Reuse of used woven or knitted textile
10988874 · 2021-04-27
Assignee
Inventors
Cpc classification
B29C70/465
PERFORMING OPERATIONS; TRANSPORTING
D04H1/58
TEXTILES; PAPER
D04H1/54
TEXTILES; PAPER
International classification
B29C70/46
PERFORMING OPERATIONS; TRANSPORTING
D04H1/54
TEXTILES; PAPER
Abstract
The invention pertains to a method of manufacturing a product from used woven or knitted textile comprising vegetable or animal fibres, in particular cotton or wool, the method comprising the steps of: collecting the used woven or knitted textile, granulating the used woven or knitted textile into fibres having an average fiber length of between 3.6 mm and 5.5 mm, mixing the granulated used woven or knitted textile with a thermoplastic fiber based binder, and forming a nonwoven mat from the mixture of the granulated used woven or knitted textile and fiber based binder, the nonwoven mat comprising 59% to 75% of vegetable fiber, or alternatively the nonwoven mat comprising at least 80% animal fibres. The invention also pertains to a product produced by said method.
Claims
1. A method of manufacturing a product from used woven or knitted textile comprising vegetable or animal fibers, the method comprising the steps of: collecting different types of used woven or knitted textiles into a least first and second textile collections, said first and second textile collections being different from each other by having different types of used woven or knitted textile, granulating said first and second textile collections into fibers having an average fiber length of between 3.5 mm and 5.5 mm, separately mixing each of said granulated first and second textile collections said with a thermoplastic fiber based binder and a coupling agent to form first and second mixtures, respectively, and forming a nonwoven mat from the first and second mixtures, wherein said nonwoven mat comprises 59% to 67% by weight of vegetable fiber, or alternatively said nonwoven mat comprises at least 80% by weight animal fibers, wherein the step of forming said nonwoven mat comprises substeps of: forming at least one first precursor nonwoven mat from said first mixture and at least one second precursor nonwoven mat from said second mixture, and arranging said at least one first precursor nonwoven mat and said at least one second precursor nonwoven mat on top of each other to form said nonwoven mat, and wherein said method further comprises the step of: heating said nonwoven mat to at least 140° C., and wherein said nonwoven mat comprises about 3% by weight of the coupling agent.
2. The method according to claim 1, said coupling agent being Maleic Anhydride Polyethylene (MAPE).
3. The method according to claim 1, further comprising the steps of: placing said nonwoven mat in a preheated three-dimensional mold or a flat press, and pressing said nonwoven mat into a product having a shape determined by the shape of said three-dimensional mold or the flat press.
4. The method according to claim 3, wherein 50% to 90% by weight of said fiber based thermoplastic binder is made up of a recycled polypropylene plastic.
5. The method according to claim 3, further comprising the step of: positioning a plastic film between said nonwoven mat and said three-dimensional mold or flat press prior to said pressing.
6. The method according to claim 3, said pressing being performed at a temperature between 160 to 200° C. at a pressure of 40-100 ton/m.sup.2 for 5-15 minutes.
7. The method according to claim 3, wherein said preheated three-dimensional mold or flat press comprises first and second complimentary shaped mold or press parts for defining said shape.
8. The method according to claim 1, wherein said first and second textile collections comprise used woven or knitted cotton textile or used woven or knitted wool textile selected from any of: trimmings, end pieces, faulty sections, experimental pieces and rejected pieces from the textile industry, used textiles, used clothes, used bed linens, used towels, used work uniforms, used upholstery, or used curtains.
9. The method according to claim 1, further comprising the steps of: collecting at least a piece of the nonwoven mat manufactured or remanufactured by the method, or at least a piece of a product manufactured by the method, granulating said piece into fibers having an average fiber length of between 3.5 mm and 5.5 mm, and mixing said granulated piece with said granulated first and second textile collections.
10. The method according to claim 1, wherein at least one of said precursor nonwoven mats is pressed separately by performing the steps of: placing at least one of said precursor nonwoven mats in a preheated three-dimensional mold or a flat press, and pressing at least one of said precursor nonwoven mats into a pressed mat having a shape determined by the shape of said three-dimensional mold or the flat press, before said pressed mat is arranged with other precursor nonwoven mats, at least one of said precursor nonwoven mats is pressed to a density which is different from the density of at least one of the other precursor nonwoven mats.
11. The method according to claim 10, further comprising the steps of: placing said precursor nonwoven mats having different densities in a preheated three-dimensional mold or a flat press, and pressing said precursor nonwoven mats into a product having a shape determined by the shape of said three-dimensional mold or the flat press.
12. The method according to claim 1, wherein each of said first and second textile collections comprises a mixture of wool and cotton, a mixture of different wools, and/or a mixture of different cottons.
13. The method according to claim 1, wherein: the step of collecting said different types of used woven or knitted textiles comprises substeps of: collecting a first amount of used woven or knitted textile comprising a majority of cotton, and collecting a second amount of used woven or knitted textile comprising a majority of wool.
14. The method according to claim 1, further comprising the step of: coating said product with a wax, oil or lacquer.
15. The method according to claim 1, further comprising the step of: affixing a print, optionally through silk screen printing, to said product.
16. The method according to claim 1, further comprising the step of cutting said collected used woven or knitted textile into pieces having a maximal length of 30 cm and a maximal width of 30 cm before commencing the step of granulating said first and second textile collections.
17. The method according to claim 1, wherein the granulated textile fibers have an average length of between 3.5 and 4.5 mm.
18. The method according to claim 1, wherein the fibers of thermoplastics have an average length between 1 mm and 15 mm.
19. The method according to claim 1, wherein the fibers of thermoplastics are at least in part manufactured from reused plastics.
20. The method according to claim 1, wherein the fibers of thermoplastics are manufactured from renewable natural resources.
21. The method according to claim 1, wherein the fibers of thermoplastics are manufactured from biodegradable plastics.
22. The method according to claim 21, wherein each of the plastic fibers comprises a mixture of biodegradable plastics and conventional plastics.
23. The method according to claim 22, wherein the biodegradable plastics constitutes at least 70% per weight of said mixture.
24. The method according to claim 23, wherein said mixture comprises at least 70% per weight of fibers made from biodegradable plastics and the remainder being fibers made from conventional plastics.
25. The method according to claim 1, wherein each of the thermoplastic fibers comprises a core formed by a first type of plastic and a cladding surrounding the core, which cladding is formed by a second type of plastic, said first type of plastic having a significantly higher melting point than said second type of plastic.
26. The method according to claim 25, wherein the first type of plastic has a melting point which is between 30° C. and 80° C. higher than the melting point of the second type of plastic.
27. The method according to claim 25, wherein the first type of plastic has a melting point of between 100° C. and 140° C.
28. The method according to claim 25, wherein the second type of plastic has a melting point of between 150° C. and 200° C.
29. The method according to claim 1, wherein the step of forming the nonwoven mat from the first and second mixtures comprises a substep of heating said mixtures to a temperature of between 100° C. and 140° C.
