Method for manufacturing a compound body and a method for manufacturing a molded product and a molded product

Abstract

The present invention aims to provide a method for producing a compound in which a cotton-like pulverized material containing multiple paper fibers, generated from paper and coated paper having a polyolefin-containing film covering one side of the paper, is dispersed in polyvinyl chloride. [Solution] The present invention provides a method for manufacturing a molded product, comprising the steps of: crushing paper and a coated paper having a polyolefin-containing film covering one surface of the paper to produce a cotton-like pulverized body containing a plurality of paper fibers; heating a resin body containing polyvinyl chloride as the main component to a predetermined thermoplastic temperature of polyvinyl chloride to make the resin body a molten body; and kneading a composite of the molten body and the cotton-like pulverized body while heating to a predetermined kneading temperature higher than the predetermined thermoplastic temperature to produce a kneaded body in which the cotton-like pulverized body is dispersed in polyvinyl chloride.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a kneaded body, a method for manufacturing a molded article, and a molded article.

Background Art

[0002] In Patent Documents 1 and 2, in the recycling of vinyl chloride resin wallpaper, a technique is disclosed in which discarded wallpaper is pulverized, decomposed into paper (or paper fibers) and vinyl chloride, and then collected and recycled separately. Patent Document 3 discloses a technique for producing a recycled material from paper (paper fibers) generated from wallpaper together with a vinyl chloride resin. Patent Document 4 discloses a dividing step (first step S10) of dividing a polyvinyl chloride-containing wallpaper (wallpaper 10) having paper (paper 20) and a coating film (coating film 30) containing polyvinyl chloride and adhered to one surface of the paper to cover the one surface to generate a plurality of divided bodies (divided body 10A), and using a rotating device including a housing and a plurality of blades arranged inside the housing and rotating around an axis, causing the plurality of divided bodies generated in the dividing step to collide with the plurality of blades rotating around the axis to pulverize and generate a cotton-like pulverized body (cotton-like pulverized body 10) containing a plurality of paper fibers (paper fibers PF), and further, causing the generated cotton-like pulverized body to collide with a plurality of blades rotating around the axis together with a resin body containing polyvinyl chloride as a main component accommodated inside the housing, thereby kneading the cotton-like pulverized body and the resin body containing polyvinyl chloride as a main component to generate a kneaded body, and a method for manufacturing a kneaded body containing polyvinyl chloride-containing wallpaper as a raw material is disclosed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

[0004] As mentioned above, wallpaper containing polyvinyl chloride is commonly used, but in recent years, wallpaper containing polyolefin resin (hereinafter referred to as polyolefin in this specification) has begun to be used as a substitute for polyvinyl chloride (hereinafter referred to as polyolefin-containing wallpaper in this specification). However, the technologies disclosed in the three patent documents relate to wallpaper containing polyvinyl chloride, and not to wallpaper containing polyolefin.

[0005] One of the objectives of the present invention is to provide a method for producing a compound in which a cotton-like pulverized material containing multiple paper fibers, produced from paper and coated paper having a polyolefin-containing film covering one side of the paper, is dispersed in polyvinyl chloride. [Means for solving the problem]

