• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The invention relates to a process for manufacturing a polyurethane or single-material latex sheet from recycled mattresses, said process comprising the following successive steps: A step of dismantling used mattresses, making it possible to supply separate base materials, the base materials comprising in particular polyurethane foams and latex foams, a step of selecting polyurethane foams, respectively of uncontaminated latex, a step of grinding said foams obtained in step b), to obtain flakes of polyurethane foam, respectively of latex, uncontaminated having an average particle size less than or equal to 20 mm, A step of forming a single material sheet of polyurethane respectively of latex, comprising the mixture of the flakes of polyurethane foam respectively of latex of the step d) with a binder. The invention is useful for making mattresses and upholstery.
    公开号:FR3088558A1
    申请号:FR1871674
    申请日:2018-11-21
    公开日:2020-05-22
    发明作者:Angèle ABOU'OU
    申请人:Suez R & R Belgium SA；
    IPC主号:
    专利说明:

    Description
    Title of the invention: METHOD OF MANUFACTURING TABLECLOTHS
    The present invention relates to furnishing products such as mattresses, and more particularly to a process for manufacturing sheets of foam from recycled mattress foams, and furniture products comprising said sheets .
    In general today, at the end of life, the mattresses are cremated. Some initiatives exist to propose alternatives to this state of affairs:
    • Dismantling of the mattresses with recovery of the metal and incineration of the remaining materials;
    • Dismantling of the mattresses with recovery of the metal and recovery of the foams in carpet underlayers, or in cow carpet, or in sound and / or thermal insulation panels.
    The low cost of virgin polyurethane and latex foams does not encourage recycling, especially in countries where no recycling incentive (including regulatory and / or tax) is in place.
    The problem of regulated chemicals is also unacceptable for this sector of activity. Indeed, the number of chemicals to be sorted is very high and will continue to evolve.
    This leads to a situation where recycled foam has a higher price than virgin foam.
    Thus, there are few initiatives tending to manufacture sheets of recycled foam from old mattresses, to reintegrate these foams in a circular fashion in new mattresses and other high-end products.
    [0007] Mention may nevertheless be made of patent application WO2012 / 022888, which proposes a method for recycling furniture products, in particular mattresses, box springs and seats, said method leading to sheets of material. It includes the following steps:
    - A dismembering step, in which the basic materials are obtained by dismembering the bedding element;
    - A sorting step, in which the base materials are separated into several families of materials, depending on the nature of the base materials;
    - A step of grinding the different families of materials;
    - a mixing step, in which a mixture is prepared, the mixture comprising a predetermined amount of at least one family of ground materials;
    - A step of forming a sheet of non-woven non-consolidated material from the mixture;
    - A step of consolidating the sheet of unconsolidated nonwoven material; and a step of calendering the sheet of nonwoven material, consolidated.
    However, such a process is not entirely satisfactory. Indeed, such a process necessarily leads to mixed sheets, that is to say comprising several types of materials of different nature. The process does not indicate how to obtain "single-material" tablecloths, which have sufficient strength and comfort for use as a furniture upholstery or mattress component.
    In addition, this process leads to sheets which are difficult to recycle, because they are not "single-material".
    Finally, European legislation for chemicals is constantly evolving. Chemicals authorized today in the composition of mattress foam can then be banned. Used furniture mattresses and upholstery may therefore contain chemicals that are now regulated. To be in compliance with the regulations in force, a process for recycling used foam for the manufacture of new mattresses must be able to sort the foam efficiently, so as not to reintroduce prohibited materials on the market.
    There is therefore a need for a method for obtaining mattresses and furniture fittings based on recycled mattresses, which are themselves recyclable and which have a comfort similar to a mattress obtained from virgin materials. The process is also expected to meet standards for constantly evolving chemicals.
    Summary of the invention The present invention aims to overcome the problems of the prior art by proposing a method of manufacturing mattresses and furniture upholstery from recycled mattresses, the core of said mattress or furniture lining being constituted “single material” sheets.
    For the purposes of the present invention, a "single-material" sheet means a sheet essentially consisting of flakes of a single material, said flakes being bonded using a binder. The binder advantageously meets the criteria of the regulations in force as regards furnishings and / or mattresses. The single-layer tablecloths can also contain additives, which also advantageously meet the criteria of the regulations in force with regard to upholstery, and / or mattresses. But unlike the webs of WO2012 / 022888, the single-layer webs of the invention do not include any other material, in particular they do not include a mixture of polyurethane foam and latex.
    Indeed, in the method of the invention, the sheets are made of a single material in the form of flakes, whose cohesion is ensured by a binder, if possible of the same nature as the fragmentary material. Such a process makes it possible to manufacture mattresses and furniture fittings that are easily recyclable, and the quality and comfort of which are easy to control: the technical performance of the mattresses produced by the process of the invention are stable and known in advance.
    Thus, an object of the invention relates to a method of manufacturing a polyurethane web from recycled mattresses.
    Another object of the invention is a process for manufacturing a sheet of latex from recycled mattresses.
