Improved method for recycling shoes and / or shoe parts

Abstract

The invention relates to a method for recycling shoes or shoe parts comprising the following steps: step 1) the grinding of the shoes and / or shoe parts into a ground fraction; step 2) the sorting of the ground fraction; The method is known in the field and is described in the Chinese patent publication CN108453953A. The known method has the following disadvantages: First of all, all materials of a shoe are granulated by the operations in the first step and the second step. Second of all, in both the first and second step no glue is removed from the ground fraction. Third of all, fibre particles of a recycled shoe will remain after the first step and the second step. The invention aims to provide an improved method according to the preamble that eliminates the above-mentioned disadvantages.

Description

[0001] IMPROVED METHOD FOR RECYCLING SHOES AND / OR SHOE PARTS

[0002] The invention relates to a method for recycling shoes and / or shoe parts comprising the following steps: step 1). the grinding of the shoes and / or shoe parts into a ground fraction; step 2). the sorting of the ground fraction;

[0003] The method is known in the field and is described in the Chinese patent publication CN108453953A.

[0004] The known method comprises the following steps for recycling shoes.

[0005] The first step is coarsely grinding the whole shoes into a coarse shoe fraction using vertically rotating saw blades.

[0006] The second step is pulverizing the coarse shoe fraction into a granulated fraction using horizontally rotating rollers.

[0007] The third step is sorting the granulated fraction based on weight by blowing the granulated fraction upwards and collecting the upwardly blown fraction at different heights.

[0008] The known method has the following disadvantages:

[0009] Firstly, all materials of a shoe are granulated by the operations in the first step and the second step, as a result of which in the third step only sorting by weight is possible.

[0010] Secondly, in both the first step and the second step no glue is removed from the ground fraction, which may cause glue residues to remain on the particles of the granulated fraction. Because of this, further application of the sorted particles is more limited than if there would be no glue resides on the particles.

[0011] Thirdly, fibre particles (fluff) of a recycled shoe will remain after the first step and the second step. These fibre particles have different sizes and therefore a different weight. These fibre particles will pollute the sorted fraction after the third step because they are sorted by weight. The fibre particles can accumulate in the granulator causing this to eventually jam.

[0012] The invention aims to provide an improved method according to the preamble that eliminates the above-mentioned disadvantages.

[0013] Thereto the method according to the invention is characterized, in that in step 1) the shoes and / or shoe parts are ground by slamming against the shoes and / or shoe parts with at least one horizontally rotating hammer with a velocity of at least 40 m / s, wherein additionally the shoe chips created by grinding are warming up such that glue on the shoe chips is warmed and is slammed off of the shoe chips by at least one rotating hammer and is disposed separately, causing the final ground fraction to be virtually free of glue residues; and step 2) comprises the following sub steps: step 2a) the separation of textile and / or leather from the ground fraction, after which the textile and / or leather is stored and a foam-rubber fraction is further processed; step 2b) the separation of the foam-rubber fraction into different fractions based on the difference in density of foam and rubber; and wherein during step 1) and step 2b) light fibre fraction is extracted from the fractions. The above-mentioned measures have as a first effect that due to the method of grinding used in step 1) the foam the rubber of the shoes and / or shoe parts and the textile and / or leather of the shoes and / or shoe parts is separated from each other wherein furthermore the glue residues is slammed off of the shoe chips. The shoe chips made up of foam or rubber generally have a size between 0 and 30 mm, while the shoe chips of textile or leather are generally larger than 30 mm. Because of this, the shoe chips of textile or leather in step 2a) can be separated from the shoe chips of foam and rubber in a simple way, resulting in a fraction textile and leather containing virtually no foam, rubber or glue residue.

[0014] The above-mentioned measures have as a second effect that by separately processing the foam-rubber fraction in step 2b) containing no textile and / or leather residues, it is possible to separate the foam from the rubber based on the difference in density of foam and rubber, resulting in a separate fraction of foam and a separate fraction of rubber.

[0015] In practice it has been shown that during the grinding of shoes and shoe parts a fibre fraction also forms. This fibre fraction mostly consists of fluffy material originating from the textile and or leather of the shoes and / or shoe parts. The above-mentioned measures has as a third effect that during step 1) and step 2b) this light fibre fraction is extracted from the fractions and is collected separately.

[0016] In a first preferred method of the method according to the invention step 2a) comprises the following sub step: step 2a-1) the sieving of the ground fraction (shoe chips) of step 1) by a first sieve, wherein the textile and / or leather fraction is separated from the foam-rubber fraction, wherein the foam-rubber fraction falls through the first sieve and the textile and / or leather fraction passes through first sieve.

[0017] In order to still separate foam or rubber that does not fall through the first sieve from the textile and / or leather fraction, step 2a) preferably comprises the following sub step: step 2a-2) the separation of the textile and / or leather fraction wherein any potentially remaining foam and rubber is separated and is combined with the foam-rubber fraction.

[0018] The separation of the textile and / or leather fraction can take place by means of a separation device, such as an optical or ballistic separator.

