Apparatus for decomposing polyurethane foam, method for decomposing polyurethane foam, and method for producing reaction product

Abstract

A technique relating to the decomposition and treatment of polyurethane foam is provided. The polyurethane foam decomposition and treatment apparatus (1) includes: a cylinder (20) having a raw material inlet (21) and a discharge outlet (23) for discharging the decomposed product; and a screw (11) housed within the cylinder (20). An inlet mechanism (30) is provided at the raw material inlet (21) for pressing a mixture of pulverized polyurethane foam and a decomposition agent into the raw material inlet (21).

Description

Technical Field

[0001] This disclosure relates to an apparatus for decomposing polyurethane foam, a method for decomposing polyurethane foam, and a method for manufacturing reaction products.

[0002] This application asserts a priority interest in Japanese Patent Application No. 2023-190554, filed on November 8, 2023, and Japanese Patent Application No. 2024-068476, filed on April 19, 2024, the entire contents of which are incorporated herein by reference. Background Technology

[0003] Polyurethane foam is used in various fields. An attempt is being made to chemically decompose and reuse polyurethane foam end materials and already used polyurethane foam.

[0004] Patent Document 1 describes a biaxial extruder as a decomposition device for foamed resin. This biaxial extruder has a raw material inlet and a decomposition agent injection port, which is different from the raw material inlet, on its cylinder. Furthermore, in the technology described in Patent Document 1, broken pieces of polyurethane foam are placed into the raw material inlet, and a decomposition agent is injected through the decomposition agent injection port, which is different from the raw material inlet.

[0005] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2000-281831 Summary of the Invention The problem the invention aims to solve The technology described in Patent Document 1 has the problem that broken pieces of polyurethane foam remain near the raw material inlet and cannot be smoothly fed into the cylinder. Furthermore, because the decomposing agent is added after the broken polyurethane foam is added into the cylinder, the temperature near the decomposing agent injection port decreases, making it difficult to stabilize the reaction between the polyurethane foam and the decomposing agent. Additionally, the technology described in Patent Document 1 also suffers from a problem where the ratio of broken polyurethane foam to decomposing agent becomes locally uneven within the cylinder, further hindering the stabilization of the reaction between the polyurethane foam and the decomposing agent.

[0006] This disclosure is made in view of the foregoing circumstances and is intended to solve at least one of the foregoing problems. This disclosure may be implemented in the following ways.

[0007] means for solving problems A polyurethane foam decomposition and processing apparatus, comprising: The cylinder body has a raw material inlet and a discharge outlet for discharging the decomposed waste; and The screw is housed within the cylinder. An infeeding mechanism is provided at the raw material inlet, which simultaneously presses in the mixture of pulverized polyurethane foam and decomposing agent into the raw material inlet.

[0008] Invention Effects According to this disclosure, at least one of the above-mentioned problems is solved. For example, pulverized polyurethane foam can be smoothly fed into the raw material inlet. Additionally, the reaction between the polyurethane foam and the decomposition agent can be stabilized. Attached Figure Description

[0009] Figure 1 This is a schematic diagram illustrating the disassembly processing apparatus of Embodiment 1.

[0010] Figure 2 Is Figure 1 The diagram is cut along line II-II and schematically shows a pair of rollers.

[0011] Figure 3 This is a schematic diagram illustrating the disassembly processing apparatus of Embodiment 2.

[0012] Figure 4 This is a schematic diagram illustrating the disassembly processing apparatus of Embodiment 3.

[0013] Figure 5 This is a schematic diagram illustrating the disassembly processing apparatus of Embodiment 4. Detailed Implementation

[0014] Preferred examples of this disclosure are shown herein.

[0015] [1] A polyurethane foam decomposition and treatment apparatus, comprising: The cylinder body has a raw material inlet and a discharge outlet for discharging the decomposed waste; and The screw is housed within the cylinder. An infeeding mechanism is provided at the raw material inlet, which simultaneously presses in the mixture of pulverized polyurethane foam and decomposing agent into the raw material inlet.

[0016] [2] A method for decomposing polyurethane foam, using an extruder with a cylinder, wherein, The mixture of pulverized polyurethane foam and the decomposing agent is simultaneously pressed into the raw material inlet of the cylinder. The polyurethane foam is broken down by conveying and heating the mixture within the cylinder.