    Another object of the invention is a method of manufacturing mattresses from recycled mattresses.
    Another object of the invention relates to a process for the manufacture of furniture fittings from recycled mattresses.
    Detailed description Firstly, the invention relates to a process for manufacturing a polyurethane web from recycled mattresses, said process comprising the following successive steps:
    at. A step of dismantling used mattresses, making it possible to provide separate base materials, the base materials comprising in particular polyurethane foams and latex foams,
    b. A step of selecting uncontaminated polyurethane foams,
    vs. A step of grinding said foams obtained in step b), to obtain flakes of uncontaminated polyurethane foam having an average particle size less than or equal to 20 mm,
    d. A step of forming a polyurethane sheet, comprising mixing the polyurethane foam flakes from step d) with a binder.
    The polyurethane sheet thus obtained is a single-material sheet, that is to say that it consists of flakes of polyurethane foam and binder (preferably a polyurethane binder), and optionally of additives. In particular, the tablecloth of the invention is devoid of latex and / or textile fibers, unlike the tablecloths disclosed in application WO2012 / 022888.
    For the purposes of the present invention, the term "polyurethane" means a polymer in which the monomer units are combined by urethane groups of general formula —NH-CO-O— or -O-CO-NH-. A polyurethane is generally obtained by step polymerization of two functional oligomers: a polyol (i.e. a compound comprising at least 2 primary alcohol groups -OH) and a polyisocyanate, compound comprising at least 2 isocyanate groups -NCO). Polyurethane foam is obtained when the synthesis of polyurethane takes place simultaneously with the release of an expansion gas in the polyurethane, physically or chemically, which leads to the creation of an alveolar structure.
    The additives used are all in accordance with European regulations, in particular the REACH regulation (regulation n ° 1907/2006 / EC). However, according to a preferred embodiment, the polyurethane sheet does not include any additives, and in particular no fire-fighting additives, unlike the sheets described in WO2012 / 022888.
    The nanomaterial polyurethane sheet of the invention can also be described as a sheet of agglomerates, the flakes of which it is made are all of an identical nature (i.e. polyurethane foam).
    Step a) During step a) of dismantling, the basic materials of the used mattresses are separated in the form of different fractions: metal, felts, other textile materials, polyurethane foam and latex foam.
    Polyurethane foams are recovered, and this fraction is not mixed with the other fractions.
    Step b) The polyurethane foams from step a) are subjected to an analysis in order to discard the polyurethane foams contaminated with regulated organic products and to obtain the uncontaminated polyurethane foams.
    The term "uncontaminated polyurethane foams" means polyurethane foams having a maximum of 2% of non-polyurethane foam by weight relative to the total weight of the foams (for example latex foams).
    This step is essential to guarantee the safety of the polyurethane layers produced, and to avoid the reintroduction of products now prohibited on the market. It is sought in particular to remove polyurethane foams comprising heavy metals and brominated products, in particular brominated flame retardants.
    In practice, the polyurethane foams from step a) are analyzed to detect regulated chemicals, and the foam is discarded when the measured quantity of heavy metals is above a predetermined threshold, typically in accordance with the regulations. in force, such as that established in CLP Regulation No. 1272/2008 / EC of 16/12/2008. Preferably, the predetermined threshold is lower, for example by at least 20%, preferably by at least 50%, than the threshold in force.
    The measurements can be carried out by different techniques. One can for example use spectrophotometry with X fluorescence, spectrometry by atomic absorption, analytical techniques by induced plasma (ICP), in particular spectrometry on plasma induced by laser (LIBS).
    Preferably, we will use X-ray fluorescence spectrophotometry, because of its precision (in particular by comparison with the LIBS technique), its ease of implementation, the analysis times and its cost of implementation. implemented.
    Preferably, the measurement is carried out by X-ray fluorescence spectrophotometry (XRF measurement).
    During step b) of selection, preferably unsullied foams are chosen. It is also preferred to select non-wet foams. These two selections are optional, and independent of each other. They can for example be implemented by simple visual selection.
    Hygienization The idea of sleeping on a mattress containing recycled materials can be unacceptable.
    Thus, according to a preferred embodiment, a step b2) of hygienistation is carried out between steps b) and c), which aims to guarantee the hygiene and safety of the sorted foams. According to another embodiment, a step c2) of sanitation is implemented between steps c) and d).
    Hygienization is typically carried out by fumigation, in particular by bringing polyurethane foams into contact with a smoke gas, preferably sulfuryl fluoride SO 2 E 2 . The duration of contact is sufficient to carry out hygienization, in particular to disinsect (in particular to eliminate possible bed fleas) the foams. In the case of sulfuryl fluoride, the duration of contacting is typically 4 hours.
    Preferably, the hygienization comprises an aeration step following the fumigation step, before the implementation of the next step.
    Hygienization can also be implemented by contacting a disinfectant.
    It can also be implemented by electromagnetic waves, as described in application WO 2012/022888 (page 6).
    Step c) The grinding step is carried out according to usual techniques known to those skilled in the art. We could for example use a knife mill.
