Waste fiber composition, preparation method, molded product and application thereof

Abstract

The invention relates to a waste fiber composition, a preparation method, a molded product and application thereof, and the waste fiber composition comprises more than 95 wt% but less than 100 wt% of a fiber body and an adhesive accounting for the residual weight of the waste fiber composition based on 100 wt% of the total weight. Wherein the fiber bodies are taken from residual or recycled waste materials with fibers, the waste materials form a fluffy cotton wool shape through a grinding procedure, and the size of the fiber bodies ranges from 0.1 mm to 50 mm; the adhesive is an acrylic copolymer; supplying the waste fiber composition to an extruder, and heating, melting, mixing and extruding to obtain a strip-shaped or sheet-shaped or plate-shaped molded product; the obtained strip-shaped molded product can be used as a plastic master batch through a granulation procedure, and the sheet-shaped molded product or the plate-shaped molded product is subjected to secondary stamping processing to form a frame body, a net body, a shell body and a laminate surface to replace part of metal or plastic products.

Description

Technical Field

[0001] This invention relates to a waste fiber composition, preparation method, molded product and its application, belonging to the field of waste fiber recycling technology. Background Technology

[0002] In some products that use fibrous materials (such as non-woven fabrics), such as diapers, sanitary napkins, bags, filters, clothing, and building materials, the leftover scraps from the manufacturing process, or after use or damage, are often discarded directly, resulting in resource waste and contradicting green economy policies. Therefore, how to recycle and reuse leftover fibrous materials or discarded products is a pressing issue that relevant industries are eager to address.

[0003] This invention is developed to utilize such waste materials for recycling and reuse, and to produce environmentally friendly products in order to reduce the environmental burden. Summary of the Invention

[0004] One objective of this invention is to provide a waste fiber composition, wherein the waste fibers are taken from waste materials containing fiber components, such as processing surplus substrates (such as scraps and offcuts) or waste recycled substrates.

[0005] A second objective of this invention is to provide a method for preparing a waste fiber composition, wherein the obtained waste containing fiber components is crushed and then an adhesive is added in proportion and stirred evenly.

[0006] A third objective of the present invention is to provide a molded article formed by extruding the above-mentioned waste fiber composition through an extruder.

[0007] The fourth objective of this invention is to provide an application of an extruded molded article for replacing a portion of a metal or plastic article.

[0008] The above objectives are achieved by the following technologies:

[0009] A waste fiber composition, wherein the waste fiber composition comprises, by weight 100wt%, 95wt% or more but less than 100wt% of fiber bodies, and a remaining weight percentage of binder in the waste fiber composition; wherein the fiber bodies are taken from residual or recycled fibrous waste, and are crushed to form the waste into a fluffy cotton-like shape, and the size of the fiber bodies is between 0.1mm and 50mm; the binder is an acrylic copolymer.

[0010] The fiber body is one or a combination of two or more of the following: nylon, nonwoven fabric, cotton, acrylic, polypropylene, polyethylene, and polyethylene terephthalate.

[0011] A method for preparing a waste fiber composition includes: first, crushing waste materials taken from surplus or recycled materials containing fibers to form a fibrous body with a fluffy, cotton-like structure and a size between 0.1 mm and 50 mm; then, mixing an adhesive comprising 95 wt% or more but less than 100 wt% of the fiber body and the remaining weight percentage of the waste fiber composition, based on a total weight of 100 wt% of the waste fiber composition, wherein the adhesive is an acrylic copolymer.

[0012] The fiber body is one or a combination of two or more of the following: nylon, nonwoven fabric, cotton, acrylic, polypropylene, polyethylene, and polyethylene terephthalate.

[0013] A molded article of waste fiber composition is obtained by feeding the waste fiber composition as described above into an extruder and heating, melting, mixing and extruding it to obtain a strip, sheet or plate molded article.

[0014] The extruder heating temperature is 90-180℃.

[0015] Application of a molded article composed of waste fiber, wherein the molded article, which is in the form of strips as described above, is granulated to become a plastic masterbatch.

[0016] Application of a molded article composed of waste fiber, wherein the molded article, which is in sheet or plate form as described above, is formed by secondary stamping to create one of a frame, mesh, shell, or layer surface.

[0017] The advantages of this invention are:

[0018] 1. The fiber body of the present invention is taken from processing waste or discarded waste, which can solve the problem of recycling and processing waste and discarded waste, and is conducive to the sustainable recycling and reuse of resources.

[0019] 2. The fiber body of the present invention, by adjusting the ratio between the fiber body and the adhesive, can make the molded product either rigid or flexible and bendable, thereby replacing part of the metal or plastic products. Attached Figure Description

[0020] Figure 1 This is a flowchart illustrating the molding process of the molded article of the present invention;

[0021] Figure 2 This is a schematic diagram of the molded article of the present invention applied to the surface of a tabletop;

[0022] Figure 3 This is a schematic diagram of the molded product of the present invention applied to the surface of a modular floor mat.

[0023] Explanation of main icon numbers:

[0024] A: Tabletop

[0025] B: Floor mat

[0026] 1: Molded product Detailed Implementation

[0027] To provide a more complete and clear disclosure of the technical content, inventive purpose, and effects achieved by this invention, the following detailed description is provided, and please refer to the disclosed drawings:

[0028] The composition according to the present invention comprises a fibrous body and an adhesive; wherein, the waste fibrous composition, based on a total weight of 100 wt%, comprises 95 wt% or more (inclusive) but less than 100 wt% (exclusive) of fibrous body, and an adhesive by the remaining weight percentage of the waste fibrous composition; wherein, the adhesive is an acrylic copolymer.