30. The method according to claim 29, further comprising a substep of dry forming the precursor mats by blowing the first and second mixtures into a forming head disposed above a forming wire prior to or simultaneously to heating said mixture.
31. The method according to claim 30, further comprising a substep of blowing at least one of said first and second mixtures into a forming head placed above a vacuum box disposed on the forming wire where the at least one of said first and second mixtures is deposited and held by a vacuum.
32. The method according to claim 1, wherein at least one of said first and second precursor nonwoven mats is formed using air laying.
33. The method according to claim 1, wherein the step of granulating the first and second textile collections comprises a substep of processing said first and second textile collections using a rasper and/or fine granulator.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings. In the following, preferred embodiments of the invention is explained in more detail with reference to the drawings, wherein
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DETAILED DESCRIPTION
(8) The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. The invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like reference numerals refer to like elements throughput. Like elements will, thus, not be described in detail with respect to the description of each figure.
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(10) Then in the third step 8, the used woven or knitted textile is granulated into fibres baying an average fiber length of approximately 1 mm, preferably with a low spreading around 1 mm. By a low spreading is meant a deviation of less than 10%-20% from 1 mm. The granulation of the used woven or knitted textile may be performed by commercially available fine granulators.
(11) In the forth step 10, said granulated textile fibres are mixed with a thermoplastic binder in the form of fibres made from thermoplastic, where each of said plastic fibres comprises a core formed by a first type of thermoplastic and a cladding surrounding the core, which cladding is formed by a second type of thermoplastic, said first type of plastic having a significantly higher melting point than said second type of plastic.
(12) In order to provide optimal inter-fibre bonds (between the textile fibres), the fibres of thermoplastics have a length between 3 mm and 12 mm. The step 10 of mixing the textile fibres with the binder may comprise the substep of mixing said textile fibres and the binder in a ratio such that the binder will constitute between 10% and 30% weight of the finished mixture. The amount (and type) of binder used may be conveniently chosen in dependence of what kind of product is to be produced by the method according to the invention.
(13) Examples of binders may be fibres of thermoplastic. The binders may also be provided in the form of synthetic fibres, for example bi-component fibres consisting of polypropylene and polyethylene, polyester, vinyl etc. The fibres of thermoplastic may at least in part be manufactured from reused plastics. Hereby is achieved that a product is produced by the method according to the invention is a 100% recycled product, because only waste materials, which otherwise would have been disposed with at a landfill or in a refuse incineration plant, are used as start materials. The fibres of thermoplastic may also be manufactured from renewable natural recourses, whereby is achieved a carbon dioxide neutral product, because both the waste textile fibres, which are majorly or substantially 100% cotton fibres or wool fibres, and the thermoplastic is produced from renewable natural recourses. The fibres of thermoplastic may also be manufactured from biodegradable plastics, whereby is achieved a much more environmentally friendly solution, where the end product produced by the method 2 is a “cradle to cradle” product, i.e. a product which will in a natural way become part of the biological environment from which it is formed. Here, it is understood that by the word biodegradable it is meant degradable by a biological process, e.g. anaerobic or aerobic bacterial breakdown of the product. The biodegradable plastic fibres may be formed from any of the following materials: bio-epoxy, polyhydroxyalkanoates, polylactic acid, polybutylene succinate, polycaprolactone, polyanhydrides, and polyvinyl alcohol.
(14) However, in order to provide an optimal tradeoff between price, and quality of the end products produced by the method 2, each of the plastic fibres may in a further embodiment comprise a mix of biodegradable plastic and conventional plastic. Said mix of biodegradable plastic and conventional plastic may be a mix, where the biodegradable plastic constitutes at least 70% per weight of said mix. Alternatively, the plastic fibres comprise a mix of fibres made from biodegradable plastic and of fibres made from conventional plastic.
(15) Then in the fifth step 12 a nonwoven mat is formed by heating the mix of textile fibres and plastic fibres up to and preferably slightly beyond the melting temperature of the second type of plastic (but not up to the melting temperature of the first type of plastic). This will cause the cladding of the plastic fibres to melt and form inter-fibre bonds between the individual textile fibres, whereby a coherent mat similar to rock or stone wool is produced. For example if the first type of plastic (which constitutes the cladding of the individual plastic fibres) has a melting point of between 100 degrees Celsius and 140 degrees Celsius, the step 12 of forming the nonwoven mat comprises a heating of the mixture of plastic fibres and granulated used woven or knitted textile fibres to a temperature of at least between 100 degrees Celsius and 140 degrees Celsius.
(16) The nonwoven mat is preferably formed in a dry airborne process, which makes it possible to make the fibre mat with greater or lesser degree of compacting and with greater or lesser thickness. It will thus be possible to make the fibre mats with thicknesses from 2-5 mm up to thicknesses of 2-300 mm or even thicker. The density of the manufactures nonwoven fibre mats is in one embodiment 30 grams per cubic meters to 3000 grams per cubic meters or more.
(17) Then in the sixth step 14, the nonwoven mat is placed in a preheated three-dimensional mould or flat press.
(18) In the seventh step 16, the nonwoven mat is pressed into a product having a shape determined by the shape of the three-dimensional mould or flat press. During the pressing step 18 the nonwoven mat is heated to, or preferably beyond, the melting temperature of the first type of plastic, which constitutes the core of the plastic fibres. Hence the core of the plastic fibres will melt during this pressing step and the melted plastic fibres will, when cured, form a matrix embedding the textile fibres. For example if the second type of plastic has a melting point of between 150 degrees Celsius and 200 degrees Celsius, the step 16 of pressing the nonwoven mat in the preheated matched three-dimensional mould or flat press may comprise a heating of the nonwoven mat to a temperature of at least between 150 degrees Celsius and 200 degrees Celsius during the step 16 of pressing the mat into the desired shape, which shape may be a three-dimensional shape of a flat pressed panel.
(19) In the eighth step 18, the product (for example a plate) is removed from the three-dimensional mould or flat press, and excess material is cut and/or trimmed away in order to provide a product having the desired finish.
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Example 1: Sound Absorption
(22) In the following a series of acoustic tests performed on samples of plates (and nonwoven mats) manufactured in accordance with an embodiment of the inventive method will be discussed. The acoustic tests have been performed by DELTA Akustik. The sound absorption was measured for a sound field having an incidence that is perpendicular to the plates that were examined.
(23) The so called transfer measurement method in accordance with the standard EN ISO 10534-2 was used, where the incidence sound and the reflected sound from a test sample placed in a tube is measured with two microphones. The ratio between these two measurements is characterized by a frequency dependent transfer function. The diameter of the tube implies an upper cutoff frequency, which in this particular setup is 2000 Hz. The measurement accuracy for the complete measurement setup gives a lower cutoff frequency. In the particular system used this lower cutoff frequency is 50 Hz.
