Process for producing insulating boards from the refuses of the nonwoven fabric production

Abstract: The processing foresees the pre-arrangement of the raw material, consisting of the refuses formed by the strips cut long the sides of the nonwoven fabric, for the subsequent mixing acting its tertiary crushing by means of a knife cutting up machine. In the mixing the raw material is initially mechanical mixed with the alumina trihydrate by means of a mixer; then into the mixer are added the other components: unsaturated polyester resin, 1,1 Di(Ter-butylperoxide)cyclohexane, zinc stearate and parabenzoquinone solution to 10% in styren previously mixed by a propeller mixer. The mixing is going on for five minutes and then the obtained shaving mass is discharged by a screw conveyor placed on the mixer bottom. Said shaving mass is then molded with hot pressing at a temperautre of 145°C by means of a punch press with molding pressure of 50 Kg/cm2 and foreseen a molding time of five minutes for each thickness centimeter. In this way four-sided plate insulating boards are formed.

Description: The invention refers to a processing for producing a new insulating material in rigid plane with distinguished sound absorbent, heat insulator and self-extinguished characteristics as well as a good damp resistance. Said new material to be produced by a new process of components quantitatively given in basic formulation which foresees the use of the conventional refuses coming from the working of nonwoven fabrics and synthetic fibers. In the finishing process of said textiles, particularly in the trimming of the sides, refuses are caused. Said refuses, long irregular strip shaped, to be arranged in bales to be sent into the area landfill for their disposal like special wastes. Currently the necessity to must destroy said special wastes creates two drawbacks. The first drawback for the manufacturer who trust transport the special wastes into the area landfill or otherwise, within an agreement, he must make use of someone specialized in transport and the second drawback coming from the presence of a lot of special wastes to be destroyed in the local disposal plant. The described processing comes to avoid the two aforesaid drawbacks and moreover it permits the use of current refuses coming from the nonwoven fabric working like raw material for the producing of new insulating material. The obtained insulating material, for effect of the connatural insulating features of its components, looks distinguished insulating characteristics from the noise and from the heat and also a good resistance to the damp and to the flame; this last feature particularly due to the fact that, if licked up from a flame, the material tends to put out the same emitting steam. These insulating features to be adjusted in the intensity of their effect so to be suited to the various use necessities only therefor opportunely changing the board density in the moulding phase. The process foresees the pre-arrangement of the raw material consisting of the refuses formed by the strips cut long the sides in the nonwoven fabric finishing working. Said raw material taking through a collecting system from the various places to be prepared for the subsequent working acting its tertiary crushing by means of a knife cutting up machine. After this treatment the raw material is then used in the process to produce a mass to be moulded. The process to produce mass foresees the mixing of the following components (in the given weight percent): 1) raw material consists of the refuses of nonwoven fabric working sodden with acrylic resin for 47,25%; 2) unsaturated polyester resin for 10%; 3) 1,1 Di(tert-butylperoxide)cyclohexane (organic peroxide) for 0,9%; 4) alumina trihydrate for 40%; 5) zinc stearate for 1,8% and 6) parabenzoquinone solution to 10% in styrene for 0,05%. In the mixing proceeding the raw material is initially mechanically mixed with the alumina trihydrate by means of a mixer. Then into the mixer the other components previously mixed by a propeller mixer are added. The mixing is going on for five minutes and then the obtained mass is discharged by means of a screw conveyor placed on the mixer bottom. The mass is then moulded by hot pressing at a temperature of 145°C by means of a punch press with a moulding pressure of 50 Kg/cm2 for a moulding time of five minutes per each centimetre of thickness. In this way square plate insulating boards are formed. To adeguate the obtained insulating material to the various use necessities is thereof changed the density during the moulding. To produce boards of lower density the ejector half of the punch press is to be foreseen with closing on steel end of stroke external frame. This external frame with its height thereof to the use necessities. Then the mass is put into the die for the moulding in the requested quantity. When the moulding is ended and with the punch forging press opened, the insulating board is taken out by means of a hydraulic device which raises to a taking place the board formed on the bottom of the fixed lower punch of the punch forging press. In an embodiment the mass, discharged by the screw conveyor at the end of the mixing, is put into film casing impermeable to the styrene and then these casings are housed in container so to permit the afterwards moulding. Before the moulding the mass in the requested quantity is let into the fixed lower punch and it is processed by surface vibrators or with other vibrating means to increase the mass homogeneity. To colour the mass, so to produce coloured insulating boards, during the mixing are added suited pigments. The proceed can foresee also the use of a plant for continuous moulding. Moreover instead of acrylic resin can be used a different resin like phenol-formaldehyde resin or epoxy resin.

Claims: Process for producing insulating boards from the refuses from the production of non-woven fabrics, wherein as raw material the strips cut from the sides of the non-woven fabric, and comminuted in a knife cutting machine are employed, wherein the following components are mixed: (a) 47.25% of the above mentioned raw material sodden with acrylic resin, (b) 10% of an unsaturated polyester resin, (c) 0.9% of 1,1-di(tert.-butylperoxide)cyclohexane, (d) 40% of alumina trihydrate, (e) 1,8% of zinc stearate and (f) 0.05% of a 10% solution of parabenzoquinone in styrene. The mixing being carried out by the following steps: (i) mixing the above mentioned components (a) and (d) by means of a mixer to form a first premix, (ii) preparing a second premix from the remaining components (b), (c), (e) and (f) in a propeller mixer and (iii) then mixing the thus obtained premixes for five minutes; (iv) discharging the thus obtained mass by means of a screw conveyor placed on the mixer bottom and (v) subsequently moulding said mass by hot pressing at a temperature of 145°C by means of a punch press with a moulding pressure of 50 kg/cm 2 for a moulding time of five minutes per each centimetre of thickness to form square plate insulating boards. Process for producing insulating boards from the refuses of the nonwoven fabric production, as defined in claim 1; wherein when the molding is ended and the punch forging press opened, the insulating board is taken out by means of a hydraulic device which raises to a taking place the board formed on the bottom of the fixed lower punch of the punch forging press. Process for producing insulating boards from the refuses of the nonwoven fabric production, as defined in claim 1, wherein the mass, discharged by the screw conveyor at the end of the mixing, is put into film casing impermeable to the styrene and then these casing are put up in container so to permit the afterwards moulding. Process for producing insulating boards from the refuses of the nonwoven fabric production, as defined in claim 1, wherein before the moulding the mass in the requested quantity is let into the fixed lower punch and it is processed by surface vibrators or with other vibrating means to increase the mass homogeneity. Process for producing insulating boards from the refuses of the nonwoven fabric production, as defined in claim 1, wherein suited pigments are added during the mixing to colour the shaving mass so to produce coloured insulating boards.

Inventors: NEBBIAI CARLO, NEBBIAI, CARLO
Applicants: MARINA SPA, LA MARINA SPA
Application year: 1993
Main classification: B29C70
IPC codes: B29C70, C08J11, B29B17, B29B11