    A particle size less than or equal to 20 mm makes it possible to guarantee the mechanical performance of the ply, and in particular makes it possible to prevent the ply from tearing too easily.
    The particle size distribution of the flakes can be checked using different techniques including sieving dry. For this purpose, a sieve column comprising sieves of different cuts and provided with an electric eccentric drive moves the column vertically according to a controlled vibratory regime. Depending on the cuts of the sieves used, and the weight of the material retained in each sieve, the particle size distribution of the foam flakes is determined.
    The particle size of the flakes is preferably between 5 mm and 20 mm, for example between 6 mm and 15 mm. It is typically less than or equal to 10 mm, for example around 8 mm.
    Step d) The binder used in step d) is advantageously an isocyanate, in particular chosen from diphenylmethylene diisocyanate (MDI) or toluene diisocyanate (TDI or tolylene-2,4-diisocyanate), preferably the MDI.
    The mixture of binder and flakes comprises from 5% to 20%, preferably from 6% to 15%, in particular from 6% to 12% by mass of binder relative to the total weight of the mixture.
    The mixture thus obtained is typically poured into a mold and then undergoes compression. In the case of MDI, mixing and compression preferably take place at room temperature (typically, no heating is applied).
    In the case where the binder is TDI, preferably water vapor is added, typically under pressure, and typically at a temperature T of between 100 ° C and 150 ° C, for example between 110 ° C and 125 ° C. The addition of water vapor provides heat which will catalyze the reaction of the TDI binder with the flakes.
    The mixture is kept under pressure and at temperature T for a period of between 2 h and 10 h, preferably between 3 and 5 hours.
    Then the cake thus obtained is removed from the mold, and advantageously cut to obtain sheets of desired thickness and length.
    The thickness of the sheets is typically between 5 and 20 cm, in particular from 8 to 18 cm. For example, the tablecloths may have a thickness of 8 to 10 cm, or 15 cm.
    "Standard" width tablecloths: 70 cm, 80 cm, 90 cm, 120 cm, 140 cm, 160 cm, 180 cm are achievable. The tablecloths are generally of "standard" length: 190 cm, 200 cm or 210 cm. Thus, typically, the dimensions of the sheet after cutting are: 80 cm x 200 cm x 15 cm, 90 cm x 200 cm x 15 cm, 140 cm x 200 cm x 15 cm, 160 cm x 200 cm x 15 cm.
    The density of the sheets is a function of the quantity of foam flakes introduced into the mold and of the pressure exerted on the foam / binder mixture. It is considered in the field of bedding that the density of a comfortable virgin foam mattress is at least 30 kg / m 3 . It is also accepted that the same mechanical properties are obtained as virgin foam with double density agglomerate. Thus, the density of the polyurethane sheets of the invention is preferably between 60 and 130 kg / m 3 .
    When the sheets are used to manufacture mattresses, the density will preferably be between 60 kg / m3 and 80 kg / m 3 , in particular between 68 and 75 kg / m 3 . For use in the manufacture of furniture fittings, the density will preferably be between 70 kg / m 3 and 120 kg / m 3 , in particular between 110 and 125 kg / m 3 .
    All the combinations of preferred and particular embodiments of the method are envisaged in the invention.
    1. Method for manufacturing a sheet of latex [0067] Firstly, the invention relates to a process for manufacturing a sheet of latex from recycled mattresses, said process comprising the following successive steps:
    at. A step of dismantling used mattresses, making it possible to provide separate base materials, the base materials comprising in particular polyurethane foams and latex foams,
    b. A step of selecting uncontaminated latex foams,
    vs. A step of grinding the latex foams obtained in step b), to obtain latex foam flakes having an average particle size less than or equal to 35 mm,
    d. A step for forming a sheet of latex, comprising mixing the latex foam flakes from step d) with a binder.
    The latex ply thus obtained is a single-ply, that is to say that it consists of flakes of latex foam and of binder (preferably a polyurethane binder), and possibly of additives. In particular, the latex sheet of the invention is devoid of polyurethane and / or textile fibers, unlike the sheets disclosed in application WO2012 / 022888.
    For the purposes of the present invention, the term "latex" means natural latex (typically from rubber) and / or synthetic latexes and / or hybrid latexes.
    The additives used are all in accordance with European regulations, in particular the REACH regulations. However, according to a preferred embodiment, the latex sheet does not include any additives, and in particular no fire additives, unlike the sheets described in WO2012 / 022888.
    The nanomaterial latex sheet of the invention can also be qualified as a sheet of agglomerates, the flakes of which it is made are all of an identical nature (i.e. latex foam).
    Step a) [a] Step a) dismantling can be implemented in a similar manner to step
    a) the process for manufacturing polyurethane plies described above.
    Step b) Step b) of dismantling selection can be implemented in a similar manner to step a) of the process for manufacturing polyurethane plies described above. Hygienization According to a preferred embodiment, a step b2) of hygienistation is carried out between steps b) and c), which aims to guarantee the hygiene and the safety of the sorted sorted latex. . According to another embodiment, a step c2) of sanitation is implemented between steps c) and d).