(24) In
(25) The placement of the test samples within the tube is very critical, because even small cracks and leaks, for example between the test sample and tube, may affect the sound absorption considerably. The leaks between the tube and test samples were minimized by using a special crème as filler between the tube and test sample.
(26) The following measurement equipment was used for the tests:
(27) TABLE-US-00001 Item Brand Type no. DELTA No. Measurement tube Brüel & Kjær — — Amplifier DELTA — — Microphones Brüel & Kjær 4165/4190 4213/0694L/1072L Power supply Brüel & Kjær 2669 1080L/1207L/1215L Calibrator Brüel & Kjær 4231 118T Spectral analyzer Brüel & Kjær PULSE #2665538
(28) By the measurement setup 20, the absorption coefficient is determined with a frequency resolution of 2 Hz in the frequency interval from 50 Hz to 2000 Hz. This frequency interval is determined by the maximal microphone distance and the inner diameter of the tube 24.
(29) In order to provide an estimation of the sound absorption for building purposes, the absorption coefficients have been recalculated to ⅓ octave frequency bands.
(30) Sound absorption of selected samples listed in the table below was conducted using the set up and method described above. The samples used were:
(31) TABLE-US-00002 Sample Contents Thickness No1 Nonwoven mat comprising fibres from used woven or knitted 64 textile (lint) from industrial drying machines to which has been added 25% by weight of bicomponent fibres. No1a The mat of sample No1 which has been pressed during heating 33 (179° C. at 3 minutes) in a manual press (manual flat bed fusing press/manual heat transfer press) to the stated thickness. No1b Four mats of sample No1 which have been pressed during 29 heating to the stated thickness. No2 Nonwoven mat formed from sheep wool to which has been 75 added 20% by weight of bicomponent fibres. No2a The mat of sample No2 which has been pressed during heating 30 (179° C. at 3 minutes) in a manual press (manual flat bed fusing press/manual heat transfer press) to the stated thickness. No2b Four mats of sample No2 which have been pressed during 40 heating to the stated thickness. No3 Nonwoven mat formed from fibres of black wool to which has 35 been added 25% by weight of bicomponent fibres. No3a The mat of sample No3 which has been pressed during heating 15 (179° C. at 3 minutes) in a manual press (manual flat bed fusing press/manual heat transfer press) to the stated thickness. No3b Four mats of sample No3 which have been pressed during 23 heating to the stated thickness. No4 Nonwoven mat formed from mixed fibres (granulated earlier 45 produced mats) to which has been added 25% by weight of bicomponent fibres. No4a The mat of sample No4 which has been pressed during heating 20 (179° C. at 3 minutes) in a manual press (manual flat bed fusing press/manual heat transfer press) to the stated thickness. No4b Four mats of sample No4 which have been pressed during 32 heating to the stated thickness. No5 Nonwoven mat formed from fibres from Cotton (Jeans) to 45 which has been added 25% by weight of bicomponent fibres. No5a The mat of sample No5 which has been pressed during heating 28 (179° C. at 3 minutes) in a manual press (manual flat bed fusing press/manual heat transfer press) to the stated thickness. No5b Four mats of sample No5 which have been pressed during 27 heating to the stated thickness. No6b Four mats of green wool to which has been added 25% by 24 weight of bicomponent fibres and which have been pressed during heating to the stated thickness.
(32) The absorption coefficient for these samples, and for 50 mm glass wool, is shown in
(33) From the figures the following conclusions may be drawn:
(34) Samples No2 and No4 have absorption coefficients which match those of glass wool and may therefore be used as a substitute to glass wool for acoustic insulation or acoustic sheets.
(35) Other samples useful for acoustic sheets placed on walls and ceilings include samples No1, No2, No2a, No3, No4, and No5.
(36) Furthermore there is a need for sound absorbing materials which have a good absorption for low frequencies and which have at least passable absorption in the higher frequencies, i.e. do not reflect so much higher frequency sound so as to worsen the acoustic environment in noisy environments. Suitable samples for these type of absorbents include No1a, No2b and No4b.
(37) For use as a sound insulation in partition walls the samples No1, No2, No2a, No3, No4 and No5 could be useful.
(38) Samples No3a, No4a and No5a could possibly be used as floor underlayment to dampen step sound.
(39) Possibly the samples No1b, No3b, No5b and No6b could be used as sound absorbing sheets on partition walls.
Example 2-1: Further Test Samples
(40) Further tests were made on the following samples, as described in the table below, produced by the method according to the present invention.
(41) TABLE-US-00003 Sample designation Contents of product Average fiber length Sample 1 Used woven or knitted textile (lint) from industrial 0.5-4 mm drying machines to which has been added 25% by weight of bicomponent fibres. Sample 2 White cotton (from used bed sheets) to which has Granulated used bed (P2.1KS) been added 25% by weight of bicomponent fibres. sheets result in fibres having homogenous appearance and an average fiber length of 0.5-4 mm. Sample 3 White cotton (from used bed sheets) to which has As above. (P3.1KS) been added 25% by weight of bicomponent fiber and 2% by weight of a wetting agent (maleic anhydride polypropylene). Sample 4 White cotton (from used bed sheets) to which has As above. (P4.1KS) been added 10% by weight of bicomponent fiber, 2% by weight of wetting agent and 18% by weight of recycled polyethylene Sample 5 Black wool (from waste woven piece goods) to The granulated waste (P5.1KS) which has been added 25% by weight of woven piece goods result bicomponent fibres. in fibres having homogenous appearance and an average fiber length of 0.5-4 mm. Sample 6 Black wool to which has been added 25% by As above. (P6.1KS) weight of bicomponent fiber and 2% by weight of wetting agent (maleic anhydride polypropylene). Sample 7 Black wool to which has been added 10% by As above. (P7.1KS) weight of bicomponent fiber, 2% by weight of wetting agent and 18% by weight of recycled polyethylene. Sample 8 Brown wool to which has been added 25% by 0.5-4 mm weight of bicomponent fiber Sample 9 Fiber mix of 50% white cotton (from used bed 0.5-4 mm (P11.1KS) sheets) and 50% black wool to which has been added 25% by weight of bicomponent fibres. Sample 10 Sheep wool from spinning process to which has Sheep wool has an average (P13.1KS) been added 20% by weight of bicomponent fibres. fiber length of 2,097 mm yet about 19% of the sheep wool fibres are 4.5-7.5 mm. Sample 11 Fiber mix of 50% sheep wool and 50% black wool 0.5-4 mm (P8.1KS) to which has been added 20% by weight of bicomponent fibres. Sample 12 Mix of 50% Turquoise wool and 50% cork to 0.5-4 mm. P.18_KS which has been added 25% by weight of The cork was granulated to bicomponent fiber. pieces each having a diameter of 3-10 mm. Sample 13 Cotton (from jeans textile) to which has been The granulated waste P.16_KS added 25% by weight of bicomponent fiber. jeans textile resulted in fibres having an average fiber length between 0.5 and 4 mm, specifically 1,134 mm, and a mean width of 21.9 micron. Sample 14 Mixed fibres (remnants, waste and leftovers from 0.5-4 mm (P.14.1KS) the production of the above samples excluding wool and cork) to which has been added 5% bicomponent fibres
(42) The bicomponent fiber used for the above samples is AL-Adhesion-C-1.7 dtex, 6 mm, from ES fibervisions, Engdraget 22 DK-6800 Varde, Denmark. The bicomponent fibres comprise polyethylene and poly propylene with respective soft points of 124 C and 140 C and respective melting points of 130° C. and 162° C.