[0006] The method for producing the compound according to embodiment A1 is: A step of crushing paper and coated paper having a polyolefin-containing film covering one side of the paper to produce a cotton-like pulverized material containing multiple paper fibers, A process of heating a resin body containing polyvinyl chloride as the main component to a specified thermoplastic temperature for polyvinyl chloride to form a molten body, A step of kneading a composite made by adding the cotton-like pulverized material to the molten material while heating it to a predetermined kneading temperature that is higher than the predetermined thermoplasticization temperature, thereby producing a kneaded body in which the cotton-like pulverized material is dispersed in polyvinyl chloride, Includes. The method for producing the compounded body according to embodiment A2 is: In the manufacturing method of the compounded material according to embodiment A1, The aforementioned thermoplasticization temperature is set to a temperature between 150°C and less than 180°C. The method for producing the compound according to embodiment A3 is: In the manufacturing method of the compounded material according to embodiment A1 or embodiment A2, The aforementioned kneading temperature is set to a temperature below 220°C. One embodiment of a method for manufacturing a molded product is: A method for manufacturing a compound according to any one of the three embodiments A1 to A3, A step of forming the aforementioned kneaded body into at least one molded product having a predetermined shape, Includes. One embodiment of a molded product is: A cotton-like pulverized material produced from polyolefin-coated paper and containing multiple paper fibers, A polyvinyl chloride body holding the cotton-like pulverized material, It is equipped with. A method for producing a compound containing polyolefin-containing wallpaper as a raw material according to embodiment B1 is: A dividing step to produce a plurality of divided parts by dividing a polyolefin-containing wallpaper having paper and a coating film containing polyolefin that is adhered to one surface of the paper and covers that surface, A rotating device comprising a housing and a plurality of blades arranged inside the housing and rotating around an axis is used to crush a plurality of divided bodies generated in the dividing process by colliding them with the plurality of blades rotating around an axis to produce a cotton-like crushed body containing a plurality of paper fibers, and further, a kneading process is performed in which the generated cotton-like crushed body is collided with the plurality of blades rotating around an axis together with a resin body containing polyolefin as the main component, which is housed inside the housing, to knead the cotton-like crushed body and the resin body containing polyolefin as the main component to produce a kneaded body, Includes. A method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B1 is: A method for producing a compound containing polyolefin-containing wallpaper as a raw material according to embodiment B1, A molding step to form the kneaded body produced in the kneading step into at least one molded product having a defined shape, Includes. A method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B2 is: A first step of dividing a polyolefin-containing wallpaper having paper and a coating film containing polyolefin and calcium carbonate that is adhered to one surface of the paper and covers that surface, to produce a plurality of divided parts, A second step of crushing a plurality of divided materials generated in the first step to produce a cotton-like pulverized material containing a plurality of paper fibers, wherein at least 20% by weight of the plurality of paper fibers contained in the produced cotton-like pulverized material remain with polyolefin particles attached to each other, A third step involves kneading the cotton-like pulverized material produced in the second step with a resin body containing polyolefin as its main component to produce a kneaded material. A fourth step is to form the kneaded body produced in the third step into at least one molded product having a defined shape, Includes, The second and third steps are carried out continuously using a rotating device that includes a housing and a plurality of blades arranged inside the housing and rotating around an axis, (1) the rotation speed of the plurality of blades is set so that the temperature of the plurality of objects to be divided, which are housed inside the housing and collide with the plurality of blades, is within a specific range of 200°C to less than 210°C, and the plurality of objects to be divided are collided with the plurality of blades rotating around an axis to produce a cotton-like pulverized material, and (2) the cotton-like pulverized material, which is within the specific range of temperature, is collided with the plurality of blades rotating around an axis together with a resin body containing polyolefin as the main component, which is housed inside the housing, thereby kneading the cotton-like pulverized material and the resin body containing polyolefin as the main component to produce a kneaded material. The method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B3 is: moreover, In the second step, less than 80% by weight of the multiple paper fibers contained in the resulting cotton-like pulverized material remain with polyolefin particles attached to them. The manufacturing method of a molded product containing polyolefin-containing wallpaper as the raw material of the B4 aspect is as follows. A first step of dividing a polyolefin-containing wallpaper having paper and a coating film that contains polyolefin and calcium carbonate and is adhered to one surface of the paper to cover the one surface to generate a plurality of divided bodies. A second step of pulverizing the plurality of divided bodies generated in the first step to generate a cotton-like pulverized body containing a plurality of paper fibers, where the bulk specific gravity of the generated cotton-like pulverized body is less than 0.15 (g / cc). A third step of kneading the cotton-like pulverized body generated in the second step and a resin body containing polyolefin as the main component to generate a kneaded body. A fourth step of forming the kneaded body generated in the third step into at least one molded product having a defined shape. including The second step and the third step are continuously performed using a rotating device including a housing and a plurality of blades arranged inside the housing and rotating around an axis. (1) The rotation speed of the plurality of blades is set so that the temperature of the plurality of divided bodies accommodated inside the housing and colliding with the plurality of blades is within a specific range of 200°C or more and less than 210°C. The plurality of divided bodies are collided with the plurality of blades rotating around the axis to be pulverized to generate a cotton-like pulverized body. (2) The cotton-like pulverized body within the generated specific temperature range is collided with the plurality of blades rotating around the axis together with a resin body containing polyolefin as the main component accommodated inside the housing, thereby kneading the cotton-like pulverized body and the resin body containing polyolefin as the main component to generate a kneaded body. The manufacturing method of a molded product containing polyolefin-containing wallpaper as the raw material of the B5 aspect is as follows. Furthermore, In the second step, the bulk specific gravity of the generated cotton-like pulverized body is at least 0.01 (g / cc) or more. The manufacturing method of a molded product containing polyolefin-containing wallpaper as the raw material of the B6 aspect is as follows. Furthermore, The rotation time of the multiple blades for generating the cotton-like pulverized material in the two steps described above is set to a time such that the average length of the multiple paper fibers contained in the generated cotton-like pulverized material does not fall below 100 μm. A method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B7 is: moreover, The polyolefin contained in the resin mixed with the cotton-like pulverized material in the three steps described above is virgin material, and its amount is less than the amount of polyolefin contained in the cotton-like pulverized material. A method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B8 is: moreover, In the cotton-like pulverized material produced in the second step, 10% to less than 90% by weight of the calcium carbonate contained in the polyolefin-containing wallpaper is fixed to the polyolefin particles that remain adhered to multiple paper fibers. A method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B9 is: A dividing step to produce a plurality of divided parts by dividing a polyolefin-containing wallpaper having paper and a coating film containing polyolefin that is adhered to one surface of the paper and covers that surface, A mixing step is performed by using a housing and a rotating device equipped with a plurality of blades arranged inside the housing and rotating around an axis, to crush the plurality of objects to be divided in the dividing step by colliding them with the plurality of blades rotating around an axis to produce a cotton-like pulverized material containing a plurality of paper fibers, and further by colliding the generated cotton-like pulverized material with the plurality of blades rotating around an axis together with a resin body containing polyvinyl chloride as the main component, which is housed inside the housing, to knead the cotton-like pulverized material and the resin body containing polyolefin and polyvinyl chloride as the main components to produce a kneaded material, Includes. A method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B10 is: A method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B9, A molding step to form the kneaded body produced in the kneading step into at least one molded product having a defined shape, Includes. A method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B11 is: A first step of dividing a polyolefin-containing wallpaper having paper and a coating film containing polyolefin and calcium carbonate that is adhered to one surface of the paper and covers that surface, to produce a plurality of divided parts, A second step of crushing a plurality of divided materials generated in the first step to produce a cotton-like pulverized material containing a plurality of paper fibers, wherein at least 20% by weight of the plurality of paper fibers contained in the produced cotton-like pulverized material remain with polyolefin particles attached to each other, A third step involves kneading the cotton-like pulverized material produced in the second step with a resin body containing polyvinyl chloride as its main component to produce a kneaded material, A fourth step is to form the kneaded body produced in the third step into at least one molded product having a defined shape, Includes, The second and third steps are carried out continuously using a rotating device that includes a housing and a plurality of blades arranged inside the housing and rotating around an axis, (1) the rotation speed of the plurality of blades is set so that the temperature of the plurality of objects to be divided, which are housed inside the housing and collide with the plurality of blades, is within a specific range of 140°C to less than 200°C, and the plurality of objects to be divided are collided with the plurality of blades rotating around an axis to produce a cotton-like pulverized material, and (2) the cotton-like pulverized material, which is at the temperature within the specific range, is collided with the plurality of blades rotating around an axis together with a resin body containing polyvinyl chloride as the main component, which is housed inside the housing, thereby kneading the cotton-like pulverized material and the resin body containing polyolefin and polyvinyl chloride as the main components to produce a kneaded material. A method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B12 is: In a method for producing a molded product containing polyolefin-containing wallpaper as a raw material according to embodiment B11, In the second step, less than 80% by weight of the multiple paper fibers contained in the resulting cotton-like pulverized material remain with polyolefin particles attached to them. [Brief explanation of the drawing]

[0007] [Figure 1] This is a process diagram of a method for manufacturing a molded product including wallpaper according to the first embodiment. [Figure 2] This is a schematic diagram illustrating the first step of the first embodiment (the step of dividing wallpaper to generate multiple divided objects). [Figure 3] This is a schematic diagram illustrating the second step of the first embodiment (the step of crushing multiple materials to be divided to produce a cotton-like pulverized material). [Figure 4] These are photographs of the multiple molded products produced after the completion of the fourth step of the first embodiment (the step of turning the kneaded body into multiple molded products (primary products (multiple pellets))). [Figure 5] This is a process diagram of a method for manufacturing a molded product including wallpaper according to a second embodiment of the present invention. [Figure 6] This is a partial cross-sectional view of the rotating device used in the combined process (second and third processes) of the second embodiment. [Figure 7] Fig. 1 shows the relationship between (1) the bulk density of the cotton-like pulverized material and the operating time, and Fig. 2 shows the relationship between the average length of multiple paper fibers and the operating time, when using the rotary device used in the composite process (second and third processes) of the second embodiment. [Figure 8] This is a process diagram of a method for manufacturing a molded product including wallpaper according to the third embodiment. [Figure 9] This is a process diagram of a method for manufacturing a molded product including wallpaper, which is a modified example of the third embodiment. [Modes for carrying out the invention]

[0008] The first embodiment, the second embodiment, and the third embodiment, as well as several modifications (including supplementary examples), will be described below in the order they are described. Note that in this specification, the same or similar reference numerals are used for components having similar functions in the drawings referenced in different embodiments, etc.

[0009] ≪First Embodiment≫ The first embodiment will be described below. First, the manufacturing method (hereinafter referred to as the manufacturing method S100 of the first embodiment) of a plurality of pellets 40 (an example of a plurality of primary products and a plurality of molded products) containing the polyolefin-containing wallpaper 10 of this embodiment (hereinafter referred to as wallpaper 10; see Figure 1) will be described with reference to Figures 1 to 4. Next, the effects of this embodiment will be described.

