JP4241556B2 - Pellet manufacturing method and pellet manufacturing apparatus - Google Patents

Description

  The present invention relates to a pellet manufacturing method, a pellet manufacturing apparatus, and a manufactured pellet for manufacturing a pellet used as a raw material for extrusion molding or injection molding.

  Conventionally, plastic molding is performed by heating a predetermined material containing a thermoplastic resin in an extrusion molding machine, mixing while melting the thermoplastic resin (hereinafter also referred to as melt mixing), and extrusion molding (preliminary molding). Manufactures pellets used for post-molding (main molding). As a raw material for pellets, in order to effectively use waste materials, fly ash, quartz-based minerals, etc., a combination of materials obtained by atomizing wood-based materials such as waste materials and thermoplastic resins, a combination of fly ash and thermoplastic resins, quartz A combination of a mineral and a thermoplastic resin may be used. In the case of pellets using a wood-based material, for example, by mixing the particles of the material with a mixer having a mixing stirring blade to cause heat generation and heat mixing, or by shear mixing the material with an extruder, Form good quality pellets. Here, the extruder is equipped with a die having a number of extrusion ports with a diameter of about 3 to 5 mm. While rotating the internal screw, the softened material is pushed out from the extrusion port of the die into a substantially rod shape, and is extended by a cutter. It is cut to about 3 to 7 mm and formed into a pellet shape.

Further, in the technique described in Patent Document 1, a predetermined material softened by an extrusion mechanism is mixed and extruded in an irregular shape, and the extruded material is introduced into a container for a molding machine in an irregular shape, and the introduced irregular shape is introduced. This material is formed into a pellet shape by a pellet forming apparatus.
JP 2004-17502 A

In the former technique, if the content of the thermoplastic resin in the material is small, the flow rate of the material is small even if the thermoplastic resin is melted, so the extrusion flow rate from the die is small, and mass production of pellets is possible. could not.
With the latter technique, it is possible to mass-produce pellets even with a material with low fluidity. However, it has been desired to further improve the amount of pellet production per unit time. In addition, the pellets to be produced are made more homogeneous, and the molded products and aggregates made from the pellets are made more homogeneous, or plastic molding, injection molding, blow molding, etc. are made from the pellets. It is possible to produce pellets that can be easily formed into post-molded molded products by dispersing and dispersing the pellets more easily in the kneading stage where heat is applied while maintaining the pellet shape at the raw material stage when performing It was desired.

Furthermore, when a material containing a plurality of synthetic resins having different physical properties is mixed and extruded while melting the synthetic resin and extruded into an indeterminate shape, each synthetic resin becomes compatible with other synthetic resins. The pellet which left the physical property of each synthetic resin was not able to be manufactured. On the other hand, when producing pellets in which the synthetic resin is blended with each synthetic resin, the pellets are not sufficiently mixed at the time of post-molding using the produced multiple types of pellets as raw materials, and sufficiently good physical properties are obtained at the time of post-molding. It was not possible to produce a molded product having it.
For example, MFR (melt mass flow rate) specified in JIS K7210 is 100 (unit: g / 10min) or more and high fluidity polypropylene (hereinafter also referred to as PP), and MFR is less than 100 and high strength. When high-strength PP and both PP and wood powder of equal weight or more are mixed and solidified while melting PP to form pellets, both PPs become familiar with each other, and the manufactured pellets are used as raw materials. Sufficient fluidity cannot be obtained during molding. On the other hand, if a post-molding process is performed using pellets blended with high-fluidity PP and pellets blended with high-strength PP, a molded product with sufficient strength cannot be obtained.
In addition, PP having MFR of 100 or more, modified PP modified with maleic acid, polyamide having a high MFR of less than 100 (hereinafter also referred to as PA), PP, modified PP, and PA are equal to or more than the total weight. When wood powder is mixed with PP, modified PP, and PA and solidified to form pellets, the modified PP and PA react with each other to form a polymer alloy, and PP and PA become familiar with each other. In addition, sufficient fluidity cannot be obtained during post-molding using the produced pellets as a raw material. On the other hand, when a post-molding is performed using pellets blended with high-fluidity PP and pellets blended with PA as a raw material, a molded product with sufficient strength cannot be obtained.

  The present invention has been made in view of the above problems, and an object of the present invention is to produce high quality pellets in which the physical properties of a plurality of different resins are left.

In order to achieve the above object, the invention of the pellet manufacturing method according to claim 1 is to pulverize and pulverize at least a first material softened to a pulverizable level having at least a first resin by a predetermined pulverization mechanism. A pulverizing and mixing step for producing a mixture containing at least a second material having at least a second resin having different physical properties from the first resin, and the mixture produced above. And a molding step of molding into a pellet shape by a predetermined molding mechanism. That is, in the pulverization and mixing step, at least the first material softened to a pulverizable level having at least the first resin is pulverized by a predetermined pulverization mechanism. Moreover, the mixture which mix | blended at least the ground 1st raw material and the 2nd raw material which has at least 2nd resin is produced | generated. Here, the second resin is a resin having different physical properties from the first resin. In the forming step, the generated mixture is formed into a pellet shape by a predetermined forming mechanism. Since the molded mixture is blended with the softened first material, it is cured (including solidification) while maintaining the pellet shape.
As a result, at the time of producing the pellet, at least the familiarity between the first resin and the second resin can be reduced, so that the physical properties of the first and second (first and second) resins remain. Pellets can be produced. Then, when post-molding such as plastic molding using the pellet as a raw material, it is not necessary to mix the pellet containing the first resin and the pellet containing the second resin, so the first resin and the second resin It is possible to obtain a high-quality molded product that is sufficiently familiar with the above.

The first material may be a material partially made of the first resin, or may be a material made entirely of the first resin. The second material may be a material partially made of the second resin, or may be a material made entirely of the second resin. When the mixture is generated, a mixture containing a material different from the first and second materials may be generated.
Therefore, in the pulverization and mixing step, a mixture containing a third material different from the first and second materials, a fourth material different from the first, second and third materials, is generated. Any of these cases may be included in the invention described in claim 1.
In the pulverization and mixing step, at least the first material may be pulverized, the first material alone may be pulverized to produce a mixture, or the first and second materials may be pulverized together to form a mixture. It may be produced, or each material may be pulverized separately to produce a mixture, and both cases are included in the invention of claim 1.
In addition, you may further provide the process of hardening or solidifying the mixture shape | molded by pellet shape (henceforth a molded object).
If the cooling process which cools a molded object with a cooling mechanism is provided, a molded object can be solidified rapidly. Moreover, it can prevent that a molded object adheres mutually. The cooling mechanism may have various configurations such as a configuration in which the molded product is immersed in a cooling tank and cooled by water, and a configuration in which the molded product is cooled by air while dropping in a dropping path portion having a predetermined dropping path.

In addition, the method further comprises an extrusion process in which the softened first material is mixed by an extrusion mechanism and extruded in an irregular shape. In the pulverization and mixing process, the first amorphous material extruded by the pulverization mechanism is provided. It is good also as a structure which produces | generates the said mixture with which the said 1st raw material and said 2nd raw material were mix | blended at least. When the softened first material is extruded in an indeterminate state by the extrusion mechanism, it can be easily pulverized in the pulverization and mixing step.
If the extrusion mechanism extrudes the first material in an irregular shape and supplies it to the crushing mechanism, the extrusion flow rate of the first material is not limited. Therefore, even if the material used for pellet production is a material with low fluidity, it is possible to mass-produce pellets. Here, the amorphous first material extruded by the extrusion mechanism is once pulverized and supplied to the molding mechanism, so that the material can be molded into a pellet shape in a more uniform state. Thereby, the manufactured pellet can be made more homogeneous, and high-quality pellets that can make the molded product and aggregate made from the pellet more uniform can be mass-produced. In addition, the pellet shape is maintained in the raw material stage when post-molding such as plastic molding using the produced pellets as a raw material, while the pellet is more easily broken in the kneading stage where heat is applied, and dispersibility is improved. It is possible to easily form a post-molded product. Furthermore, since the amorphous first material is pulverized, it becomes easy to enter molding holes, gaps, and the like when the pellets are molded, so that the amount of pellets produced per unit time can be further increased.

  In addition, when the softened material is mixed and extruded without being extruded and formed into a pellet shape, the whole material is formed into a pellet without adapting, so that a pellet that is easily broken into a powder is produced. Then, when trying to perform the subsequent molding using the pellet as a raw material, the pellet collapses into a powder form from the raw material stage, so it is not easy to uniformly knead the raw material in the kneading stage. In the present invention, since the softened material is mixed and extruded and then pulverized and formed into a pellet shape, pellets are manufactured after the whole material is well blended, and a pellet that does not collapse so as to become powdery is produced. The Therefore, since the pellets are collapsed in the kneading stage in which heat is applied without breaking into a powdery form when the post-molding is performed using the pellets as raw materials, the raw materials can be easily and uniformly kneaded in the kneading stage. .

  In particular, when the first material includes at least a filler (filler) and an equal weight or less meltable resin, the material is pulverized into a pellet shape without mixing and extruding. When the molding is performed, the resin is pelletized without conforming to the high filling amount of the filler, so that the filler and the resin are broken apart and easily become powdery. When the molten resin and the filler are mixed and extruded as a softened material and then pulverized and formed into a pellet shape, the resin is well blended with the filler and then pelletized. Therefore, when pellets molded with a high filling amount of filler are used as raw materials, the pellets are broken and dispersed in the kneading stage without breaking into powder in the raw material stage. The raw materials can be easily kneaded uniformly.

Here, the extrusion mechanism may have various configurations, and a softened material can be extruded in an indefinite state by applying a general-purpose single-screw kneading extruder or a twin-screw kneading extruder.
In addition, even with materials that have a large proportion of resin in the material and the pellets that have been molded together with conventional extruders, molding is performed by crushing the irregular shaped material into a pellet shape. The subsequent pellets do not stick together and become separated. This is considered to be because the softened material is not formed into a pellet shape immediately after being extruded in an indeterminate state, so that the degree of softening decreases due to a temperature decrease of the material. Moreover, even if it is a material that is blended with a resin (thermosetting resin, adhesive, etc.) whose softening degree decreases with the passage of time and the conventional extrusion molding machine is a material where the pellets after molding are stuck together, By pulverizing the amorphous material and then forming it into a pellet shape, the pellets after forming are separated without sticking to each other. This is thought to be due to the fact that the degree of softening of the material decreases over time because it is not immediately formed into a pellet shape. If the pellets are stuck together, the raw materials will not be smoothly fed into the kneading step during the subsequent molding using the pellets as raw materials. When this pellet manufacturing apparatus is used, it is possible to prevent the pellets from sticking to each other, so that the raw material is smoothly fed into the kneading process during post-molding, and a post-molded molded product can be manufactured smoothly.

As an example, the first material can be configured to include at least a meltable resin and a particulate woody material. That is, when the resin is in a molten state, the raw material is softened, and the molten resin and the fine-grained woody material are mixed and extruded in an indefinite state. Here, the molten resin adheres while oozing into the woody material. Then, after the resin is well blended with the woody material, it is pelletized, and when the molded pellet is used as a raw material and then molded, the raw material stage is a kneading stage where heat is applied without breaking the powder into a powder. The raw material can be easily and uniformly kneaded in the kneading stage. Moreover, it can be used as a lightweight aggregate for reducing the weight of concrete or the like. Note that mixing a wood-based material with the same wood-based material and a meltable resin having an equal weight or less results in a material with low fluidity, but the above-described configuration enables mass production of pellets.
Here, various materials such as wood flour, wood wool, wood fragments, wood fiber, wood pulp, wood fiber bundle, etc. can be adopted as the wood-based material, and bamboo fiber, hemp fiber, bacus, rice bran, rice straw, etc. What mixed the material which has a cellulose as a main component may be used.

Here, the fine particles refer to powder particles or particles that are finer than the pellets to be formed, and include powder particles and fine fiber particles. The same applies hereinafter. In addition, the intensity | strength of a pellet can be adjusted if the particle size of a wood type material is adjusted. Wood is commonly used in every scene, such as furniture factories and construction sites. Waste wood, furniture, and building materials generated after wood chips are used as wood-based materials or wood itself is used as a raw material for furniture and building materials are discarded. An object can be pulverized into a woody material.
Of course, as the first material, various materials such as a finely divided inorganic material such as a finely divided porous inorganic material can be adopted. As the fine porous inorganic material, fine fly ash, fine granular quartz mineral and the like can be considered. The filler may contain materials other than inorganic materials. The second material can be the same material as the first material.

  When the first resin is a first thermoplastic resin, the first material is a material in which at least a filler and the first thermoplastic resin equal to or less than the weight of the filler are blended. The extrusion process includes a material heating process in which the first material is heated and softened by a predetermined heating mechanism, and the first material softened in the material heating process is not mixed. You may extrude in a fixed state. The first material can be easily heated and softened by heating the first material with the heating mechanism. Further, since the first material is highly filled with filler (the filler is present in the material in a weight ratio or more than the resin), the first material having an irregular shape can be easily pulverized in the pulverization and mixing step. Here, the blending ratio of the filler and the first thermoplastic resin is preferably 51 to 99% by weight (more preferably 70 to 95% by weight) of the filler and 1 to 49% by weight (more preferably 5 to 5%) of the thermoplastic resin. 30% by weight).

