Fusion material manufacturing method, fusion material manufacturing device, and fusion material

Abstract

To provide a manufacturing method of a fusion material, which reduces an environmental load and a raw material cost, capable of manufacturing a material uniform in an environmentally friendly component, by heightening a ratio of a biomass material, without requiring an additive, a manufacturing apparatus of a fusion material, and a fusion material.SOLUTION: A manufacturing method of a fusion material comprises: a mixing step in which at least one kind of an inorganic material or a biomass material and at least one kind of plastic materials are mixed by rotating blades 10 and a screw 12 in a mixing container 3 by a motor 2; a melting step in which the blade 10 and the screw 12 are rotated at the number of rotations higher than the number of rotations in the mixing step; and a fusion step of subsequently driving the motor 2 to rotate a rotation shaft 5, the blade 10, and the screw 12 to promote a reaction of the material, in which the mixing step, the melting step, and the fusion step are performed as a series of steps.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a method for producing a fusion material, an apparatus for producing a fusion material, and the fusion material. [Background technology]

[0002] In recent years, the concentration of carbon dioxide in the atmosphere has increased, and climate change such as global warming has become a problem. In order to suppress environmental abnormalities such as global warming and reduce the use of fossil resources that are in danger of being depleted, the use of biomass, a renewable resource that effectively utilizes biotechnology, has been promoted. Regarding the production of biomass materials, a technology has been disclosed for forming a wood-based composite resin material from a wood-based filler material, a lubricant, a thermoplastic resin raw material, and an oxygen modifier (see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2018-83876 A [Patent Document 2] Patent No. 4489017 Summary of the Invention [Problem to be solved by the invention]

[0004] Conventionally, additives have been required to promote the fusion of biomass materials and thermoplastic resin raw materials, as in the production of biomass materials described in Patent Document 1, but the use of additives has a negative impact on the environment. In addition, the ratio of biomass materials mixed with thermoplastic resin raw materials is generally 50% or less, which increases the environmental load and raw material costs. Furthermore, there is no description of the fusion of inorganic materials and thermoplastic resin raw materials.

[0005] In view of the above-mentioned problems, the present invention aims to provide a manufacturing method for a fusion material that does not require additives and has a higher proportion of inorganic materials and biomass materials compared to plastic materials, a manufacturing apparatus for a fusion material, and a fusion material. [Means for solving the problem]

[0006] A method for producing a fusion material according to one embodiment of the present invention includes the steps of: A motor; A mixing vessel; A control unit for controlling the rotation speed or torque of the motor; A rotating shaft rotated by the motor; A plurality of blades formed on the outer periphery of the rotating shaft in the mixing vessel; a helical screw formed on the outer periphery of the rotating shaft in the mixing vessel; A pressure sensor for detecting the pressure in the mixing vessel; A temperature sensor for detecting a temperature inside the mixing vessel; A rotation speed sensor that detects the rotation speed of the motor; A torque sensor that detects the torque of the motor; Equipped with The control unit feedback controls the motor in accordance with values ​​from the pressure sensor, the temperature sensor, the rotation speed sensor, and the torque sensor. A method for producing a fusion material using a fusion material production device, comprising: A mixing step of rotating the blade and the screw in the mixing vessel by the motor to mix at least one of the pulverized inorganic material and the pulverized biomass material and at least one of the pulverized plastic material; a melting step of rotating the blade and the screw at a rotation speed higher than the rotation speed in the mixing step; A fusion process is then performed by driving the motor to rotate the rotating shaft, the blade, and the screw to promote the reaction of the materials. having The mixing step, the melting step, and the fusing step are carried out as a single continuous step.