[0019] In a ballistic separator the differences in shape of the textile and leather chips (2D or flexible material) with respect to the foam and rubber chips (3D or rolling material) is used. The ballistic separator throws the 2D material upwards and it is collected, while the 3D material rolls off of the ballistic separator and can be collected separately.

[0020] In an optical separator, one or more optical recording elements are used to determine for each particle whether it is textile or leather. Based on this a separation element, such as an extraction element or blowing element, is controlled to separate the particle.

[0021] Since the leather and the textile of a shoe often contain metal particles, step 2a) preferably comprises the following sub step: step 2a-3) the removal of metal from the textile and / or leather fraction.

[0022] Preferably the first sieve is arranged for the sieving of the foam-rubber fraction to multiple foam-rubber fractions with particles in a specific size range, such as for example 0-8 mm, 8-14 mm, and 14-30 mm. This has the effect that the fibre fractions from the foam- rubber fractions with different sizes can be separately extracted, which allows for a better separation of the fibre fraction and the foam-rubber fraction.

[0023] Preferably the first sieve is a drum sieve.

[0024] In the first preferred method according to the method according to the invention step 2b) comprises the following sub step: step 2b-1) the separate sieving of each foam-rubber fraction by a separate second sieve, wherein each separate second sieve is arranged for the sieving of particles in a specific size range and separates the fibre fraction present in the foam-rubber fraction, after which the fibre fraction is extracted to a fibre collection means.

[0025] Preferably the second sieve is a vibrating sieve.

[0026] Preferably step 2b) comprises the following sub step: step 2b-2) the individual separation of a part of the fibre fraction from a foam-rubber fraction using a first separator, after which the fibre fraction is extracted to the fibre collection means.

[0027] This has the effect that the fibre fraction can further be removed from the foam- rubber fraction.

[0028] Preferably the first separator is a zig-zag air separator. Hereby the foam-rubber fraction (partly with fibre fraction) is guided into a zigzag-shaped sieve channel via an airtight feed mechanism. Here the lighter materials are separated from the heavier ones by means of a multiple cross feed sieve process. The air needed for this separation process flows from bottom to top through the sieve channel. The lighter fibre particles are carried along by the air flow, while the heavier foam and rubber particles fall down against the air flow and can be discharged at the bottom of the zigzag air separator. The fibre particles carried along by the air flow are discharged via the top of the zigzag air separator.

[0029] In the first preferred method according to the method according to the invention step 2b) comprises the following sub step: step 2b-3) the reduction of the foam-rubber fraction with the largest particle size, for example 14-30 mm, to a smaller particle size, for example 0-12 mm, after which the reduced foam-rubber fraction is returned to the first sieve. In the foam-rubber fraction with the largest particle size foam and rubber particles can eventually still be stuck together. By reducing these in size, the particles can still be separated from each other.

[0030] Preferably in step 2b-3), before the reduction of the foam-rubber fraction, the metal is first removed from the foam-rubber fraction.

[0031] Preferably step 2b) comprises the following sub step: step 2b-4) for removing metal from each foam-rubber fraction after attempting to extract the fibers from the foam-rubber fractions with the first separator.

[0032] In the first preferred method according to the method according to the invention step 2b) comprises the following sub step: step 2b-5) the separation of the foam-rubber fraction to different fractions based on density in a foam fraction and a rubber fraction using a sink / float separation tank.

[0033] The sink / float separation tank is filled with fluid in which foam floats and rubber sinks. Preferably the fluid is water. This allows the foam and rubber to be separated in an effective manner. The density of the fluid can potentially be influenced by chemical additives, such as for example salt.

[0034] An additional advantage of the application of the sink / float separation tank is that any dirt on the foam or on the rubber will be separated by the fluid.

[0035] In a first preferred method according to the method according to the invention step 2b) comprises the following sub step: step 2b-6) the drying of the rubber fraction; step 2b-7) the reduction of the rubber fraction, for example to a particle size of 0-6 mm; step 2b-8) the sieving of the reduced rubber fraction into two rubber fractions with different particle size, such as for example 0-2 mm and 2-6 mm; step 2b-9) the extraction of the rubber fraction with the smallest particle size, for example 0-2 mm, to a fibre collection means; step 2b-10) the individual separation of fibre fraction of the rubber fraction with the largest particle size, such as for example 2-6 mm, using a second separator, after which the fibre fraction is extracted to the fibre collection means; step 2b-11 ) the removal of the metal from the remaining rubber fraction of step 2b-10; step 2b-12) the storage of the remaining rubber fraction of step 2b-11 ).

[0036] These measures result in a rubber fraction with a high purity which is very suitable to be reused.

[0037] Preferably the second separator is a zig-zag air separator. In the first preferred method according to the method according to the invention step

[0038] 2b) comprises the following sub step: step 2b-13) the drying of the foam fraction; step 2b-14) the reduction of the foam fraction, for example to a particle size of 0-6 mm; step 2b-15) the sieving of the reduced foam fraction into two foam fractions with different particle size, such as for example 0-2 mm and 2-6 mm; step 2b-16) the extraction of the foam fraction with the smallest particle size, for example 0-2 mm, to a fibre collection means; step 2b-17) the storage of the remaining foam fraction.