[0017] [3] A method for manufacturing a reaction product, wherein a reaction product of polyurethane foam and a decomposing agent is obtained, wherein, It is carried out using an extruder with a cylinder. The mixture of pulverized polyurethane foam and the decomposing agent is fed into the raw material inlet of the cylinder while being pressed in. The reaction product is obtained by conveying and heating the mixture within the cylinder.

[0018] An example of a preferred polyurethane foam decomposition treatment apparatus is shown.

[0019] A polyurethane foam decomposition processing apparatus, wherein the feeding mechanism has a pair of rotating parts arranged side by side, the feeding mechanism having the function of causing the mixture to be drawn between the pair of rotating parts by rotating each of the rotating parts in different directions, and pressing the mixture into the raw material input port.

[0020] An example of a preferred method for decomposing polyurethane foam is shown.

[0021] A method for decomposing polyurethane foam, wherein, The mixture is fed into a feeding mechanism having a pair of rotating parts arranged side by side. By rotating each of the rotating components in different directions, the mixture is drawn between the pair of rotating components and pressed into the raw material inlet.

[0022] The present disclosure will now be described in detail. Furthermore, in this specification, the use of "~" to indicate numerical ranges includes both the lower and upper limits unless otherwise specified. For example, in the description "10 to 20", both the lower limit "10" and the upper limit "20" are included. That is, "10 to 20" means the same as "more than 10 and less than 20". Additionally, in this specification, the upper and lower limits of each numerical range can be arbitrarily combined.

[0023] 1. Polyurethane foam decomposition and treatment device 1 like Figure 1 and Figure 2 As shown, the polyurethane foam decomposition processing apparatus 1 of Embodiment 1 includes: a cylinder 20 having a raw material inlet 21 and a discharge outlet 23 for discharging decomposed products; and a screw 11 housed within the cylinder 20. An inlet mechanism 30 is attached to the raw material inlet 21, which presses in a mixture of pulverized polyurethane foam and a decomposition agent while simultaneously feeding it into the raw material inlet 21. Hereinafter, in the decomposition processing apparatus 1, the portion having the cylinder 20 and the screw 11 will be simply referred to as the extruder 10.

[0024] (1) Extruder 10 The cylinder body 20 is generally cylindrical. The cylinder body 20 has a raw material inlet 21 at one end and a outlet 23 at the other end. A heating section 25 is provided in the cylinder body 20 to heat the contents inside.

[0025] The raw material inlet 21 is located on the side of the cylinder body 20. The raw material inlet 21 opens upwards, for example. The screw 11 is located below the raw material inlet 21.

[0026] The screw 11 is coaxial with the cylinder 20. The screw 11 has helical grooves on its side. The screw 11 is driven to rotate by the drive unit 13. The rotation of the screw 11 mixes the contents of the cylinder 20 while conveying them to the discharge port 23. The extruder 10 may have one screw 11, for example; that is, the extruder 10 is a single-screw extruder. Alternatively, the extruder 10 may have two screws 11.

[0027] (2) 30 investment institutions The feeding mechanism 30 feeds a mixture of pulverized polyurethane foam and a decomposing agent into the raw material inlet 21 while pressing it in. The feeding mechanism 30 includes, for example, a pair of rotating parts 33, 33, a drive unit (not shown) that drives the pair of rotating parts 33, 33 to rotate, and a hopper 31. In this embodiment, the pair of rotating parts 33, 33 is provided inside the hopper 31. The arrangement of the pair of rotating parts 33, 33 is not limited to this.

[0028] A pair of rotating components 33, 33 are arranged side by side. The structure of each rotating component 33, 33 is not particularly limited. For example, each rotating component 33 has a plurality of teeth 35 arranged circumferentially on its outer peripheral surface. The teeth 35 are protrusions extending axially along the rotating component 33. Between the rotating components 33, 33, the teeth 35 of one rotating component 33 are opposite to the teeth 35 of the other rotating component 33, and the valleys between the teeth 35 are aligned. The pair of rotating components 33, 33 are configured to press the mixture in through the teeth 35 of one rotating component 33 and the teeth 35 of the other rotating component 33 being staggered.