  The second resin is a synthetic resin, and the second material is a material in which at least a filler and the second resin equal to or less than the filler are mixed, and the pulverized and mixed The process includes a second extrusion process in which the softened second material is mixed by an extrusion mechanism and extruded in an irregular shape, and is the same as the amorphous first material extruded in the extrusion process. It is good also as a structure which grind | pulverizes the irregular-shaped 2nd raw material extruded by the 2 extrusion process, and produces | generates the said mixture with which the grind | pulverized 1st and 2nd raw material was mix | blended at least. Since the second material is highly filled, it is possible to easily pulverize the amorphous second material in the pulverization and mixing step. The synthetic resin may be a thermoplastic resin or a thermosetting resin. Here, the preferable blending ratio of the filler and the synthetic resin is 51 to 99% by weight (more preferably 70 to 95% by weight) of the filler and 1 to 49% by weight (more preferably 5 to 30% by weight) of the synthetic resin. is there.

  When the second resin is a second thermoplastic resin, the second extrusion step includes a second material heating step of heating and softening the second material with a predetermined heating mechanism. The second material softened in the second material heating step may be mixed and extruded in an indeterminate state. The second material can be easily heated and softened by heating the second material with the heating mechanism.

  At least one of the first and second resins is a thermoplastic resin, and the MFR at the melting temperature when the pellets produced by the present pellet production method are melted, mixed and then molded is 100 g / 10 min. It is good also as a structure made into the above. Here, MFR is a melt mass flow rate defined in JIS K7210. One of the first and second resins is a thermoplastic resin of MFR100 or higher, and the other is a resin having functions such as high strength, water resistance, light resistance, impact resistance, heat resistance, flame resistance, etc. As a result, good fluidity can be obtained during post-molding and molding can be easily performed, and a high-quality molded product of polymer blend or polymer alloy having these functions can be obtained.

  The second resin is a liquid thermosetting resin, and the second extrusion step is performed by mixing at least the second material in which the liquid thermosetting resin and the filler are blended. It is good also as a structure extruded in a fixed state. Then, post-molding such as extrusion molding, injection molding and blow molding using a thermosetting resin as a raw material, which could not be performed conventionally, can be performed. Here, the liquid includes from a low-viscosity liquid to a high-viscosity liquid. At that time, if the MFR at the temperature when the pellets manufactured by the present pellet manufacturing method are mixed and post-molded is 100 or more, a pellet having very good fluidity at the time of post-molding is obtained. Can do.

  When the softened second resin is mixed and extruded in an irregular shape, in the grinding and mixing step, at least the irregular first material and the irregular second material are produced by the grinding mechanism. It is good also as a structure which grind | pulverizes together and produces | generates the said mixture. Of course, in the pulverization and mixing step, after the irregular first material and the irregular second material are separately pulverized by the pulverization mechanism, at least the pulverized first material and pulverization are performed. It is good also as a structure which mixes the made 2nd raw material and produces | generates the said mixture.

  When the second resin is a finely divided synthetic resin and the second material is a finely divided material, in the pulverizing and mixing step, the pulverizing mechanism softens the second resin so as to be pulverizable. One material may be at least pulverized, and the mixture containing at least the pulverized first material and the fine particulate second material may be generated.

  At that time, in the pulverizing and mixing step, the mixture is obtained by pulverizing by the pulverizing mechanism in a state where at least the first material softened to such an extent that it can be pulverized and the fine second resin are combined. It is good also as a structure which produces | generates. Of course, in the pulverization and mixing step, after pulverizing the first material softened to such an extent that it can be pulverized by the pulverization mechanism, at least the pulverized first material and the fine particulate second resin It is good also as a structure which mixes and produces | generates the said mixture.

When the second resin is a liquid synthetic resin and the second material is a liquid material, in the pulverizing and mixing step, the first material softened to the pulverizable level is supplied to the pulverizing mechanism. After the pulverization, at least the pulverized first material and the liquid second resin may be mixed to produce the mixture. At that time, if the MFR at the temperature at which the pellets produced by the present pellet production method are mixed and post-molded is 100 or more, a pellet is obtained that has very good fluidity during post-molding molding. Can do.
If the synthetic resin is a thermosetting resin, post-molding such as extrusion molding, injection molding, or blow molding using a thermosetting resin as a raw material, which has not been possible in the past, can be performed.

  The pulverizing and mixing step may be configured to pulverize at least the amorphous first material introduced into the amorphous material introducing portion that introduces the first material extruded from the extrusion mechanism in an irregular shape. That is, the first material extruded in an irregular shape from the extrusion mechanism is once introduced into the irregular material introduction portion, and the irregular first material introduced into the irregular material introduction portion is crushed. , Less material loss. In addition, a belt conveyor and a pulverizer hopper are provided in the amorphous material introduction section, and the irregular material extruded from the extrusion mechanism is placed on the belt conveyor and transferred to the pulverizer hopper. The amorphous material may be crushed within.

  As an example of the molding mechanism, the molding mechanism is provided with a pulverized material introducing portion that is provided with an extrusion port and introduces the material pulverized by the pulverizing mechanism, and the pulverized material introduced into the pulverized material introducing portion. It is good also as a structure shape | molded in the shape of a pellet by extruding from the same extrusion port out of the same pulverization raw material introduction part, and cut | disconnecting. That is, the pulverized material is accommodated in the pulverized material introduction part, extruded from the extrusion port provided in the pulverized material introduction part, out of the pulverized material introduction part, cut, and formed into a pellet shape.

By the way, the pellet manufacturing apparatus according to claim 15 has the same operations and effects as the above-described manufacturing method. Of course, it is also possible to adapt the configuration described in claims 2 to 14 in the pellet manufacturing apparatus.

As described above, according to the inventions according to claims 1 and 15 , it is possible to produce a high-quality pellet in which the physical properties of a plurality of different resins are left, and plastic molding using the pellet as a raw material. Thus, it becomes possible to obtain a high-quality molded product in which each resin is sufficiently blended during post-molding.
In the invention according to claim 2, when producing pellets using a material with low fluidity, the amount of pellets produced per unit time can be further improved, and the produced pellets are made more homogeneous, Good quality pellets that make the molded products and aggregates made of pellets more homogeneous, or make the pellets easier to collapse during post-molding using the pellets as a raw material, making the molded products of post-molding easier It can be manufactured.
In the invention according to claim 3, since the first material can be easily softened by heating, the convenience can be improved, and the amorphous first material can be easily pulverized. . Furthermore, since the pellets do not stick to each other, it becomes possible to smoothly manufacture a post-molded molded product.
In the invention according to claim 4, since the second material is also highly filled, it is possible to easily pulverize the amorphous first and second materials in the pulverization and mixing step.
In the invention concerning Claim 5, since a 2nd raw material can be heat-softened easily, the convenience can be improved. Further, since the pellets do not stick to each other, it becomes possible to smoothly manufacture a post-molded product.

In the invention concerning Claim 6, the pellet which makes fluidity | liquidity very favorable at the time of shaping | molding can be obtained.
In the invention concerning Claim 7, when a pellet is manufactured using a liquid thermosetting resin, a suitable structure can be provided. Further, post-molding such as extrusion molding, injection molding, and blow molding can be performed using a thermosetting resin as a raw material.
In the invention according to the eighth aspect, since the first and second materials are mixed by pulverizing them together, it is possible to simplify the mixing of both materials. On the other hand, in the invention according to claim 9, since the familiarity of the two materials can be reduced by separately crushing the first and second materials, the physical properties of a plurality of different resins are more reliably left. It becomes possible to produce high quality pellets.
In the invention concerning Claim 10, when a pellet is manufactured using a granular material, a suitable structure can be provided.

In the invention concerning Claim 11, since it mixes by grind | pulverizing a 1st and 2nd raw material together, it becomes possible to simplify mixing of both raw materials. On the other hand, in the invention according to the twelfth aspect, since the first material is pulverized separately from the fine second material, the familiarity between the two materials can be reduced. It becomes possible to produce high quality pellets that retain their physical properties.
In the invention concerning Claim 13, when a pellet is manufactured using a liquid raw material, a suitable structure can be provided.
In the invention concerning Claim 14, it becomes possible to reduce the loss of a raw material and to mass-produce a pellet more efficiently .

Hereinafter, embodiments of the present invention will be described in the following order.
(1) About pellets:
(2) Configuration of pellet manufacturing apparatus:
(3) Action and effect of pellet manufacturing method:
(4) Example of the first embodiment:
(5) Various modifications:
(6) Second embodiment:
(7) Third embodiment:

(1) About pellets:
FIG. 1 is a flow chart showing an outline of pre-molding pellets using the pellet manufacturing method according to the first embodiment of the present invention, and manufacturing a molded product of extrusion molding (post-molding) using the pellets as raw materials. Show. The present manufacturing method includes an extrusion step S1 in which a first material softened to a pulverizable level having at least a first resin M1 and a filler M2 is mixed by a predetermined extrusion mechanism A1 and extruded in an indefinite state. A second extruding step S2 in which a second material softened to a pulverizable level having at least a second resin M3 and a filler M4 is mixed by a predetermined extruding mechanism A2 and extruded in an indefinite state; The first amorphous material M5 extruded in the step S1 and the second amorphous material M6 extruded in the second extrusion step S2 are pulverized by the pulverization and mixing mechanism A3. A crushing and mixing step S3 for generating a mixture M7 containing the second material, and a forming step S4 for forming the generated mixture M7 into a pellet shape by a predetermined forming mechanism A4.

  As the fillers M2 and M4, for example, finely divided wood powder can be used. A fine woody material obtained by pulverizing waste materials generated in various factories can be used as the filler. Various particle diameters can be adopted as the particle size of the wood-based material, and any particle size may be used as long as the wood-based materials can be bonded to each other by the resins M1 and M3. Note that the same filler may be used as the fillers M2 and M4, or different fillers may be used.

For the resins M1 and M3, for example, thermoplastic resins (meltable resins) having different physical properties can be used. Various resins can be used as the thermoplastic resin, such as polypropylene (PP), polyethylene, polystyrene, polymethyl methacrylate, vinyl chloride, polyamide (nylon), polycarbonate, polyacetal, polybutylene terephthalate, polyethylene terephthalate, etc. Can be used. For example, the resin M1 is a high fluidity thermoplastic resin (first thermoplastic resin) with MFR (g / 10min) of 100 or more, and the other resin M3 is high strength, water resistance, light resistance, impact resistance, heat resistance. If it is a thermoplastic resin (second thermoplastic resin) having functions such as heat resistance and flame retardancy, good fluidity is obtained at the time of post-molding and it can be easily molded, and a polymer blend having these functions A high quality molded article of polymer alloy can be obtained. The resin M1 may be a thermoplastic resin (first thermoplastic resin) having a function such as high strength, and the other resin M3 may be a highly fluid thermoplastic resin (second thermoplastic resin). Each resin M1, M3 may be a combination of a plurality of the above-described resins.
Moreover, even if it is resin of the same name, if a physical property differs mutually, it can be used. For example, the high fluidity PP having an MFR of 100 or more and the high strength PP having an MFR of less than 100 can be used as the resins M1 and M3. In addition, when thrown into the extrusion mechanisms A1 and A2, it may be thrown as a solid raw material or may be put in a molten state.

Resin M1 is obtained by selecting one of the thermoplastic resins as a main component of resins M1 and M3 and modifying the selected resin with maleic acid (predetermined acid) that imparts a hydrophilic group to the resin. , M3. Of course, the acid that modifies the thermoplastic resin may be an organic acid having a carboxyl group, such as fumaric acid, or a modification of a resin different from the main component may be used as a subcomponent of the resins M1 and M3. Furthermore, since a resin obtained by modifying a thermoplastic resin with an acid is also usually a thermoplastic resin, only the modified resin may be used as the resins M1 and M3.
In order to produce the modified resin, for example, addition polymerization may be performed by adding maleic acid to the raw material before addition polymerization. Then, a carboxyl group which is one of hydrophilic groups is added to the polymer after addition polymerization. Therefore, the modified resins contained in the resins M1 and M3 have better compatibility with the wood-based material that is the filler.

  The mixing ratio of the fillers M2 and M4 and the resins M1 and M3 can be appropriately determined according to the use of the pellets. In the case of using a wood-based material as a filler, if there is a large amount of the wood-based material, deformation due to temperature change is small, the weight is reduced, and the wood texture is improved. Here, when the wood-based material is a rich material, the material has low fluidity even when softened by heating, but it is possible to mass-produce pellets by the action described later. On the other hand, when there are many thermoplastic resins, the fluidity | liquidity of the raw material heat-softened is large, the mechanical performance which means the intensity | strength of the manufactured pellet becomes large, and water resistance improves. As the weight ratio of both, a preferable ratio can be appropriately selected according to the properties required for the pellets.

The extrusion mechanisms A1 and A2 have predetermined heating mechanisms that heat and soften the first and second materials, respectively. The extrusion mechanisms A1 and A2 may share a single extrusion mechanism.
In the present embodiment, the thermoplastic material (resin M1, M3) equal to or less than the weight of the wood material (fillers M2, M4) and the wood material is used as the first and second materials. While the resin is melted, it is extruded in an indeterminate state without being mixed and molded by the extrusion mechanisms A1 and A2. Since the first and second materials are highly filled, it is possible to easily pulverize the unshaped materials M5 and M6 in the pulverization and mixing step. Here, a preferable blending ratio for imparting toughness to the pellets and enabling processing of screws or the like is 70 to 99.9% by weight of the wood-based material, and a thermoplastic resin (for example, a raw material for polypropylene before addition polymerization) PP) obtained by adding a modified PP modified by addition polymerization by adding maleic acid to 0.1 to 30% by weight. The reason why the wood-based material is made 70% by weight or more is to obtain suitable toughness, and the reason why the thermoplastic resin is made 0.1% by weight or more is to bond and harden the wood-based materials.
Further, the preferred blending ratio of the wood-based material for easily crushing the irregular shaped materials M5 and M6 and the thermoplastic resin (for example, PP to which modified PP modified with maleic acid is added) is wood-based materials 51 to 99. % By weight (more preferably 70 to 95% by weight) and 1 to 49% by weight (more preferably 5 to 30% by weight) of thermoplastic resin. The reason why the woody material is 51% by weight (70% by weight) or more is to make the fluidity of the softened material small enough to be pulverized, and the thermoplastic resin is 1% by weight (5% by weight) or more. The reason for this is to prevent the manufactured pellets from collapsing to a powder form.
Note that the blending ratio of the filler M2 and the resin M1 in the first material and the blending ratio of the filler M4 and the resin M3 in the second material may be the same or different.