[0039] These measures result in a foam fraction with high purity and one that’s very suitable to be reused.

[0040] In order to increase the purity of the foam- and rubber fraction, in practice it has been shown that before carrying out step 1) it is necessary to carry out step 0), wherein the shoes that are to be recycled are sorted by shoe type or brand in different batches and wherein each batch of sorted shoes is separately processed from step 1) onwards.

[0041] The following table shows the type of foam and rubber per shoe type.

[0042] The first column shows the shoe parts, such as Outsole, Midsole, Insole, Upper.

[0043] Outsole

[0044] This is the bottom layer of the shoe that is in direct contact with the ground.

[0045] Midsole

[0046] This layer is located between the outsole and the insole and often provides cushioning and comfort.

[0047] Insole This is the inside of the shoe on which the foot rests. It is also called the footbed.

[0048] Upper

[0049] This refers to the entire upper portion of the shoe that covers and encloses the foot.

[0050] The abbreviations for the materials are explained below.

[0051] EVA (Ethylene Vinyl Acetate):

[0052] EVA is a synthetic material that is often used for soles. It is lightweight, resilient and provides good cushioning. EVA-soles are durable, wear-resistant and flexible, allowing them to follow the natural movement of the foot.

[0053] SBR (Styrene Butadiene Rubber):

[0054] This is a type of synthetic rubber that is often used in shoe soles for its durability and resistance to wear.

[0055] ETPU (Expanded Thermoplastic Polyurethane):

[0056] A lightweight, elastic material often used in athletic shoes for cushioning and energy recovery.

[0057] PA (Polyamide):

[0058] Also known as nylon, this material is often used in shoe uppers for its strength and durability. NBR (Nitrile Butadiene Rubber):

[0059] A synthetic rubber that is oil and fuel resistant, often used in work boots.

[0060] PVC (Polyvinyl Chloride):

[0061] A versatile plastic used in various parts of shoes, especially in waterproof or weatherproof models.

[0062] TPU (Thermoplastic Polyurethane):

[0063] A flexible, wear- resista nt material often used in soles and other shoe parts that require durability.

[0064] PU (Polyurethane):

[0065] A versatile material used in both soles and uppers of shoes.

[0066] TPE (Thermoplastic Elastomer):

[0067] TPE is a versatile material that combines properties of both rubber and plastic: TPE is often used in applications such as shoe soles, grips, and medical devices

[0068] PP (Polypropylene):

[0069] PP is a thermoplastic polymer: It is stiffer and harder than TPE, but still relatively lightweight.

[0070] By pre-sorting by shoe type or shoe brand, it is possible to obtain a foam and / or rubber fraction with a high purity, such as: a foam fraction only consisting of:

[0071] EVA or ETPU or PU a rubber fraction only consisting of:

[0072] SBR or NBR or TPR.

[0073] Materials that can be present in both foam and in non-foamed form (rubber-like):

[0074] 1. TPU (Thermoplastic Polyurethane)

[0075] TPU can be used in both solid as in foamed form.

[0076] 2. ETPLI (Expanded Thermoplastic Polyurethane)

[0077] ETPLI is a foamed version of TPU and is thus considered to be foam.

[0078] The remaining materials are not officially foam or rubber, but can be sorted as such by the method.

[0079] In the following embodiment of the method according to the invention step 2b) comprises the following sub steps: step 2b-18) the extruding of the foam fraction of step 2b-17) in an extruder into a foam ribbon; step 2b-19) the cooling down of the foam ribbon; step 2b-20) the pelletizing of the foam ribbon into foam pellets.

[0080] In this way, the foam fraction can be made into foam pellets in a cost-effective manner. In further processing, these can serve as raw material for the production of new shoes.

[0081] In the following embodiment of the method according to the invention, the temperature of the foam fraction in step 2b-18) lies between 130 and 260 °C and the foam fraction is under a pressure of 20-75 bar.

[0082] In the following embodiment of the method according to the invention, the foam fraction in step 2b-18) is first powdered.

[0083] This is especially important if the foam fraction has a high elasticity, as is often the case with EVA. This makes it difficult to make pellets out of this foam fraction. By firstly powdering the foam fraction, this foam fraction loses its elasticity and it becomes possible to make pellets out of it.

[0084] In the following embodiment of the method according to the invention step 2b-18) comprises the following consecutive step: step 2b-19a) the addition of unused or new foam to the extruder in a predetermined ratio during extrusion.

[0085] Due to this step, the quality of the foam pellets is increased and the foam pellets are better suited for producing new shoes.

[0086] In the following embodiment of the method according to the invention step 2b) comprises the following sub steps: step 2b-20) the extruding of the rubber fraction of step 2b-12) in an extruder into a rubber ribbon wherein the temperature of the rubber fraction lies between 130 and 260 °C and the rubber fraction is under a pressure of 150-300 bar, such that the rubber fraction devulcanizes during extrusion; step 2b-19) the cooling down of the rubber ribbon; step 2b-20) the pelletizing of the rubber ribbon into rubber pellets.

[0087] Due to these steps, the rubber fraction can be converted to rubber pellets that are suitable for manufacturing new shoe parts, such as for example soles.