[0029] The pair of rotating parts 33, 33 can be configured to either crush and press polyurethane foam simultaneously, or to press polyurethane foam in without crushing it. The structure for crushing and not crushing polyurethane foam can be appropriately set, for example, by adjusting the gap between the pair of rotating parts 33, 33. Specifically, by making the gap between the pair of rotating parts 33, 33 smaller than the size of the polyurethane foam passing between the pair of rotating parts 33, 33, the polyurethane foam can be crushed appropriately. Furthermore, in the structure for crushing polyurethane foam, by appropriately designing the shape of the teeth provided on the outer peripheral surface of the rotating parts 33, the polyurethane foam can be crushed appropriately.

[0030] The hopper 31, when viewed from above, is a roughly rectangular box shape. The hopper 31 has an upper opening that faces upwards. This upper opening is wider than the raw material inlet 21 of the cylinder 20. The hopper 31 also has a lower opening that faces downwards. This lower opening is connected to the raw material inlet 21 of the cylinder 20. The hopper 31 is configured to guide the mixture, which has passed through a pair of rotating components 33, 33, to the raw material inlet 21.

[0031] The feeding mechanism 30 has the function of causing the mixture to be drawn between a pair of rotating parts 33, 33 by rotating the rotating parts 33, 33 in different directions, and pressing the mixture into the raw material inlet 21. An example of the feeding mechanism 30 is described in detail below.

[0032] The feeding mechanism 30 rotates the rotating components 33, 33, causing the mixture in contact with the rotating components 33, 33 to move in the rotation direction of the rotating components 33, 33. When the rotating component 33 has teeth 35, the mixture located above the pair of rotating components 33, 33 is scraped by the teeth 35, thereby moving in the rotation direction of the rotating components 33, 33.

[0033] The feeding mechanism 30 draws the mixture, which moves with the rotation of the rotating components 33, 33, into and through the space between them. As the mixture passes through the rotating components 33, 33, the polyurethane foam can be compressed. Additionally, the polyurethane foam can be pulverized as the mixture passes through the rotating components 33, 33. Furthermore, if the mixture is in clumps, these clumps can be broken up as the mixture passes through the rotating components 33, 33. Compared to a structure where the mixture does not pass through the rotating components 33, 33, the structure allows for proper distribution of the decomposing agent among the pulverized polyurethane foam.

[0034] The feeding mechanism 30 sequentially feeds the mixture drawn between a pair of rotating parts 33, 33 to the raw material feeding port 21 and presses it into the raw material feeding port 21. The mixture pressed into the raw material feeding port 21 is conveyed to the discharge port 23 within the cylinder 20 as the screw 11 rotates. The decomposition processing device 1, by linking the pair of rotating parts 33, 33 and the screw 11, enables the mixture to be conveyed sequentially through the pair of rotating parts 33, 33 from the raw material feeding port 21 to the discharge port 23.

[0035] (3) Mixture A mixture can be obtained by appropriately mixing pulverized polyurethane foam and a decomposing agent. For example, a mixture can be obtained by coating the pulverized polyurethane foam with the decomposing agent. There are no particular limitations on the method of coating the pulverized polyurethane foam with the decomposing agent. For example, the decomposing agent can be sprayed in a mist and coated onto the pulverized polyurethane foam. For example, the pulverized polyurethane foam can be conveyed using a conveyor unit such as a conveyor belt while the decomposing agent is sprayed in a mist and coated onto the conveyed pulverized material, and then directly placed into the feeding mechanism 30. Alternatively, the pulverized polyurethane foam and the decomposing agent can be placed in a container such as a bag, and the contents can be stirred within the container to perform the coating.

[0036] There are no particular limitations on the pulverized polyurethane foam. The polyurethane foam can be any of rigid polyurethane foam, semi-rigid polyurethane foam, and flexible polyurethane foam. The polyurethane foam can be a continuous bubble structure or an independent bubble structure. In this embodiment, the method of pre-pulverizing the polyurethane foam before processing by the feeding mechanism 30 will be described. Alternatively, the polyurethane foam may not be pre-pulverized before processing by the feeding mechanism 30, but may be pulverized by the feeding mechanism 30 to become pulverized material. The polyurethane foam may, for example, be end material discharged during the manufacturing process of polyurethane foam, or used polyurethane foam intended for disposal.