[0007] In addition, the manufacturing apparatus for the fusion material according to the embodiment of the present invention includes: A motor; A mixing vessel; A control unit for controlling the rotation speed or torque of the motor; A rotating shaft rotated by the motor; A plurality of blades formed on the outer periphery of the rotating shaft in the mixing vessel; a helical screw formed on the outer periphery of the rotating shaft in the mixing vessel; A pressure sensor for detecting the pressure in the mixing vessel; A temperature sensor for detecting a temperature inside the mixing vessel; A rotation speed sensor that detects the rotation speed of the motor; A torque sensor that detects the torque of the motor 2; Equipped with The control unit feedback controls the motor in accordance with values ​​from the pressure sensor, the temperature sensor, the rotation speed sensor, and the torque sensor. Effect of the Invention

[0009] The fusion material manufacturing method, fusion material manufacturing apparatus, and fusion material of the present invention do not require additives, can increase the proportion of biomass material, and can produce environmentally friendly materials with uniform components, thereby reducing the environmental burden and raw material costs. [Brief description of the drawings]

[0010] [Figure 1] An example of a method for producing the fusion material according to this embodiment will be described. [Diagram 2] 1 shows an example of an apparatus for producing a fusion material according to this embodiment. [Diagram 3] 1 shows the fusion material of Example 1 manufactured by the fusion material manufacturing method of this embodiment. [Figure 4] 1 shows the fusion material of Example 2 manufactured by the fusion material manufacturing method of this embodiment. [Diagram 5] 1 shows the fusion material of Example 3 manufactured by the fusion material manufacturing method of this embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Fig. 1 shows an example of a method for producing a fusion material according to the present embodiment. Fig. 2 shows an example of a part of an apparatus 1 for producing a fusion material according to the present embodiment.

[0012] The manufacturing method of the fusion material of this embodiment includes a grinding process for grinding a material, a mixing process for mixing the ground material, a melting process for melting the mixed material, and a fusion process for fusing the molten material.

[0013] As shown in FIG. 2, the fusion material manufacturing apparatus 1 of this embodiment includes a motor 2, a mixing container 3, a control unit 4 that controls the rotation speed or torque of the motor 2, a rotating shaft 5 rotated by the motor 2, a plurality of blades 10 formed on the outer periphery of the rotating shaft 5 within the mixing container 3, a helical screw 12 formed on the outer periphery of the rotating shaft 5 within the mixing container 3, a pressure sensor 6 that detects the pressure within the mixing container 3, a temperature sensor 7 that detects the temperature within the mixing container 3, a rotation speed sensor 8 that detects the rotation speed of the motor 2, and a torque sensor 9 that detects the torque of the motor 2.

[0014] It is preferable that the control unit 4 performs feedback control of the motor 2 according to values ​​from the pressure sensor 6, the temperature sensor 7, the rotation speed sensor 8, and the torque sensor 9. For example, when the actual load is large and the rotation speed of the motor 2 is lower than the setting, feedback control can be used to control the rotation speed to an appropriate value.

[0015] It is not necessary to use the pressure sensor 6, the temperature sensor 7, the rotation speed sensor 8, and the torque sensor 9. The rotation speed and torque of the motor 2 from the pulverization process to the fusion process may be set in advance in the control unit 4. As the manufacturing device 1 of the fusion material of this embodiment, for example, the mixing and pulverization device described in Patent Document 2 may be used.

[0016] The materials for producing the fusion material are at least one of inorganic materials or biomass materials, and at least one plastic material. When producing the fusion material of this embodiment, no additives are required.

[0017] The inorganic material is an inorganic substance, and includes carbon fiber reinforced plastics (CFRP), gypsum, carbonic acid, calcium oxide, shells, glass, metal film, vapor-deposited metal, metal powder, and the like.

[0018] Biomass materials are renewable organic resources derived from living organisms that can be utilized, including waste materials such as food, construction waste, and waste paper, and resource crops such as plants. Examples include food waste, wood, paper, and seaweed.

[0019] The plastic material includes polypropylene, polyethylene, polyethylene terephthalate, polytrimethylene terephthalate, polyvinyl chloride, polystyrene, PLA resin, ABS resin, polycarbonate, polyamide, polyurethane, nylon, or the like.