    This hygienization step can be implemented in a similar manner to the hygienization step of polyurethane foams described above. Preferably, the foams undergo a subsequent aeration step, before the implementation of the next step.
    Step c) [0080] Step c) of grinding is carried out according to usual techniques known to those skilled in the art.
    A particle size less than or equal to 35 mm makes it possible to guarantee the mechanical performance of the sheet of latex foam, and in particular makes it possible to prevent the sheet from tearing too easily.
    The particle size of the flakes is preferably between 20 mm and 30 mm, for example between 22 mm and 28 mm.
    Step d} The binder used in step d) is preferably an isocyanate, in particular chosen from diphenylmethylene diisocyanate (MDI) or toluene diisocyanate (TDI or tolylene-2,4-diisocyanate) , preferably MDI.
    The mixture of binder and flakes comprises from 5% to 20%, preferably from 6% to 15%, in particular from 6% to 12% by mass of binder relative to the total weight of the mixture.
    Step d) of the method for manufacturing the latex plies can be implemented in a similar manner to step d) of the method for manufacturing the polyurethane plies.
    The density of the sheets of latex thus obtained is preferably between 100 and 150 kg / m 3 , preferably between 110 and 125 kg / m 3 .
    The thickness of the sheets is typically between 3 and 10 cm, for example between 3 and 6 cm. According to a first embodiment, the sheets have a thickness of between 4 and 6 cm. According to a second embodiment, the sheets have a thickness of between 3 and 5 cm.
    "Standard" width tablecloths: 70 cm, 80 cm, 90 cm, 120 cm, 140 cm, 160 cm, 180 cm are achievable. The tablecloths are generally of "standard" length: 190 cm, 200 cm or 210 cm.
    All the combinations of preferred and particular embodiments of the method are envisaged in the invention.
    1. Method for manufacturing mattresses The invention also relates to a method for manufacturing a mattress, comprising the assembly of a polyurethane sheet produced according to the process of the invention, of a latex sheet produced according to the method of the invention, and of a reception layer, advantageously in this order.
    The reception layer consists of a sheet of polyurethane with preferably virgin shape memory, and preferably certified in accordance with the regulations in force. It preferably has a density of between 40 and 60 kg / m 3 , in particular between 48 and 52 kg / m 3 . It also advantageously has a thickness of 3 to 10 cm, for example from 4 to 7 cm.
    The assembly is typically carried out by gluing the layers together. The adhesives used to assemble the mattress are preferably certified to comply with REACH regulations. Usual adhesives can be used for the manufacture of mattresses. Preferably, they are devoid of solvents. For example, a hot-melt adhesive based on polyurethane will be used.
    The glue is preferably deposited on a strip of 10 to 20 cm on the edge of one of the surfaces to be bonded, which is sufficient for the good performance of the three layers of the mattress.
    The polyurethane sheet is bonded to the latex sheet, then the welcoming layer of memory foam is bonded to the layer of latex.
    The three-layer mattress is typically covered with a ticking, in particular in tencel.
    The method according to the invention may also include an optional step of quality control of the mattress. This step consists of carrying out a measurement of the organic products that cannot be detected during step b) of selection of the polyurethane and / or latex foams.
    For mattress quality control, a sample of latex agglomerate and a sample of polyurethane agglomerate are typically taken from a batch of mattresses.
    These samples are analyzed to detect all the organic substances which may be present in used mattress foams and which are listed in Annex XVII to the REACH regulation N ° 1907/2006 / EC of 18/12/2006, or in the POP regulation N ° 850/2004 / EC of 04/29/2004 / EC or in the CLP Regulation N ° 1272/2008 of 16/12/2008.
    The batch of mattresses is discarded when the measured quantity of regulated chemicals, for example heavy metals, is greater than a predetermined threshold, typically in accordance with the regulations in force, such as that established in the CLP Regulation No. 1272/2008 / EC of 16/12/2008. Preferably, the predetermined threshold is lower, for example by at least 20%, preferably by at least 50%, than the threshold in force.
    1. Method for manufacturing a furniture covering [0101] The polyurethane or latex sheets produced according to the methods of the invention are also useful as furniture upholstery, or for manufacturing furniture upholstery. These are typically seats.
    According to one embodiment, said lining comprises or consists of sheets of latex.
    According to another embodiment, said lining comprises or consists of sheets of polyurethane.
    In particular, according to one embodiment, said furniture trim does not include laminated material.
    According to a particular embodiment, the sheet is a polyurethane sheet with a density between 70 kg / m 3 and 120 kg / m 3 .
    The polyurethane or latex sheet used for the preparation of furniture upholstery advantageously has a density of between 110 and 125 kg / m 3 .
    Brief description of the drawings [0107] [fig-1] shows an embodiment of the mattress manufacturing process of the invention.