[0037] As a decomposing agent, there are no particular restrictions as long as it is a substance that can chemically decompose and liquefy polyurethane bonds. From the point of view of reactivity and cost, compounds with hydroxyl groups or amine compounds are preferred.

[0038] Examples of compounds containing hydroxyl groups include ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, trimethylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, polyoxyethylene glycol, polyoxypropylene glycol, glycerol, and polyethylene glycol. These compounds containing hydroxyl groups can be used alone or in combination of two or more. Dipropylene glycol and 1,4-butanediol are preferred among these.

[0039] In addition, examples of amine compounds include polyetheramines, ethylenediamine, tetramethylenediamine, hexamethylenediamine, propylenediamine, 2-ethylhexylamine, isopropanolamine, 2-(2-aminoethylamino)ethanol, 2-amino-2-hydroxymethyl-1,3-propanediol, ethylaminoethanol, aminobutanol, n-propylamine, di-n-propylamine, n-pentylamine, isobutylamine, methyldiethylamine, monoethanolamine, diethanolamine, triethanolamine, cyclohexylamine, piperazine, piperidine, aniline, toluidine, benzylamine, phenylenediamine, toluenediamine, 4-4'-diphenylmethanediamine, phenylenediamine, chloroaniline, pyridine, methylpyridine, N-methylmorpholine, ethylmorpholine, pyrazole, etc. These amine compounds can be used alone or in mixtures of two or more. Polyetheramines, diethanolamine, and triethanolamine are preferred among these.

[0040] There is no particular limitation on the amount of decomposing agent added. When using polyetheramine as a decomposing agent, the mass ratio of polyurethane foam to polyetheramine (polyurethane foam: polyetheramine) is preferably 1:0.1 to 1:10, more preferably 1:0.1 to 1:7, more preferably 1:0.5 to 1:5, and can also be 1:0.5 to 1:3.

[0041] In decomposition reactions using decomposition agents, decomposition catalysts can be added as needed to increase the reaction rate.

[0042] As an added catalyst, preferably a catalyst used in the manufacture of polyurethane foam, examples include triethylamine, N,N-dimethylcyclohexylamine, N,N,N',N'-tetramethylethylenediamine, N,N,N',N'-tetramethyl1,3-propanediamine, N,N,N',N'-tetramethyl1,6-hexanediamine, N,N,N',N",N"-pentamethyldiethylenetriamine, N,N,N',N",N"-pentamethyldipropylenetriamine, tetramethylguanidine, triethylenediamine, N,N'-dimethylpiperazine, N,-methyl,N'-(2-dimethylamino)ethylpiperazine, N-methylmorpholine, N,N'-dimethylamino ...-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N-methylmorpholine, N The following compounds are listed: N-(2-dimethyl)morpholine, 1,2-dimethylimidazolium, hexamethylenetetramine, dimethylaminoethanol, dimethylaminoethoxyethanol, N,N,N'-trimethylaminoethylethanolamine, N-methyl-N'-(2-hydroxyethyl)piperazine, N-(2-hydroxyethyl)morpholine, bis(2-dimethylaminoethyl) ether, ethylene glycol bis(3-dimethylamino)propyl ether, diazabicycloundecene, stannous octoate, dibutyltin diacetate, dibutyltin dilaurate, dibutyltin thiolate, dibutyltin thiocarboxylate, dibutyltin maleate, dioctyltin thiolate, dioctyltin thiocarboxylate, lead octanoate, zinc octanoate, calcium octanoate, potassium acetate, potassium octanoate, etc. Among these, triethylenediamine, diazabicycloundecene, potassium acetate, and potassium octanoate are preferred.

[0043] The amount of catalyst added relative to 100 parts by mass of the decomposer is more preferably 0 parts by mass or more than 30 parts by mass, and even more preferably 5 parts by mass or more than 20 parts by mass.

[0044] 2. Decomposition and treatment methods for polyurethane foam An example of a method for decomposing polyurethane foam is illustrated. The method for decomposing polyurethane foam uses an extruder 10 having a cylinder 20. The method involves feeding a mixture of pulverized polyurethane foam and a decomposing agent into the raw material inlet 21 of the cylinder 20 while pressing it in, and heating the mixture while conveying it within the cylinder 20, thereby decomposing the polyurethane foam.