[0088] In the following embodiment of the method according to the invention step 2b-20) comprises the following consecutive step: step 2b-20a) the addition of unused or new rubber to the extruder in a predetermined ratio during extrusion.

[0089] Due to this step, the quality of the rubber pellets is increased and the rubber pellets are better suited for producing new shoes.

[0090] Preferably step 2a) comprises the following sub step: step 2a-4) the separation of the textile and / or leather fraction in a textile fraction and a leather fraction. By separating these fractions from each other it is possible to reuse these individual fractions.

[0091] In the following embodiment of the method according to the invention step 2a) comprises the following sub step: step 2a-5) the opening up the textile fraction, wherein the textile fraction is pulled apart by means of needles; step 2a-6) the fiberization of the opened up textile fraction of step 2a-5); step 2a-7) the removal of contamination from the fibres of step 2a-6); step 2a-8) the making of a sliver of the cleaned fibres of step 2a-7); step 2a-9) the spinning of yarn from the sliver of step 2a-8) with a predetermined thickness. Due to these measures, it is possible to make a yarn that can be reused for the production of new shoes based on the textile fraction.

[0092] In the following embodiment of the method according to the invention the step 2a-7) comprises the following consecutive step: step 2a-7a) the addition of recycled textile and / or polyester obtained from a different process.

[0093] Due to this step, the quality of the yarn is increased and the yarn is better suited for producing new shoes.

[0094] In the following embodiment of the method according to the invention step 2a) comprises the following sub step: step 2a-9) the powdering of the leather fraction; step 2a-10) the sieving of the powdered leather fraction of step 2a-9); step 2a-11) the mixing of the sieved and powdered leather fraction of step 2a-10) with a binder into a leather mixture; step 2a-12) the waltzing and rolling of the leather mixture of step 2a-11); step 2a-13) the cutting of the waltzed rolls of step 2a-12) into sheets of leather.

[0095] Due to these steps, it is possible to make plates of leather that are suitable for the production of new shoes.

[0096] In the following embodiment of the method according to the invention step 2b) comprises the following sub steps: step 2b-23) the heating of the collected fibre fraction; step 2b-24) the pelletizing of the heated fibre fraction of step 2b-23).

[0097] The invention will be further explained with reference to the following figures, wherein:

[0098] Figure 1 schematically shows the different steps of the method according to claim 1;

[0099] Figure 2 schematically shows the different steps of the preferred embodiment of the method according to the invention;

[0100] Figure 3 shows an elaboration of the preferred embodiment of the method according to the invention;

[0101] Figure 4 shows an elaboration of step 1 and step 2a of the preferred embodiment of the method according to the invention as shown in Figure 3;

[0102] Figure 5 shows an elaboration of step 2b-1 , step 2b-2 and step 2b-3 of the preferred embodiment of the method according to the invention as shown in Figure 3;

[0103] Figure 6 shows an elaboration of step 2b-4 and step 2b-5 of the preferred embodiment of the method according to the invention as shown in Figure 3;

[0104] Figure 7 shows an elaboration of step 2b-6 up to and including step 2b-12 of the preferred embodiment of the method according to the invention as shown in Figure 3;

[0105] Figure 8 shows an elaboration of step 2b-13 up to and including step 2b-17 of the preferred embodiment of the method according to the invention as shown in Figure 3;

[0106] Similar reference numbers in different figures indicate similar parts.

[0107] Figure 1 schematically shows the different steps of the method according to claim 1.

[0108] In step 1) the shoes and / or shoe parts are ground by slamming against the shoes and / or shoe parts with at least one horizontally rotating hammer with a velocity of at least 40 m / s, wherein additionally the shoe chips created by grinding are warming up such that glue on the shoe chips is warmed and is slammed off of the shoe chips by at least one rotating hammer and is disposed separately, causing the final ground fraction to be virtually free of glue residues;

[0109] In step 2) the ground fraction is sorted. Step 2) comprises the following sub steps: step 2a) the separation of textile and / or leather from the ground fraction, after which the textile and / or leather is stored and a foam-rubber fraction is further processed; and step 2b) the separation of the foam-rubber fraction into different fractions based on the difference in density of foam and rubber.

[0110] In all steps, during the execution of the method, light fiber fraction is extracted from the (partial) fractions created in the steps.