[0020] The manufacturing method of the fusion material of this embodiment is carried out in the order of a crushing process, a mixing process, a melting process, and a fusion process, as shown in FIG. 1. Although each process may be switched manually, it is preferable to carry out the processes as one process by automatically changing the rotation speed etc. according to time.

[0021] In the manufacturing method of the fusion material of this embodiment, first, in step 1, a pulverization process is performed. In the pulverization process, materials are put into the mixing container 3 of the fusion device shown in FIG. 2 through an opening (not shown), and the motor 2 is driven to rotate the rotating shaft 5, the blades 10, and the screw 12 to finely pulverize the inorganic material or biomass material and the plastic material. The size of the pulverized particles is preferably about 2 to 7 mm. The pulverization process is not performed when materials that have been pulverized in advance by another device are simply put in.

[0022] Next, in step 2, a mixing process is performed. In the mixing process, the motor 2 is subsequently driven to rotate the rotating shaft 5, the blades 10, and the screw 12 to mix the pulverized inorganic material or biomass material and the plastic material. In conventional manufacturing methods, only one type of biomass material is mixed, and the ratio of the biomass material mixed with the plastic material is generally less than 50%. In this embodiment, multiple biomass materials can be mixed at 50% or more and up to 97%. By increasing the mixing ratio of the biomass material, the environmental burden and the cost of raw materials can be reduced.

[0023] In addition, in the production of the fusion material of this embodiment, it is not necessary to use additives for compatibility. By not using additives, environmental friendliness is improved. Furthermore, in the mixing process of this embodiment, it is preferable to add moisture. By adding moisture, the internal pressure can be increased in the subsequent process.

[0024] Next, in step 3, the melting process is carried out. In the melting process, the motor 2 continues to be driven to rotate the rotating shaft 5, the blades 10, and the screw 12. The rotation speed of the blades in the melting process is set to be higher than that in the mixing process. When the blades 10 are rotated at high speed, the temperature inside the mixing vessel 3 rises due to the movement of the materials themselves and friction caused by the materials colliding with each other. After that, steam is generated from the moisture, the pressure inside the mixing vessel 3 increases, and each material melts. Then, decomposition and separation of the biomass begins in the mixing vessel 3, and the torque decreases while the rotation speed remains constant.

[0025] Next, in step 4, the fusion process is carried out. In the fusion process, the motor 2 continues to be driven to rotate the rotating shaft 5, the blades 10, and the screw 12 to advance the reaction of the materials. As the reaction progresses, the materials are refined and re-resinized, and their density and viscosity increase, causing them to stick to the inner wall of the outer periphery and increasing the torque. At the same time, the moisture is vaporized and discharged to the outside from an outlet (not shown) of the mixing vessel 3. Therefore, the inside of the mixing vessel 3 dries, and a fusion product from which moisture and the like have been removed is obtained.

[0026] The resulting fusion product is a new material that is uniformly fused at the molecular level and can be molded by injection, extrusion, blowing, pressing, etc., so it can be used for a variety of purposes.

[0027] In addition, the manufacturing method of the fusion material of this embodiment is performed in less than 1800 seconds. Usually, the more heat input a plastic material is, the more severe the deterioration becomes. In the manufacturing method of the fusion material of this embodiment, the time for which heat is applied to the plastic material is short. Therefore, the fusion material manufactured by the manufacturing method of the fusion material of this embodiment is less deteriorated and can maintain its strength. In addition, since the fusion material manufactured by the manufacturing method of the fusion material of this embodiment is less deteriorated, the completed fusion product can be reused.

[0028] Next, an example of a fusion material manufactured by the manufacturing method of the fusion material of this embodiment will be described.

[0029] Fig. 3 shows the fusion material of Example 1 produced by the fusion material production method of this embodiment. Fig. 3(a) shows the surface of the fusion material of Example 1, and Fig. 3(b) shows a scanning electron microscope photograph of the fusion material of Example 1.