[0045] The decomposition treatment method for polyurethane foam can be performed, for example, using the "1. Polyurethane Foam Decomposition Treatment Apparatus 1" described above. Furthermore, in the description of the extruder 10 having the cylinder 20, the description of "(1) Extruder 10" in the "1. Polyurethane Foam Decomposition Treatment Apparatus 1" section is directly applicable. In the description of the mixture of pulverized polyurethane foam and the decomposing agent, the description of "(3) Mixture" in the "1. Polyurethane Foam Decomposition Treatment Apparatus 1" section is directly applicable.

[0046] There are no particular limitations on the method of feeding the above-mentioned mixture. For example, the feeding of the above-mentioned mixture can be carried out using a feeding mechanism 30 having a pair of rotating parts 33, 33 arranged side by side. In the description of the feeding mechanism 30, the description of "(2) Feeding mechanism 30" in the section "1. Decomposition and processing apparatus 1 for polyurethane foam" is directly applicable. That is, the above-mentioned mixture is fed by rotating each of the rotating parts 33, 33 in different directions, thereby causing the mixture to be drawn between the pair of rotating parts, and pressing the mixture into the raw material feeding port 21.

[0047] There is no particular limitation on the heating temperature at which the mixture is heated while being conveyed within the cylinder 20. From the viewpoint of simultaneously increasing the decomposition rate of the polyurethane foam and suppressing the decomposition of the polyols as reaction products, the heating temperature is preferably 80°C to 300°C, more preferably 100°C to 270°C, and even more preferably 150°C to 250°C. The heating temperature can be changed by adjusting the set temperature of the heating unit 25. The heating temperature should be appropriately set to a temperature suitable for the decomposition of the polyurethane foam.

[0048] There is no particular limitation on the residence time of the mixture within the cylinder 20. The residence time can be, for example, between 0.5 minutes and 5 hours, or between 1 minute and 10 minutes. The residence time can be changed by adjusting the rotation speed of the screw 11. The residence time can be appropriately set according to the time required for the decomposition of the polyurethane foam.

[0049] 3. Methods for preparing reaction products An example of a method for manufacturing the reaction product is described. The method for manufacturing the reaction product yields a reaction product of polyurethane foam and a decomposing agent. The method for manufacturing the reaction product is carried out using an extruder 10 having a cylinder 20. A mixture of pulverized polyurethane foam and a decomposing agent is fed into the raw material inlet 21 of the cylinder 20 while being pressed in. The mixture is heated while being conveyed within the cylinder to obtain the reaction product.

[0050] The reaction product can be manufactured, for example, using the "1. Polyurethane Foam Decomposition Processing Apparatus 1" described above. Furthermore, in the description of the extruder 10 having the cylinder 20, the description of "(1) Extruder 10" in the "1. Polyurethane Foam Decomposition Processing Apparatus 1" section is directly applicable. In the description of the mixture of pulverized polyurethane foam and the decomposing agent, the description of "(3) Mixture" in the "1. Polyurethane Foam Decomposition Processing Apparatus 1" section is directly applicable.

[0051] In the description of "method of adding mixture", "heating temperature" and "retention time" in the method of manufacturing reaction products, the description of "method of adding mixture", "heating temperature" and "retention time" in the "2. Decomposition treatment method of polyurethane foam" section is directly applicable.

[0052] The reaction products may include, for example, polyols derived from polyurethane foam raw material polyols. In addition, the reaction products may also contain amines, polyols, and components with molecular weights lower than those of amines.

[0053] The reaction product is preferably obtained in a liquid state. When the reaction product is obtained in a liquid state, it can be directly added to the composition for recycled polyurethane foam during manufacturing, thus facilitating reuse. If the reaction product contains solid impurities, it can be separated using a filter or the like. To obtain the reaction product in a liquid state, the type of decomposing agent can be appropriately selected. For example, by using polyetheramine as a decomposing agent, the reaction product can preferably be obtained in a liquid state.

[0054] 4. Manufacturing method of recycled polyurethane foam The method for manufacturing recycled polyurethane foam uses reaction products to produce recycled polyurethane foam.

[0055] Furthermore, in the description of the "reaction products" in the method for manufacturing recycled polyurethane foam, the description in section "3. Method for manufacturing reaction products" is directly applicable.