(43) The recycled polyethylene used for the above samples was PE MD ROTA Black, ID 45796, from Aage Vestergaard Larsen A/S, Klostermarken 3 DK-9550 Mariager, Denmark.
Example 2-2: Effects of Material Composition on Fulfillment of MDF Standards
(44) A number of the above samples, as pressed boards, were tested for swelling, internal bond, bending strength and mean modulus of elasticity for comparison with the standards required of MDF plates, and the results are displayed in the table below:
(45) TABLE-US-00004 Thickness Swelling Bending strength Modulus of elasticity (measured) Density (EN 317 - 24 h) (MOR) (EN 310) (MOE) (EN 310) Board_ID [mm]/COV [kg/m3]/COV [%]/COV [MPa]/COV [MPa]/COV P2.1KS 9.47 0.9 994.4 1.1 22.5 0.6 40.24 8.05 3705 10 P3.1KS 11.82 0.6 1061.3 0.5 24.6 1.4 27.67 4.7 2620 11 P4.1KS 9.4 0.7 1028.4 0.2 12.8 3.3 27.66 4.65 2687 5 P5.1KS 8.88 1.3 1194.7 0.2 1.9 0 36.75 1.13 2690 0 P6.1KS 10.14 2 1161 1 1.1 0 36.99 6.26 2423 4 P7.1KS 9.96 1 1152.1 0.7 1.1 0 29.05 4.25 1773 3 P8.1KS 9.73 8.5 1177.2 2.3 10.6 10 33.13 11.48 2014 7
(46) Sample P8.1KS, comprising the mix of black wool (having short fibres) and sheep wool (having fibres longer than 4 mm, has much higher swelling than the sample P5.1KS having only short fibres. Thus there is a need for using short fibres and a homogenous distribution, i.e. low spreading, of fiber length.
(47) The table further shows the good properties of wool (samples P5.1KS to P8.1KS) in relation to cotton (samples P2.1KS to P4.1KS) as regards swelling. In fact, all the wool samples fulfil the EN-622-5MDF and the EN-622-5MDF.H (for humid conditions) standard for swelling while none of the cotton samples fulfils the EN-622-5MDF.H standard and only sample P4.1KS of the cotton sample fulfils the EN-622-5MDF standard.
(48) The result for sample P4.1KS further shows that the recycled polyethylene, and thereby presumably also virgin polyethylene, is beneficial to improving swelling properties as the other cotton samples which do not contain recycled polyethylene do not fulfil the requirements of the standard.
(49) The table below further shows results for further samples as pressed boards
(50) TABLE-US-00005 Thickness Swelling Internal Bond Bending Strength Modulus of elasticity Process (measured) Density (EN 317 - 24 h) (EN 319) (MOR) (EN 310) MOE (EN 310) Board_ID description [mm]/COV [kg/m3]/COV [%]/COV [MPa]/COV [MPa]/COV [MPa]/COV P4.1KS/ White cotton 7.05 0.4 1017.9 2.8 11.3 2.3 1 11.7 26.87 11.22 2595 13 P10.1KS 100% + 2% WA + PE P11.1KS Black wool 8.1 0.4 1059.3 1.7 13.3 3.4 0.68 9.2 29.56 8.65 2081 6 50%/50% Cotton P5.1KS/ Black 100% 7.72 0.4 936.3 0.4 14.8 1 0.13 8.2 17.08 31.27 1054 23 P12.1KS wool/wool P13.1KS Sheep wool 5.9 3.2 919.5 3.2 33.5 31.6 Not tested 9.91 21.58 554 28 P14.1KS Mixed fibre 7.37 2.2 977 7.1 4 35.4 0.94 6.9 33.7 5.43 1966 4
(51) Of the above samples, only P4.1KS, P11.1KS and P14.1KS fulfil the requirements of the swelling, bending strength and internal bond standards for MDF plates. P13.1KS fails all these requirements, while P5.1KS fulfils the requirement for swelling, but not the other two.
(52) The results further show that addition of the recycled polyethylene results in improved internal bond as sample P4.1KS has the highest internal bond.
(53) From sample P11.1KS it ban be seen that this sample has improved swelling properties, when compared to the sample P2.1KS, due to the wool fibres inmixed with the cotton fibres.
Example 2-3: Effects of Material Composition on Hardness
(54) A number of samples, as pressed boards, were tested for hardness according to Shore D (ISO 868), Brinell (EN 1534), and Scratch (SIS 839117), see the results in the table below:
(55) TABLE-US-00006 Shore D - mean of HB Scratch at 3 N and Board_ID Material 10 points [N/mm.sup.2] 5 N P.8-2_KS Wool + 61 42.02 Visible scratch when Wool light hits the plate and is reflected P14.1KS/ Mixed fibre 73 50.99 Visible scratch when P.15_KS light hits the plate and is reflected P.16_KS Jeans 72 44.99 Visible scratch when light hits the plate and is reflected P.17_KS Sheep wool 42 18.95 Visible scratch when light hits the plate and is reflected P.18_KS Turquoise 68 29.28 Visible scratch when Wool/Kork light hits the plate and is reflected
(56) As can be seen from the table, the sheep wool has a significantly lower hardness than the other samples due to the presence of longer fibres.
Example 2-4: Ignitability
(57) Fire testing was performed with single test single flame source according to EN ISO 11925-2 for the following samples as pressed boards.
(58) TABLE-US-00007 Thickness Sample number Contents (mm) Density 1 (corresponds to 80% wool + 20% 11.2 1145 Sample 5 in example bicomponent fibres. 2-1 excluding lanolin) Covered with lanolin 2 (corresponds to 80% wool + 20% 7.1 1142 Sample 5 in example bicomponent fibres. 2-1 excluding Covered with Burnblock) Burnblock ® 3 (corresponds to 80% wool + 20% 7.2 1086 Sample 5 in example bicomponent fibres. 2-1) 4 (corresponds to Mixed wool and cotton + 11.1 919 Sample 9 in example 20% 2-1) bicomponent fibres. 5 (corresponds to Cotton(Jeans) + 20% 8.4 1262 Sample 13 in example bicomponent fibres. 2-1) 6 (corresponds to Cotton (jeans) + 20% 8.5 1066 Sample 13 in example bicomponent fibres, 2-1 excluding coated with Burnblock) Burnblock ®
(59) Burnblock® is a fire retardant marketed by BURNBLOCK ApS. Kgs Nytorv. 15, 1050 Copenhagen K, Denmark.