  In the pulverization and mixing step S3, as shown in the upper part of FIG. 2, at least the first amorphous material M5 and the second irregular material M6 are pulverized together by the pulverization mechanism A5 to generate a mixture M7. Alternatively, as shown in the upper part of FIG. 3, after the materials M5 and M6 are separately pulverized by the pulverizing mechanisms A7 and A8, at least the pulverized first material (the pulverized product M11) and the pulverized first The second material (the pulverized product M12) may be mixed, for example, in the molding mechanism A4 to generate the mixture M7. In the former, the pulverizing mechanism A5 constitutes the pulverizing and mixing mechanism A3, and in the latter, at least the pulverizing mechanisms A7 and A8 constitute the pulverizing and mixing mechanism A3.

When the two materials are mixed before pulverization, they are mixed by pulverizing the soft, indeterminate materials M5 and M6 together, which is preferable in that the mixing of both materials can be simplified. Of course, as shown in the lower part of FIG. 2, after the irregular shaped materials M5 and M6 are mixed by a predetermined mixing mechanism A6 (mixing step S5), the mixture is pulverized by a predetermined pulverizing mechanism A5 (pulverizing step). S6) You may do it. Then, since the first and second materials having an irregular shape are reliably mixed, it is preferable in that the manufactured pellets can be made more uniform.
When the irregular shaped materials M5 and M6 are pulverized together, the third material M10 may be pulverized together. If there is a fourth material, a fifth material, etc., these may be pulverized together. In such a case, if the third material M10, the fourth material,... Are fine (powder or finer than the pellet to be molded), the first and second materials having an indefinite shape Since it is easy to mix, it is suitable at the point which makes it possible to make the manufactured pellet more uniform.

When mixing the first and second materials after pulverization, it is possible to reduce the familiarity of both materials by separately pulverizing the soft, indeterminate materials M5 and M6. It is preferable in that it is possible to produce a high-quality pellet that retains the above physical properties. As shown in the lower part of FIG. 3, a pulverized product M11 is generated by a predetermined pulverization mechanism A7 (first pulverization step S7), and a pulverized product M12 is generated by a predetermined pulverization mechanism A8 (second pulverization step). S8) After mixing by a predetermined mixing mechanism A9 to generate the mixture M7 (mixing step S9), the mixture M7 may be formed into a pellet shape (molding step S4). Then, since the pulverized first and second materials are surely mixed, it is preferable in that the manufactured pellets can be more reliably homogenized.
When mixing the pulverized products M11 and M12, the third material M10 may be mixed together. If there is a fourth material, a fifth material, etc., these may be mixed together. In such a case, the third material M10, the fourth material,... Are fine particles (powdered or finer than the pellets to be formed) or low-viscosity (high fluidity) liquid (for example, when mixed) When the MFR at the temperature is 100 or more, it is easy to mix with the pulverized first and second materials, which is preferable in that the manufactured pellets can be made more uniform. .
A single crushing mechanism may be shared by the crushing mechanisms A7 and A8.

When the first material having the first resin M1 and the filler A2 is put into the extrusion mechanism A1, the material is heated and softened by the extrusion mechanism A1, and the amorphous material is mixed while the softened materials are mixed. Extrude in state. When the second material having the second resin M3 and the filler A4 is put into the extrusion mechanism A2, the extrusion mechanism A2 heats and softens the material, and mixes the softened material with an irregular shape. Extrude in state. Thereafter, amorphous materials M5 and M6 are introduced into the pulverizing and mixing mechanism A3 and pulverized to produce a mixture M7. The mixture M7 is introduced into the forming mechanism A4 and formed into a pellet shape to be solidified. To manufacture.
In the above-described embodiment, the thermoplastic resin is used as the binding material with the wood-based material. However, a thermosetting resin, an adhesive, other organic polymer compounds, or the like may be used as the binding material.

The pellet M8 is charged into the hopper A21 of the extrusion molding apparatus A20 as a raw material for the main molding, and a thermoplastic resin or the like is appropriately input as a raw material for the main molding, and is kneaded while being heated by the extruder A22 with a heater. Softened. The pellet M8 is heated and kneaded so as to collapse and disperse, and is uniformly mixed. The kneaded raw material is extruded from a die having a predetermined shape and cut by a cutting machine A23. As a result, a molded product M9 of the main molding is obtained.
In addition, since the pellet M8 is lightweight, you may mix | blend with a building material. Building materials are mainly composed of cement, and by using pellets as an alternative to gravel, a lighter building material can be obtained. For example, when the pellet M8, cement raw material powder, and water are put into a stirring container and stirred, and poured into a female mold of a building material having a predetermined shape, the material hardens with time and becomes a building material. Can be used for things. Of course, gravel or the like may be added.

(2) Configuration of pellet manufacturing apparatus:
FIG. 4 is an external side view of an embodiment of a pellet manufacturing apparatus used for carrying out this pellet manufacturing method, and FIG. 5 is an external top view of the pellet manufacturing apparatus. The pellet manufacturing apparatus 10 generally includes a material supply device 11, a material conveying device 12, a material heating device 13, a pellet forming device 20, a sorting and conveying device 14, and a control panel 15.

  The material supply device 11 has a hopper device 11a which is formed in a hollow and substantially cylindrical shape and has an opening 11a1 on the upper surface. The material supply device 11 is composed of a fine-grained wood-based material and a thermoplastic resin pulverized into a fragment shape. A predetermined material is introduced from the opening 11a1 and accommodated in the hopper device 11a. Inside the hopper device 11a, a stirring blade 11a2 and a stirring blade connection disk 11a3 to which the stirring blade 11a2 is connected are arranged. The stirring blade connection disk 11a3 is connected to the stirring blade via a belt 11a4. It is connected to the drive motor 11a5. The drive of the motor 11a5 is transmitted to the disk 11a3 via the belt 11a4, and thereby the disk 11a3 and the stirring blade 11a2 are rotationally driven. Thereby, the raw material accommodated in the hopper device 11a is mixed while being stirred in a granular form. The mixed raw material is supplied from the mixed material supply port 11a6 to the raw material transport device 12 which is a device for the next process.

  The material conveying device 12 is connected to the mixed material supply port 11a6 of the material supply device at the mixed material inlet 12a, and receives the mixed material supplied from the mixed material supply port 11a6 at the mixed material inlet 12a. Here, a screw shaft 12c in which a part (the right side in FIGS. 4 and 5) is inserted into the pellet forming apparatus 20 is disposed inside the substantially cylindrical hollow tube 12b. The screw shaft 12c is formed with a screw thread having a plurality of flights along the axial direction.

  At this time, the raw material supplied at the mixed material inlet 12a is accommodated in a space formed by the hollow tube 12b, the screw shaft 12c, and the screw thread. The screw shaft 12c is connected to a screw shaft drive motor 12e via a gear portion 12d. When the screw is rotated by driving the motor 12e, the material accommodated in the space formed by the hollow tube 12b, the screw shaft 12c and the screw thread is a predetermined shape formed by the rotating operation. Based on the extrusion speed, the mixed material is extruded from the mixed material inlet 12a toward the fluid outlet 12f while being mixed.

  The material supplied from the mixed material inlet 12a is heated by a material heating device (heating mechanism) 13 provided in the material conveying device 12, and the thermoplastic resin is melted to soften the material. Accordingly, the material pushed out by the rotation of the screw is pushed out to the fluid outlet 12f in a softened state. The material heating device 13 generally includes a plurality of heater portions 13a and a plurality of blower portions 13b corresponding to the heater portions 13a. The heater part 13a has a heating element, and the material in the hollow pipe 12b is heated by blowing air heated to a high temperature by the heating element to the hollow pipe 12b by the blower part 13b.

Here, the heater part should just be able to raise to the temperature which melts a thermoplastic resin, and should just determine the heating capability of a heater according to the kind of thermoplastic resin. If the heating of the heater is set so that the temperature of the raw material is higher than the melting point of the thermoplastic resin and the wood-based material is not carbonized, both can be melt-mixed without carbonizing the wood-based material.
Note that the ability of the material conveying device 12 to convey the material may be determined according to the properties such as the viscosity of the softened material. In addition, when the raw materials are well melted and mixed by the raw material transport device, high-quality pellets using a wood-based material can be manufactured.

The softened material is pushed into the pellet forming apparatus 20 from the fluid outlet 12f. Then, the material is extruded in an indeterminate state without being formed, introduced into the introduction portion in an indefinite shape in a softened state, formed into a pellet shape, and cooled in the cooling bath 40. Details of the pellet forming apparatus 20 will be described later.
The cooling tank 40 is filled with cold water cooled by a cooler (not shown), and solidifies the molded material falling from the pellet forming apparatus 20 with cold water. That is, the cooling tank 40 and the cooler constitute a cooling mechanism that cools the formed material. By immediately solidifying the molded material, it is possible to prevent the molded materials from adhering to each other.

  The solidified pellets flow into the sorting and conveying device 14 from the pellet inlet 14a. The sorting / conveying device 14 has a sorting / conveying network, a conveying net vibration motor, and a pellet storage section in which a large number of substantially circular small holes having a predetermined diameter are formed. The pellets are sequentially put into the sorting and transporting network, and the sorting and transporting network is vibrated by the transporting network vibration motor, whereby the size is sorted at the small holes of the sorting and transporting network. Then, the pellets remaining on the sorting and conveying network move toward the pellet collecting unit on the sorting and conveying network, and are accommodated in the pellet accommodating unit by a cyclone (not shown). Also, the pellets that have fallen from the sorting and conveying network are collected and reused.

  The control panel 15 is provided with a plurality of operation buttons and an operation display for monitoring the setting of operation conditions and the operation state of the pellet manufacturing apparatus 10 on the front surface. An operator of the apparatus 10 performs various operations using the control panel 15.

FIG. 6 is a perspective view of the main part of the pellet forming apparatus 20, and FIGS. 7 and 8 are vertical sectional views as seen from the direction B of FIG. In FIG. 7, the screw shaft 12c and the screw thread are shown in side view. Hereinafter, the arrangement of each member will be described based on the vertical and horizontal relationships with reference to FIGS. 7 and 8.
The pellet forming apparatus 20 has a cylindrical metal outer cylinder portion 21 centering on the direction of extrusion of the softened material, and a metal attached to the end of the outer cylinder portion 21 on the material outlet side (right side in the figure). A crusher (pulverizer) provided with an irregular shaped material introducing portion 31 for introducing an irregular shaped material m1 to be pushed out by being installed with the opening 31a facing upward on the lower side of the outlet portion 22 and the outlet portion 22 formed as members. Mechanism) 30, a molding machine container 23 formed with a pulverized material introduction part 24 for introducing the material m2 crushed by the pulverizer 30, two push rollers 25, 25 provided in the container 23, molding A metal die face cutter unit 26 rotatably attached to the lower side of the machine container 23, an electric motor 27 for rotating the die face cutter unit 26, and the like are provided.
A material inlet 21 a is provided on the left side of the outer cylinder portion 21, and the softened material flows into the material inlet 21 a from the material conveying device 12. In the present embodiment, the distal end portion (left end portion) of the screw 12g is inserted into the outer cylinder portion 21, and the softened material conveyed into the outer cylinder portion 21 is mixed by the rotational operation of the screw 12g. It is designed to be pushed to the right. And it extrudes to the right side from the exit part 22, and falls in the metal pulverizer hopper 32 as the unshaped material m1.
The outlet 22 is formed with three openings 22a that are much larger in diameter than the pellets to be produced, and the softened and mixed material is indefinite without being formed through the openings 22a. Extruded in a state. Of course, the number of openings in the outlet portion can be various, or a single opening.
Thus, the raw material conveyance apparatus 12, the outer cylinder part 21, and the exit part 22 comprise the extrusion mechanism which mixes the predetermined softened material and extrudes it in an indefinite state.