[0030] In Example 1, 55% wood material and 45% polypropylene were fused together. Table 1 shows the surface state components of Example 1. It is estimated that the oxygen content is about 20 Atom%, and the polypropylene content is high on the surface. The wood and polypropylene components are fused together evenly, resulting in a uniform appearance. [Table 1]

[0031] 4 shows the fusion material of Example 2 produced by the fusion material production method of the present embodiment. Fig. 4(a) shows the surface of the fusion material of Example 2, and Fig. 4(b) shows a scanning electron microscope photograph of the fusion material of Example 2.

[0032] In Example 2, 50% scallop shells, 37.5% polypropylene, 12.5% ​​polyethylene terephthalate, and 300 g of water were fused together. Table 2 shows the surface state components of Example 2. Calculations show that carbon is about 62 Atom%, oxygen is about 29 Atom%, and calcium is about 8 Atom%, and since there is a lot of carbon, it is estimated that there is a lot of polypropylene component on the surface. The calcium carbonate component, polypropylene component, and polyethylene terephthalate component of the scallop shells are fused together uniformly, resulting in a uniform appearance. [Table 2]

[0033] Fig. 5 shows the fusion material of Example 3 produced by the fusion material production method of this embodiment. Fig. 5(a) shows the surface of the fusion material of Example 3, and Fig. 5(b) shows a scanning electron microscope photograph of the fusion material of Example 3.

[0034] In Example 3, 50% nylon, 50% polyethylene, and 300 g of water were fused together. Table 3 shows the surface state components of Example 3. Calculations showed that carbon was about 93 Atom% and oxygen was about 7 Atom%, which means that there is a lot of carbon, and therefore it is estimated that there is a lot of polypropylene components on the surface. The nylon components and polyethylene components are fused together uniformly, resulting in a uniform appearance. [Table 3]

[0035] As described above, according to the present embodiment, the method for producing a fusion material uses a fusion material production device 1 equipped with a motor 2, a mixing vessel 3, a rotating shaft 5 rotated by the motor 2, a plurality of blades 10 formed on the outer periphery of the rotating shaft 5 in the mixing vessel 3, and a spiral screw 12 formed on the outer periphery of the rotating shaft 5 in the mixing vessel 3. The method includes a mixing process in which the blades 10 and the screw 12 are rotated in the mixing vessel 3 by the motor 2 to mix at least one type of inorganic material or biomass material and at least one type of plastic material, a melting process in which the blades 10 and the screw 12 are rotated at a higher rotation speed than the rotation speed in the mixing process, and a fusion process in which the motor 2 is subsequently driven to rotate the rotating shaft 5, the blades 10, and the screw 12 to promote the reaction of the materials. Since the mixing process, melting process, and fusion process are performed as a series of steps, no additives are required, the ratio of biomass material is increased, and an environmentally friendly material with uniform components can be produced, which reduces the environmental load and raw material costs.

[0036] Furthermore, according to the manufacturing method for the fusion material of this embodiment, a crushing process is performed before the mixing process to finely crush the material, and the crushing process, mixing process, melting process, and fusion process are performed as a single continuous process. This means that no additives are required, the proportion of biomass material is increased, and an environmentally friendly material with uniform components can be manufactured, further reducing the environmental burden and raw material costs.

[0037] Furthermore, according to the method for producing a fusion material of this embodiment, since the mixing step causes the material to contain moisture, the internal pressure of the mixing vessel 3 can be increased, and a more uniform material can be produced.

[0038] Furthermore, according to the manufacturing method of the fusion material of this embodiment, since the plastic material contains the fusion material, the manufactured fusion material can be reused.

[0039] Furthermore, according to the method for producing a fusion material of this embodiment, the mixing process, melting process, and fusion process are carried out in less than 1,800 seconds, so that a fusion material with a short heat input time can be produced in a short time, and a fusion material with uniform components can be produced efficiently and at low cost.