(60) None of the samples ignited during the 30 seconds during which the flame was directed at the edge of the sample. There further were no burning droplets.
Example 2-5: Influence of Fiber Direction on Mechanical Properties
(61) The table below shows the bending strength of various samples as pressed boards having different fiber directions.
(62) TABLE-US-00008 Thickness Process Thickness (measured) MOR (EN 310) MOE (EN 310) Board_ID Material description Control (nom.) [mm] [mm]/COV [MPa]/COV [MPa]/COV PB3KS Cotton Parallel Automatic 9 8.73 1.25 36.91 6.38 4123 10 (Sample 2 in direction Example 2-1) PB4KS Cotton orthogonal Automatic 9 8.68 0.41 19.01 5.09 2126 14 (Sample 2 in direction Example 2-1) PU2KS Wool Parallel Automatic 9 8.26 0.29 22.72 8.35 1323 10 (Sample 5 in direction Example 2-1) PU3KS Wool orthogonal Automatic 9 8.2 1.25 26.38 6.04 1515 6 (Sample 5 in direction Example 2-1)
(63) Of the above samples, PB3KS, PU3KS filfil the EN 310 bending strength requirement for MDF according to the EM 622-5 MDF standard, while only PB3KS fulfils the bending strength required by the EN 622-6 MDF.H standard.
Example 2-6: Effects of Coating Products Produced by the Method According to the Present Invention
(64) The following samples, as pressed plates of approximately 8 mm thickness, were tested:
(65) TABLE-US-00009 Swelling % thickness after Sample Coating 24 hours P2.1KS Oil 21.4 P2.1KS Oil 21.2 P2.1KS Wax 22.2 P2.1KS Wax 21.8 P2.1KS Lacquer 21.5 P2.1KS Lacquer 22.2 P3.1KS Oil 22.8 P3.1KS Oil 22.6 P3.1KS Wax 24.8 P3.1KS Wax 24.8 P3.1KS Lacquer 23.6 P3.1KS Lacquer 23.3 P4.1KS Oil 5.7 P4.1KS Oil 2.2 P4.1KS Wax 12.0 P4.1KS Wax 12.6 P4.1KS Lacquer 0.1 P4.1KS Lacquer 0.1 P5.1KS Oil 0.3 P5.1KS Oil 0.8 P5.1KS Wax 2.4 P5.1KS Wax 2.1 P5.1KS Lacquer 0.0 P5.1KS Lacquer 0.2 P6.1KS Oil 0.1 P6.1KS Oil 0.0 P6.1KS Wax 1.2 P6.1KS Wax 1.6 P6.1KS Lacquer 0.0 P6.1KS Lacquer −0.1 P7.1KS Oil 0.3 P7.1KS Oil 0.4 P7.1KS Wax 1.2 P7.1KS Wax 1.3 P7.1KS Lacquer 0.0 P7.1KS Lacquer −0.1
(66) The wax used was “Nordin Voks” from Farvefabrikken Skovgaard & Frydensberg Gadestaevnet 6-8, 2650 Hvidovre, Denmark.
(67) The oil used was “Junckers Rustic BordpladeOlie klar” a hardening urethane oil from Junckers Industrier A/S, Vaerftsvej 4, 4600 Køage, Denmark.
(68) The lacquer used was Plastofix 96RF 52156, which is a 2 component acid hardening lacquer comprising alkyde, melamin resin and cellulose nitrate from Akzo Nobel, Holmbladsgade 70, DK2300 Copenhagen S, Denmark.
(69) As can be seen from the table above, samples P2.1KS and P3.1KS have equally high swelling regardless of coating method, while sample P4.1KS generally obtains lower swelling, and in particular a good low result is seen if coated by lacquer.
(70) In contrast to the cotton samples, i.e. P2.1KS-P4.1KS, the wool samples, i.e. P5.1KS-P7.1KS, provide much lower swelling, especially if coated with lacquer.
Example 2-7: 1.SUP.st .and 2.SUP.nd .Generation Products
(71) Test were carried out where a product produced by the method according to the present invention was used as used woven or knitted textile for producing a new product, i.e. a 1.sup.st generation product (closed loop#1), and where this 1.sup.st generation product was used to make a new 2.sup.nd generation product (closed loop#2).
(72) TABLE-US-00010 Thickness Bending strength Modulus of elasticity Process (measured) (MOR) (EN 310) (MOE) (EN 310) Board_ID Material description [mm]/COV [MPa]/COV [MPa]/COV B.1 Cotton 170° C. 8.84 0.7 36.58 12.23 4067 11 (Sample 2 in STD PRG. Example 2-1) P9.8KS Wool 170° C. 8.15 0.3 47.21 7.38 2464 11.1 (Sample 5 in STD PRG. Example 2-1) P37.3 KS Wool Closed 9.9 — 49.47 — 2633 — (Sample 5 in loop #1 Example 2-1) P40 KS Wool Closed 8.5 — 38.48 — 2647 — (Sample 5 in loop #2 Example 2-1) P38.3 KS Cotton Closed 10.3 — 11.8 — 1588 — (Sample 2 in loop #1 Example 2-1) P41 KS Cotton Closed 8.5 — 23.31 — 3399 — (Sample 2 in loop #2 Example 2-1) P39.3 KS Cotton + Wool Closed 9.7 — 18.15 — 1743 (Sample 9 in loop #1 Example 2-1) P42 KS Cotton + Wool Closed 9.8 — 37.15 — 3226 — (Sample 9 in loop #2 Example 2-1)
(73) The samples B.1 and P9.8KS are included for reference.
(74) As can be seen from the table, the 2.sup.nd generation wool product sample P40 KS has a somewhat lower bending strength than the first generation wool sample P37.3KS. For cotton however the bending strength actually increases between the first generation sample P 38.3 KS and the second generation sample P 41 KS. An increase in bending strength is also seen between the 1.sup.st generation cotton+wool sample P39.3 KS and the 2.sup.nd generation cotton+wool sample.
Example 2-8: Addition of 3% Glass Fibres
(75) Tests were carried out for measuring bending strength dependent on the addition of 3% glass fibres for samples as pressed boards. The results are shown in the table below (samples B.1 and P9.8KS serving as reference:
(76) TABLE-US-00011 Thickness Bending strength Modulus of elasticity Process (measured) (MOR) (EN 310) (MOE) (EN 310) Board_ID Material description [mm]/COV [MPa]/COV [MPa]/COV B.1 Cotton 170° C. STD PRG. 8.84 0.7 36.58 12.23 4067 11 (Sample 2 in Example 2-1) P9.8KS Wool 170° C. STD PRG. 8.15 0.3 47.21 7.38 2464 11.1 (Sample 2 in Example 2-1) P45 KS Black and Without glass fibre 9 0.1 29.41 30 1822 24 brown wool (50/50 mix of samples 5 and 8 in Example 2-1) P46 KS Black and With glass fibre 8.8 0.9 36.53 19 2113 9 brown wool (50/50 mix of samples 5 and 8 in Example 2-1) P47 KS Cotton Without glass fibre 9.0 0.5 24.93 12 2468 17 (Sample 2 in Example 2-1) P48 KS Cotton With glass fibre 9.65 0.7 28.94 25 2644 16 (Sample 2 in Example 2-1)
(77) The glass fibre reinforcement used in the above samples was the “UNIFORM GYPSUM Wet Used Chopped Strands” from UCOMPOSITES A/S, Bakkedraget 5 4793 Boø, Denmark, The diameter of the filaments was 17 micron and the length was 6.3 mm (¼″).