In this embodiment, in order to extrude the first and second materials separately, as shown in FIG. 14, the combination of the material supply device 11, the material transport device 12, the material heating device 13, the outer cylinder portion 21 and the outlet portion 22 is used. A plurality may be provided. By adjusting the extrusion flow rate per unit time of the materials M5 and M6 extruded from the extrusion mechanisms A1 and A2, the first and second materials can be set to a predetermined ratio. Of course, when this combination is made into a single unit, for example, the first and second amorphous materials extruded from the outlet portion 22 are once separately accommodated in the first and second irregular material containers (accommodating portions). The first irregular shaped material contained in the first irregular shaped material container and the second irregular shaped material contained in the second irregular shaped material container are mixed at a predetermined mixing ratio. What is necessary is just to throw into the hopper 32. When there is a third material, a fourth material, ..., these are accommodated in a third amorphous material container (accommodating portion), a fourth irregular material container (accommodating portion), ... What is necessary is just to throw into the hopper 32 by a predetermined | prescribed mixture ratio. When any one of the irregular shaped materials is directly introduced into the irregular shaped material introduction unit 31, it is not necessary to provide an irregular shaped material container that accommodates the irregular shaped material.
Moreover, when mixing after pulverizing an amorphous raw material, as shown in FIG. 15, you may provide multiple combinations which added the grinder 30 to the said combination. By adjusting the discharge amount per unit time of each material discharged from each crushing mechanism, the first and second materials can be set to a predetermined ratio. Of course, when this combination is made single, for example, the pulverized first and second materials discharged from the powder transport machine 37 of the pulverizer are once separated into the first and second pulverized material containers (accommodating). Part) and the first amorphous material contained in the first crushed container and the second irregular material contained in the second crushed container at a predetermined blending ratio. What is necessary is just to throw into the container 23 for molding machines. When there is a third material, a fourth material,..., These are accommodated in a third pulverized material container (accommodating portion), a fourth pulverized material container (accommodating portion),. What is necessary is just to throw into the container 23 for molding machines by the compounding ratio of these. When any of the pulverized products is directly introduced into the pulverized material introduction unit 24, a pulverized product container for storing the pulverized products may not be provided.

Conventionally, instead of the outlet portion 22, a die in which a large number of through holes having substantially the same diameter as the pellets are formed is attached to the right end portion of the outer cylinder portion 21. However, in the case of a material with a small blending ratio of the thermoplastic resin, even if the thermoplastic resin is melted, the fluidity of the material is small. I could not. In the present embodiment, such a die is not attached to the outer cylinder portion 21, and no great resistance is generated at the outlet portion 22, so that the extrusion flow rate of the material is increased.
The molding pressure (pressure applied to the material in the direction of the extrusion port) for forming pellets with an extrusion molding machine in which a die for pellet molding (for example, the extrusion port has a diameter of 5 mm) is attached to the end of the outer cylinder is 25 MPa or more. With regard to the raw material, conventional extrusion molding machines do not perform pellet molding from the viewpoint of machine durability. In general, a material in which the mixing ratio of the fine-grained wood-based material and the thermoplastic resin is 70 to 99.9: 0.1 to 30 by weight is such that the molding pressure becomes 25 MPa or more with the resin softened by heating. However, even with such a material, the pellet manufacturing apparatus of the present invention can extrude the material while kneading by an extrusion mechanism, and can mass-produce pellets.

The crusher hopper 32 temporarily stores the irregular shaped material m1 pushed out from the opening 22a of the outlet, and is softened from the lower opening 32b into the cylindrical metal crushing chamber 33 having a substantially vertical direction as a central axis. It is possible to supply irregular materials. Since the hopper opening 32a is separated from the outlet portion 22 and is located below the outlet portion 22, the extruded material m1 does not obstruct the extrusion of the subsequent material m1, and the hopper 32 opens the outlet portion. The amorphous material m1 extruded from 22a can be accommodated. Then, the amorphous material introducing portion 31 for introducing the material extruded from the extrusion mechanism in an irregular shape is formed in the hopper 32 and the crushing chamber 33. Of course, the amorphous material introducing portion may be structured so as not to be separated from the extrusion mechanism but partially connected to the extrusion mechanism.
Further, as shown in FIG. 9, there may be provided a conveyor (for example, a belt conveyor) 51 for placing and transferring the irregular shaped material m1 from the lower side of the outlet portion 22 of the extrusion mechanism to the upper side of the hopper 32 for the crusher. Good. That is, the unshaped material m1 extruded from the extrusion mechanism is placed on the conveyor 51, transferred in the direction of the hopper 32, accommodated in the hopper 32, and supplied into the crushing chamber 33. In this case, an amorphous material introduction unit 50 is configured by the conveyor 51, the hopper 32, and the crushing chamber 33 for transferring the irregular material.

The crusher 30 has a crushing chamber 33 in which an upper opening communicating with the hopper 32 and a lower opening 32b of the hopper is formed on the lower side of the hopper 32, and a rotating shaft is directed in the vertical direction in a lower portion in the crushing chamber 33. A rotary table 34 that can be rotated and a plurality of rotary blades 35 and 35 that are attached to the upper surface of the rotary table 34 and crush the irregular shaped material in the crushing chamber 33 by rotational movement, and are arranged in the vertical direction. The pulverized material m2 is transferred to the electric motor 36 that rotates the rotary table 34 through the columnar rotation drive shaft 36a and the powder discharge port 37a that opens downward in the upper part of the molding machine container 23. Powder transporting machine 37 and the like. A cylindrical metal powder storage chamber 33a having substantially the same diameter as the pulverization chamber 33 is provided below the pulverization chamber 33 (from the lower surface of the rotary table 34). A powder suction port 37b through which the raw material is sucked into the powder transport machine 37 is formed. That is, the irregular shaped material m1 introduced into the crushing chamber 33 is crushed by the rotating rotary blades 35, 35, and falls from the 33b between the inner peripheral surface of the crushing chamber 33 and the outer peripheral surface of the rotary table 34. The powder is sucked into the powder transport machine 37 from the powder suction port 37b, is transported obliquely upward to the upper side of the powder discharge port 37a, and is discharged from the powder discharge port 37a.
When the rotary blade as described above is provided, in particular, when pellets are manufactured from a material mainly composed of a wood-based material (for example, a wood-based material and a resin having a weight equal to or less than that of the wood-based material), it is not easy to produce pellets. It is preferable because a regular material can be pulverized.

  The molding machine container 23 includes a cylindrical container outer cylinder portion 23a having a substantially vertical direction as a central axis, and a bottom disc 23b attached so as to close the lower opening of the container outer cylinder portion 23a. It is configured. A large number of through holes 23d having a diameter of, for example, about 3 to 5 mm are formed in the bottom disk 23b serving as the bottom of the molding machine container 23 in a substantially vertical direction. Since the upper opening 23c of the outer cylinder portion 23a for the container is separated from the powder discharge port 37a of the pulverizer and is located below the discharge port 37a, the container 23 for the molding machine is located downward from the discharge port 37a. The crushed material m2 discharged toward the container can be accommodated. Then, the pulverized material introduction part 24 for introducing the material pulverized by the pulverization mechanism is formed in the molding machine container 23. Of course, the pulverized material introduction part may be structured so as not to be separated from the pulverizing mechanism but partially connected to the pulverizing mechanism.

  FIG. 10 is a top view of the bottom disk 23b as seen from above. The attachment position of the die face cutter unit 26 is indicated by a dotted line. The bottom disk 23b has a large number of substantially circular through holes 23d (in the figure, 16 concentric circles × 2 rows). And the raw material after the grinding | pulverization extruded from each through-hole 23d is made into substantially rod shape. The size of the through hole 23d can be various sizes and diameters depending on the use of the pellet to be manufactured.

The pushing rollers 25, 25 are provided in the molding machine container 23, and circulate on the bottom disk 23b while rotating by themselves. Both rollers 25, 25 are rotatably attached at both ends of a substantially columnar rod-like member 25a installed substantially horizontally. The rod-like member 25a is fixed to a rotating shaft member 25b provided in a substantially vertical direction at an intermediate portion from both ends, and is provided so as to be rotatable about the rotating shaft member 25b as a central axis. The rotating shaft member 25b is attached to a roller driving electric motor 25c. Therefore, when the motor 25c is energized and operated to rotate the rotating shaft member 25b, the rollers 25 and 25 at both ends of the rod-like member 25a circulate on the bottom disk 23b (counterclockwise in FIG. 6). ). At this time, the rollers 25 and 25 rotate by themselves (by counterclockwise in the roller 25 shown in FIG. 7) by the frictional force between the upper surface of the bottom disc 23b and the rollers 25 and 25, and the molding machine container 23 It is possible to push the material after pulverization from one of the openings (upper openings) of the many through holes 23d.
The material pushed from the upper opening of the through hole 23d is pressurized by the rollers 25 and 25 and is pushed out in a substantially rod shape from the other opening (lower opening) of the through hole 23d. The number of pushing rollers may be one or three or more.

  The die face cutter unit 26 is provided below the molding machine container 23 and is rotated by an electric motor 27 for driving the cutter. As shown in FIGS. 8 and 10, the die face cutter unit 26 includes a cutter table 26 a serving as a mounting unit to the motor 27, and a plurality (two in the present embodiment) that are mounted and fixed to the cutter table 26 a. And a cutter 26b. Each cutter 26b slides on the bottom surface of the bottom disk 23b and rotates to cut a substantially rod-shaped material pushed downward from the lower opening of the through hole 23d to a length of about 3 to 7 mm.

Bolt holes are formed in the attachment portion of the cutter 26b to the table 26a, and the cutter 26b can be screwed to the table 26a with bolts (not shown). The cutter 26b has a sharp cutting edge, and the same material is cut into a pellet shape by moving the cutting edge in the cross-sectional direction of the material to be extruded in a substantially rod shape. Of course, the cutting edge of the cutter 26b may be formed in a rounded shape or an obtuse angle shape. In these cases, the cutting edge can be cut while being crushed in the cross-sectional direction by pressing the cutting edge against the material. .
Thus, the molding machine container 23 having a plurality of through holes 23d, the pressing rollers 25 and 25, the mechanisms 25a to 25c for driving the pressing rollers, the die face cutter unit 26 having the cutter 26b, and the cutter driving The electric motor 27 constitutes a forming mechanism for forming the material crushed by the pulverizing mechanism into a pellet shape.
When the resin used for the material is a resin having a relatively low melting point, the pulverized material is heated to a sufficiently strong pellet by the frictional force between the bottom disc 23b and the roller 25 without being heated by a molding mechanism. Molded. On the other hand, if the resin used for the material is a resin having a relatively high melting point such as nylon, polyethylene terephthalate (PET), polycarbonate, etc., a heater is embedded in the molding machine container 23 (bottom disk 23b, etc.), the roller 25, etc. When the temperature is increased by energizing the heater or the like and the material is heated by the molding machine container 23, the roller 25, or the like whose temperature has been increased, it is preferable because the material is molded into a sufficiently strong pellet.

(3) Action and effect of pellet manufacturing method:
Hereinafter, the operation of the present pellet manufacturing method will be described together with the operation of the pellet manufacturing apparatus. First, the combination of the first and second resins is a combination of a high-fluidity resin and a high-strength resin. To explain the case of using high-strength PP as a high-strength PP and high-strength resin (second resin, but the first resin is acceptable) and mixing the first and second materials before pulverization To do. Here, the high-fluidity resin can be a resin having an MFR of 100 (g / 10 min) or more at the melting temperature when the pellets produced by the present pellet production method are melted and mixed and then molded. As the type of resin, a thermoplastic resin is suitable. In the case of a thermoplastic resin such as PP, generally, the smaller the molecular weight, the greater the fluidity (the MFR becomes larger), so a relatively low molecular weight thermoplastic resin can be used as a high fluidity resin. In the case of pellets using PP, since post-molding is performed at about 200 to 230 ° C., PP having an MFR of 100 or more within this temperature range can be used as a highly fluid resin. Note that the PP test conditions specified in the ISO standard related to JIS K7210 are the conditions M (test temperature 230 ° C.) in Appendix A Table 1 of JIS K7210. May be a highly fluid resin.
On the other hand, a high-strength resin may be a thermoplastic resin such as PP that has a MFR of less than 100 at the melting temperature when the pellets produced by this pellet production method are melted and mixed for subsequent molding. it can. In a thermoplastic resin such as PP, since the MFR generally decreases and the strength increases as the molecular weight increases, a relatively high molecular weight thermoplastic resin can be used as a high-strength resin. In the case of pellets using PP, PP having an MFR of less than 100 at a temperature of about 200 to 230 ° C. or PP having an MFR of less than 100 under the condition M in Annex A Table 1 of JIS K7210 can be used as a high-strength resin. . In addition, even if it is resin more than MFR100, since high intensity | strength resin exists, it is good also considering such resin as high intensity | strength resin.
The high fluidity PP and the high strength PP in all the resins used for pellet production can be used in various ratios such as 4: 6, 5: 5, 6: 4, and the like.

When a fine granular woody material (filler) and a granular thermoplastic resin (high fluidity PP or high strength PP) equal to or less than the same weight as the woody material are put into the material supply device 11, the material conveying device 12 is The wood-based material and the material having the thermoplastic resin are mixed and conveyed toward the pellet forming apparatus 20. At this time, since the material heating device 13 heats the material, the thermoplastic resin is melted and the material is softened. When PP is used as the thermoplastic resin, the material is heated so that the temperature is about 200 to 230 ° C., which is the same as the temperature of heat-melting during post-molding. Here, since the material is highly filled with filler, even if the resin is melted, the solid content is large, so that the fluidity does not become too large and softens to the extent that it can be pulverized. The material conveying device 12 pushes the softened material into the outer cylinder portion 21 of the pellet forming device while mixing with the screw 12g. Here, since the molten thermoplastic resin adheres to the fine-grained woody material while adsorbing, an amorphous material in which the thermoplastic resin is familiar (compatibilized) with the woody material is formed.
Since the tip of the screw 12g is inserted into the outer tube portion 21, the screw 12g is pushed toward the outlet portion 22 while mixing the softened material also in the outer tube portion 21. Then, the softened material is extruded in an indefinite shape without being molded. This state is shown as an irregular material m1 in FIG. Note that if the mixing ratio of the wood-based material in the material is large, the material m1 is pushed out in a powdery feeling, and if the mixing ratio of the thermoplastic resin in the material is large, the material m1 is extruded in a thick noodle shape. In this embodiment, since the first and second materials are mixed before pulverization, the first material is softened by heating the first material with the material heating device 13 (material heating process). These materials are mixed and extruded in an irregular shape (extrusion process). The first material is heated and softened by the material heating device 13 (second material heating step), and the softened second material is mixed and extruded in an indefinite state (first Two extrusion process). Then, the irregular first material using the high fluidity PP and the irregular second material using the high strength PP are accommodated in the same crusher hopper 32. As shown in FIG. 14, when a plurality of extrusion mechanisms A <b> 1 and A <b> 2 are provided, the irregular first and second materials M <b> 5 and M <b> 6 are accommodated in a common hopper 32 and supplied into the crushing chamber 33. In other words, the materials M5 and M6 are introduced into the amorphous material introduction unit 31 while remaining in an irregular shape. Here, a mixing mechanism having a rotating stirring blade may be provided in the hopper 32, and the raw materials M5 and M6 may be mixed by the stirring blade.