[0010] <Method for manufacturing a molded product including wallpaper according to the first embodiment> Figure 1 is a process diagram of the manufacturing method S100 of this embodiment. The manufacturing method S100 of this embodiment relates to a method for manufacturing a plurality of pellets 40 containing wallpaper 10 as a raw material, and as shown in Figure 1, includes a first step S10, a second step S20, a third step S30, a fourth step S40, and a fifth step S50. Each step will be described below.

[0011] [1st process] Figure 2 is a schematic diagram illustrating the first step S10 of this embodiment. The first step S10 is a step of dividing the wallpaper 10 to produce a plurality of divided parts 10A. Here, as shown in Figure 2, the wallpaper 10 is composed of, for example, a sheet of paper 20 and a coating film 30 that is in contact with and covers one surface of the paper 20. The coating film 30 also contains, for example, polyolefin and calcium carbonate. Please note that in the central diagram of Figure 2, the thickness of the wallpaper 10 is shown to be extremely thick for convenience. Also, in this specification, polyolefin means polyolefin resin, as mentioned above. Examples of polyolefin resins are polyethylene (PE), polypropylene (PP), etc. In other words, polyolefin means, as an example, any of (1) polyethylene (PE), (2) polypropylene (PP), or (3) a mixed resin of polyethylene (PE) and (2) polypropylene (PP). Furthermore, the polyolefin particles Ppo, as described later, mean, as an example, any of (1) particles made of polyethylene (PE), (2) particles made of polypropylene (PP), or (3) particles made of a mixed resin of polyethylene (PE) and (2) polypropylene (PP).

[0012] As an example, the weight ratio of paper 20, polyolefin, and calcium carbonate that make up the wallpaper 10 is 25% by weight or more and less than 35% by weight for each component. Furthermore, the wallpaper 10 used in the first step S10 of this embodiment may, for example, be waste material before or after use.

[0013] The first step S10 is performed, for example, by dividing the sheet-like wallpaper 10 using a cutting machine (not shown), thereby generating multiple divided parts 10A from the wallpaper 10. Here, as shown in Figure 2, each divided part 10A, when viewed from the thickness direction, has multiple paper fibers PF slightly frayed from its four end faces. Each divided part 10A is, for example, a rectangle with a side length of 5 mm or more and less than 80 mm.

[0014] [Second process] Figure 3 is a schematic diagram illustrating the second step S20 of this embodiment. The second step S20 is a step of crushing the plurality of objects to be divided 10A generated in the first step S10 to produce a cotton-like crushed material 10B containing a plurality of paper fibers PF. The second step S20 is performed, for example, using a rotating device (not shown) that comprises a housing and a plurality of blades housed inside the housing that rotate around an axis, and the cotton-like crushed material 10B is produced by crushing the plurality of objects to be divided 10A housed inside the housing by colliding them with the plurality of blades rotating around an axis. However, the second step S20 of this embodiment is not simply a matter of crushing the multiple pieces to be divided 10A, but is characterized by the following points.

[0015] <First characteristic> In the cotton-like pulverized material 10B produced after the completion of the second step S20, at least 20% by weight of the multiple paper fibers PF contained therein remain with polyolefin particles Ppo attached to them. Therefore, in the second step S20, the upper limits of the rotational speed (angular velocity) and operating time of the multiple blades in the rotating device are adjusted to satisfy this characteristic.

[0016] <Second characteristic> In the cotton-like pulverized material 10B produced after the completion of the second step S20, less than 80% by weight of the multiple paper fibers PF contained therein remain with polyolefin particles Ppo attached to them. Therefore, in the second step S20, the lower limits of the rotational speed (angular velocity) and operating time of the multiple blades in the rotating device are adjusted to satisfy this characteristic.

[0017] <Third characteristic> The cotton-like pulverized material 10B produced after the completion of the second step S20 has a bulk density of less than 0.15 (g / cc). Therefore, in the second step S20, the lower limits of the rotational speed (angular velocity) and operating time of the multiple blades in the rotating device are adjusted to satisfy this characteristic.

[0018] <Fourth characteristic> The cotton-like pulverized material 10B produced after the completion of the second step S20 has a bulk density of at least 0.01 (g / cc). Therefore, in the second step S20, the upper limits of the rotational speed (angular velocity) and operating time of the multiple blades in the rotating device are adjusted to satisfy this characteristic.

[0019] <Fifth characteristic> In the second step S20, the rotational speed of the multiple blades constituting the rotating device is set so that the temperature of the multiple divided objects 10A that collide with the multiple blades is 200°C or more and less than 210°C during the period of this step. Therefore, in the second step S20, the upper and lower limits of the rotational speed (angular velocity) and operating time of the multiple blades in the rotating device are adjusted so as to satisfy this characteristic. Here, the temperature of the multiple divided parts 10A set during this process, "200°C or higher and less than 210°C," is the same regardless of whether the polyolefin contained in the wallpaper 10 is (1) polyethylene (PE), (2) polypropylene (PP), or (3) a mixed resin of polyethylene (PE) and (2) polypropylene (PP). This means that polyolefins exhibit equivalent or nearly equivalent thermal properties.

[0020] <The sixth characteristic> In the second step S20, the rotation time of the multiple blades constituting the rotating device is set to a time that does not result in the average length of the multiple paper fibers PF contained in the generated cotton-like pulverized material 10B being less than 100 μm. Therefore, in the second step S20, the upper limits of the rotation speed (angular velocity) and operating time of the multiple blades in the rotating device are adjusted to satisfy this characteristic.

[0021] [3rd step] The third step S30 is a process of kneading the cotton-like pulverized material 10B (see Figure 3) produced in the second step S20 with a resin body (not shown) containing polyolefin as its main component to produce a kneaded body (not shown). The third step S30 is carried out, for example, using a twin-screw extruder with a vent (not shown), and a mass is produced by kneading the cotton-like pulverized material 10B (see Figure 3) and the resin body (not shown). In the third step S30, the cotton-like pulverized material 10B and the resin body moving inside the twin-screw extruder with a vent are heated to a temperature above the glass transition temperature of the polyolefin contained in the resin body.

[0022] [4th step] Figure 4 is a photograph of the multiple pellets 40 produced after the completion of the fourth step S40 of this embodiment. The fourth step S40 is to transform the kneaded body (not shown) produced in the third step S30 into multiple pellets 40 having a predetermined shape (for example, a cylinder). The fourth step S40 is carried out using, for example, a hot melt crusher (not shown). Here, the multiple pellets 40 produced after the completion of the fourth step S40 are so-called recycled materials.

[0023] [5th ​​process] The fifth step, S50, is a process in which the multiple pellets 40 (primary products) generated in the fourth step, S40, are further processed into secondary products (not shown). Examples of secondary products include protective sheets used at construction sites, and baseboards and flooring materials (backer material) used as building materials for houses.

[0024] In the descriptions of the third and fourth features mentioned above, the state of the cotton-like pulverized material 10B produced after the completion of the second step S20 is identified by its "bulk density." The method for measuring the "bulk density" is as follows. JIS K 7365:1999 "Plastics - Method for determining the apparent density of a material that can be poured from a standard funnel" (ISO 60:1977, MOD)

[0025] The above is a description of the manufacturing method S100 of this embodiment.

[0026] <Effects of the First Embodiment> Next, the effects of this embodiment will be described.