[0040] Furthermore, according to the fusion material manufacturing apparatus of this embodiment, the apparatus includes a motor 2, a mixing vessel 3, a control unit 4 that controls the rotation speed or torque of the motor 2, a rotating shaft 5 rotated by the motor 2, a plurality of blades 10 formed on the outer periphery of the rotating shaft 5 in the mixing vessel 3, a helical screw 12 formed on the outer periphery of the rotating shaft 5 in the mixing vessel 3, a pressure sensor 6 that detects the pressure in the mixing vessel 3, a temperature sensor 7 that detects the temperature in the mixing vessel 3, a rotation speed sensor 8 that detects the rotation speed of the motor 2, and a torque sensor 9 that detects the torque of the motor 2. The control unit 4 feedback controls the motor 2 according to the values ​​from the pressure sensor 6, the temperature sensor 7, the rotation speed sensor 8, and the torque sensor 9, so that additives are not required, the ratio of biomass material is increased, and an environmentally friendly material with uniform components can be manufactured, thereby reducing the environmental burden and raw material costs.

[0041] Furthermore, according to the fusion material manufacturing apparatus of this embodiment, since the fusion material is manufactured using the fusion material manufacturing method or the fusion material manufacturing apparatus, no additives are required, the ratio of biomass material is increased, and the material has a uniform composition of environmentally friendly components, thereby reducing the environmental burden and raw material costs.

[0042] The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit and scope of the present invention. All such modifications are included in the technical concept of the present invention. [Explanation of symbols]

[0043] 1... Fusion material manufacturing device, 2... Motor, 3... Mixing vessel, 4... Control unit, 5... Rotating shaft, 6... Pressure sensor, 7... Temperature sensor, 8... Rotational speed sensor, 9... Torque sensor, 10... Blade, 12... Screw

Claims

1. A motor; A mixing vessel; A control unit for controlling the rotation speed or torque of the motor; A rotating shaft rotated by the motor; A plurality of blades formed on the outer periphery of the rotating shaft in the mixing vessel; a helical screw formed on the outer periphery of the rotating shaft in the mixing vessel; A pressure sensor for detecting the pressure in the mixing vessel; A temperature sensor for detecting a temperature inside the mixing vessel; A rotation speed sensor that detects the rotation speed of the motor; A torque sensor that detects the torque of the motor; Equipped with The control unit feedback-controls the motor in accordance with values ​​from the pressure sensor, the temperature sensor, the rotation speed sensor, and the torque sensor. A method for producing a fusion material using a fusion material production device, comprising: A mixing step of rotating the blade and the screw in the mixing vessel by the motor to mix at least one of the pulverized inorganic material and the pulverized biomass material and at least one of the pulverized plastic material; a melting step of rotating the blade and the screw at a rotation speed higher than the rotation speed in the mixing step; A fusion process is then performed by driving the motor to rotate the rotating shaft, the blade, and the screw to promote the reaction of the materials. having The mixing step, the melting step, and the fusing step are carried out as a single continuous step. Methods for producing fusion materials.

2. A grinding step of finely grinding the material is provided before the mixing step, The grinding step, the mixing step, the melting step, and the fusing step are carried out as a single continuous step. A method for producing the fusion material of claim 1 .

3. The mixing step includes adding moisture to the material. A method for producing the fusion material according to claim 1 or 2.

4. The plastic material includes the fusion material. A method for producing the fusion material according to any one of claims 1 to 3.

5. The mixing, melting and fusing steps are carried out in less than 1800 seconds. A method for producing the fusion material according to any one of claims 1 to 4.

6. A motor; A mixing vessel; A control unit for controlling the rotation speed or torque of the motor; A rotating shaft rotated by the motor; A plurality of blades formed on the outer periphery of the rotating shaft in the mixing vessel; a helical screw formed on the outer periphery of the rotating shaft in the mixing vessel; A pressure sensor for detecting the pressure in the mixing vessel; A temperature sensor for detecting a temperature inside the mixing vessel; A rotation speed sensor that detects the rotation speed of the motor; A torque sensor that detects the torque of the motor 2; Equipped with The control unit feedback controls the motor in response to values ​​from the pressure sensor, the temperature sensor, the rotation speed sensor, and the torque sensor. Fusion material manufacturing equipment.

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