    [Fig. 2] shows the structure of a mattress manufactured in Example 4. 1: Reception layer: 5 cm of memory foam; 2: Upper face of the mattress: unpigued tencel, 500gr / m3; 3: Intermediate layer: 5 cm of recycled latex; 4: Core of the mattress: 15 cm of recycled PU foam.
    [Fig. 3] represents a photograph of a polyurethane sheet produced according to the process of the invention with 8 mm particle size flakes. Some flakes are shown as an example by circle. F: Foam flakes.
    [Fig. 4] represents a photograph of a polyurethane sheet produced according to the process of the invention with 25 mm particle size flakes. Some flakes are shown as an example by circle. F: Foam flakes [0111] [fig.5] represents a photograph of a sheet of latex manufactured according to the process of the invention with flakes of particle size between 22 and 28 mm. Some flakes are shown as an example by circle. F: Foam flakes EXAMPLES The example which follows is given purely by way of illustration and should not be considered as limiting the invention in any way.
    EXAMPLE 1; Manufacture of polyurethane and latex sheets [0114] 1. Dismantling of the mattresses and selection (steps a and b) [0115] The various materials constituting the old mattresses are recovered, and separate fractions are prepared: metal, felts , other textile materials, polyurethane foam and latex foam.
    [0116] Then, the operator performs a first sorting, according to his good judgment. The polyurethane and latex foams chosen are those which appear to it to be the least soiled possible, but above all not damp.
    Next, each foam preselected by the operators to integrate the manufacturing circuit of the Again® mattress is analyzed using the x-ray fluorescence spectrometer. The operator points the analyzer gun against the face of a foam and the results of the foam analysis are displayed on the device screen as soon as the measurement is complete. If one of the following elements appears in the composition of a foam, even in very small quantities (200 ppm), the foam is removed from the batch of foams used in the preparation of Again® mattresses: bromine, tin, antimony, arsenic , chromium, cobalt, copper, mercury, nickel, lead, selenium, and fluorine. Indeed, these elements are part of the composition of chemicals regulated today.
    At this stage, it is possible that certain regulated organic chemicals have not yet been detected. A second quality control relative to the chemical composition can thus be provided for at a later stage.
    2. Hygienization (optional step b2) The sorted foams are hygienized, preferably by fumigation.
    To do this, the foam balls are placed in a sealed chamber. The chamber is maintained at a temperature at least equal to 15 ° C, in particular is approximately 19 ° C, if necessary using a heating system.
    The smoke gas is then introduced into the chamber with pressure control, and the bullets are thus maintained under a controlled atmosphere for at least 5 hours. Then the bedroom is open; after 4 hours a professional fan is activated for one hour to improve the ventilation of the foam balls. The bales will still be naturally ventilated pending the next step, which takes two to ten days.
    The smoke gas used for the hygienization of the foams is sulfuryl fluoride SO 2 E 2 . It is a disinfectant gas effective against mites, bedbugs, cockroaches, and other insects. When ingested by an insect, the gas dissociates into fluoride and sulfate. Fluoride interacts with the insect's metabolism, leading to its death. By keeping the insects and their eggs under a sulfuryl fluoride atmosphere, they are deprived of oxygen. In this other way, we also control the hygienization of the foam balls. Sulfuryl fluoride is a gas which easily penetrates the material to be disinfected, but which also dissipates very quickly as soon as the material is no longer confined in the gaseous medium.
    3. Preparation of the polyurethane sheets of the invention (step c) [0125] The polyurethane foams from the hygienization step are ground to make them flakes with a particle size of less than 8 mm. The flakes are then mixed with an isocyanate binder based on diphenylmethylene diisocyanate (MDI). The mixture which comprises 6 to 12% by mass of binder is poured into a rectangular mold and pressed there. The MDI then reacts with the moisture naturally present in the foams and under the effect of the catalyst included in the binder to form a network of glue through the flakes of foam. The release takes place 3 to 5 hours later.
    The cake is cut to obtain tablecloths of thickness and desired length.
    An example of a sheet according to example 1; 15 cm thick, is shown in the figure
    1.
    The density of the polyurethane foam sheets prepared for the manufacture of the mattress is of the order of 68 to 75 kg / m 3 .
    Example 2; Polyurethane layer with flakes of grain size> 20 mm The process of Example 1 is implemented, with the difference that the sorted foams are ground so as to obtain flakes of grain size from 20 to 25 mm ( see figure 4). The sheets obtained are 15 cm thick, and have a density of 40 kg.m 3 .
    The plies obtained are easily torn by simply stretching them by hand. While the plates produced according to Example 1, with flakes of grain size less than 8 mm, withstand the same test better.
    Example 3. Preparation of the latex sheets (step c) [0133] The latex sheets are obtained according to a process similar to the process of Example 1.
    After the hygienization step, the latex foams are ground. The grain size of the flakes in this case is between 22 mm and 28 mm (see Figure 5). The agglomerated plies prepared with these particle sizes resist tearing by hand as well as the polyurethane agglomerated plies prepared with flakes of particle size less than or equal to 8 mm. The sheet of latex agglomerate is preferably prepared with MDI as a binder, like the polyurethane agglomerate. But it can just as easily be prepared with TDI.