[0111] Figure 2 schematically shows different steps of the preferred embodiment of the method according to the invention, wherein step 2a) and step 2b) from Figure 1 are further defined: step 2a-1) the sieving of the ground fraction of step 1) by a first sieve, wherein the textile and / or leather fraction is separated from the foam-rubber fraction, wherein the foam- rubber fraction falls through the first sieve and the textile and / or leather fraction passes through first sieve, wherein the first sieve is arranged for the sieving of the foam-rubber fraction to multiple foam-rubber fractions with particles in a specific size range, such as for example 0-8 mm, 8-14 mm, and 14-30 mm and wherein the first sieve is a drum sieve: step 2a-2) the separation of the textile and / or leather fraction by means of a separation device (0725) wherein any potentially remaining foam and rubber is separated and is combined with the foam-rubber fraction: step 2a-3) the removal of metal from the textile and / or leather fraction: step 2b-1) the separate sieving of each foam-rubber fraction by a separate second sieve, wherein each separate second sieve is arranged for the sieving of particles in a specific size range and separates the fibre fraction present in the foam-rubber fraction, after which the fibre fraction is extracted to a fibre collection means and wherein the second sieve is a vibrating sieve: step 2b-2) the individual separation of fibre fraction from a foam-rubber fraction using a first separator, after which the fibre fraction is extracted to the fibre collection means, wherein the first separator is a zig-zag air separator: step 2b-3) the reduction of the foam-rubber fraction with the largest particle size, for example 14-30 mm, to a smaller particle size, for example 0-12 mm, after which the reduced foam-rubber fraction is returned to the first sieve, wherein for the reduction of the foam- rubber fraction metal is first removed from the foam-rubber fraction: step 2b-4) the removal of metal from each foam-rubber fraction: step 2b-5) the separation of the foam-rubber fraction to different fractions based on density in a foam fraction and a rubber fraction using a sink / float separation tank: step 2b-6) the drying of the rubber fraction: step 2b-7) the reduction of the rubber fraction, for example to a particle size of 0-6 mm: step 2b-8) the sieving of the reduced rubber fraction into two rubber fractions with different particle size, such as for example 0-2 mm and 2-6 mm: step 2b-9) the extraction of the rubber fraction with the smallest particle size, for example 0-2 mm, to a fibre collection means: step 2b-10) the individual separation of fibre fraction of the rubber fraction with the largest particle size, such as for example 2-6 mm, using a second separator, after which the fibre fraction is extracted to the fibre collection means, wherein the second separator is a zig-zag air separator: step 2b-11 ) the removal of the metal from the remaining rubber fraction of step 2b-10: step 2b-12) the storage of the remaining rubber fraction of step 2b-11): step 2b-13) the drying of the foam fraction: step 2b-14) the reduction of the foam fraction, for example to a particle size of 0-6 mm: step 2b-15) the sieving of the reduced foam fraction into two foam fractions with different particle size, such as for example 0-2 mm and 2-6 mm: step 2b-16) the extraction of the foam fraction with the smallest particle size, for example 0-2 mm, to a fibre collection means: step 2b-17) the storage of the remaining foam fraction.

[0112] Figure 3 shows an elaboration of the preferred embodiment of the method according to the invention. The parts shown are:

[0113] 0030 Stock of shoes or shoe parts

[0114] 0035 Conveyor belt

[0115] 0040 Conveyor belt

[0116] 0045 Shoe grinder

[0117] 0050 Shoe grinder

[0118] 0055 Conveyor belt

[0119] 0056 Conveyor belt

[0120] 0065 Diverter valve

[0121] 0070 Conveyor belt

[0122] 0095 Drum sieve

[0123] 0100 Vibrating sieve

[0124] 0105 Conveyor belt

[0125] 0110 Rotary valve

[0126] 0115 Zigzag air separator 0120 Fan

[0127] 0125 Vibrating sieve

[0128] 0130 Conveyor belt

[0129] 0135 Rotary valve

[0130] 0140 Zigzag air separator

[0131] 0145 Fan

[0132] 0150 Vibrating sieve

[0133] 0155 Conveyor belt

[0134] 0160 Magnetic belt

[0135] 0165 Conveyor belt

[0136] 0170 Non-ferrous metal separator (based on Eddy Current)

[0137] 0175 Conveyor belt

[0138] 0180 Rotary valve

[0139] 0185 Pre-sorter for light fibres (K-Sifter)

[0140] 0190 Granulator 14-30mm

[0141] 0195 Fan

[0142] 0200 Cyclone

[0143] 0205 Rotary valve

[0144] 0210 Conveyor belt

[0145] 0235 Fan

[0146] 0240 Cyclone

[0147] 0255 Cyclone

[0148] 0260 Rotary valve

[0149] 0265 ZIGZAG AIR SEPARATOR

[0150] 0270 Conveyor belt

[0151] 0275 Conveyor belt

[0152] 0280 Two-way valve

[0153] 0285 Magnetic belt

[0154] 0290 Non-ferrous metal separator (based on Eddy Current)