[0027] [First effect] The first effect is due to the fact that the manufacturing method S100 of this embodiment includes a step of crushing a plurality of objects to be divided 10A to produce a cotton-like crushed material 10B (see Figure 1). This effect will be explained in comparison with the first comparison method (not shown) described later.

[0028] The first comparative method differs from the manufacturing method S100 of this embodiment only in that, after generating multiple pieces to be divided 10A in the first step S10, the second step S20 is omitted, and instead of the third step S30, the multiple pieces to be divided 10A and a resin body containing polyolefin as the main component are kneaded to produce a kneaded body. In other words, the first comparative method can produce multiple pellets and secondary products (not shown) having the same composition as the manufacturing method S100 of this embodiment.

[0029] However, according to tests conducted by the inventors of this invention, it was confirmed that the pellets produced by the first comparative method were more prone to cracking than the pellets 40 produced by the manufacturing method S100 of this embodiment. This test involves rotating multiple pellets manufactured using each method around an 18-liter pail at a rotation speed of 1 revolution per second for 20 minutes. The more powdery fragments produced from the pellets, the more easily they are judged to break.

[0030] As described above, the multiple pellets produced by the first comparative method have the same composition as the multiple pellets 40 produced by the manufacturing method S100 of this embodiment, but they differ in terms of their crackability. The inventors of this application conducted several tests and considered this matter, and came to the following conclusion. In other words, in the first comparative method, since a mixed body is produced by kneading multiple pieces to be divided 10A with a resin body, the multiple pieces to be divided 10A can be kneaded with the resin body without being separated into multiple paper fibers PF. This has been confirmed by breaking open multiple pellets produced by the first comparative method and observing them using a microscope. In contrast, in this embodiment, instead of simply kneading multiple pieces to be divided 10A with the resin, the multiple pieces to be divided 10A are first made into a cotton-like pulverized body 10B before being kneaded with the resin body (see Figures 1 and 3). As a result, the multiple pieces to be divided 10A are separated into multiple paper fibers PF. In other words, the resin body is interwoven between the multiple paper fibers PF. This fact has also been confirmed by the inventors' inspection results. As a result, the multiple pellets 40 produced by the manufacturing method S100 of this embodiment maintain the bonding strength between the resins constituting the resin body more easily than the multiple pellets produced by the first comparative method.

[0031] Therefore, as in this embodiment, including the step of crushing multiple pieces to be divided 10A to produce a cotton-like crushed material 10B makes it possible to produce multiple pellets 40 that are less prone to cracking compared to the first comparative method. Accordingly, the manufacturing method S100 of this embodiment can produce secondary products that are less prone to cracking compared to the first comparative method.

[0032] [Second effect] The second effect is due to the fact that each divided object 10A produced in the first step S10 is rectangular in shape (see Figures 2 and 3). This effect will be explained in comparison with the second comparison method (not shown) described later.

[0033] In the second comparative method, the only difference from the manufacturing method S100 of this embodiment is that the multiple divided objects (not shown) produced in the first step S10 are elongated (or tape-shaped) rather than rectangular. In other words, the second comparative method can produce multiple pellets and secondary products (not shown) composed of the same composition as the manufacturing method S100 of this embodiment.

[0034] However, according to the cracking tests conducted by the inventors of this invention, it was confirmed that the pellets produced by the second comparative method were more prone to cracking than the pellets 40 produced by the manufacturing method S100 of this embodiment.

[0035] According to the test results of the inventors of this application, in the case of the second comparison method, it was observed that the multiple divided objects 10A were separated into multiple paper fibers PF compared to the case of the first comparison method. In contrast, in the case of the second comparison method, it was observed that the multiple divided objects 10A were not separated into multiple paper fibers PF compared to the case of this embodiment. The reason for obtaining such results is thought to be due to the following mechanism. That is, as shown in Figures 2 and 3, when multiple divided objects 10A are produced in the first step S10 of the manufacturing method S100 of this embodiment, multiple paper fibers PF are frayed from the outer edge of each divided object 10A, making it easier to produce a cotton-like material in subsequent steps.

[0036] Therefore, in this embodiment, in which each divided object 10A produced in the first step S10 is rectangular in shape, it is possible to produce multiple pellets 40 that are less prone to cracking compared to the second comparative method. Accordingly, the manufacturing method S100 of this embodiment can produce secondary products that are less prone to cracking compared to the second comparative method.

[0037] [Third effect] The third effect is due to the fact that at least 20% by weight of the multiple paper fibers PF contained in the cotton-like pulverized material 10B produced in the second step retains the polyolefin particles Ppo attached to each fiber. This effect will be explained in comparison with the third comparison method (not shown) described later.

[0038] The third comparative method differs from the manufacturing method S100 of this embodiment only in that less than 20% by weight of the multiple paper fibers PF contained in the cotton-like pulverized material 10B produced in the second step remains with polyolefin particles Ppo attached to each of them. In other words, the third comparative method can produce multiple pellets and secondary products (not shown) having the same composition as the manufacturing method S100 of this embodiment.

[0039] However, according to the cracking tests conducted by the inventors of this invention, it was confirmed that the pellets produced by the third comparative method were more prone to cracking than the pellets 40 produced by the manufacturing method S100 of this embodiment.

[0040] In the third comparative method, the fragments of pellets formed inside the pail after the cracking test contained multiple paper fibers PF separated from the resin body. In contrast, the amount of pellet fragments formed inside the pail after the cracking test in this embodiment was less than in the third comparative method. Furthermore, the proportion of multiple paper fibers PF separated from the resin body in the fragments in this embodiment was less than in the third comparative method. The reason for these results is thought to be due to the following mechanism. That is, as shown in Figure 3, the cotton-like pulverized material 10B produced in the second step S20 of the manufacturing method S100 of this embodiment has more polyolefin particles Ppo adhered to the multiple paper fibers PF compared to the third comparative method. Then, when the cotton-like pulverized material 10B and the resin body are kneaded in the third step S30, which is performed after the second step S20, the resin body adheres more easily to the polyolefin particles Ppo adhered to the cotton-like pulverized material 10B. As a result, it is thought that the adhesive strength of the resin in the multiple pellets 40 produced is ensured.

[0041] Therefore, in this embodiment, which is characterized in that at least 20% by weight of the multiple paper fibers PF contained in the cotton-like pulverized material 10B produced in the second step remain with polyolefin particles Ppo attached to them, it is possible to produce multiple pellets 40 that are less prone to cracking compared to the third comparative method. Accordingly, the manufacturing method S100 of this embodiment can produce secondary products that are less prone to cracking compared to the third comparative method.

[0042] [Fourth effect] The fourth effect is due to the fact that less than 80% by weight of the multiple paper fibers PF contained in the cotton-like pulverized material 10B produced in the second step retains the polyolefin particles Ppo attached to each fiber. This effect will be explained in comparison with the fourth comparison method (not shown) described later.

[0043] The fourth comparative method differs from the manufacturing method S100 of this embodiment only in that 80% by weight or more of the multiple paper fibers PF contained in the cotton-like pulverized material 10B produced in the second step remain with polyolefin particles Ppo attached to them. In other words, the fourth comparative method can produce multiple pellets and secondary products (not shown) having the same composition as the manufacturing method S100 of this embodiment.