    The density of the latex plates thus obtained is between 110 and 125 kg / m 3 . The thickness of these layers is of the order of 4 to 6 cm.
    EXAMPLE 4 Manufacturing of Mattresses The polyurethane sheet is bonded to the latex sheet, then the reception layer of memory foam is bonded to the layer of latex. The three-layer mattress is then covered with its tencel ticking for the sleeping surface and the sides and in non-slip fabrics for the underside of the mattress.
    The viscoelastic foam which acts as a welcome layer is a virgin layer, it is therefore certified to comply with the regulations in force. It is a polyurethane shape memory foam with a density between 48 kg / m 3 and 52 kg / m 3 from 4 to 7 cm thick.
    The adhesive used is a hot-melt adhesive based on polyurethane, of the brand Intadmet MTH-10 sold by the company Intad. The glue is only deposited on a strip of 10 to 20 cm on the edge of one of the surfaces to be glued.
    Quality control (optional step) [0140] Preferably, for each batch of 200 mattresses or less to be produced, a sample of latex agglomerate and a sample of polyurethane agglomerate are taken. These samples are analyzed by an external laboratory. Several analysis methods are used for this purpose:
    [0141] ICP - AES; induced plasma mass spectrometry.
    [0142] GC - MS; gas chromatography followed by mass spectrometry.
    [0143] CI - GC - MS; chemical ionization followed by gas chromatography and mass spectrometry.
    LC-MS-MS; liquid chromatography combined with tandem mass spectrometry of quadrupoles.
    LC-DAD-MS; combined liquid chromatography with diode array detection and mass spectrometry.
    The analyzes are carried out either according to methods internal to the requested laboratories, or according to European standards in force when they exist. This is the case, for example, for the analysis of organotins and brominated flame retardants which are carried out according to ISO 17353: 2004 and IEC 62321 standards, or for the analysis of dimethylfuramate according to ISO16186: 2012 standard.
    In the context of these chemical analyzes, all the organic substances which may be present in used mattress foam are sought and which are listed in Annex XVII to the REACH regulation No. 1907/2006 / EC of 12/18/2006, or in the POP regulation N ° 850/2004 / CE of 04/29/2004 or in the CLP Regulation N ° 1272/2008 / CE of the 12/16/2008.
    If an SVHC substance (substance of very high concern) is detected beyond 0.1% and / or the specific concentration limit established in CLP Regulation (EC) N ° 1272/2008, and its amendments , the batch of agglomerates from which the analyzed sample comes is eliminated by incineration. It is preferably not used for mounting the mattresses of the invention.
    The results of the chemical analyzes for each batch therefore condition the rest of the production chain. When the chemical analyzes are all good, that is to say that no SVHC is found in the polyurethane or latex agglomerate, the mattresses themselves can then be produced.
    This quality control step makes it possible not to place on the market substances prohibited by European regulations which could not have been detected during the first quality controls.
    [0151] Chemical characteristics [0152] In the XRF analyzes as well as those of the quality control, no chemical substance regulated beyond the thresholds fixed by the legislation is detected. The results of the analysis of a mattress revealed traces of dibutyltin-DBT (0.16 ppm) and a phthalate, DEHP (16.5 ppm) in agglomerated polyurethane foam, and carbon disulfide (2 , 71 ppm) has been detected in agglomerated latex foam, but these values are far below the regulations in force and the thresholds set by the European eco-label for bed mattresses, ie 1000 ppm.
    [0153] Table 1: Technical sheet of the Again® mattress [Tables 1]
    DimensionsThe ticking The. mattress exists in your. dimensions .standards; .Sl> x 190; Sûx. 190; 140 x190; £ 0 X2Ç0; 90 x 200; 140X2.Û0; 160x200 .; 1S0 κ 200. The thickness of the Again mattress is 25cm. The mattress weight varies from 29 kg (gO xl: 5O) to 68 kgflSO ................................ .................................................. .................................................. .All textiles meet the 100 GEKOTEX standard The welcome layer Foam-shaped to conform to the ata ndard 100 OEKQTEX, Layerintermediate This layer in. latex's role is to provide elasticity to the mattress, with semi-firm to firm comfort. [ The soul of the mattress Made of high density polyurethane, it welds the sleeper and prevents any heel effect, as well as a pocket spring mattress. | Box spring anduse Any flat surface can be used as a support for the mattress. The mattress preferably does not have a single sleeping surface. |
    Mechanical characteristics [0155] Static fatigue tests were carried out on the mattress of Example 4, according to standard NF EN 1957. The loss of thickness on the sleeping surface was of the order of 6 mm. , and the loss of thickness on the edges of the mattress was 0.1 mm (target value <18mm, according to the CTB bedding standard for high-end products, defined by the FCBA Technological Institute in France).
    In tissue roll tests, the mattress of Example 4 slightly gained in hardness of 3.4% and lost in firmness of + 2.3% for the sleeping surface, while the firmness indices n have not varied at the edges of the mattress. The variations recorded remain well below the maximum limit set for high-end products (18%).