[0155] 0295 Conveyor belt

[0156] 0310 Conveyor belt

[0157] 0315 Sink / float unit

[0158] 0320 Mechanical dryer

[0159] 0321 Screwjack

[0160] 0325 Cyclone mechanical dry rubber

[0161] 0330 Cutting mill Rubber 0-6mm

[0162] 0335 Fan 0340 Cyclone

[0163] 0345 Rotary valve

[0164] 0347 Big-bag station

[0165] 0350 Two-way valve

[0166] 0360 Mechanical dryer

[0167] 0361 Screwjack

[0168] 0365 Cyclone

[0169] 0370 Cutting mill foam 0-3mm

[0170] 0375 Fan

[0171] 0380 Cyclone cutting mill Foam

[0172] 0385 Rotary valve

[0173] 0390 Screening machine Foam

[0174] 0395 Round screen cover

[0175] 0400 Conveyor belt

[0176] 0405 Two-way valve

[0177] 0410 Big-bag station

[0178] 0500 Fan

[0179] 0505 Cyclone

[0180] 0510 Rotary valve

[0181] 0515 Two-way valve

[0182] 0520 Big Bag Glue Fluff

[0183] 0550 Fan

[0184] 0555 Cyclone

[0185] 0560 Rotary valve

[0186] 0565 Two-way valve

[0187] 0571 Big-bag station

[0188] 0575 Fan

[0189] 0650 Screening machine

[0190] 0660 Conveyor belt

[0191] 0665 Oscillating sieve

[0192] 0675 Conveyor belt

[0193] 0680 Two-way valve

[0194] 0690 Two-way valve

[0195] 0690 Fan

[0196] 0695 Cyclone

[0197] 0700 Rotary valve

[0198] 0705 Two-way valve 0710 Fan

[0199] 0715 Big-bag station 0720 Big-bag station 0725 Separation unit 0735 Rotary valve 0740 Spreader

[0200] Figure 4 shows an elaboration of step 1 and step 2a of the preferred embodiment of the method according to the invention as shown in Figure 3. The shoes or shoe parts that are to be recycled are accumulated in the storage with shoes or shoe parts (0030). The shoes and / or shoe parts are transported with conveyor belts (0035; 0040) to the top of the shoe grinders (0045;0050), after which the shoes and / or shoe parts fall into the shoe grinders (0045;0050). After and / or during the grinding of the shoes and / or shoe parts, fibres from the shoe grinders (0045;0050) are extracted via the cyclone (0505), after which the fibres are collected in a big bag. The ground shoes and / or shoe parts or ground fraction falls onto the conveyor belt (0055) after the processing of the shoe grinders (0045;0050) and ends up on a subsequent conveyor belt (0070) via conveyor belt (0056) and diverter valve (0065) which transports the ground fraction to the drum sieve (0095). On this conveyor belt (0070) fraction D that originates from step 2b-3) is also deposited by cyclone (0200). The drum sieve (0095) sieves foam-rubber fractions in 3 different size ranges (fraction A, fraction B, fraction C) from the ground fraction. Potentially more or less different sizes can be sieved. Fraction A preferably has a size range of 0-8mm. Fraction B preferably has a size range of 8- 14mm. Fraction C preferably has a size range of 14-30mm. The portion that does not fall through the drum sieve (0095) mostly consists of textile and leather and is taken away to the spreader (0740). This spreader (0740) separates the textile and leather from the fraction of foam and rubber that has not fallen through the drum sieve (0095). This foam- and rubber fraction is then returned to flow C by conveyor belt (0675). The textile and leather originating from the separation device is collected in big bags (0715) via cyclone (0695).

[0201] Figure 5 shows an elaboration of step 2b-1 , step 2b-2, and step 2b-3 of the preferred embodiment of the method according to the invention as shown in Figure 3. The fraction A, B, and C are each carried through a vibration sieve (0100;0125;0150), wherein during the sieving with the vibration sieve (0100;0125;0150) the fibre faction is extracted by means of cyclone (0555), wherein the fibres are stored in big bags (0571).

[0202] The sieved fraction A and B are further separated from fibres via conveyor belts (0105;0130) in a zigzag air separator (0115;0140), wherein these fibres are also taken away via cyclone (0555). The sieved fraction C is brought to a metal separation device (0165;0160;0170) via a conveyor belt (0155), wherein the metal from fraction C is removed. This metal fraction is separately stored. After the metal has been removed from fraction C, this fraction is transported via conveyor belt (0175) to a pre-sorter for light fibres (0185) which preferably comprises a zigzag air separator, preferably with one zigzag. The fibres that are sieved by de pre-sorter (0185) are also extracted by cyclone (0555). The remaining fraction C is reduced by a granulator (0190) to a fraction D, that preferably has a size range of 0-12mm. The fraction D is then by means of cyclone (0200) returned to conveyor belt (0070) which returns the fraction back into the drum sieve (0095).

[0203] Figure 6 shows an elaboration of step 2b-4 and step 2b-5 of the preferred embodiment of the method according to the invention as shown in Figure 3.

[0204] Via the bottom of the zigzag air separators (0115;0140), the sieved fraction A and B (now called fraction E) is carried through another metal separation device (0285;0280;0290) via conveyor belts (0270;0275), wherein the metal from the fraction E is removed. After fraction E has passed through the metal separation device, fraction E is brought inside the sink / float unit (0315) via conveyor belt (0310). The rubber in fraction E will sink, while the foam in fraction E will float. The rubber fraction (F) is removed from below the fluid surface in the sink / float unit (0315) and is separately processed. The foam fraction (fraction G) is then removed from the fluid surface in the sink / float unit (0315) and separately processed further.

[0205] Figure 7 shows an elaboration of step 2b-6 up to and including step 2b-12 of the preferred embodiment of the method according to the invention as shown in Figure 3.