[0029] The different mixing ratios of fibers and binders in the composition will result in variations in the toughness and rigidity of the molded product. In other words, different product applications can be achieved by adjusting the mixing ratio of fibers and binders. For example, to make shell-like, frame-like, or rod-like objects, increased rigidity is required, so the proportion of fibers is increased; to make surfaces (tabletops, mat surfaces) or board-like objects, a balance of toughness and rigidity is needed, so the proportion of fibers is decreased; to make filter support frames, increased toughness is needed, so the proportion of fibers is decreased. That is, when applying the molded product to a product with high rigidity, the closer the weight percentage of fibers is to 100 wt%, while when applying the molded product to a product with high toughness, the closer the weight percentage of fibers is to 95 wt%.

[0030] In a preferred embodiment, the fiber body is taken from residual or recycled fibrous waste, and the waste is crushed to form a fluffy cotton-like shape, wherein the size of the fiber body is between 0.1 mm and 50 mm.

[0031] In a preferred embodiment, the fiber body is one or a combination of two or more of nylon (PA), nonwoven fabric, cotton, acrylic, polypropylene (PP), polyethylene (PE), and polyethylene terephthalate (PVC).

[0032] The molded article of the present invention is obtained by feeding the waste fiber composition described above into an extruder and subjecting it to heating, melting, mixing, and extrusion. Specifically (see [link to relevant documentation]). Figure 1First, the recycled fibrous waste is crushed to form a fluffy, cotton-like structure. Then, fibers with a size between 0.1mm and 50mm are selected and mixed with an adhesive to form a gel-like waste fiber composition. This waste fiber composition, by weight, contains at least 95wt% but less than 100wt% fiber, plus the remaining weight percentage of adhesive. The waste fiber composition is then fed to an extruder, where it is heated, melted, and mixed before being extruded into a molded product. Depending on the extruder die, the molded product can be in strip, sheet, or plate shape. The heating temperature is 90–180°C. Before feeding the waste fiber composition to the extruder, excess adhesive can be extruded from the uniformly mixed waste fiber composition.

[0033] When the molded article of the present invention is in the form of a strip, the strip can be granulated to become a plastic masterbatch. When the molded article of the present invention is in the form of a sheet or plate, the sheet or plate can be subjected to secondary stamping to form a frame, mesh, shell, or shelf surface, serving as: a material for laminates, sheets, building materials, flooring materials, wall materials, ceiling materials, floor mats, decorative panels, tabletops, door and window frames, filter support frames, or the outer shell of vehicles or electrical equipment. Figure 2 The image shows an embodiment of the present invention in which the molded product 1 is applied to the surface of the tabletop A through a secondary stamping process. Figure 3 The image shows an embodiment of the present invention in which the molded product 1 is applied to the surface of the interlocking floor mat B after a second stamping process.

[0034] To enhance the perceived value of the product, the waste fiber composition of the present invention further includes color powder, that is, an appropriate amount of color powder is added during the mixing process of adding adhesive to the crushed fiber body, so that the molded product formed from the waste fiber composition presents different colors depending on the color of the added color powder; or a baking paint coating is sprayed on the surface of the molded product; or the molded product is immersed in the baking paint coating to form at least one colored layer on the surface of the molded product.

[0035] The examples given above are only some embodiments of the present invention and are not intended to limit the present invention. Any modifications or variations made in accordance with the inventive spirit and features of the present invention should also be included within the scope of this patent.

Claims

1. A waste fiber composition, said waste fiber composition comprising, by weight 100wt%, 95wt% or more but less than 100wt% fiber body, and a binder by weight percentage of said waste fiber composition; wherein, The fiber body is taken from residual or recycled fibrous waste, which is crushed to form a fluffy cotton-like structure. The size of the fiber body is between 0.1 mm and 50 mm. The adhesive is an acrylic copolymer.

2. The waste fiber composition according to claim 1, wherein, The fibrous material is one or a combination of two or more of the following: nylon, nonwoven fabric, cotton, acrylic, polypropylene, polyethylene, and polyethylene terephthalate.

3. A method for preparing a waste fiber composition, comprising: first, crushing waste material taken from surplus or recycled materials containing fibers to form a fibrous body with a fluffy, cotton-like structure and a size between 0.1 mm and 50 mm; then, mixing an adhesive comprising 95 wt% or more but less than 100 wt% of the fibrous body and the remaining weight percentage of the waste fiber composition, based on a total weight of 100 wt% of the waste fiber composition, wherein the adhesive is an acrylic copolymer.

4. The method for preparing waste fiber composition according to claim 3, wherein, The fibrous material is one or a combination of two or more of the following: nylon, nonwoven fabric, cotton, acrylic, polypropylene, polyethylene, and polyethylene terephthalate.

5. A molded article of waste fiber composition, wherein the waste fiber composition according to any one of claims 1-2 is fed to an extruder and heated, melted, mixed and extruded to obtain a strip-shaped, sheet-shaped or plate-shaped molded article.

6. The molded article of the waste fiber composition according to claim 5, wherein, The extruder heating temperature is 90-180℃.

7. An application of a molded article composed of waste fiber, wherein, The molded article in strip shape according to claim 5 or 6 is granulated to become a plastic masterbatch.

8. An application of a molded article composed of waste fiber, wherein, The molded article, which is in sheet or plate form according to claim 5 or 6, is formed by secondary stamping to create one of the following: frame, mesh, shell, or shelf surface.

Images