In the pulverizer 30, the motor 36 is always energized, and the rotary table 34 is rotationally driven via the rotary drive shaft 36a. Then, the rotary blades 35 and 35 fixed to the upper surface of the rotary table 34 are rotated, and the soft material indefinite material m1 (M5 and M6) introduced into the crushing chamber 33 is crushed. Here, the material m1 is a material in which a thermoplastic resin is familiar to a fine-grained woody material, and the woody material familiar to the resin is pulverized and homogenized. In addition, since the irregularly shaped first and second materials M5 and M6 are mixed at the time of pulverization, there is no need to provide a separate mixing step using a mixing mechanism. Here, since both the raw materials M5 and M6 are melted and not kneaded by the extrusion mechanism, the first resin and the second resin are pulverized without being too familiar, and the physical properties of both resins remain. It becomes.
As shown in the lower part of FIG. 16, when the first and second materials containing the first and second resins are mixed together by an extrusion mechanism and extruded in an irregular shape, the irregular material M91 that is extruded. Is a material in which both resins are compatible with each other by kneading in the extrusion mechanism. When the same material M91 is pulverized, the pulverized product M92 produced is homogeneous, and even if the pulverized product M92 is formed into a pellet shape, the pellet M93 gathers the material M91 'in which both resins are familiar, and the physical properties of both resins gather. It is an erased pellet.
On the other hand, as shown in the upper part of FIG. 16, when the first and second materials are separately extruded in an indeterminate state by an extrusion mechanism and then the indeterminate shapes M5 and M6 are crushed, a pulverized product is produced. Is substantially a mixture M7 of the pulverized material M5 ′ of the material M5 and the pulverized material M6 ′ of the material M6, and therefore, the first and second resins are almost incompatible with each other. Therefore, the resulting mixture M7 retains the physical properties of both resins.

The air blower (for example, a blower) of the powder transporter 37 is always energized, and is crushed from the material m1 and falls into the housing chamber 33a from 33b between the inner peripheral surface of the pulverizing chamber 33 and the outer peripheral surface of the rotary table 34. The sucked material is sucked into the powder transport machine 37 from the powder suction port 37b and discharged downward from the powder discharge port 37a. Then, the crushed material m2 (mixture M7) falls and is accommodated in the molding machine container 23. This state is shown in the main part sectional view of FIG.
The above is the pulverization and mixing step.

As shown in FIG. 12, the crushed material m3 introduced into the pulverized material introduction unit 24 is pushed in from the upper openings of a number of through holes 23d by push rollers 25 and 25. In addition, since the raw material is pulverized, it is easy to enter the through hole 23d, and the amount of pellet forming per unit time is large. In addition, in the state of entering the through hole 23d, an appropriate gap (a gap that is broken in the kneading step in which heat is applied during post-forming) is generated between the raw material particles. The crushed material m3 pushed into the through hole 23d is pushed out in a substantially rod shape from the lower opening of the through hole 23d. Note that the cutter 26b with the cutting edge directed to the material m4 extruded in a substantially rod shape approaches the substantially rod-shaped material m4 by driving the cutter driving electric motor 27 as compared with the state of FIG. When the cutter 26b further rotates, the substantially rod-shaped material m4 is cut in the cross-sectional direction by the cutter 26b and formed into a pellet shape. The above is the molding process.
Thereafter, as shown in FIG. 13, the pellet-shaped material m <b> 5 falls into the cooling tank 40, and is cooled and solidified to become a manufactured pellet m <b> 6. The pellet m6 is recovered from the cooling bath 40.
As shown in the upper part of FIG. 16, the crushed material m3 is substantially a mixture M7 of the pulverized material M5 ′ of the material M5 and the pulverized material M6 ′ of the material M6, and the first and second resins are familiar to each other. There are few. The pellet M8 produced by collecting such pulverized materials is a new pellet in which the physical properties of both resins remain.

As described above, according to this method for producing pellets, the familiarity of a plurality of resins can be reduced when producing pellets, and therefore, pellets in which the respective physical properties of the respective resins remain can be produced. When post-molding such as plastic extrusion, injection molding, blow molding, etc. is performed using this pellet as a raw material, each resin contained in the pellet is heated and melted, and at this stage, the resin is familiar with each other and has a good polymer blend Can be manufactured. And since there is no need to mix the pellets containing the first resin and the pellets containing the second resin (and the corresponding pellets if there are more resins), the quality of the resin is fully blended. It becomes possible to obtain a molded article. Moreover, the pellet which makes fluidity | liquidity very favorable at the time of post-molding can be obtained by using highly fluid resin.
In addition, by using the above-described method, an additive that contributes to the moldability of post-molding, but is modified or reacts with a resin or the like depending on the temperature conditions during compounding (during mixing) (for example, at 200 ° C. Denatured oil) can also be used.

  Since this pellet manufacturing apparatus 10 should just mix the predetermined softened raw material and extrude it in an indefinite state, the extrusion flow rate of a raw material is not restrict | limited. Therefore, even if it is a raw material with small fluidity, it is possible to mass-produce pellets. In addition, the irregularly shaped material introduced into the pulverized material introduction part is extruded into a substantially rod shape with a push-in roller and cut with a cutter. It can be formed into a shape. Furthermore, by using a thermoplastic resin as one of the raw materials, pellets can be mass-produced by a simple process of heating and melting and mixing with a wooden material to soften the raw material and cooling to solidify. In addition, if it is a factory which manufactures a resin product, since expensive capital investment is unnecessary, it becomes possible to mass-produce a pellet easily. Furthermore, since the molten thermoplastic resin adheres to the wood-based material while oozing, it is possible to obtain good strength, and the molded pellets are used as lightweight aggregates for reducing the weight of concrete or the like. It becomes possible. Here, since the wood-based material is used as the predetermined material, it is possible to promote the effective use of the wood-based material.

  In addition, since the amorphous material extruded by the extrusion mechanism is once pulverized and supplied to the molding mechanism, the material can be molded into a pellet shape in a more uniform state. Thereby, the manufactured pellet can be homogenized more, and the high quality pellet which can homogenize the molded article and aggregate which used the said pellet as a raw material can be mass-produced. In addition, since the resin is well blended (compatibilized) with the filler, it is pelletized, so that the pellet shape can be maintained at the raw material stage during extrusion molding and injection molding after the pellet is used as a raw material. In the kneading stage where the slag is added, the pellets are more easily broken and dispersed well. Accordingly, it becomes easier to form a post-molded molded product as compared with a case where no crushing mechanism is provided. Furthermore, since the amorphous material is pulverized, it becomes easy to enter holes and gaps for molding when the pellets are molded, so that it is possible to further increase the amount of pellets produced per unit time.

  In particular, if a material containing a high filling amount of a filler and a heat-softened thermoplastic resin is mixed and extruded (kneaded) without pulverizing and forming into a pellet shape, the resin does not conform to the filler. Since it is pelletized, pellets that are easily broken down into powder are produced. Of course, if the thermoplastic resin is not softened, pellets that are more likely to collapse into powder are produced. Then, when trying to perform the subsequent molding using the pellet as a raw material, the pellet collapses into a powder form from the raw material stage, so it is not easy to uniformly knead the raw material in the kneading stage. In the pellet manufacturing apparatus of the present invention, the molten resin and the filler are mixed and extruded as a softened material, and then pulverized and formed into a pellet shape. Pellets that do not collapse so as to become a body are produced. Therefore, when the pellet is used as a raw material, the pellets are disintegrated and dispersed in the kneading stage where heat is applied in the raw material stage without collapsing into powder, so the raw materials are easily and uniformly kneaded in the kneading stage. be able to.

Furthermore, even if the blending ratio of the resin in the material is large and the conventional extrusion molding machine sticks the pellets after molding, using this pellet manufacturing device will separate the pellets after molding without sticking. It will be in the state. This is because, after extruding the softened material in an indeterminate state, it is not immediately molded into a pellet shape, so the material with a thermoplastic resin has a temperature drop, so the material with a thermosetting resin or adhesive This is because the degree of material softening is presumed to decrease with time. If the pellets are stuck together, the pellets are not smoothly fed into the kneading process during post-molding, but since the pellets are separated, a post-molded molded product can be produced smoothly.
In addition, after introducing the pulverized material into the pulverized material introducing unit 24, a predetermined fiber such as a resin fiber may be mixed with the pulverized material and then formed into a pellet shape. Then, since the fiber is not crushed by the screw or the rotary blade, the strength of the pellet can be improved by adding the fiber to the material.

In addition, high-fluidity PP and a modified PP (compatibilizer) obtained by modifying PP with maleic acid may be used as the high-fluidity resin, and high-strength nylon (also referred to as Ny) may be used as the high-strength resin. . When a hydrophilic modified PP is added to a highly fluid PP exhibiting hydrophobic properties, the highly fluid PP and the modified PP become familiar with each other, exhibit hydrophilic properties, and become familiar with Ny, which exhibits hydrophilic properties. In the case of pellets using Ny, since post-molding is performed at about 270 to 290 ° C., Ny having an MFR of 100 or more within this temperature range can be made to be highly fluid Ny.
The high fluidity PP, modified PP and Ny in all resins used for pellet production can be used in various ratios such as 45: 5: 50 and 40:10:50.

When the irregular first material using high fluidity PP and modified PP and the irregular second material using Ny are accommodated in the same crusher hopper 32, they are supplied into the crushing chamber 33. Crushed. Here, the material m3 after pulverization is substantially a mixture M7 of the pulverized material M5 ′ of the material M5 and the pulverized material M6 ′ of the material M6 as shown in the upper part of FIG. And Ny are not familiar to each other. The pellet M8 produced by collecting such pulverized materials is a new pellet in which the physical properties of both resins remain. When post-molding such as plastic molding is performed using this pellet as a raw material, the high fluidity PP and modified PP and Ny contained in the pellet are heated and melted, and at this stage, the high fluidity PP and Ny are familiar through the modified PP. In addition, a molded product having a high-quality polymer alloy can be produced by causing a chemical reaction between the carboxyl group of the modified PP and the amino group of Ny. And since it is not necessary to mix the pellet containing high fluidity PP and modified PP, and the pellet containing Ny, it is possible to obtain a high quality molded product in which high fluidity PP, modified PP and Ny are sufficiently blended. It becomes possible.
In addition to the above, polyolefin resin such as polyethylene resin can also be used as the high fluidity resin. Examples of resins having functions such as high strength, water resistance, light resistance, impact resistance, heat resistance, and flame resistance include polycarbonate resins (PC), various engineering plastics, acrylic resins, acrylonitrile styrene copolymer resins ( AS), acrylonitrile butadiene styrene copolymer resin (ABS), and the like may be used. The resin having such a function may be a resin having a high fluidity of MFR 100 or more.

Next, the case where the first and second materials are mixed after pulverization will be described. When the pulverized material M11 of the first material is produced, the soft material of the amorphous material m1 (M5) introduced into the pulverizing chamber 33 is pulverized, and the pulverized material M11 is moved downward from the powder discharge port 37a. It is discharged toward. When the pulverized material M12 of the second material is produced, the soft material of the amorphous material m1 (M6) introduced into the pulverizing chamber 33 is pulverized, and the pulverized material M12 is moved downward from the powder discharge port 37a. It is discharged toward. In order to mix the first and second materials after pulverization, for example, the pulverized product M11 using high-fluidity PP and the pulverized product M12 using high-strength PP are accommodated in the same molding machine container 23. When a plurality of crushing mechanisms A7 and A8 are provided as shown in FIG. 15, the pulverized products M11 and M12 are accommodated in a common molding machine container 23. In other words, the pulverized products M11 and M12 are introduced into the pulverized material introduction unit 24. Here, a mixing mechanism having a rotating stirring blade may be provided in the container 23, and both pulverized products M11 and M12 may be mixed by the stirring blade.
The above is the pulverization and mixing step.
The material m3 after pulverization introduced into the pulverized material introduction unit 24 is formed into a pellet shape and becomes a pellet m6. When the first and second materials are separately extruded in an irregular shape by an extrusion mechanism, and the irregularly shaped materials M5 and M6 are separately pulverized and mixed, as shown in the upper part of FIG. Since the product is almost a mixture M7 of the pulverized product M5 ′ of the material M5 and the pulverized product M6 ′ of the material M6, the first and second resins are almost unfamiliar with each other. Therefore, the resulting mixture M7 retains the physical properties of both resins. And the pellet M8 produced by gathering such pulverized products retains the physical properties of both resins.