(78) As can be seen from the table, the samples with added glass fibre have slightly higher bending strength. Of the samples P45 KS-P48 KS, all except P47 KS fulfil the requirements for binding strength of the EN 622-5 MDF standard.
Example 2-9: Multiple Layer Sandwich
(79) A single sample made up of 10 layers from 5 different sources of used woven or knitted textile, the layers being from one side to the other. Black wool—Mixed—Cotton (Jeans)—Brown wool—Cotton (white)—Brown wool—Cotton (white)—Cotton (Jeans)—Mixed—Black wool.
(80) The table below shows the test results for this sample:
(81) TABLE-US-00012 Thickness Swelling Internal Bond Bending strength Modulus of elasticity (measured) Density (EN 317 - 24 h) (EN 319) (MOR) (EN 310) (MOE) (EN 310) Board_ID Material [mm]/COV [kg/m3]/COV [%]/COV [MPa]/COV [MPa]/COV [MPa]/COV P23.1 Mixed 18.35 0.1 1142.9 0.6 17.3 4.1 0.25 19.7 36.95 7.05 2411 21 KS materials as above
(82) This sample fulfilled the requirement for bending strength for the EN 622-5 MDF standard, but not the requirements for swelling and internal bond.
Example 2.10: Different Press and Heating Programmes
(83) The table below details samples pressed to a nominal thickness of 9 mm in a standard pressing program at 170° C. defined by
(84) TABLE-US-00013 Thickness Swelling Internal Bond Bending strength Modulus of elasticity (measured) Density (EN 317 - 24 h) (EN 319) (MOR) (EN 310) (MOE) (EN 310) Board_ID Material [mm]/COV [kg/m3]/COV [%]/COV [MPa]/COV [MPa]/COV [MPa]/COV B.1 Cotton 8.84 0.7 1024.8 0.4 24.2 0.2 0.39 3.1 36.58 12.23 4067 11 (Sample 2 in Example 2-1) P9.8KS Wool 8.15 0.3 1039.3 1.9 1.7 20.4 0.77 17.6 47.21 7.38 2464 11.1 (Sample 5 in) Example 2-1)
(85) As can be seen from
(86) As can be seen from
(87) The table below details samples pressed to a nominal thickness of 9 mm in a quick pressing program at 170° C. aimed at pressing at twice the speed of the standard program. The quick program is defined by
(88) TABLE-US-00014 Thickness Swelling Internal Bond Bending Strength Modulus of elasticity (measured) Density (EN 317 - 24 h) (EN 319) (MOR) (EN 310) (MOE) (EN 310) Board_ID Material [mm]/COV [kg/m3]/COV [%]/COV [MPa]/COV [MPa]/COV [MPa]/COV P9.3 KS Cotton 9.17 0.4 1104.4 0.4 26.6 2.8 0.43 8.7 30.55 8.64 3691 8 (Sample 2 in Example 2-1) B.1 Cotton 8.84 0.7 1024.8 0.4 24.2 0.2 0.39 3.1 36.58 12.23 4067 11 (Sample 2 in Example 2-1) P9.7 KS Wool 8.31 0.3 1114.3 2.1 2.9 15.4 0.73 34.7 42.49 8.97 2553 8 (Sample 5 in Example 2-1) P9.8 KS Wool 8.15 0.3 1039.3 1.9 1.7 20.4 0.77 17.6 47.21 7.38 2464 11.1 (Sample 5 in Example 2-1)
(89) In the above table samples, B.1 and P9.8KS at standard temperature and pressing time have been included for reference.
(90) The table below details samples pressed to a nominal thickness of 9 mm at a temperature of 200° C. and at half the time of the standard program. The program is defined by
(91) TABLE-US-00015 Thickness Swelling Internal Bond Bending strength Modulus of elasticity (measured) Density (EN 317 - 24 h) (EN 319) (MOR) (EN 310) (MOE) (EN 310) Board_ID Material [mm]/COV [kg/m3]/COV [%]/COV [MPa]/COV [MPa]/COV [MPa]/COV B.1 Cotton 8.84 0.7 1024.8 0.4 24.2 0.2 0.39 3.1 36.58 12.23 4067 11 (Sample 2 in Example 2-1) P9.2 KS Cotton 9.05 0.2 1125.5 1.3 19 11.1 0.51 4.4 37.74 6.21 3997 7 (Sample 2 in Example 2-1) P9.8 KS Wool 8.15 0.3 1039.3 1.9 1.7 20.4 0.77 17.6 47.21 7.38 2464 11.1 (Sample 5 in Example 2-1) A1.1 Wool 8.34 0.8 963.3 0.9 4 6.3 0.71 32.3 41.97 11.01 1903 12 (Sample 5 in Example 2-1)
(92) In the above table, samples B.1 and P9.8KS at standard temperature and pressing time have been included for reference.
(93) The table below details three mats pressed to plates with a nominal thickness of 13.5 mm in a standard program at 170° C. The standard program is defined by
(94) TABLE-US-00016 Thickness Swelling Internal Bond Bending strength Modulus of elasticity (measured) Density (EN 317 - 24 h) (EN 319) (MOR) (EN 310) (MOE) (EN 310) Board_ID Material [mm]/COV [kg/m3]/COV [%]/COV [MPa]/COV [MPa]/COV [MPa]/COV P9.4 KS Cotton (3 mats 15.73 1.5 971.9 0.5 28.4 3 0.27 2.6 23.29 2.08 2786 3 of Sample 2 in Example 2-1) B.1 Cotton 8.84 0.7 1024.8 0.4 24.2 0.2 0.39 3.1 36.58 12.23 4067 11 (Sample 2 in Example 2-1) P9.6 KS Wool (3 mats 13.99 0.7 926.6 0.5 Not Not 0.18 38 Not Not Not Not of Sample 5 in tested tested tested tested tested tested Example 2-1) P9.8 KS Wool 8.15 0.3 1039.3 1.9 1.7 20.4 0.77 17.6 47.21 7.38 2464 11.1 (Sample 5 in Example 2-1)
(95) In the above table, samples B.1 and P9.8KS pressed to a nominal thickness of 9 mm at standard temperature and pressing time have been included for reference.
(96) From the figures it can be seen that the time during which the temperature in the middle if the samples is above 160° C. is longer for cotton than wool.
