpet surface. The waste carpets are then placed on the scraping, washing, brushing, sucking and drying cleaning machine 9. The scraping, washing, brushing, sucking and drying cleaning machine 9 is provided with a brush for cleaning the surface of the waste carpet. The brush rotates and deflects inside the scraping, washing, brushing, sucking and drying cleaning machine 9. The scraping, washing, brushing, sucking and drying cleaning machine 9 is used to remove pollutants on the surface of the waste carpet, and foreign objects such as sand, granules, metal pins and paper clips fall off, and the surface of the waste carpet is cleaned, which is conducive to the shaved fluff and the shaved non-woven fabric to enter the granulation stage or the loosening stage.

[0025] Place the old carpets flat on the scraping, brushing, sucking and drying cleaning machine in turn, use a straight metal scraper to scrape up the fallen pile, spray high-pressure water on the carpet surface and the back of the carpet for rinsing, and use a rotating wire brush to clean the stains remaining on the carpet surface and the back of the carpet. The high-pressure vacuum cleaner will suck out the particles on the carpet surface and the back of the carpet, and use several groups of pressure rollers to squeeze out the moisture in the carpet, and then transfer the cleaned old carpets to the oven for drying. The old carpets go through the pre-processing processes of removing foreign matter, cleaning, drying, etc. in turn, which is conducive to the subsequent processing operations of the old carpets.

[0026] The tufting material components of the waste carpet include chemical fibers of various materials such as nylon, polyester, polypropylene, etc. The covering components of the waste carpet include materials such as polyolefin, calcium carbonate, EVA and polyvinyl alcohol. The 1500Ⅰ type tuft head shaving machine 3 is used to shave off the carpet fluff, and the carpet backing including non-woven fabric is transferred to the next non-woven fabric shaving process. The shaved fluff is directly transferred to the granulator 7 for processing into particles, and the particles are sold directly.

[0027] The carpet backing containing non-woven fabric is shaved off by a 1500Ⅱ type tuft head shaving machine 4, and the carpet backing without tuft and non-woven fabric is transferred to a shredder 5 to be broken into 3 mm particles. There are two recycling processes for the shaved non-woven fabric. One is to transfer the shaved non-woven fabric to a granulator 8 to be processed into polyester particles for sale; the other is to transfer the shaved non-woven fabric to an opening and combing machine 10 to be processed into short fibers to make new non-woven fabric.

[0028] The shaved carpet fluff, carpet pile roots selected by multi-mesh vibration screens, and shaved non-woven fabrics are directly sold through granulation to form nylon particles, polyester particles, and polypropylene particles; the shaved carpet non-woven fabrics are processed by opening and combing machines to form short fibers to make new non-woven fabrics.

[0029] The back of the waste carpet is shredded into 3 mm particles by the shredder 5, and then transferred to the low-temperature air separation grinder 6 for grinding. The 3 mm particles are mainly composed of colloidal calcium carbonate and short fibers from the velvet root left over from the shaving process. The colloidal calcium carbonate particles are further ground into 50 mesh powder, and the short fibers from the velvet root are separated from the colloidal calcium carbonate. The powder and the separated short fibers from the velvet root are sucked away by the negative pressure fan, and the colloidal calcium carbonate that does not reach 50 mesh and the particles that are not completely separated continue to be ground in the mold cavity.

[0030] The micro powder and short fibers processed by the low-temperature air separation grinder are transferred to the multi-layer mesh vibration screen 11 to separate the micro powder and short fibers. The micro powder is used to make new carpets, and the short fibers are granulated and sold directly. The colloidal calcium carbonate micro powder selected by the vibration screening is used to make new carpets.

[0031] Physical recycling is the process of recycling waste carpets, which uses mechanical processing to make physical changes on the surface of waste carpets instead of chemical reactions, so that different components of materials are precipitated separately.

[0032] The fluff and non-woven fabric separated from the waste carpet are put into the pile granulator 7 and the non-woven fabric granulator 8 for granulation one by one. The micro powder formed by the crushing and grinding of the carpet back is used to replace the new material glue and calcium carbonate to make new carpets. The particles formed by the fluff granulation are used as raw materials for spinning and recycled for new carpets, so that the waste carpets are fully recycled, new raw materials are effectively saved, and it has environmental advantages.