  Mixing after crushing an irregular shaped material can more reliably reduce the familiarity of multiple resins when manufacturing pellets, so make new pellets that retain the respective physical properties of each resin Can do. Then, when post-molding such as plastic molding is performed using this pellet as a raw material, it is possible to manufacture a molded product having a good polymer blend at this stage and mixing multiple types of pellets for each resin Therefore, it is possible to obtain a high-quality molded product in which the resins are sufficiently blended with each other.

In addition, you may use resin other than a thermoplastic resin as 1st, 2nd resin. Hereinafter, the combination of the first and second resins is a high-fluidity thermoplastic resin (first resin, but the second resin may be used) and a thermosetting resin (second resin, The case of using a liquid resin as the thermosetting resin and mixing the first and second materials before pulverization will be described. As the thermosetting resin, phenol resin, urea resin, melamine resin, unsaturated polyester resin, epoxy resin, or the like can be used. When producing an amorphous material using a thermosetting resin, heating is generally not performed, and thus the material heating device can be omitted. The thermosetting resin and thermosetting resin in all the resins used for pellet production can be used in various ratios such as 4: 6, 5: 5, 6: 4, and the like.
When using a liquid thermosetting resin, if it is a low viscosity (high fluidity) liquid (for example, MFR at the temperature when mixing is 100 or more), it is easy to mix with the filler. This is preferable in that it can be made more uniform.

When a fine-grained wood-based material (filler) and a liquid thermosetting resin equal to or less than the same weight as the wood-based material are put into the material supply device 11, the material conveying device 12 receives the wood-based material and the thermosetting resin. It conveys to the pellet forming apparatus 20 direction, mixing the raw material which has. Here, since the raw material is highly filled with filler, the fluidity does not become too large due to a large solid content even if the resin is in a liquid state, and it is in a softened state that can be pulverized. The material conveying device 12 pushes the softened material into the outer cylinder portion 21 of the pellet forming device while mixing with the screw 12g. Here, the liquid thermosetting resin adheres to the fine-grained woody material while adsorbing, so that an amorphous material in which the thermosetting resin is familiar (compatibilized) with the woody material is formed. The screw 12g is pushed toward the outlet portion 22 while mixing the softened material even in the outer cylinder portion 21. Then, the softened material is extruded in an indeterminate state.
When mixing the first and second materials before crushing, for example, the amorphous first material using high fluidity PP and the amorphous second material using thermosetting resin are used for the same crusher. It is accommodated in the hopper 32.
On the other hand, when the first and second materials are mixed after pulverization, for example, the pulverized product M11 using high fluidity PP and the pulverized product M12 using thermosetting resin are accommodated in the same molding machine container 23.

  The material m3 after pulverization introduced into the pulverized material introduction unit 24 is formed into a pellet shape and becomes a pellet m6. Apart from mixing the first material using a thermoplastic resin while heating and melting and extruding it in an indeterminate state, the second material using a thermosetting resin is mixed (without heating). When the mixture M7 is produced by extruding in an irregular shape and pulverizing the irregularly shaped materials M5 and M6, the mixture M7 is substantially composed of the pulverized material M5 ′ of the material M5 and the material M6 as shown in the upper part of FIG. Since the mixture M7 is mixed with the pulverized product M6 ′, the physical properties of the first and second resins remain. And the pellet M8 manufactured by collecting such pulverized materials is a new pellet in which the physical properties of the thermoplastic resin and the thermosetting resin remain. As a result, post-molding such as extrusion molding, injection molding, and blow molding can be performed using a thermosetting resin as a raw material. Therefore, when post-molding such as plastic molding is performed using this pellet as a raw material, a molded product having a novel polymer blend in which the thermoplastic resin and the thermosetting resin are compatible with each other can be produced at this stage.

(4) Example of the first embodiment:
EXAMPLES Hereinafter, although an Example is shown and this invention is demonstrated concretely, this invention is not limited by the following examples.
[Example]
As the wood powder, wood powder having a water content of 15% by weight was used. As the high fluidity PP, granular polypropylene having an MFR of 1000 (g / 10 min) under condition M (test temperature 230 ° C.) in Appendix A, Table 1 of JIS K7210 was used. As the high-strength PP, granular polypropylene having an MFR of 30 (g / 10 min) under the same conditions was used.
Wood powder and high-flowability PP are charged into a kneading extruder with a heater at the blending amount of the first material described below, and the material is heated to 230 ° C. and extruded in an indeterminate state while mixing. The first material having an irregular shape was pulverized by a pulverizer to prepare a pulverized product (first pulverized material).
Also, wood powder and high-strength PP are charged into a kneading extruder with a heater at the blending amount of the second material described below, and the material is heated to 230 ° C. and extruded in an indeterminate state. The second material having an irregular shape was crushed by a hopper and pulverized by a pulverizer to prepare a pulverized product (second pulverized material).
Then, the 1st raw material ground with the compounding quantity of the ground raw material described below, and the 2nd raw material ground were mixed, it formed into the shape of a pellet with a pellet molding machine, and water-cooled and produced the pellet.
Then, the prepared pellets were put into a kneading extrusion molding machine equipped with a heater, and extruded to 110 mm × 9 mm square while mixing by heating to 230 ° C., and a molded product was prototyped.

First material mix:
70% by weight of wood flour
High fluidity PP 30% by weight
100% by weight

Second material mix:
70% by weight of wood flour
High strength PP 30% by weight
100% by weight

Amount of crushed material:
50% by weight of ground first material
50% by weight of second ground material
100% by weight

[Comparative Example 1]
The same wood flour and high fluidity PP as in the examples were used.
Wood powder and high-fluidity PP are introduced into a kneading extruder with a heater at the blending amount of the materials described below, and the materials are heated to 230 ° C. and extruded in an indeterminate state while being mixed and received by a hopper. The amorphous material was pulverized with a pulverizer to prepare a pulverized product. Thereafter, the pulverized product was formed into a pellet shape with a pellet molding machine, and cooled with water to produce a pellet.
Then, the prepared pellets were put into a kneading extrusion molding machine equipped with a heater, and extruded to 110 mm × 9 mm square while mixing by heating to 230 ° C., and a molded product was prototyped.

Material content:
70% by weight of wood flour
High fluidity PP 30% by weight
100% by weight

[Comparative Example 2]
The same wood flour and high-strength PP as in the examples were used.
Wood powder and high-strength PP are charged into a kneading extruder with a heater at the blending amount of the materials described below, and the materials are heated to 230 ° C. and extruded in an indeterminate state while being mixed and received by a hopper and pulverized. The amorphous material was pulverized by a machine to prepare a pulverized product. Thereafter, the pulverized product was formed into a pellet shape with a pellet molding machine, and cooled with water to produce a pellet.
Then, the prepared pellets were put into a kneading extrusion molding machine equipped with a heater, and extruded to 110 mm × 9 mm square while mixing by heating to 230 ° C., and a molded product was prototyped.

Material content:
70% by weight of wood flour
High strength PP 30% by weight
100% by weight

[Comparative Example 3]
Wood flour, high fluidity PP, and high strength PP were the same as in the examples.
The wood powder, high fluidity PP and high strength PP are put together in the blending amount of the materials described below, and are put into a kneading extruder equipped with a heater, and the materials are extruded to an irregular shape while being heated to 230 ° C. and mixed. Then, it was received by a hopper, and the amorphous material was pulverized by a pulverizer to prepare a pulverized product. Thereafter, the pulverized product was formed into a pellet shape with a pellet molding machine, and cooled with water to produce a pellet.
Then, the prepared pellets were put into a kneading extrusion molding machine equipped with a heater, and extruded to 110 mm × 9 mm square while mixing by heating to 230 ° C., and a molded product was prototyped.

Material content:
70% by weight of wood flour
High fluidity PP 15% by weight
High strength PP 15% by weight
100% by weight

[Comparative Example 4]
Wood flour, high fluidity PP, and high strength PP were the same as in the examples.
A wood powder and high-flowability PP are charged into a kneading extruder with a heater at the blending amount of the first material described below, and the material is heated to 230 ° C. and extruded in an indeterminate state while mixing. The first material having an irregular shape was pulverized by a pulverizer to prepare a pulverized product. Thereafter, the pulverized product was formed into a pellet shape with a pellet molding machine and cooled with water to produce a pellet of the first material.
Also, wood powder and high-strength PP are charged into a kneading extruder with a heater at the blending amount of the second material described below, and the material is heated to 230 ° C. and extruded in an indeterminate state. The second material having an irregular shape was crushed by a hopper and pulverized by a pulverizer. Thereafter, the pulverized product was formed into a pellet shape with a pellet molding machine, and cooled with water to produce a pellet of the second material.
Then, the pellets of the first material and the pellets of the second material are put into a kneading extruder with a heater at the blending amount of the pellets described below, and heated to 230 ° C. and mixed while being 110 mm × 9 mm square A molded product was prototyped.

First material mix:
70% by weight of wood flour
High fluidity PP 30% by weight
100% by weight

Second material mix:
70% by weight of wood flour
High strength PP 30% by weight
100% by weight

Pellet content:
50% by weight of first material pellets
50% by weight of second material pellets
100% by weight

About the above Example and Comparative Examples 1-4, the molding pressure (MPa unit) in the kneading extrusion molding machine with a heater corresponding to post-molding, and the bending strength (MPa unit) of the molded product shape | molded with the said molding machine Were measured and evaluated. In addition, the autograph was used for the measurement of bending strength. The measurement results and evaluation results are shown in the table.

In Comparative Example 1, since a molded product was produced using pellets blended with only the high fluidity PP, the molding pressure was as small as 112 MPa and the fluidity was high, but the bending strength was as small as 74 MPa and low strength. On the other hand, in Comparative Example 2, since a molded product was produced using pellets blended with only high-strength PP, the bending strength was as high as 86 MPa and high strength, but the molding pressure was as large as 124 MPa and the fluidity was small. It has become.
In Comparative Example 3, the bending strength is as high as 85 MPa and high strength, but the molding pressure is close to that of Comparative Example 2 using only 120 MPa and high strength PP, and the fluidity is relatively small. ing. This is presumably because most of the physical properties of the high-fluidity PP were erased by the physical properties of the high-strength PP because the high-fluidity PP and the high-strength PP became compatible with each other.
In Comparative Example 4, the molding pressure is 117 MPa, which is smaller than that of Comparative Example 3, and the fluidity is slightly increased. However, the bending strength is 82 MPa, which is smaller than that of Comparative Example 3, and the strength is slightly decreased. By producing a molded product using pellets blended only with high-fluidity PP and pellets blended with only high-strength PP, the physical properties of high-fluidity PP are strong in the melt-kneaded product and molded product before molding. There are a mixture of places where the physical properties of the high strength PP are strong and the physical properties of the high fluidity PP with a relatively high fluidity appear in terms of fluidity, while the physical properties of the high fluidity PP with a relatively low strength appear. This is presumably because the physical properties of high fluidity PP appear strongly.
In contrast, in the examples, the molding pressure is 113 MPa, which is as large as Comparative Example 1, and the fluidity is large, and the bending strength is 85 MPa, which is as large as Comparative Example 2, and high strength. This is because the first material having the high fluidity PP and the second material having the high strength PP are separately mixed and extruded to produce a mixture of the first and second materials. It is presumed that pellets are produced in a state where the familiarity between PP and high-strength PP is reduced, and the physical properties of high-fluidity PP remain even at the time of post-molding. Moreover, the physical properties of both PPs remain in the same pellet, and it is not necessary to mix pellets containing high-fluidity PP and pellets containing high-strength PP at the time of post-molding. It is presumed that the physical properties of the high fluidity PP do not appear strongly. Therefore, it was confirmed that high-quality pellets in which the physical properties of high fluidity PP and high strength PP were left were obtained.

(5) Various modifications:
A thermosetting resin may be used for the first resin. In this case, the material heating device 13 can be omitted. The first material may be composed of only the first resin. Of course, the second material may also be composed of only the second resin.
In addition to the wood-based material, various materials such as a particulate porous inorganic material can be used for the filler. In the case of organic fillers, cellulose materials such as wood powder (wood), pulp (paper), and grass, thermoplastic resins, thermosetting resins, FRP waste materials, and the like can be used. In the case of inorganic fillers, silica such as talc, calcium carbonate, fly ash, magnesium compounds, calcium silicate, metal inorganic materials, metal oxides, and the like can be used. In addition, although the mixture ratio of each raw material in a raw material changes according to the kind of filler and resin, if it is a filler of 100 micrometer-1 mm diameter, for example, resin (with respect to 60-99.9 weight% of fillers) ( 0.1 to 40% by weight (including acid-modified resin) and 1 to 100 μm filler, 40 to 50% by weight of resin (including acid-modified resin) and 1 nm to 1 μm diameter relative to 50 to 60% by weight of filler In the case of the filler, the resin (including the acid-modified resin) may be 50 to 80% by weight with respect to 20 to 50% by weight of the filler.
Various known pulverizers can be used for the pulverization mechanism.
You may provide the container heating means which heats the said container for molding machines. When a heater is embedded in the molding machine container 23 and the heater is energized, the molding machine container 23 can be heated. Then, solidification by cooling of the amorphous material accommodated in the molding machine container 23 can be prevented, and the production efficiency of pellets can be further improved.
A cutter heating means for heating the cutter may be provided. For example, when a heater is embedded in the cutter table 26a and the heater is energized, the cutter can be heated. Then, the raw material containing a thermoplastic resin can be softened in the vicinity of the cutter and easily cut, and the manufacturing efficiency of pellets can be further improved.