[0044] However, according to the cracking tests conducted by the inventors of this invention, it was confirmed that the pellets produced by the fourth comparative method were more prone to cracking than the pellets 40 produced by the manufacturing method S100 of this embodiment.

[0045] In the fourth comparison method, the fragments of pellets formed inside the pail after the cracking test contained multiple paper fibers PF with the resin body still attached. In contrast, the amount of fragments of pellets formed inside the pail after the cracking test in this embodiment was less than in the fourth comparison method. Furthermore, the proportion of multiple paper fibers PF separated from the resin body in the fragments in this embodiment was higher than in the fourth comparison method. The reason for these results is thought to be due to the following mechanism. That is, the cotton-like pulverized material produced by the fourth comparison method has a larger amount of multiple paper fibers PF coated with polyolefin particles Ppo compared to the cotton-like pulverized material 10B produced in the second step S20 of the manufacturing method S100 of this embodiment. In the fourth comparison method, each paper fiber PF is less likely to be directly coated with polyolefin particles Ppo in the third step S30 performed after the second step S20. As a result, the proportion of the resin body that is bonded across polyolefin particles Ppo and paper fibers PF in the resin body kneaded with the cotton-like pulverized material in the third step S30 is less than in the manufacturing method S100 of this embodiment.

[0046] Therefore, in this embodiment, which is characterized in that less than 80% by weight of the multiple paper fibers PF contained in the cotton-like pulverized material 10B produced in the second step remain with polyolefin particles Ppo attached to them, it is possible to produce multiple pellets 40 that are less prone to cracking compared to the fourth comparative method. Accordingly, the manufacturing method S100 of this embodiment can produce secondary products that are less prone to cracking compared to the third comparative method.

[0047] [Fifth effect] The fifth effect is due to the fact that the bulk density of the cotton-like pulverized material 10B produced in the second step is at least 0.01 (g / cc). This effect will be explained in comparison with the fifth comparison method (not shown) described later.

[0048] The fifth comparison method differs from the manufacturing method S100 of this embodiment only in that the bulk density of the cotton-like pulverized material 10B produced in the second step is less than 0.01 (g / cc). In other words, the fourth comparison method can produce multiple pellets and secondary products (not shown) composed of the same composition as the manufacturing method S100 of this embodiment.

[0049] However, according to the cracking tests conducted by the inventors of this invention, it was confirmed that the pellets produced by the fifth comparative method were more prone to cracking than the pellets 40 produced by the manufacturing method S100 of this embodiment.

[0050] In the fifth comparison method, the amount of multiple pellet fragments formed inside the pail after the aforementioned cracking test was greater than in the manufacturing method S100 of this embodiment. The reason for this result is thought to be due to the following mechanism. That is, in both the fifth comparison method and the manufacturing method S100 of this embodiment, the cotton-like pulverized material 10B is produced using a rotating device in the second step S20, but the setting conditions of each rotating device are different. Specifically, in the fifth comparison method, for example, even with the same operating time as in the manufacturing method S100 of this embodiment, the rotational speed (angular velocity) of the multiple blades is faster (larger), or even with the same rotational speed (angular velocity) of the multiple blades, the operating time is longer. As a result, in the fifth comparison method, the average length of the multiple paper fibers PF contained in the produced cotton-like pulverized material 10B is shorter compared to the manufacturing method S100 of this embodiment. Consequently, the multiple pellets produced by the fifth comparison method are thought to have lower strength compared to the multiple pellets 40 produced by the manufacturing method S100 of this embodiment, because the average length of the paper fibers PF contained therein is shorter (for example, an average length of less than 100 μm of multiple paper fibers PF corresponds to "short" in this context).

[0051] Therefore, in this embodiment, characterized in that the bulk density of the cotton-like pulverized material 10B produced in the second step is at least 0.01 (g / cc), it is possible to produce multiple pellets 40 that are less prone to cracking compared to the fifth comparative method. Accordingly, the manufacturing method S100 of this embodiment can produce secondary products that are less prone to cracking compared to the fifth comparative method.

[0052] [Sixth effect] The sixth effect is due to the fact that the bulk density of the cotton-like pulverized material 10B produced in the second step is less than 0.15 (g / cc). This effect will be explained in comparison with the sixth comparison method (not shown) described later.

[0053] The sixth comparison method differs from the manufacturing method S100 of this embodiment only in that the bulk density of the cotton-like pulverized material 10B produced in the second step is 0.15 (g / cc) or higher. In other words, the sixth comparison method can produce multiple pellets and secondary products (not shown) composed of the same composition as the manufacturing method S100 of this embodiment.

[0054] However, according to the cracking tests conducted by the inventors of this invention, it was confirmed that the pellets produced by the sixth comparative method were more prone to cracking than the pellets 40 produced by the manufacturing method S100 of this embodiment.

[0055] In the case of the sixth comparison method, the amount of multiple pellet fragments formed inside the pail after the aforementioned cracking test was greater than in the case of the manufacturing method S100 of this embodiment. The reason for this result is thought to be due to the following mechanism. That is, in both the case of the sixth comparison method and the manufacturing method S100 of this embodiment, the cotton-like pulverized material 10B is produced using a rotating device in the second step S20, but the setting conditions of each rotating device are different. Specifically, in the case of the sixth comparison method, for example, even with the same operating time as in the case of the manufacturing method S100 of this embodiment, the rotational speed (angular velocity) of the multiple blades is slower (smaller), or even with the same rotational speed (angular velocity) of the multiple blades, the operating time is shorter. As a result, in the case of the sixth comparison method, compared to the case of the manufacturing method S100 of this embodiment, some of the multiple paper fibers PF contained in the produced cotton-like pulverized material 10B exist in a clump-like form. Accordingly, it is thought that the strength of each pellet produced in the sixth comparison method is lower than that of the multiple pellets 40 produced in the manufacturing method S100 of this embodiment because the multiple paper fibers PF are not mixed and solidified with the resin body.

[0056] Therefore, in this embodiment, characterized in that the bulk density of the cotton-like pulverized material 10B produced in the second step is less than 0.15 (g / cc), it is possible to produce multiple pellets 40 that are less prone to cracking compared to the sixth comparative method. Accordingly, the manufacturing method S100 of this embodiment can produce secondary products that are less prone to cracking compared to the sixth comparative method.

[0057] The above is a description of the first embodiment.

[0058] ≪Second Embodiment≫ Next, a second embodiment will be described. In this embodiment, only the parts that differ from the first embodiment (see Figures 1 to 4) described above will be explained, but please note that components of the first embodiment will be appropriately incorporated in this embodiment where possible. The following describes the manufacturing method (manufacturing method S100A of this embodiment) for multiple pellets 40 (an example of multiple primary products and multiple molded products) including the wallpaper 10 (see Figure 1) of this embodiment, mainly with reference to Figures 5 and 6. Next, the effects of this embodiment will be described.

[0059] <Method for manufacturing a molded product including wallpaper according to the second embodiment> Figure 5 is a process diagram of the manufacturing method according to this embodiment. The only difference between this embodiment and the first embodiment (see Figure 1) is that the second step S20 and the third step S30 of the first embodiment have been changed to a combined step S20A. In other words, the manufacturing method S100A of this embodiment consists of the first step S10, the combined step S20A, the fourth step S40, and the fifth step S50, and each step is performed in the order described above.