[0206] The wet rubber fraction F originating from the sink / float unit (0315) is dried in the mechanical dryer (0320), wherein remaining fluid is stripped of dirt by means of a screwjack (0321). The dirt and fluid are disposed separately. After drying the rubber fraction F it is brought to a cutting mill or granulator by means of the cyclone (0325), which cuts the rubber, preferably to a size between 0 and 6 mm. The fraction F is then guided through a sieve (0395) by means of a cyclone (0340), which sieves out particles with a small size, preferably 0-2 mm. These particles are disposed by means of cyclone (024). The remaining particles from the rubber fraction, preferably with particle size 2-6 mm are guided through a zigzag air separator (0265) by means of a cyclone (0255), wherein any still remaining fibre fraction is removed from the rubber fraction. The remaining rubber fraction is guided through a metal detector (0665) via a conveyor belt (0660), after which then the rubber fraction (without metal particles) is collected in big bags (0347).

[0207] Figure 8 shows an elaboration of step 2b-13 up to and including step 2b-17 of the preferred embodiment of the method according to the invention as shown in Figure 3.

[0208] The wet foam fraction originating from the sink / float unit (0315) is dried in the mechanical drier (0360), wherein remaining fluid is stripped of dirt by means of screwjack (0361). The dirt and fluid are disposed separately. The dried foam fraction G is then by means of a cyclone (0365) further reduced by a cutting mill or granulator, preferably to particles with a size between 0 and 3 mm. The reduced foam fraction G is then taken through a sieve (0390) by means of a cyclone (0380), wherein any fibres are extracted by means of the cyclone (0240), while the smallest foam particles pass through the sieve (0390). The sieved foam particles then go through another sieve (0650), which disposed small foam particles (specify size). The larger foam particles (specify size) are collected in big bags (0410) via a conveyor belt (0400).

[0209] In the application, leather refers only to animal leather. The method according to the invention can process 2.500 shoes or shoe parts per hour by means of the above-mentioned measures. The shoes and / or shoe parts are thereto separated into foam, rubber, textile, leather and fibres (fluff). These are output as pellets or yarn. All types of shoes or shoe parts, both pre- and post-consumer shoes, can be recycled by means of the method, including unused materials or leftovers from the production process and sample and monster shoes that have never been worn and are not intended for sale.

Claims

CLAIMS1 . Method for recycling shoes or shoe parts comprising the following steps: step 1) the grinding of the shoes and / or shoe parts into a ground fraction; step 2) the sorting of the ground fraction; characterized, in that in step 1) the shoes and / or shoe parts are ground by slamming against the shoes and / or shoe parts with at least one horizontally rotating hammer with a velocity of at least 40 m / s, wherein additionally the shoe chips created by grinding are warming up such that glue on the shoe chips is warmed and is slammed off of the shoe chips by at least one rotating hammer and is disposed separately, causing the final ground fraction to be virtually free of glue residues; and step 2) comprises the following sub steps: step 2a) the separation of textile and / or leather from the ground fraction, after which the textile and / or leather is stored and a foam-rubber fraction is further processed; step 2b) the separation of the foam-rubber fraction into different fractions based on the difference in density of foam and rubber; and wherein during step 1) and step 2b) light fibre fraction is extracted from the fractions.

2. Method according to claim 1 , wherein step 2a) comprises the following sub step: step 2a-1) the sieving of the ground fraction of step 1) by a first sieve, wherein the textile and / or leather fraction is separated from the foam-rubber fraction, wherein the foam-rubber fraction falls through the first sieve and the textile and / or leather fraction passes through first sieve.

3. Method according to claim 1 or 2, wherein step 2a) comprises the following sub step: step 2a-2) the separation of the textile and / or leather fraction wherein any potentially remaining foam and rubber is separated and is combined with the foam-rubber fraction.

4. Method according to claim 1 or 2, wherein step 2a) comprises the following sub step: step 2a-3) the removal of metal from the textile and / or leather fraction.

5. Method according to claim 2, 3, or 4, wherein in step 2a-1) the first sieve is arranged for the sieving of the foam-rubber fraction to multiple foam-rubber fractions with particles in a specific size range, such as for example 0-8 mm, 8-14 mm, and 14-30 mm.

6. Method according to claim 2, 3, 4, or 5, wherein the first sieve is a drum sieve.

7. Method according to one of the preceding claims, wherein step 2b) comprises the following sub step: step 2b-1) the separate sieving of each foam-rubber fraction by a separate second sieve, wherein each separate second sieve is arranged for the sieving of particles in a specific size range and separates the fibre fraction present in the foam-rubber fraction, after which the fibre fraction is extracted to a fibre collection means.

8. Method according to claim 7, wherein the second sieve is a vibrating sieve.

9. Method according to one of the preceding claims, wherein step 2b) comprises the following sub step: step 2b-2) the distinct separation of fibre fraction from a foam-rubber fraction using a first separator, after which the fibre fraction is extracted to the fibre collection means.

10. Method according to claim 9, wherein the first separator is a zig-zag air separator.

11. Method according to one of the preceding claims dependent of claim 5, wherein step 2b) comprises the following sub step: step 2b-3) the reduction of the foam-rubber fraction with the largest particle size, for example 14-30 mm, to a smaller particle size, for example 0-12 mm, after which the reduced foam-rubber fraction is returned to the first sieve.