    Tests on the reception foam, according to standard EN ISO 1856 method C, with humidity were carried out, to determine the persistence with compression of this foam. The median value of the compression remanence obtained was 8.2%. It is lower than the 12% threshold value set for high-end products. The remanence value after 24 hours of rest was 4.4%, which reflects the fact that the foam quickly returns to its initial shape. Thus, the mattresses produced according to example 2 are in compliance with European standards.
    [0158] RESULTS [0159] The mattress of Example 4 has the mechanical characteristics of a high-end mattress, but above all, does not contain any substance regulated in unauthorized concentrations.
    The mattress of Example 4, made from recycled polyurethane and latex foams from used mattresses, consists of three layers of superimposed foams which simultaneously offer it great comfort, elasticity and firm support (see Ligure 2).
    EXAMPLE 5 Comparative Example [0161] Another mattress comprising three layers was manufactured and tested. The layers of this mattress were as follows:
    • A 15 cm layer of agglomerate of polyurethane foam from Example 1, 15 cm thick, the same as that used for the mattress of Example 4, • An intermediate layer of 5 cm from virgin hybrid foam density 35 kg / m 3 . This polyurethane foam included hygroscopic beads, • A welcome layer of 5 cm of viscoelastic foam with a density of 50 kg / m 3 , the same as that used for the mattress of Example 4.
    The mechanical properties of this mattress were not found to be as good as that of the mattress in Example 4, although it incorporated two blank layers. Compression remanence tests according to NE EN ISO 1856 Method C (with humidity) revealed a median value of compression remanence of more than 70%. The intermediate hybrid foam layer therefore collapses completely. These tests demonstrate that the intermediate layer of agglomerated latex of the mattress of Example 4 brings elasticity to the mattress and contributes to its long service life.
    权利要求:
    Claims (1)
    [1" id="c-fr-0001]
    Claims [Claim 1] Method for manufacturing a polyurethane sheet from recycled mattresses, said method comprising the following successive steps:a) a step of dismantling used mattresses, making it possible to provide separate base materials, the base materials comprising in particular polyurethane foams and latex foams,b) a step of selecting uncontaminated polyurethane foams,c) a step of grinding said foams obtained in step b), to obtain flakes of uncontaminated polyurethane foam having an average particle size less than or equal to 20 mm,d) a step of forming a polyurethane sheet, comprising mixing the polyurethane foam flakes from step d) with a binder, said sheet being monomaterial. [Claim 2] Method according to claim 1, characterized in that the flakes of step c) have a particle size between 5 mm and 20 mm, for example between 6 mm and 15 mm. [Claim 3] Process according to either of Claims 1 and 2, characterized in that the density of the sheets is between 60 kg / m3 and 80 kg / m 3 , in particular between 68 and 75 kg / m 3 . [Claim 4] Method according to any one of claims 1 to 3, characterized in that the thickness of the sheets is between 5 and 20 cm, in particular from 8 to 18 cm. [Claim 5] Method for manufacturing a sheet of latex from recycled mattresses, said method comprising the following successive steps:a) A step of dismantling used mattresses, making it possible to supply separate base materials, the base materials comprising in particular polyurethane foams and latex foams,b) A step of selecting uncontaminated latex foams,c) A step of grinding the latex foams obtained in step b), in order to obtain flakes of latex foam having an average particle size less than or equal to 35 mm,d) A step of forming a sheet of latex, comprising mixing the latex foam flakes from step d) with a binder,said sheet being monomaterial. [Claim 6] Method according to claim 5, characterized in that the flakes of step c) have a particle size between 20 mm and 30 mm, for example between 22 mm and 28 mm.
    [Claim 7] Process according to either of Claims 5 and 6, characterized in that the density of the sheets is between 100 and 150 kg / m 3 , preferably between 110 and 125 kg / m 3 . [Claim 8] Process according to any one of Claims 5 to 7, characterized in that the thickness of the sheets is between 3 and 10 cm, for example between 3 and 6 cm. [Claim 9] Method according to any one of claims 1 to 8, characterized in that in step b), the polyurethane foams from step a) according to claims 1 to 4 or the latex foam from step ( a) according to claims 5 to 8 are analyzed by X-ray fluorescence spectrophotometry, and the foam is discarded when the measured quantity of heavy metals is greater than a predetermined threshold, typically in accordance with the regulations in force, in particular at the threshold established in the CLP Regulation N ° 1272/2008 / EC of 16/12/2008. [Claim 10] Process according to any one of Claims 1 to 9, characterized in that a step b2) of hygienistation is carried out between steps b) and c), typically carried out by fumigation, in particular by bringing the foams into contact with a smoke gas, preferably sulfuryl fluoride SO 2 F 2 . [Claim 11] Method according to claim 10, characterized in that the hygienization step is carried out by fumigation, and comprises an aeration step following the fumigation step. [Claim 12] 12. Method according to any one of claims 1 to 10, characterized in that the binder used in step d) is an isocyanate, in particular chosen from diphenylmethylene diisocyanate (MDI) or toluene diisocyanate (TDI or tolylene -2,4-diisocyanate), preferably MDI. [Claim 13] 13. Method according to any one of claims 1 to 12, characterized in that the mixture of binder and flakes of step d) comprises from 5% to 20%, preferably from 6% to 15%, in particular of 6% to 12% by mass of binder relative to the total weight of the mixture. [Claim 14] 14. Method according to any one of claims 1 to 13, characterized in that the mixture obtained in step d) is poured into a mold and then undergoes compression. [Claim 15] A method of manufacturing a mattress, comprising assembling a polyurethane web produced by the process of any of claims 1 to 4 and 9 to 14, a latex web produced by the process any one of claims 5 to 14, and a
    [Claim 16] [Claim 17] [Claim 18] welcome layer, preferably in this order.