[0060] [Combined process] The combined process S20A of this embodiment can be described as a single process combining the second process S20 and the third process S30 of the first embodiment. Here, Figure 6 is a partial cross-sectional view of the rotating device 50 used in the combined process S20A of this embodiment (see Figure 5). The combined process S20A is carried out using the rotating device 50.

[0061] (Rotating device) Now, the rotating device 50 will be explained with reference to Figure 6. The rotating device 50 comprises a housing 60 and a rotating body 70, a portion of which is housed inside the housing 60. The housing 60 houses a portion of the rotating body 70 inside. The rotating body 70 has a rotating shaft 75, a plurality of blades 710b, 710d, 710c, and 710e attached to the outer circumference of the rotating shaft 75, a supply screw 712, two balance wheels 716, and two collars 720. The supply screw 712 supplies the material (a plurality of parts to be divided 10A and a resin body) fed into the rotating shaft corresponding to the material input section to the plurality of blades 710b, 710d, 710c, and 710e. The plurality of blades 710b, 710d, 710c, and 710e are mounted on the rotating shaft 75 at an angle such that the distance between them from each other is narrowed in the rotational direction of the rotating shaft 75. Then, inside the housing 60, the multiple pieces to be divided 10A and the resin body are mixed and crushed, and the contained moisture is dehydrated by heat generated by shearing, friction, and compression. The multiple blades 710b, 710d, 710c, and 710e each have, for example, a rectangular cross-sectional shape and a rectangular overall shape. The multiple blades 710b, 710d, 710c, and 710e face each other in the axial direction at 180-degree angular intervals around the circumference of the rotation axis 75. Furthermore, the thickness of the multiple blades 710b, 710d, 710c, and 710e is such that approximately 40% of the outer circumference is thicker than the inner circumference. When the blades 710a and 710f are rotated clockwise as viewed from the right side of Figure 6, their leading edges are inclined with respect to the rotation axis 75 at a mounting angle of approximately 15 degrees from the tip to the base of the blades, such that when they are rotated clockwise, their leading edges slide almost seamlessly against the inner surfaces of both ends of the housing 60. Furthermore, the four blades 710b, 710c, 710d, and 710e are inclined at an angle of approximately 15 degrees from the tip to the base of each blade in a staggered pattern on the outer surface of the rotating shaft 75, and are arranged so that their leading edges face both ends of the housing 60 when rotating. In other words, the four blades 710b, 710d, 710c, and 710e face each other in the axial direction of the rotating shaft 75, and are mounted on the rotating shaft 75 at a mounting angle (angle relative to the circumferential direction) of 15 degrees such that the distance between them when they face each other in the direction of rotation is reduced. The housing 60 is configured with a continuous water passage (not shown), and the housing 60 can be cooled by circulating cooling water. The above is a description of the rotating device 50.

[0062] The composite process S20A is a process in which the second process S20 and the third process S30 in the first embodiment are carried out in succession using a rotating device 50 which is equipped with a housing 60 and a plurality of blades 710b, 710d, 710c, and 710e that are arranged inside the housing 60 and rotate around an axis. The composite process S20A is carried out by (1) crushing a plurality of objects to be divided 10A housed inside the housing 60 by colliding them with a plurality of blades 710b, 710d, 710c, and 710e that rotate around an axis to produce a cotton-like crushed material 10B, and (2) colliding the generated cotton-like crushed material 10B with a resin body containing polyolefin as the main component housed inside the housing 60 and rotating around an axis with a plurality of blades 710b, 710d, 710c, and 710e to produce a kneaded material by kneading the cotton-like crushed material 10B and the resin body containing polyolefin as the main component.

[0063] <Effects of the second embodiment> Next, the effects of this embodiment will be described. The manufacturing method S100A of this embodiment is characterized in that the second step S20 and the third step S30 of the manufacturing method S100 of the first embodiment described above are performed continuously using the same machine. Therefore, according to the manufacturing method S100A of this embodiment, the manufacturing time for multiple pellets 40 can be shortened compared to the manufacturing method S100 of the first embodiment. Consequently, according to the manufacturing method S100A of this embodiment, the manufacturing time for secondary products can be shortened.

[0064] The above concludes the description of the second embodiment.

[0065] ≪Third Embodiment≫ Next, a third embodiment will be described. This embodiment will only describe the parts that differ from the first embodiment (see Figures 1 to 4) described above, but please note that components of the first embodiment will be appropriately incorporated into this embodiment where possible. The following describes the manufacturing method (manufacturing method S100B of this embodiment) for multiple pellets 40 (an example of multiple primary products and multiple molded products) including the wallpaper 10 (see Figure 1) of this embodiment, mainly with reference to Figure 7. Next, the effects of this embodiment will be described.

[0066] <Method for manufacturing a molded product including wallpaper according to the third embodiment> Figure 7 is a process diagram of manufacturing method 100B of this embodiment. The following two points differentiate this embodiment from the first embodiment (see Figure 1). [Difference 1] In this embodiment, the first step S10 and the second step S20 are performed along with the second step S24. The second step S24 will be described later. [Difference 2] The difference is that the third step S30B, described later, is performed instead of the third step S30 in the first embodiment.

[0067] [Step B] Step B, S24, is a step in which a resin body containing polyvinyl chloride as the main component is heated to a specified thermoplastic temperature (melting temperature) of polyvinyl chloride to turn the resin body into a molten body (not shown). In this embodiment, the specified thermoplasticization temperature for polyvinyl chloride is a temperature set to 150°C or higher and less than 180°C, and more preferably a temperature set to 160°C or higher and less than 170°C.

[0068] In this embodiment, the process combining the first step S10 and the second step S20 is conveniently referred to as the A step S22. As described above, the first step S10 is a process of dividing the wallpaper 10 to produce a plurality of divided parts 10A, and the second step S20 is a process of crushing the plurality of divided parts 10A produced in the first step S10 to produce a cotton-like crushed material 10B containing a plurality of paper fibers PF. To summarize based on the above, the A step S22 can be described as a process of crushing the paper 20 and the wallpaper 10 (an example of a coated paper) having a coating film 30 (an example of a polyolefin-containing film) that covers one surface of the paper 20 to produce a cotton-like crushed material 10B containing a plurality of paper fibers PF.

[0069] [3rd step] The third step S30B is a process in which a composite (not shown) is made by adding the cotton-like pulverized material 10B produced in step A S22 to the molten material produced in step B S24, and kneading it while heating it to a predetermined kneading temperature that is higher than the predetermined thermoplasticization temperature, thereby producing a kneaded body (not shown) in which the cotton-like pulverized material 10B is dispersed in polyvinyl chloride. In this embodiment, the mixing temperature is set to a temperature that is higher than the specified thermoplasticization temperature and less than 220°C.

[0070] <Effects of the Third Embodiment> Next, the effects of this embodiment will be described. Here, this embodiment will be described in comparison with the seventh comparative method, which will be described later.