[0056] Recycled polyurethane foam is obtained, for example, from a composition for recycled polyurethane foam containing a polyol, an isocyanate, and a reaction product. There is no particular limitation on the amount of reaction product added. The amount of reaction product added relative to 100 parts by mass of the polyol is preferably 0.5 parts by mass to 8 parts by mass, more preferably 1 part by mass to 6 parts by mass, and even more preferably 2 parts by mass to 4 parts by mass.

[0057] Recycled polyurethane foam can be manufactured using well-known foaming methods. These methods include preform foaming and molding foaming, and either molding method can be used. Preform foaming involves spraying a mixed polyurethane resin composition onto a conveyor belt and foaming it at room temperature under atmospheric pressure. Molding foaming, on the other hand, involves filling a mold (molding die) with a mixed polyurethane resin composition and foaming it within the mold.

[0058] 5. Polyurethane foam decomposition and treatment device 1A like Figure 3 As shown, the polyurethane foam decomposition processing apparatus 1A of Embodiment 2 includes: a cylinder 20A having a raw material inlet 21 and a discharge outlet 23A for discharging the decomposed product; and a screw 11 housed within the cylinder 20A. An input mechanism 30 is attached to the raw material inlet 21, which simultaneously presses in a mixture of pulverized polyurethane foam and the decomposing agent. In the polyurethane foam decomposition processing apparatus 1A of Embodiment 2, the same reference numerals are used for structures identical to those in the polyurethane foam decomposition processing apparatus 1 of Embodiment 1, and their descriptions are omitted. Figure 3 In the diagram, the arrow UP indicates the upper vertical direction, and the arrow DW indicates the lower vertical direction.

[0059] In this embodiment, the cylinder 20A is configured such that its inner space is horizontal from the raw material inlet 21 side towards the outlet 23A side. The inner surface of the cylinder 20A, at least in the region located at its lower vertical end, does not have a surface that rises from the raw material inlet 21 side towards the outlet 23A side. That is, at least the region located at the lower vertical end of the inner surface of the cylinder 20A is composed of a horizontal or downward-sloping surface. The region located at the lower vertical end is the region where reaction products are retained. With this structure, the reaction products can be appropriately moved from the raw material inlet 21 side towards the outlet 23A side within the inner space of the cylinder 20A.

[0060] The polyurethane foam decomposition and processing apparatus 1A has a discharge member 40A at the other end of the cylinder 20A. The discharge member 40A is tubular, with one end connected to the discharge port 23A of the cylinder 20A. The discharge member 40A extends in a generally L-shape. The discharge member 40A is arranged to bend downwards from the other end of the cylinder 20A. The other end of the discharge member 40A is open, for example, toward a reaction product recovery container (not shown). Alternatively, the other end of the discharge member 40A can be connected to the reaction product recovery container or to other tubular connecting members. This structure facilitates the recovery of reaction products discharged from the discharge port 23A of the cylinder 20A through the discharge member 40A, which is preferable.

[0061] The decomposition treatment method for polyurethane foam can be performed, for example, using "5. Polyurethane foam decomposition treatment apparatus 1A". This polyurethane foam decomposition treatment method can be performed in the same way as "2. Polyurethane foam decomposition treatment method", except that it uses polyurethane foam decomposition treatment apparatus 1A.

[0062] The method for producing the reaction product can be carried out, for example, using "5. Polyurethane foam decomposition treatment apparatus 1A". This method for producing the reaction product can be carried out in the same manner as "3. Method for producing the reaction product", except that it uses polyurethane foam decomposition treatment apparatus 1A.

[0063] 6. Polyurethane foam decomposition and treatment device 1B like Figure 4 As shown, the polyurethane foam decomposition processing apparatus 1B of Embodiment 3 includes: a cylinder 20B having a raw material inlet 21 and a discharge outlet 23B for discharging the decomposed product; and a screw 11 housed within the cylinder 20B. An inlet mechanism 30 is attached to the raw material inlet 21, which simultaneously presses in a mixture of pulverized polyurethane foam and the decomposing agent. In the polyurethane foam decomposition processing apparatus 1B of Embodiment 3, the same reference numerals are used for structures identical to those in the polyurethane foam decomposition processing apparatus 1 of Embodiment 1, and their descriptions are omitted. Figure 4 In the diagram, the arrow UP indicates the upper vertical direction, and the arrow DW indicates the lower vertical direction.