(97) However, the wool plate has better properties.
(98) Running the pressing at half the time results in a shorter time during which the middle of the sample is above 160° C. However, the samples produced using half the time are good enough.
(99) Running a high temperature program increases the properties for the sample comprising cotton, while it slightly decreases the properties for the sample comprising wool.
(100) When running samples comprises several layers, additional time and/or higher temperatures are needed if the temperature in the middle of the samples is to be maintained above 160° C. for sufficient amount of time.
(101) In the below examples 3 to 5, the tested samples have been produced similarly to sample (P2.1KS), see example 2-2 above, however with the difference that the used woven or knitted textile was granulated to fibres having an average fiber length of 3.5 mm to 5.5 mm.
Example 3: Different Proportions of Textile (Cotton) and Binder
(102) Five different test samples were made with varying proportions of used textile (cotton) and fiber based binder (bicomponent—BICO—fibres). The samples are listed in the table below.
(103) TABLE-US-00017 Sample [% textile fibres/% BICO fibres] Thickness Date Sample no. 1. 75%/25% 8 mm 17 Mar. 2015 P.53_KS 2. 71%/29% 8 mm 17 Mar. 2015 P.54_KS 3. 67%/33% 8 mm 17 Mar. 2015 P.55_KS 4. 63%/37% 8 mm 17 Mar. 2015 P.56_KS 5. 59%/41% 8 mm 17 Mar. 2015 P.57_KS
(104) The table below shows the test results of samples 1-5, in terms of mean values, with the bottom row used for comparison with a board where the proportion was 80% textile (cotton) fibres and 20% bicomponent fibres.
(105) TABLE-US-00018 Measured Before test EN 317 EN 310 EN 310 Sample Thickness Density Swelling MOR MOE Sample no. [mm] [kg/m3] [%] [MPa] [MPa] 1. (75%) P.53_KS 8.66 1087.7 15.6 42.31 3137 2. (71%) P.54_KS 9.04 1069.5 13.5 45.45 3135 3. (67%) P.55_KS 8.45 1123.3 8 60.04 4165 4. (63%) P.56_KS 8.57 1134.7 5.2 53.05 3557 5. (59%) P.57_KS 6.26 1168.9 2 62.49 3995 80% cotton/20% BICO 8.84 1024.8 24.2 36.58 4067
(106) As before, MOR refers to strength, and MOE refers to the stiffness/elasticity module.
(107) When considering sample 1, if can determined that adding 5% mm plastic to the composition of the material improves the mechanical properties in terms of swelling and strength when comparing to the 80%/20% sample.
(108) The swelling properties have been decreased from 24.2% to 15.6%, which portrays an improvement of the material.
(109) The strength of the material has been increased from 36.58 MPa to 42.31 MPa, which also shows an improvement of the material.
(110) The stiffness of the material has not improved. It has been decreased from the before of 4067 to 3137 MPa.
(111) When considering sample 2, it can be determined that adding 9% more plastic to the composition of the material improves the mechanical properties in terms of swelling and strength when comparing to the 80%/20% sample.
(112) The swelling properties have been decreased from 24.2% to 13.5%, which portrays an improvement of the material.
(113) The strength of the material has been increased from 36.58 MPa to 48.45 MPa, which also shows an improvement of the material, though a slight improvement compared to Sample 1.
(114) The stiffness of the material has not improved. It has been decreased from the before of 4067 to 3135 MPa.
(115) When considering sample 3, it can be determined that adding 13% more plastic to the composition of the material improves the mechanical properties in terms of swelling, strength and stiffness, when compared to the 80%/20% sample.
(116) The swelling properties have been decreased from 24.2% to 8%, which portrays a significant improvement of the material, and which indicates a larger improvement compared to Sample 1 and Sample 2.
(117) The strength of the material has been increased from 36.58 MPa to 60.04 MPa, which also shows a significant improvement of the material, which indicates a larger improvement compared to Sample 1 and Sample 2.
(118) The stiffness of the material has slightly improved. It has been increased from the before of 4067 to 4165 MPa.
(119) When considering sample 4, it can be determined that adding 17% more plastic to the composition of the material improves the mechanical properties in terms of swelling and strength, when compared to the 80%/20% sample.
(120) The swelling properties have been decreased from 24.2% to 5.2% which portrays a significant improvement of the material, and which indicates a larger improvement compared to Sample 1 and Sample 2, and a bit better than Sample 3.
(121) The strength of the material has been increased from 36.58 MPa to 53.05 MPa, which also shows a significant improvement of the material, and which indicates a larger improvement compared to Sample 1 and Sample 2, but less improvement compared to Sample 3.
(122) The stiffness of the material has not improved. It has been decreased from the before of 4067 to 3557 MPa. For the properties of stiffness, the results of Sample 4 are somewhat the same as for Sample 1 and Sample 2.
(123) When considering sample 5, it can be determined that adding 21% more plastic to the composition of the material improves the mechanical properties in terms of swelling and strength, when compared to the 80%/20% sample.
(124) The swelling properties have been decreased from 24.2% to 2%, which portrays a significant improvement of the material, and which indicates a larger improvement compared to Sample 1, Sample 2 and Sample 3, and a bit better than Sample 4.
(125) The strength of the material has been increased from 36.58 MPa to 62.49 MPa, which also shows a significant improvement of the material, which indicates a larger improvement compared to all previous Samples (1,2,3 & 4), though the strength for Sample 3 is almost as high as for Sample 5.
(126) The stiffness of the material has not improved. It has been decreased from the before of 4067 to 3995 MPa, though the stiffness is higher than for Sample 1, Sample 2 and Sample 4, but closer to Sample 3. This slight decrease of stiffness indicates a similar property in stiffness as before.
Example 4: Different Proportions of Textile (Cotton), Binder and Coupling Agent (MAPE)
(127) For the following tests the coupling agent used was Maleic Anhydride PolyEthylene (MAPE); product name: Polyethylene-graft-maleic anhydride, viscosity 500 cP, by Sigma-Aldrich. The coupling agent was mixed with the granulated textile fibres and the mats were heated to 140° C. prior to pressing to ensure a tight bonding of the fibres. The mixing of MAPE with the textile fibres went easy and without complications. The processing showed compatibility between cotton and MAPE.
(128) The table below shows the collected samples 6 to 8 made from the cotton-textile fibres, plastic fibres (BICO) and MAPE fibres; they are sample-numbered with descriptions of the content and thickness. The samples were made in the same way as samples 1-5 of example 3 above, however, with the addition of the steps of mixing with coupling agent and heating as described above.
(129) TABLE-US-00019 Sample [% textile fibres/ Sample % BICO fibres/% MAPE fibres] Thickness Date no. 6. 75%/22%/3% 8 mm 17 Mar. 2015 P.59_KS 7. 67%/30%/3% 8 mm 17 Mar. 2015 P.62_KS 8. 63%/34%/3% 8 mm 17 Mar. 2015 P.44_KS
(130) The test results far Sample 6, Sample 7 and Sample 8 can be seen in the table below.