[0071] The seventh comparative method is a method similar to the manufacturing method of the first embodiment (see Figure 1). In the first embodiment, in the third step S30, the cotton-like pulverized material 10B (see Figure 3) produced in the second step S20 is mixed with a resin body (not shown) containing polyolefin as the main component, and then kneaded while heating from room temperature to above the melting temperature of polyolefin to produce a kneaded body (not shown). However, in the third step of the seventh comparative method, the cotton-like pulverized material 10B produced in the second step S20 is mixed with a resin body (not shown) containing polyvinyl chloride as the main component, and then kneaded while heating from room temperature to above the melting temperature of polyvinyl chloride to produce a kneaded body (not shown). This is the only difference between the seventh comparative method and the manufacturing method of the first embodiment. In the seventh comparison method, the process can be carried out up to the second step S20. However, in the third step, the cotton-like pulverized material 10B is burned and turned into dust before the polyvinyl chloride is melted. Therefore, it is not possible to produce a compound of the cotton-like pulverized material 10B and a resin body containing polyvinyl chloride as the main component. Consequently, the fourth step S40 and subsequent steps (refer to Figure 1) cannot be carried out either. If the fourth step S40 is carried out and a pellet-shaped molded product is produced, it will be prone to cracking and will have problems in terms of strength because it is a molded product in which foreign matter, which is the burnt, dust-like foreign matter of the cotton-like pulverized material 10B, is dispersed.

[0072] In contrast, in this embodiment, since step B S24 is performed before step 3 S30B, the resin body containing polyvinyl chloride as the main component is plasticized and melted by the start of step 3 S30B. Then, in step 3 S30B, the cotton-like pulverized material 10B is added to the molten resin body and then kneaded. For this reason, in this embodiment, the cotton-like pulverized material 10B is not burned and turned into dust, as in the seventh comparative method. Consequently, in this embodiment, steps 4 S40 and beyond can also be performed.

[0073] As described above, according to this embodiment, a cotton-like pulverized material containing multiple paper fibers, produced from paper and a coated paper having a polyolefin-containing film covering one surface of the paper, can be dispersed in polyvinyl chloride to form a kneaded body and a molded product dispersed in polyvinyl chloride (polyvinyl chloride body).

[0074] [Supplement to the third embodiment] In the above description, it was assumed that the first step S10 and the second step S20, along with the B step S24, are performed after the start of this embodiment (see Figure 8). However, the B step S24 only needs to be performed before the cotton-like pulverized material 10B in the third step S30B is mixed into the resin body. For example, as in the modified manufacturing method S100B1 in Figure 9, it may be performed after the second step S20 and before the third step S30B. Furthermore, just as the first embodiment was modified into the second embodiment (see Figure 5), the manufacturing method 100B of the third embodiment (see Figure 8) and its modified example, manufacturing method 100B1 (see Figure 9), may also be modified as in the second embodiment. In this case, in the composite process, the resin body, which has been preheated to its melting temperature, should be placed inside the housing 60 of the rotating device 50 (see Figure 6).

[0075] The above is a description of the third embodiment.

[0076] Variations (including supplementary information) As described above, the present invention has been explained using the first and second embodiments as examples. However, it should be noted that the technical scope of the present invention is not limited to these embodiments. For example, the technical scope of the present invention also includes the following modifications and supplementary information.

[0077] For example, in each embodiment, the weight ratios of paper 20, polyolefin, and calcium carbonate constituting the wallpaper 10 were described as, for example, 25% by weight or more and less than 35% by weight each. However, the example weight ratios for each component do not have to be 25% by weight or more and less than 35% by weight. For example, the lower limit of the weight ratio of the wallpaper 10 may be 5% by weight, meaning that at least paper 20 is included as a component of the wallpaper 10, and the weight ratios of the other components, polyolefin and calcium carbonate, may be large.

[0078] Furthermore, in each embodiment, for example, examples of the multiple components of the wallpaper 10 were described as paper 20, polyolefin, and calcium carbonate. However, the multiple components of the wallpaper 10 used in the manufacturing method of each embodiment may include other components other than paper 20, polyolefin, and calcium carbonate. For example, an example of other components may be ink (pigment: phthalocyanine, for example) that forms the pattern of the wallpaper 10.

[0079] Furthermore, in each embodiment, for example, it was explained that the multiple divided parts 10A were rectangular in shape (see Figures 2 and 3). However, if the wallpaper 10 is divided into multiple parts, the shape of each divided part 10A does not have to be rectangular. For example, it may be circular, polygonal, or other shapes.

[0080] Furthermore, in each embodiment, for example, it was described as if the multiple pieces to be divided 10A were rectangular in shape and of approximately the same size (see Figures 2 and 3). However, the sizes of the multiple pieces to be divided 10A generated before the second step S20 or the composite step S20A do not have to be the same. For example, the pieces to be divided 10A may consist of multiple groups of sizes, such as some being 10 mm square, some being 20 mm square, and yet another being 30 mm square. This results in the paper fiber FP contained in the multiple pellets 40 being generated having multiple peaks in length. As a result, it is possible to generate multiple pellets 40 with more stable strength.

[0081] Furthermore, for example, the resin body kneaded with the cotton-like pulverized material 10B in the third step S30 or the composite step S20A may be recycled material or so-called virgin material. In each embodiment, as described above, multiple pellets 40 are produced as so-called recycled products, but they have the effect of being less prone to cracking compared to the multiple pellets produced by each comparative method. Therefore, when virgin material is used as the resin body kneaded in the third step S30 or the composite step S20A, the amount of polyolefin can be reduced to less than the amount of polyolefin contained in the cotton-like pulverized body 10B.

[0082] Furthermore, although the descriptions of each embodiment do not mention the temperature of the divided body 10A during the process in the second step S20 and the composite step S20A, it is preferable to set it to, for example, 200°C or more and less than 210°C. The reason for this is that in each embodiment, if the temperature is set to around 200°C or higher, the polyolefin tends to separate easily from the paper fibers PF, and if it is set to around 210°C or higher, there is a risk of the paper burning. The temperature can be adjusted by the rotation speed (angular velocity) of the multiple blades in the rotating device, the operating time, etc.

[0083] Furthermore, in the manufacturing method S100A of the second embodiment, the composite process S20A was described as being performed using a rotating device 50 (see Figure 6). However, if the composite process S20A is performed using a housing and a rotating device having a plurality of blades arranged inside the housing that rotate around an axis, the configuration of the rotating device does not have to be the rotating device 50 shown in Figure 6.

[0084] As a supplement, in the description of the composite process S20A of the manufacturing method S100A (see Figure 5) of the second embodiment, it was stated that the second process S20 and the third process S30 of the first embodiment were combined into a single process and performed continuously using the same machine. However, according to the inventors' test research, it was confirmed that in the composite process S20A, the second process S20 and the third process S30 of the first embodiment are performed simultaneously (regardless of the proportion). In other words, because they are performed simultaneously, the multiple pieces to be divided 10A and the resin body are heated to the same temperature at room temperature, which is different from the case of the first embodiment. The inventors of the present invention have not yet been able to clarify the specific mechanism of the effect of this fact, but it is thought that this may be one of the reasons why the pellets are less prone to cracking compared to the multiple pellets produced by the comparative method.