Claims

1. A device and process for recycling waste carpets, characterized in that: The invention comprises a waste carpet recycling workshop (1), wherein the waste carpet recycling workshop (1) is equipped with a 600 type tuft head shaving machine (2), a 1500Ⅰ type tuft head shaving machine (3), a 1500Ⅱ type tuft head shaving machine (4), a back tearing machine (5), a back low-temperature air separation grinding machine (6), a tuft head granulating machine (7), a polyester non-woven fabric granulating machine (8), a scraping, washing, brushing, sucking and drying combined machine (9), and an opening and combing machine (10), wherein a multi-layer mesh vibrating screen (11) is installed on any side of the opening and combing machine (10); The steps include: S1: Beat and vibrate the recycled waste carpet to shake out the sand, dust, particles, pins, paper clips and other foreign objects mixed in the carpet surface in advance; S2: Place the waste carpets flat on the scraping, sucking, washing, brushing and drying combined machine in turn, use a straight metal scraper to scrape up the fallen pile, spray high-pressure water on the carpet surface and the back of the carpet, and use a rotating wire brush to clean the stains remaining on the carpet surface and the back of the carpet. The high-pressure vacuum cleaner will suck out the particles on the carpet surface and the back of the carpet. Several groups of pressure rollers will squeeze out the moisture in the carpet, and then put the cleaned waste carpet into the oven to dry it; S3; using 1500Ⅰ type tuft cutting machine (3) to cut the carpet fluff, including the back of the carpet back of the non-woven fabric to the next non-woven fabric cutting process, the cut fluff directly transferred to the granulator (7) processed into particles, the particles are sold directly; S4: The carpet backing containing non-woven fabric is shaved off by a 1500Ⅱ type tuft shaving machine (4), and the carpet backing without tuft and non-woven fabric is transferred to a shredder (5) to be broken into 3 mm particles. There are two recycling processes for the shaved non-woven fabric: one is to transfer the shaved non-woven fabric to a granulator (8) for processing into particles for sale; the other is to transfer the shaved non-woven fabric to an opening and combing machine (10) for processing into short fibers and making new non-woven fabric; S5: The back of the waste carpet is shredded into 3 mm particles by the shredder (5), and then transferred to the low-temperature air separation grinder (6) for grinding. The 3 mm particles are mainly composed of colloidal calcium carbonate and the velvet roots, i.e., short fibers, left over from the shaving process. The colloidal calcium carbonate particles are further ground into 50 mesh fine powder by the low-temperature air separation grinder. The velvet root short fibers and the colloidal calcium carbonate are separated, and the fine powder and the separated velvet root short fibers are sucked away by a negative pressure blower. The colloidal calcium carbonate that does not reach 50 mesh and the particles that are not completely separated continue to be ground in the mold cavity; S6: The micro powder and short fibers processed by the low temperature air separation grinder are transferred to a multi-layer mesh vibrating screen (11) to separate the micro powder and short fibers. The micro powder is recycled to make new carpets, and the short fibers are granulated and sold.

2. The device and process for recycling waste carpets as claimed in claim 1, characterized in that: The shaved carpet pile, the carpet pile roots sorted by multi-layer mesh vibrating screens and the shaved non-woven fabrics are granulated into nylon particles, polyester particles and polypropylene particles for sale.

3. The device and process for recycling waste carpets as claimed in claim 1, characterized in that: The shaved carpet nonwoven fabric is processed through an opening and carding machine to form short fibers, which are then recycled to make new nonwoven fabric.

4. The device and process for recycling waste carpets as claimed in claim 1, characterized in that: The colloidal calcium carbonate powder selected by vibration screening is recycled to make new carpets.

5. The device and process for recycling waste carpets as claimed in claim 1, characterized in that: The tufting materials of waste carpets include chemical fibers of various materials, and the covering materials of waste carpets include polyolefins, calcium carbonate, EVA, polyvinyl alcohol and other materials.

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