12. Method according to claim 11, wherein in step 2b-3) for the reduction of the foam- rubber fraction metal is first removed from the foam-rubber fraction.

13. Method according to one of the preceding claims, wherein step 2b) comprises the following sub step: step 2b-4) for removing metal from each foam-rubber fraction.

14. Method according to one of the preceding claims, wherein step 2b) comprises the following sub step: step 2b-5) the separation of the foam-rubber fraction to different fractions based on density in a foam fraction and a rubber fraction using a sink / float separation tank.

15. Method according to claim 14, wherein step 2b) comprises the following sub step: step 2b-6) the drying of the rubber fraction;step 2b-7) the reduction of the rubber fraction, for example to a particle size of 0-6 mm; step 2b-8) the sieving of the reduced rubber fraction into two rubber fractions with different particle size, such as for example 0-2 mm and 2-6 mm; step 2b-9) the extraction of the rubber fraction with the smallest particle size, for example 0-2 mm, to a fibre collection means; step 2b-10) the individual separation of fibre fraction of the rubber fraction with the largest particle size, such as for example 2-6 mm, using a second separator, after which the fibre fraction is extracted to the fibre collection means; step 2b-11 ) the removal of the metal from the remaining rubber fraction of step 2b-10; step 2b-12) the storage of the remaining rubber fraction of step 2b-11 ).

16. Method according to claim 15, wherein the second separator is a zig-zag air separator.

17. Method according to claim 14, wherein step 2b) comprises the following sub step: step 2b-13) the drying of the foam fraction; step 2b-14) the reduction of the foam fraction, for example to a particle size of 0-6 mm; step 2b-15) the sieving of the reduced foam fraction into two foam fractions with different particle size, such as for example 0-2 mm and 2-6 mm; step 2b-16) the extraction of the foam fraction with the smallest particle size, for example 0-2 mm, to a fibre collection means; step 2b-17) the storage of the remaining foam fraction.

18. Method according to one of the preceding claims, wherein the method comprises the following step, which takes place before step 1): step 0) the sorting of the shoes that are to be recycled according to shoe type and / or brand in different batches and the separate further treatment of each batch from step 1) onwards.

19. Method according to claim 18 in combination with claim 17, wherein step 2b) comprises the following sub steps: step 2b-18) the extruding of the foam fraction of step 2b-17) in an extruder into a foam ribbon; step 2b-19) the cooling down of the foam ribbon; step 2b-20) the pelletizing of the foam ribbon into foam pellets.

20. Method according to claim 19, wherein in step 2b-18) the temperature of the foam fraction lies between 130 and 260 °C and the foam fraction is under a pressure of 20- 75 bar.

21. Method according to claim 20, wherein in step 2b-18) the foam fraction is first powdered.

22. Method according to claim 19, 20, or 21 , wherein step 2b-18) comprises the following consecutive step: step 2b-19a) the addition of unused or new foam to the extruder in a predetermined ratio during extrusion.

23. Method according to claim 18 in combination with claim 15, wherein step 2b) comprises the following sub steps: step 2b-20) the extruding of the rubber fraction of step 2b-12) in an extruder into a rubber ribbon wherein the temperature of the rubber fraction lies between 130 and 260 °C and the rubber fraction is under a pressure of 150-300 bar, such that the rubber fraction devulcanizes during extrusion; step 2b-19) the cooling down of the rubber ribbon; step 2b-20) the pelletizing of the rubber ribbon into rubber pellets.

24. Method according to claim 23, wherein step 2b-20) comprises the following consecutive step: step 2b-20a) the addition of unused or new rubber to the extruder in a predetermined ratio during extrusion.

25. Method according to claim 18 in combination with claim 4, wherein step 2a) comprises the following sub step: step 2a-4) the separation of the textile and / or leather fraction in a textile fraction and a leather fraction.

26. Method according to claim 25, wherein step 2a) comprises the following sub step: step 2a-5) the opening up the textile fraction, wherein the textile fraction is pulled apart by means of needles; step 2a-6) the fibreization of the opened up textile fraction of step 2a-5); step 2a-7) the removal of contamination from the fibres of step 2a-6);step 2a-8) the making of a sliver of the cleaned fibres of step 2a-7); step 2a-9) the spinning of yarn from the sliver of step 2a-8) with a predetermined thickness.

27. Method according to claim 25, wherein step 2a) comprises the following sub step: step 2a-7a) the addition of recycled textile and / or polyester obtained from a different process.

28. Method according to claim 25, wherein step 2a) comprises the following sub step: step 2a-9) the powdering of the leather fraction; step 2a-10) the sieving of the powdered leather fraction of step 2a-9); step 2a-11) the mixing of the sieved and powdered leather fraction of step 2a-10) with a binder into a leather mixture; step 2a-12) the waltzing and rolling of the leather mixture of step 2a-11); step 2a-13) the cutting of the waltzed rolls of step 2a-12) into sheets of leather.

29. Method according to claim 18 in combination with one or more claims 1, 7, 9, 15, or 17, wherein step 2b) comprises the following sub steps: step 2b-23) the heating of the collected fibre fraction; step 2b-24) the pelletizing of the heated fibre fraction of step 2b-23).

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