[0085] Furthermore, as a supplement, it was confirmed that in the intermediate stages of each embodiment, the cotton-like pulverized material 10B contained in the wallpaper 10 had 10% to less than 90% of the calcium carbonate particles Pcc (see Figure 3) fixed to polyolefin particles Ppo that remained adhered to multiple paper fibers PF. Although the inventors of this application have not yet been able to elucidate the specific mechanism of the effect of this fact, it is thought that this may be one of the reasons why the material is less prone to cracking compared to multiple pellets produced by the comparative method.

[0086] Furthermore, as a supplement, when generating cotton-like pulverized material 10B (see Figure 3) from multiple divided objects 10A (see Figure 2) using the rotating device 50 of the second embodiment, the inventors of the present invention have found the following tendencies to occur. Here, Fig. 1 in Figure 7 is a graph showing the relationship between the bulk density of the cotton-like pulverized material 10B and the operating time of the rotating device 50, and Fig. 2 is a graph showing the relationship between the average length of multiple paper fibers FP and the operating time of the rotating device 50. In the explanation above, it was stated that the bulk density of the cotton-like pulverized material 10B is preferably 0.01 (g / cc) or more and less than 0.15 (g / cc). However, when the cotton-like pulverized material 10B is produced using the rotating device 50 (see Figure 6), the relationship between the bulk density of the cotton-like pulverized material 10B and the operating time is as shown in Fig. 1 of Figure 7. This graph shows that, after the start of pulverization of the multiple divided materials 10A, the bulk density decreases as the operating time of the rotating device 50 increases, as the pulverization of the multiple divided materials 10A progresses. On the other hand, this graph shows that the bulk density increases after time T2-T3 (sec.). The reason for this increase in bulk density after time T2-T3 (sec.) is that the length of the multiple paper fibers PF shortens as pulverization progresses further. In this graph, for the bulk density of the cotton-like pulverized material 10B to be between 0.01 (g / cc) and less than 0.15 (g / cc), it is necessary to set the operating time of the rotating device 50 to T1-T2 and T3-T5 (sec.) under certain conditions. Furthermore, as explained above, it is preferable that the average length of the multiple paper fibers PF be 100 μm or more. When cotton-like pulverized material 10B is produced using the rotating device 50 (see Figure 6), the relationship between the operating time and the average length of the multiple paper fibers FP is as shown in Fig. 2 of Figure 7. This graph shows that, after the start of pulverization of the multiple divided materials 10A, the longer the operating time, the more the multiple divided materials 10A are pulverized and the shorter the average length of the multiple paper fibers FP becomes. In this graph, for the average length of the multiple paper fibers PF contained in the cotton-like pulverized material 10B to be 100 μm or more, it is necessary to set the operating time of the rotating device 50 to T4 or less under certain conditions. Based on the above, when generating cotton-like pulverized material 10B from multiple divided objects 10A using the rotating device 50, it is preferable to set the operating time of the rotating device 50 to T1-T2 and T3-T4 (sec.) under certain conditions.

[0087] Furthermore, as a supplement, the two processes (the second and third processes) are carried out continuously (rather than simultaneously) using a rotating device. As a prerequisite for these two processes, the wallpaper material to be divided and the resin material are both fed into the casing of the rotating device for processing. In these two processes, which are carried out continuously, the second process is performed by colliding multiple materials to be divided with multiple blades rotating around an axis. As the materials to be divided are gradually heated by the collisions (thermal energy is generated by the collisions), the temperature reaches the specific range mentioned above at the moment when cotton-like pulverized material is generated (or becomes cotton-like pulverized material). At that exact moment, the resin material that was fed into the casing softens at the temperature within that specific range, resulting in the generation of a compounded material. According to experimental research conducted by the inventors of this invention, when the operating time of the rotating device is varied and the cotton-like pulverized material inside the housing is observed, it is found that the second and third processes occur at a certain point in time. However, it has also been found that there is a short period during which both processes are performed simultaneously. More specifically, (A) the material (multiple objects to be divided 10A and a resin body) that has been fed into the housing 60 near the rotating shaft corresponding to the material input section is supplied (moved) by the supply screw 712 from the supply screw 712 side to the multiple blades 710b, 710d, 710c, and 710e side, (B) the multiple objects to be divided 10A housed inside the housing 60 are crushed by colliding them with the multiple blades 710b, 710d, 710c, and 710e rotating around the axis to produce a cotton-like crushed material 10B, and (C) the generated cotton-like crushed material 10B is collided with the multiple blades 710b, 710d, 710c, and 710e rotating around the axis together with the resin body containing polyolefin as the main component housed inside the housing 60, thereby kneading the cotton-like crushed material 10B and the resin body containing polyolefin as the main component to produce a kneaded material. In this case, the rotational speeds of the multiple blades 710b, 710d, 710c, and 710e are set so that the temperature of the multiple objects to be divided that collide with them falls within a specific range of 140°C to less than 220°C. The reason for this is that the characteristic phenomena of the present invention can be realized by setting such characteristic conditions. While it is possible to introduce the resin into the rotating device housing after the wallpaper material has been transformed into a cotton-like pulverized material, the inventors of this invention have found that even when the resin is introduced simultaneously with the wallpaper material, the cotton-like pulverized material will reach the specified temperature range, and consequently the resin will also reach the specified temperature range, which can be achieved by adjusting the rotation speed of the multiple blades. As described above, the process of performing the second and third steps simultaneously includes processing by simultaneously feeding the wallpaper material to be divided and the resin material into the rotating device. When these materials are fed into the rotating device simultaneously, the wallpaper material to be divided becomes a cotton-like pulverized material without being hindered by the existing resin material. [Explanation of Symbols]

[0088] 10 Wallpaper (an example of covering paper) 10A Multiple objects to be divided 10B Cotton-like pulverized material 20 Paper 30. Coating film (an example of a polyolefin-containing film) 40. Multiple pellets (an example of multiple molded objects) 50 Rotation device 60 cabinets 70 Rotating Bodies 710a blade 710b Feather 710c feather 710d blades 710e blade 710f blades 712 Supply Screw 716 Balance Wheel 720 Color 75 Rotation axis FP paper fibers PPO polyolefin particles Pcc (Calcium Carbonate Particles) S100 Method for manufacturing a molded product containing wallpaper as a raw material of the first embodiment S100A Method for manufacturing a molded product containing wallpaper as a raw material according to the second embodiment S10 1st process S20 2nd process S22 Project A S24 Project B S30 Project 3 S30B Project 3 S40 Project 4 S50 Project 5 S20A Composite Engineering

Claims

1. A step of crushing paper and coated paper having a polyolefin-containing film covering one side of the paper to produce a cotton-like pulverized material containing multiple paper fibers, A process of heating a resin body containing polyvinyl chloride as the main component to a thermoplasticization temperature set to either 160°C or higher and less than 170°C to form a molten body, A step of kneading a composite made by adding the cotton-like pulverized material to the molten material while heating it to a kneading temperature set to either 170°C or higher and less than 220°C, thereby producing a kneaded body in which the cotton-like pulverized material is dispersed in polyvinyl chloride, including, A method for manufacturing a compounded body.

2. A method for producing a compound according to claim 1, A step of forming the aforementioned kneaded body into at least one molded product having a predetermined shape, including, A method for manufacturing molded products.

Images