[0064] In this embodiment, the cylinder 20B is configured such that its inner space descends from the raw material inlet 21 side toward the outlet 23B side. The inner surface of the cylinder 20B, at least in the region located at its lower vertical end, does not have a surface that rises from the raw material inlet 21 side toward the outlet 23B side. That is, at least the region located at the lower vertical end of the inner surface of the cylinder 20B is composed of a horizontal or descending surface. The region located at the lower vertical end is the region where reaction products are retained. With this structure, reaction products can be appropriately moved from the raw material inlet 21 side toward the outlet 23B side within the inner space of the cylinder 20B.

[0065] The polyurethane foam decomposition and processing apparatus 1B has a discharge member 40B at the other end of the cylinder 20B. The discharge member 40B is tubular, with one end connected to the discharge port 23B of the cylinder 20B. The discharge member 40B extends in a shape with an obtuse angle. The discharge member 40B is arranged to bend downwards from the other end of the cylinder 20B. The other end of the discharge member 40B is open, for example, toward a reaction product recovery container (not shown). Alternatively, the other end of the discharge member 40B can be connected to the reaction product recovery container or to other tubular connecting members. This structure facilitates the recovery of reaction products discharged from the discharge port 23B of the cylinder 20B through the discharge member 40B, which is preferable.

[0066] The decomposition treatment method for polyurethane foam can be performed, for example, using "6. Polyurethane Foam Decomposition Treatment Apparatus 1B". This polyurethane foam decomposition treatment method can be performed in the same way as "2. Polyurethane Foam Decomposition Treatment Method", except that it uses the polyurethane foam decomposition treatment apparatus 1B.

[0067] The method for producing the reaction product can be carried out, for example, using "6. Polyurethane foam decomposition treatment apparatus 1B". This method for producing the reaction product can be carried out in the same manner as "3. Method for producing the reaction product", except that it uses polyurethane foam decomposition treatment apparatus 1B.

[0068] 7. Polyurethane foam decomposition and treatment device 1C like Figure 5 As shown, the polyurethane foam decomposition processing apparatus 1C of Embodiment 4 includes: a cylinder 20C having a raw material inlet 21 and a discharge outlet 23C for discharging the decomposed product; and a screw 11 housed within the cylinder 20C. An inlet mechanism 30 is attached to the raw material inlet 21, which simultaneously presses in a mixture of pulverized polyurethane foam and the decomposing agent. In the polyurethane foam decomposition processing apparatus 1C of Embodiment 4, the same reference numerals are used for structures identical to those in the polyurethane foam decomposition processing apparatus 1 of Embodiment 1, and their descriptions are omitted. Figure 5 In the diagram, the arrow UP indicates the upper vertical direction, and the arrow DW indicates the lower vertical direction.

[0069] In this embodiment, the cylinder 20C is configured such that its inner space descends from the raw material inlet 21 side toward the outlet 23C side. Specifically, the cylinder 20C is configured such that its inner space faces vertically. The inner surface of the cylinder 20C does not have a surface that rises from the raw material inlet 21 side toward the outlet 23C side. That is, approximately the entire inner surface of the cylinder 20C is composed of a descending surface. With this structure, the reaction product can be appropriately moved from the raw material inlet 21 side toward the outlet 23C side within the inner space of the cylinder 20C.

[0070] The decomposition treatment method for polyurethane foam can be performed, for example, using "7. Polyurethane Foam Decomposition Treatment Apparatus 1C". This polyurethane foam decomposition treatment method is the same as "2. Polyurethane Foam Decomposition Treatment Method" except that it uses the polyurethane foam decomposition treatment apparatus 1C.

[0071] The method for producing the reaction product can be carried out, for example, using "7. Polyurethane foam decomposition treatment apparatus 1C". This method for producing the reaction product can be carried out in the same manner as "3. Method for producing the reaction product", except that it uses polyurethane foam decomposition treatment apparatus 1C.

[0072] Example 1. Manufacturing of polyurethane foam A polyurethane foam composition (liquid A and liquid B) was prepared according to the proportions of "polyurethane foam" in Table 1, and polyurethane foam was manufactured by foaming a blank.