  Furthermore, you may manufacture a pellet with a pellet manufacturing apparatus provided with the pellet shaping | molding apparatus 120 shown in FIG. 17 and FIG. In addition, the thing of the same structure as 1st embodiment attaches | subjects the same code | symbol, and abbreviate | omits detailed description. The pellet forming apparatus 120 is provided with an outer cylinder portion, an outlet portion, a pulverizer (not shown), and a pulverized material of the material m12 after being pulverized by setting the opening 123a upward on the lower side of the powder discharge port 37a of the pulverizer A metal hopper 123 in which the introduction part 124 is formed, a pair of rolling rolls 125, 125 provided in the lower opening 123 b of the hopper 123, and a shredder (resin shredder) 126 installed under the hopper 123. , Etc. The upper opening 123a of the hopper is separated from the powder discharge port 37a.

  The rolling rolls 125 and 125 are connected to a rolling roll rotation drive mechanism (not shown). When the rolling roll rotation drive mechanism is driven, the left rolling roll 125a rotates clockwise in FIG. 18, and the right rolling roll 125b rotates counterclockwise at the same rotational speed as the rolling roll 125a. ing. That is, the rolling rolls 125a and 125b can roll the crushed material m13 introduced into the pulverized material introduction unit 124 into a substantially flat plate shape.

  The shredder 126 draws the rolled material m14 from the upper opening 126a, cuts it into a pellet shape, and drops it from the lower opening 126b. The shredder 126 includes a rotating roll 126c having a large number of rotating blades 126d, a rotating blade driving mechanism (not shown) that rotationally drives the rotating roll 126c, a fixed blade 126e, and the like. The rotary roll 126c rotates counterclockwise in FIG. 13 by driving the rotary blade driving mechanism, and draws the rolled material m14 downward. Here, in the bottom view of the main part shown in FIG. 18, each rotary blade 126d has a substantially triangular cross section and is inserted into a plurality of valleys 126e1 formed on the fixed blade 126e. Therefore, the rolled material m14 is shredded so as to be torn by the rotary blade 126d and the fixed blade 126e while being pulled downward by the rotating blade 126d that rotates, and is formed into a pellet shape. That is, the hopper 123, the rolling rolls 125a and 125b, the mechanism for driving the rolling rolls, and the shredder 126 constitute a forming mechanism.

The crushed material m12 discharged from the powder discharge port 37a falls and is accommodated in the hopper 123, introduced into the pulverized material introduction part 124, and is substantially reduced by the rolling rolls 125, 125 below the hopper 123. It is rolled into a flat plate shape. The rolled material m14 is shredded by a shredder 126 and formed into a pellet shape. Thereafter, the material m15 formed into a pellet shape falls into the cooling tank and is cooled and solidified to become pellets.
Even if comprised as mentioned above, the effect similar to 1st embodiment can be acquired. In addition, by using a simple and general-purpose mechanism that rolls the crushed material into a substantially flat plate with a rolling roll and shreds it with a shredder, the irregularly shaped material is reliably formed into a pellet shape. Can do. The shredder may have various structures, and may be other than the structure shown in FIG.

FIG. 19 shows a crusher (crushing mechanism) 130 of a pellet manufacturing apparatus according to a modification. In addition, an extrusion mechanism, a shaping | molding mechanism, etc. are the same as 1st embodiment. If it demonstrates using the code | symbol in 1st embodiment, this pellet manufacturing apparatus is installed in the lower side of the outer cylinder part 21, the outlet part 22, and the outlet part 22 with the opening 131a facing upward, and is not pushed out. A crusher 130 provided with an amorphous material introduction part 131 for introducing a regular material m1, a molding machine container 23 formed with a pulverized material introduction part 24 for introducing a material crushed by the crusher 130, and pushing. Rollers 25 and 25, a die face cutter unit 26, an electric motor 27, and the like are provided.
The crusher hopper 132 temporarily stores the irregular shaped material m1 pushed out from the opening 22a of the outlet portion, and supplies it from the lower opening 132b into the cylindrical metal crushing chamber 133 having the substantially vertical direction as the central axis. be able to. And the amorphous material introduction part 131 which introduce | transduces the raw material extruded from the extrusion mechanism with an irregular shape is formed in the hopper 132 and the crushing chamber 133. FIG.

  In the present embodiment, at least fly ash and the fly ash and an equal weight or less thermoplastic resin are used, and the thermoplastic resin is mixed while melted and extruded in an indeterminate state, and then molded. Fly ash is a blackish ash produced when coal is fired, and is a finely divided (including powdered) porous inorganic material containing silica. The fly ash contains particles of various particle sizes, but pellets can be produced without modification such as making the particle sizes uniform. In this case, pellets can be obtained at a very low cost and can be used for building materials and the like. Of course, the pellets may be made to have a desired strength by modifying the particle size according to the application. In order to obtain more favorable conditions, the fly ash particle size was varied and tested, and when the particle size was reduced to 500 μm or less, high-quality pellets were obtained that would be very homogeneous when used for building materials. I was able to.

The blending ratio of fly ash and thermoplastic resin can be determined as appropriate according to the use of the pellets. Generally, the higher the weight ratio of fly ash, the harder the hard stuff, and the higher the weight ratio of thermoplastic resin, the softer the ash. As the weight ratio of both, a preferable ratio can be appropriately selected according to the properties required for the pellets.
In order to make the pellets small in thermal expansion and incombustible like inorganic materials, the fly ash may be mixed with the fly ash and an equal weight or less thermoplastic resin. When fly ash is 51 to 99% by weight (preferably 70 to 95% by weight) and thermoplastic resin is 1 to 49% by weight (preferably 5 to 30% by weight), it is extremely useful as a material for building materials. High quality pellets could be obtained. Here, the reason why the thermoplastic resin is set to 1% by weight or more (preferably 5% by weight or more) is to solidify the pellets without breaking up in a solid state, and fly ash is 51% or more (preferably 70% by weight or more). ) Is to obtain a very good strength as a building material or the like.
Note that a part or all of the filler can be made into a fine-grained quartz-based mineral.

In addition, pellets can be produced using fly ash or quartz-based minerals as they are, but these are subjected to silane coupling treatment using a silane coupling agent to impart hydrophobicity and familiarity with the resin. Improved fly ash or quartz minerals may be used as fillers. The silane coupling agent has an ethoxy group or a methoxy group that gives a silanol group (Si—OH) by hydrolysis at one end of the molecule, and an organic functional group at the other end. And if a silane coupling agent is made to react with fly ash etc. and a hydrophobic organic functional group is added to fly ash etc., familiarity with resin can be improved.
For example, 1 to 49% by weight (preferably 5 to 30% by weight) of polyamide is blended with 51 to 99% by weight (preferably 70 to 95% by weight) of fly ash modified by silane coupling treatment. Can be a material.

The crusher 30 has a crushing chamber 133 in which an upper opening communicating with the lower opening 132b of the hopper 132 is formed on the lower side of the hopper 132, and a rotating shaft directed in the vertical direction in the lower portion of the crushing chamber 133. And a metal mounting table 134 on which an indeterminate material can be rotated, and columnar shaft members 135a and 135a oriented in the left-right direction are in contact with the mounting table 134 at the lower outer periphery. A plurality of metal crushing rollers 135, 135 that can roll on the table 134, and an electric motor 136 that rotationally drives the mounting table 134 via a columnar rotational drive shaft 136a disposed in the vertical direction; A powder transport machine 137 for transferring the pulverized material to a powder discharge port (not shown) opened downward in the upper part of the molding machine container 23 is provided. The shaft members 135 a and 135 a are fixed to the side wall of the crushing chamber 133. A cylindrical metal powder storage chamber 133a having substantially the same diameter as the pulverization chamber 133 is provided below the pulverization chamber 133 (lower side from the lower surface of the mounting table 134), and the pulverization is performed in the storage chamber 133a. A powder suction port 137b through which the subsequent material is sucked into the powder transport machine 137 is formed.
In the pulverizer 130, the motor 136 is always energized, and the mounting table 134 is rotationally driven via the rotation drive shaft 136a. Then, on the upper surface of the mounting table 134, the crushing roller is rotated about the horizontal direction as a result of the rotational movement about the vertical direction of the table 134, and the amorphous material introduced into the crushing chamber 133 is Then, it is pulverized between the mounting table 134 and the peripheral surfaces of the pulverizing rollers 135 and 135. Here, the introduced material is a material in which a thermoplastic resin is familiar with fine particulate fly ash, and the fly ash familiar with the resin is pulverized and homogenized. Further, the air blower of the powder transport machine 137 is always energized, and the material that has been crushed and dropped into the storage chamber 133a from the inner peripheral surface of the pulverization chamber 133 and the outer peripheral surface of the mounting table 134 is powdered. It is sucked into the powder transport machine 37 from the body suction port 37b, is transported obliquely upward to the upper side of the powder discharge port, and is discharged downward from the powder discharge port. The pulverized material falls and is accommodated in the molding machine container 23.
In particular, a hard inorganic material such as fly ash or quartz mineral is used as a main component (for example, a filler composed of at least one of fly ash and quartz mineral and a meltable resin equal to or less than the filler). In the case of producing pellets from a raw material, it is preferable because an amorphous material can be easily pulverized.
Various known pulverizers can be used as the pulverization mechanism.

Even if comprised as mentioned above, the effect similar to 1st embodiment is acquired. That is, the pellet manufacturing apparatus only has to mix a predetermined softened material and extrude it in an indeterminate state, so that the extrusion flow rate of the material is not limited. Therefore, even if it is a raw material with small fluidity, it is possible to mass-produce pellets.
In addition, since the amorphous material extruded by the extrusion mechanism is once pulverized and supplied to the molding mechanism, the manufactured pellets can be more homogenized, and molded articles and aggregates made from the pellets can be used as raw materials. High quality pellets that can be made more homogeneous can be mass produced. Also, since the resin is well blended with the filler, it is pelletized, so the pellet shape is maintained at the raw material stage during post-molding using the pellet as a raw material, and the pellet is more easily disintegrated during the kneading stage where heat is applied. Let me. Therefore, it becomes easy to form a post-molded product. Furthermore, since the irregular shaped material is pulverized, it becomes easy to enter molding holes, gaps, and the like when the pellets are molded, so that it is possible to further increase the amount of pellets produced per unit time. Furthermore, even if the blending ratio of the resin in the raw material is large and the conventional extrusion molding machine is a material in which the pellets after molding are stuck together, the pellets after molding are not stuck to each other and separated.

(6) Second embodiment:
If the second resin is finely granular, the second extrusion step described above can be omitted. FIG. 20 shows an example of a pellet manufacturing method when the second resin is a fine granular synthetic resin and the second raw material is a fine granular material. In the pulverization and mixing step S3 of the present manufacturing method, the pulverization mechanism A5 pulverizes at least the first material softened to such an extent that it can be pulverized (the amorphous first material M5), and the pulverized first material; A mixture M22 containing at least the fine particulate second material M21 is produced. FIG. 20 shows a flow of pulverization after mixing the first and second materials.
A case will be described in which a high fluidity PP (a high fluidity thermoplastic resin) is used as the first resin and a fine particle thermosetting resin (a fine particle synthetic resin) is used as the second resin. Here, the synthetic resin may be a thermoplastic resin. The fine-grained synthetic resin may be finer than powdered or molded pellets, and may be in the form of powder or fine fibers. In addition, although the second material is described as being a fine synthetic resin itself, for example, a material obtained by mixing a fine filler with a fine synthetic resin may be used. The high fluidity PP and the fine-grained synthetic resin in all resins used for pellet production can be used in various ratios such as 4: 6, 5: 5, 6: 4, and the like.
The blending ratio of the first material can be the same as in the first embodiment.

For the first resin M1 and the filler (woody material, fly ash, etc.) M2, both raw materials M1 and M2 are used in the same manner as in the first embodiment, with the amount of filler M2 being equal to or greater than the amount of resin M1. Is mixed into the extrusion mechanism A1 while melting the resin M1 with a heating mechanism, softened to such an extent that it can be pulverized, and extruded in an indefinite state. In this embodiment, since the first and second materials are mixed before pulverization, the amorphous first material using high fluidity PP and the fine particulate thermosetting resin are placed in the same pulverizer hopper 32. Accommodate. Here, a mixing mechanism may be provided in the hopper 32, and the raw materials M5 and M21 may be mixed by the mixing mechanism. Both raw materials M5 and M21 accommodated in the hopper 32 are supplied into the crushing chamber 33 and crushed to produce a mixture M22. Of course, the irregular first material extruded from the outlet 22 is once accommodated in the first irregular material container (accommodating portion), the second material M21 is accommodated in the second irregular material container, When there are three materials, a fourth material,..., These are accommodated in a third amorphous material container, a fourth amorphous material container,... Just put it in.
As described above, the mixture M22 is generated by pulverizing by the pulverization mechanism in a state in which the first material softened to such an extent that it can be pulverized and the fine second resin are combined together.

The generated mixture M22 is formed into a pellet shape by the forming mechanism A4 (forming step S4), and is used as a pellet M23.
The material after pulverization is a mixture M22 of a pulverized material M5 and a fine second material M21, and the first and second resins are in a state of little familiarity with each other. The pellet M23 produced by collecting such materials is a new pellet in which the physical properties of both resins remain.

  Also by this pellet manufacturing method, since the familiarity of a plurality of resins can be reduced when manufacturing the pellets, it is possible to manufacture pellets in which the respective physical properties of each resin remain. When post-molding such as plastic molding is performed using the pellets as a raw material, the thermoplastic resin contained in the pellets is heated and melted, and at this stage, the resins are familiar with each other, and a molded product having a good polymer blend can be manufactured. And since it becomes unnecessary to mix the pellets corresponding to each resin, it is possible to obtain a high-quality molded product in which the resins are sufficiently blended. When a thermosetting resin is used as the second resin, post-molding can produce a molded article having a novel polymer blend in which the thermoplastic resin and the thermosetting resin are compatible with each other at this stage.