(131) TABLE-US-00020 Measured Before test EN 317 EN 310 EN 310 Sample Thickness Density Swelling MOR MOE Sample no. [mm] [kg/m3] [%] [MPa] [MPa] 6. (75%) P.59_KS 8.48 962.1 13 35.5 2702 7. (67%) P.62_KS 8.13 970.6 11.1 41.54 2985 8. (63%) P.44_KS 8.49 1067.4 0.8 52.89 3206 80% cotton/20% BICO 8.84 1024.8 24.2 36.58 4067
(132) When comparing the results from Sample 6, Sample 7 and Sample 8 to the 80%/20% sample. It can be determined that adding a coupling agent (MAPE) to the composition of the material together with more plastic fibres improves the mechanical properties in terms of swelling and strength.
(133) The swelling properties have been considerably improved by the addition of MAPE, since Sample 6 has a swelling value of 13%, Sample 7 has 11.1% and Sample 8 has 0.8%, whereas before the swelling properties were as high as 24.2%. This indicates that using a coupling agent in the composition allows the sample to repel water or liquids better, which is a property that is desired in the product according to the present invention.
(134) The strength of the material has been increased from 36.58 MPa to 35.5 MPa for Sample 8 and 41.54 MPa for Sample 7, which shows minor improvements. On the other hand, when comparing to Sample 8, the improvement has increased to 52.89 MPa, which shows a significant improvement of the material.
(135) The stiffness of the material has not improved. On the contrary, the stiffness for Sample 6, Sample 7 and Sample 8 is less than the 80%/20% sample.
(136) After the tests, it can therefore be concluded that, compared to the 80%/20% sample, the new compositions with added MAPE have improved mechanical properties when considering swelling and strength, though Sample 8 has the preferable performance compared to Sample 6 and Sample 7. These improved swelling properties are desired in the product according to the present invention because a board should repel water or liquids as much as possible. This property has been improved with increased plastic content and the addition of MAPE.
Example 5: Different Proportions of Textile (Wool) and Binder
(137) The table below shows the samples 9 and 10 made from the used wool-textile fibres and plastic fibres (BICO).
(138) TABLE-US-00021 Sample [% textile fibres/% BICO fibres] Thickness Date Sample no. 9. 80%/20% 8 mm 17 Mar. 2015 P.64_KS 10. 63%/37% 8 mm 17 Mar. 2015 P.47_KS
(139) The test results for Sample 9 and Sample 10 can be seen in the table below
(140) TABLE-US-00022 Measured Before test EN 317 EN 310 EN 310 Sample Thickness Density Swelling MOR MOE Sample no. [mm] [kg/m3] [%] [MPa] [MPa] 9. (80%) P.64_KS 8.15 1039.3 1.7 47.21 2464 10. (63%) P.47_KS 8.19 1070.5 3.7 39.75 2172
(141) Surprisingly, the increase in plastic content does not increase the mechanical properties of swelling, strength and stiffness when considering how Sample 9 performs better than Sample 10 in all of the parameters. Therefore, increasing the amount of plastic does not improve these properties.
(142) The results of the above examples 3-5 have been compared to the requirements for MDF in the table below.
(143) Surprisingly, the products according to the present invention perform better than MDF in all parameters for all samples, except for sample 9 and 18 (stiffness), thus proving that the products according then the present invention may serve as replacement or substitute for MDF. In particular, as is clear from the table, a MDF board of equivalent thickness has lower test results for swelling, strength, and stiffness.
(144) TABLE-US-00023 Materials Swelling [%] MOR [MPa] MOE [MPa] MDF 6-9 mm 17 23 2700 Sample 1 (75%) 15.6 42.31 3137 Sample 2 (71%) 13.5 45.45 3135 Sample 3 (67%) 8 60.04 4165 Sample 4 (63%) 5.2 53.05 3557 Sample 5 (59%) 2 62.49 3995 Sample 6 (75% + 3%) 13 35.5 2702 Sample 7 (67% + 3%) 11.1 41.54 2985 Sample 8 (63% + 3%) 0.8 52.89 3206 Sample 9 (80%) 1.7 47.21 2464 Sample 10 (63%) 3.7 39.75 2172
(145) As before, MOR refers to strength, and MOE refers to the stiffness/elasticity module.
(146) As mentioned above, Sample 9 and Sample 10, which are comprised of wool textile fibres, have lower values regarding the stiffness.
(147) Surprisingly, the strength and stiffness of the cotton samples (samples 1-5) reach the highest values for the range of 59- to 67% textile fibres (samples 3-5) despite the expectation that a lower proportion of textile fibres would decrease stiffness. This range further gives good values for swelling, e.g. less than half of that of MDF, thus providing an advantageous range for the proportion of cotton textile fibres.
(148) Of this range, especially samples 4 and 5, i.e. the range of 63% to 67% cotton, show very advantageous values as regards the properties swelling, strength and stiffness. As regards wool, on the other hand, the proportion of textile fibres should be at least 80%, as smaller proportions, see sample 10, have worse properties.
(149) Even further advancements in decreasing swelling are obtainable by the addition of the coupling agent (MAPE), while still surpassing the MDF board as regards the properties mechanical strength and stiffness.
(150) Surprisingly, the addition of the coupling agent to sample 1, with 75% textile fibres (sample 6), results only in a small decrease in swelling, and the addition of the coupling agent to sample 2 (see sample 7) actually increases swelling, while the same addition to sample 4 (see sample 8) decreases swelling 6.5 limes to the lowest value. Thus there appears to exist a synergic effect between the coupling agent and the proportion of textile fibres/plastic.
(151) Another surprising result is that comparable low swelling properties of the wool samples can be obtained using the cheaper cotton textile fibres when combined with the coupling agent, see samples 8 and 10, while still maintaining mechanical properties that are superior to those of the wool samples.
LIST OF REFERENCE NUMBERS
(152) In the following is given a list of reference numbers that are used in the detailed description of the invention. 2 flow diagram of a method according to the invention, 4 method step of collecting used woven or knitted textile, 6 method step of cutting used woven or knitted textile into pieces, 8 method step of granulating the used woven or knitted textile, 10 method step of mixing textile fibres and binder, 12 method step of forming a nonwoven mat, 14 method step of placing the nonwoven mat in a three-dimensional mould or flat press, 16 method step of pressing the nonwoven mat in the three-dimensional mould or flat press, 18 method step of cutting or grinding off excess material of the finished product, 20 measurement setup, 22 test sample, 24 measurement tube, 26 speaker, 28, 30 microphones, 32, 38 amplifier, 34 Fast Fourier Transformer, 36 computer, and 38 printer, 40 Base mat 42 first portion 44 second portion 46 third portion 48f fourth portion 50 fifth portion 52 sixth portion 54 seventh portion 56 eight portion 60 acoustic sheet 62 hard layer 64 soft sound absorbing layer