Recycled Fabric Board Composition for Practical Textile Reuse
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Solution Overview
Problem
The market value and practicality of recycled products from out-of-season or discarded textiles are affected by their manufacturing methods, limiting their successful reuse and resource utilization.
Innovation Solution
A recycled board made from recycled fabrics, composed of fiber pieces with an average diameter of less than or equal to 10 mm, mixed with an adhesive cured under temperature, pressure, or light, and molded through processes like crushing, dry stirring, mixing, rolling, and hot pressing, with the adhesive comprising 20-50 wt% of the board's weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If recycled fabrics are used to manufacture recycled boards, then resource recycling efficiency is improved and waste is reduced, but the market value and practicality are affected by manufacturing methods
Solution Approach 1:
The recycled fabrics are crushed into small fiber pieces with specific size ranges (0.1-10mm), segmenting the material to enable better mixing, adhesive infiltration, and uniform distribution in the final product. This segmentation resolves the contradiction by making the recycling process more controllable and the product more practical.
Solution Approach 2:
The invention creates a composite material system combining fiber pieces (50-80 wt%) with adhesive (20-50 wt%), where the adhesive contains resins that cure under various conditions. This composite approach improves both the practicality (through adjustable strength) and ease of manufacture (through flexible processing conditions) while maintaining waste reduction benefits.
2Shape
If fiber pieces with smaller average diameter are used, then the appearance becomes richer and market value increases, but the manufacturing process complexity increases
Solution Approach 1:
The invention specifies fiber piece average diameter within the range of 0.1-10mm, optimizing the balance between appearance richness (achieved with smaller fibers) and manufacturing feasibility. This parameter control allows rich appearance through varied fiber sizes and shapes while keeping the crushing and mixing processes manageable.
Solution Approach 2:
The fiber pieces are pre-crushed to specific size ranges before mixing with adhesive, ensuring the appearance quality is predetermined. This preliminary action simplifies subsequent manufacturing steps while guaranteeing the rich appearance effect from the varied fiber dimensions.
3Strength
If adhesive content is increased to improve board strength, then the strength range increases to meet various applications, but the resource recycling efficiency decreases
Solution Approach 1:
The invention defines adhesive content within the range of 20-50 wt%, allowing optimization between strength requirements and recycling efficiency. For applications requiring high strength, up to 50% adhesive can be used, while for less demanding applications, lower adhesive content maintains better recycling efficiency. The resin types can also be selected based on curing conditions to optimize this balance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The recycled board achieves high market value and diverse applications by enhancing resource recycling efficiency and reducing waste, with a rich appearance and varying strength ranges due to the use of recycled fabrics and adhesive composition.
Implementation Method 1
The adhesive includes at least one resin cured under the action of temperature, pressure, a curing agent, light rays, or a combination thereof
Implementation Method 2
The adhesive includes at least one resin cured under the action of temperature, pressure, a curing agent, light rays, or a combination thereof
Implementation Method 3
performing a hot pressing process, including closing the mold and hot pressing the mixture for molding at a specific temperature
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
A recycled board includes a plurality of fiber pieces (100, 100a, 100b, 100c) and an adhesive (300) . The plurality of fiber pieces are from recycled fabrics, and each has an average diameter of less than or equal to 10 mm. The adhesive includes at least one resin cured under the action of temperature, pressure, a curing agent, light rays or a combination thereof, and is mixed with the plurality of fiber pieces and molded. The total weight of the plurality of fiber pieces accounts for 50-80 wt% of the weight of the recycled board, and the weight of the adhesive accounts for 20-50 wt% of the weight of the recycled board.