Next, a case where the first and second materials are mixed before pulverization will be described with reference to FIG. When producing the pulverized material M11 of the first material, the irregular material M5 introduced into the pulverizing chamber 33 is pulverized by the pulverizing mechanism A11 (pulverizing step S11), and the pulverized material M11 is powdered by the pulverizer. It is discharged downward from the body discharge port 37a. The blending ratio of the first material can be the same as in the first embodiment. In order to mix the pulverized product M11 and the finely divided second material M21, for example, the pulverized product M11 using high fluidity PP and the second material M21 made of finely particulate thermosetting resin are used for the same molding machine. Housed in a container 23. Here, a mixing mechanism may be provided in the molding machine container 23, and the pulverized product M11 and the second material M21 may be mixed by the mixing mechanism. Both raw materials M11 and M21 accommodated in the molding machine container 23 are molded into a pellet shape to become a pellet M23. Of course, the pulverized first material discharged from the powder transport machine 37 of the pulverizer is once accommodated in the first pulverized material container (accommodating portion), and the second material M21 is accommodated in the first pulverized material container. If there is a third material, a fourth material,..., These are accommodated in a third pulverized material container, a fourth pulverized material container,. What is necessary is just to throw into the container 23 for an operation.
After the first material softened to such an extent that it can be pulverized is pulverized by the pulverization mechanism, at least the pulverized first material and the fine second resin are mixed to obtain the mixture M22. Can be generated.
The materials M11 and M21 introduced into the pulverized material introduction unit 24 are formed into a pellet shape to become a pellet M23.

Since the resulting mixture is substantially a mixture of the pulverized material M11 and the fine second material M21, the first and second resins are almost incompatible with each other. Therefore, the pellet M23 produced by collecting such a mixture retains the physical properties of both resins.
Also by this pellet manufacturing method, the same effect as the case where it grind | pulverizes after mixing a 1st, 2nd raw material, such as being able to manufacture the pellet with which each physical property of each resin was left, is acquired.
In addition, since it mixes by grind | pulverizing together, if it grind | pulverizes after mixing a 1st, 2nd raw material, it is preferable at the point which can simplify mixing of both raw materials. On the other hand, if the first material is pulverized separately from the fine second material, the familiarity of both materials can be reduced. This is preferable in that it can be manufactured.

(7) Third embodiment:
Even if the second resin is liquid, the second extrusion step described above can be omitted. FIG. 22 shows an example of a pellet manufacturing method when the second resin is a liquid synthetic resin and the second material is a liquid material. In the pulverizing and mixing step of the present manufacturing method, after pulverizing the first material softened to such an extent that it can be pulverized by the pulverizing mechanism A11, at least the pulverized first material (pulverized product M11) and the liquid second material The material M31 is mixed to produce a mixture.
A case where a high fluidity PP (a high fluidity thermoplastic resin) is used as the first resin and a liquid thermosetting resin (a liquid synthetic resin) is used as the second resin will be described. Here, the synthetic resin may be a thermoplastic resin. When using a liquid synthetic resin, if it is a low-viscosity (high-fluidity) liquid (for example, MFR at a mixing temperature of 100 or more), it is easy to mix with the first material. This is preferable in that it can be made more uniform.
The high fluidity PP and the liquid synthetic resin in all the resins used for pellet production can be used in various ratios such as 4: 6, 5: 5, 6: 4, and the like. The blending ratio of the first material can be the same as in the first embodiment. Here, since the second material is liquid, the total weight of the first resin and the second material in the total material used for manufacturing the pellets is the filler added to the first material. When the weight is less than the weight, the filler is highly filled in a state where all materials are mixed, and the pellets are not connected to each other at the time of pellet molding, and high quality pellets can be manufactured.

When producing the pulverized material M11 of the first material, the irregular material M5 introduced into the pulverizing chamber 33 is pulverized, and the pulverized material M11 is discharged downward from the powder discharge port 37a of the pulverizer. Is done. In order to mix the pulverized material M11 and the liquid second material M31, for example, the pulverized material M11 using high fluidity PP and the second material M31 made of a liquid thermosetting resin are used in the same container 23 for a molding machine. House in. Here, a mixing mechanism may be provided in the molding machine container 23, and the pulverized product M11 and the second material M31 may be mixed by the mixing mechanism. Both raw materials M11 and M31 accommodated in the molding machine container 23 are formed into a pellet shape to become a pellet M32. Of course, the above-described pulverized product container (accommodating portion) may be provided for each material, each material may be stored in the pulverized product container, and charged into the molding machine container 23 at a predetermined blending ratio.
The materials M11 and M31 introduced into the pulverized material introduction unit 24 are formed into a pellet shape and become a pellet M23.

Since the resulting mixture is not kneaded by the extrusion mechanism, the first and second resins are almost unfamiliar with each other. Therefore, the pellet M32 produced by collecting such a mixture retains the physical properties of both resins.
Also by this pellet manufacturing method, since the familiarity of a plurality of resins can be reduced when manufacturing the pellets, it is possible to manufacture pellets in which the respective physical properties of each resin remain. When post-molding such as plastic molding is performed using the pellets as a raw material, the thermoplastic resin contained in the pellets is heated and melted, and at this stage, the resins are familiar with each other, and a molded product having a good polymer blend can be manufactured. And since it becomes unnecessary to mix the pellets corresponding to each resin, it becomes possible to obtain a high-quality molded product in which the resins are sufficiently blended. When a thermosetting resin is used as the second resin, post-molding can produce a molded article having a novel polymer blend in which the thermoplastic resin and the thermosetting resin are compatible with each other at this stage.
As described above, according to the present invention, it is possible to produce high quality pellets in which various physical properties of a plurality of different resins remain according to various aspects.

The general | schematic flowchart which shows the process which manufactures a pellet and also manufactures the post-molding molded article. The schematic flowchart which shows the process in which an amorphous material is grind | pulverized together and a mixture is produced | generated. The general | schematic flowchart which shows the process in which an irregular-shaped raw material is grind | pulverized separately and a mixture is produced | generated. The external appearance side view of a pellet manufacturing apparatus. The external appearance top view of a pellet manufacturing apparatus. The perspective view which shows the principal part of a pellet shaping | molding apparatus. The vertical sectional view which shows the principal part of a pellet shaping | molding apparatus seeing from the B direction of FIG. The vertical sectional view which shows the principal part of a pellet shaping | molding apparatus seeing from the B direction of FIG. The perspective view which shows the modification of a grinding | pulverization mechanism. The top view which shows the bottom part disk of a shaping | molding mechanism seeing from an upper surface. The principal part sectional drawing which shows a mode that the raw material after a grinding | pulverization is pushed in a through-hole. The principal part sectional drawing which shows a mode that the extruded substantially rod-shaped raw material is going to be cut | disconnected. The principal part side view which shows a mode that a shape | molded raw material is cooled in partial cross section. The perspective view which shows the principal part of a pellet shaping | molding apparatus. The perspective view which shows the principal part of a pellet shaping | molding apparatus. The figure explaining the effect | action of a pellet manufacturing method. The perspective view which shows the principal part of a pellet shaping | molding apparatus in a modification. The vertical sectional view which shows the principal part of a pellet molding apparatus seeing from the C direction of FIG. The perspective view which shows the principal part of the pellet shaping | molding apparatus in a modification. The schematic flowchart which shows the process in which a pellet is manufactured in 2nd embodiment. The schematic flowchart which shows the process in which a pellet is manufactured in 2nd embodiment. The schematic flowchart which shows the process in which a pellet is manufactured in 3rd embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Pellet manufacturing apparatus 12 ... Raw material conveying apparatus 13 ... Raw material heating apparatus 20,120 ... Pellet molding apparatus 30, 130 ... Crusher (pulverization mechanism) A1, A2 ... Extrusion mechanism A3 ... Powder mixing mechanism A4 ... Molding mechanism A5 A7, A8, A11 ... grinding mechanism A6, A9 ... mixing mechanism A20 ... extrusion molding device A21 ... hopper A22 ... extruder A23 ... cutting machine M1 ... first resin M2, M4 ... filler M3 ... second resin M5 ... Amorphous first material M6 ... Amorphous second material M7, M22 ... Mixture M8, M23, M32 ... Pellet M9 ... Molded product of final molding (post molding) M10 ... Third material M11 ... Crushed material ( 1st pulverized material) M12 ... pulverized product (2nd pulverized material) M21 ... 2nd fine material M31 ... 2nd liquid material m1 ... amorphous material 2, m3, m12, m13 ... Raw material after grinding m4 ... Substantially rod-like material m5, m15 ... Molded material m6 ... Pellet m14 ... Rolled material S1 ... Extrusion step S2 ... Second extrusion step S3 ... Grinding and mixing step S4 ... Molding step S5 ... Mixing step S6 ... Crushing step S7 ... First crushing step S8 ... Second crushing step S9 ... Mixing step S11 ... Crushing step

Claims (15)

  In a predetermined grinding mechanism, at least a first material softened to a degree that can be crushed and having at least a first resin is pulverized, and the pulverized first material and the first resin have different physical properties. A pulverizing and mixing step for generating a mixture containing at least a second material having at least two resins, and a molding step for molding the generated mixture into a pellet shape by a predetermined molding mechanism. A pellet manufacturing method.   The method further comprises an extrusion process in which the softened first material is mixed by an extrusion mechanism and extruded in an irregular shape, and in the grinding and mixing step, the amorphous first material extruded by the grinding mechanism is The pellet manufacturing method according to claim 1, wherein at least the first raw material and the second raw material are blended to produce the mixture.   The first resin is a first thermoplastic resin, and the first material is a material in which at least a filler and the first thermoplastic resin equal to or less than the weight of the filler are blended. The extruding step has a material heating step of heating and softening the first material with a predetermined heating mechanism, and the first material softened in the material heating step is mixed to be indeterminate. It extrudes in the state of this. The pellet manufacturing method of Claim 2 characterized by the above-mentioned.   The second resin is a synthetic resin, and the second material is a material in which at least a filler and the second resin equal to or less than the filler are mixed, and the pulverized and mixed The process includes a second extrusion process in which the softened second material is mixed by an extrusion mechanism and extruded in an irregular shape, and is the same as the amorphous first material extruded in the extrusion process. The amorphous second material extruded in the two-extrusion step is pulverized to produce the mixture containing at least the pulverized first and second materials. The pellet manufacturing method of Claim 3.   The second resin is a second thermoplastic resin, and the second extrusion step includes a second material heating step of heating and softening the second material with a predetermined heating mechanism. The pellet manufacturing method according to claim 4, wherein the second material softened in the two-material heating step is mixed and extruded in an indefinite state. At least one of the first and second resins is a thermoplastic resin, and the MFR at the melting temperature when the pellets produced by the present pellet production method are melted and mixed and then molded is 100 g / 10 min. It is set as the above, The pellet manufacturing method as described in any one of Claims 2-5 characterized by the above-mentioned.   The second resin is a liquid thermosetting resin, and the second extrusion step is performed by mixing at least the second material in which the liquid thermosetting resin and the filler are blended. It extrudes in a fixed state, The pellet manufacturing method of Claim 4 characterized by the above-mentioned.   6. The pulverizing and mixing step, wherein the pulverizing mechanism pulverizes at least the first amorphous material and the second amorphous material together to produce the mixture. Or the pellet manufacturing method of Claim 7.   In the pulverization and mixing step, after pulverizing the irregular first material and the irregular second material separately by the pulverization mechanism, at least the pulverized first material and pulverized. The pellet manufacturing method according to claim 5 or 7, wherein the mixture is produced by mixing a second material. The second resin is a finely divided synthetic resin, and the second raw material is a finely divided raw material. In the pulverization and mixing step, the first softened to the pulverizable level by the pulverization mechanism. 4. The mixture according to claim 1, wherein at least the first material is pulverized to produce the mixture containing at least the pulverized first material and the fine particulate second material. pellets the process according to one paragraph or.   In the pulverization and mixing step, the mixture is formed by pulverization by the pulverization mechanism in a state where at least the first material softened to the pulverizable level and the fine second resin are combined together. The pellet manufacturing method according to claim 10.   In the pulverization and mixing step, after pulverizing the first material softened to a degree that can be pulverized by the pulverization mechanism, at least the pulverized first material and the fine particulate second resin, The pellet manufacturing method according to claim 10, wherein the mixture is produced by mixing. The second resin is a liquid synthetic resin, and the second material is a liquid material. In the pulverization and mixing step, the first material softened to a degree that can be pulverized is obtained by the pulverization mechanism. after grinding, at least a first material and any one of claims 1 to 3 by mixing a second resin of the liquid, a and generates the mixture milled The pellet manufacturing method as described in 2.   The pulverizing and mixing step includes at least pulverizing the amorphous first material introduced into the amorphous material introducing portion that introduces the first material extruded from the extrusion mechanism in an irregular shape. The pellet manufacturing method of Claim 2 or Claim 3.   A pulverization mechanism for pulverizing a first material softened to a pulverizable level having at least a first resin. The first material pulverized by the pulverization mechanism and the first resin have physical properties. A pulverizing and mixing mechanism for generating a mixture containing at least a second material having at least a different second resin, and a molding mechanism for forming the mixture generated by the pulverizing and mixing mechanism into a pellet shape. Characteristic pellet manufacturing equipment.

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