[0073] The details of each raw material are as follows.

[0074] Polyol: Polyether polyol, hydroxyl value 56 mg KOH / g, model GL3000, manufactured by Sanyo Chemical Co., Ltd. Crosslinking agent: ethylenediamine, manufactured by Mitsui Takeda Corporation Polyetheramine: amino-terminated trimethylolpropane tripropylene glycol ether, amine value 352.5 mg KOH / g, functionality 3, model JEFFAMINET-403, manufactured by HUNTSMAN. Catalyst: Amine catalyst, PC-37, manufactured by EVONIC Foaming agent: SZ1136, manufactured by Dow Corning Toray. Flame retardant: Trichloropropyl phosphate (TMCP) Foaming agent: water Isocyanate: Crude MDI, NCO% 31% [Table 1]

[0075] 2. Decomposition Treatment of Polyurethane Foam The obtained polyurethane foam was pulverized using a pulverizer to obtain pulverized polyurethane foam. 100g of pulverized polyurethane foam and 200g of polyetheramine (polyurethane foam: polyetheramine = 1:2) were put into a bag and stirred to obtain a mixture.

[0076] The obtained mixture is decomposed using the decomposition processing apparatus described in Embodiment 1. Specifically, the mixture is fed into the raw material inlet while being pressed in using the feeding mechanism. The mixture is in a state where it is easier to clump together than the monomers of the pulverized polyurethane foam. In this embodiment, by using the feeding mechanism, the pulverized polyurethane foam can be smoothly fed into the raw material inlet even in the state of the mixture.

[0077] Polyurethane foam was decomposed by simultaneously conveying and heating the mixture into the cylinder through the feed inlet. The heating temperature was 200°C, and the residence time was 5 minutes. The polyurethane foam was then decomposed, yielding a brown liquid reaction product.

[0078] 3. Manufacturing of recycled polyurethane foam A composition (liquid A and liquid B) for recycled polyurethane foam was prepared by mixing the obtained reaction product with other components in the proportions listed in Table 1 for "Recycled Polyurethane Foam". The temperature of liquids A and B was adjusted to 10°C, and the mixture was stirred in a 1000 mL dropping cup and foamed in a 200 mm × 200 mm × 300 mm foaming bag to produce recycled polyurethane foam. The resulting recycled polyurethane foam had a good appearance.

[0079] 4. Effects of the Implementation Example According to this embodiment, pulverized polyurethane foam can be smoothly fed into the raw material inlet. According to this embodiment, the reaction between the polyurethane foam and the decomposition agent can be stabilized. Furthermore, according to this embodiment, even large-volume polyurethane foam can be decomposed using a small-scale decomposition processing device. According to this embodiment, a highly efficient continuous chemical decomposition method for polyurethane foam can be provided.

[0080] This disclosure is not limited to the embodiments described in the detailed description above, and various modifications or alterations can be made within the scope of this disclosure.

[0081] Explanation of reference numerals in the attached figures 1, 1A, 1B, 1C: Decomposition and processing device; 10: Extruder; 11: Screw; 20, 20A, 20B, 20C: Cylinder; 21: Raw material inlet; 23, 23A, 23B, 23C: Discharge outlet; 30: Feeding mechanism.

Claims

1. A device for decomposing and processing polyurethane foam, wherein, have: The cylinder body has a raw material inlet and a discharge outlet for discharging the decomposed waste; and The screw is housed within the cylinder. An infeeding mechanism is provided at the raw material inlet, which simultaneously presses in the mixture of pulverized polyurethane foam and decomposing agent into the raw material inlet.

2. A method for decomposing polyurethane foam, using an extruder with a cylinder, wherein, The mixture of pulverized polyurethane foam and the decomposing agent is simultaneously pressed into the raw material inlet of the cylinder. The polyurethane foam is broken down by conveying and heating the mixture within the cylinder.

3. A method for manufacturing a reaction product, wherein a reaction product of polyurethane foam and a decomposing agent is obtained, wherein, It is carried out using an extruder with a cylinder. The mixture of pulverized polyurethane foam and the decomposing agent is fed into the raw material inlet of the cylinder while being pressed in. The reaction product is obtained by conveying and heating the mixture within the cylinder.

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