    Method according to claim 15, characterized in that the assembly is carried out by bonding the plies together.
    Method according to claim 16, characterized in that the bonding is carried out using a hot-melt adhesive based on polyurethane.
    Method according to claim 16 or 17, characterized in that the adhesive is deposited on a strip of 10 to 20 cm on the edge of one of the surfaces to be bonded.
    [Claim 19] [Claim 20]
    Method according to any one of claims 15 to 18, characterized in that the mattress is covered with a ticking.
    Use of a polyurethane sheet produced according to the process of any one of Claims 1 to 4 and 9 to 14, and / or a latex sheet produced according to the process of any one of Claims 5 to 14, as upholstery, or to make upholstery.
    类似技术:
    公开号 | 公开日 | 专利标题
    EP3656525A1|2020-05-27|Method for manufacturing recycled foam sheets.
    Bucheli et al.2000|Development of ochratoxin A during Robusta | coffee cherry drying
    Nocentini et al.2010|Nature and reactivity of charcoal produced and added to soil during wildfire are particle-size dependent
    US20060251881A1|2006-11-09|Bonded foam product manufactured with vegetable oil polyol and method for manufacturing
    Cabon et al.1996|Contact allergy to aeroallergens in children with atopic dermatitis: comparison with allergic contact dermatitis
    US20130111672A1|2013-05-09|Mattresses Having a Matrix Core of Foam Elements
    EP2598260B1|2016-07-13|Process for recycling furniture, in particular mattresses ,bed bases and seats and associated recycling installation
    Fallik et al.1997|Heat treatment temporarily inhibits aroma volatile compound emission from Golden Delicious apples
    FR3063503A1|2018-09-07|ACOUSTIC PANEL FOR REALIZING A FLOOR COVER
    US20150298346A1|2015-10-22|Method for reducing the emissions of volatile organic compounds from wooden materials and wooden material
    Mattiolo et al.2017|Volatile profiling of durum wheat kernels by HS–SPME/GC–MS
    Khatibi et al.2014|A comparison of two milling strategies to reduce the mycotoxin deoxynivalenol in barley
    Cosereanu et al.2019|Morphology, physical, and mechanical properties of particleboard made from rape straw and wood particles glued with urea-formaldehyde resin
    Givianrad2012|Characterization and assessment of flavor compounds and some allergens in three Iranian rice cultivars during gelatinization process by HS-SPME/GC-MS
    JP6957882B2|2021-11-02|Method for producing simulated odor composition
    Burns et al.2010|Using NIRS to predict composition characteristics of Lolium perenne L. cultivars
    Juliana et al.2012|Properties of three-layer particleboards made from kenaf | and rubberwood |
    US20080078026A1|2008-04-03|Integrated Mattress and Foundation
    Koivula et al.2005|Emissions from thermal insulations—part 2: evaluation of emissions from organic and inorganic insulations
    Grigg et al.2015|Impacts of kernel thickness and associated physical properties on milling yields of long-grain rice
    EP1415800B1|2005-05-11|Surface coating treated against humidity and method of treating
    CN109310081A|2019-02-05|Culicifuge and method for eliminating mosquito
    Katagiri et al.2011|Changes in textural properties of Japanese tenobe somen noodles during storage
    Lin et al.2016|Analysis of peanut using near-infrared spectroscopy and gas chromatography–mass spectrometry: correlation of chemical components and volatile compounds
    EP2598259B1|2015-12-16|Process for recycling materials from furniture, in particular mattresses, bed bases and seats
    同族专利:
    公开号 | 公开日
    EP3656525A1|2020-05-27|
    FR3088558B1|2021-05-21|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    CN102160724A|2010-02-21|2011-08-24|六圣有限公司|Manufacturing method of latex pads and structure of latex pads|
    WO2012022888A1|2010-07-29|2012-02-23|Ecoval Environnement|Method for recycling furniture materials, in particular mattress, box-spring, and seat materials, sheet of material obtained by such a method, and related recycling facility|
    US20130206878A1|2010-07-29|2013-08-15|Ecoval Environnement|Method for cleaning up materials that result from the recycling of furniture, in particular mattresses, bed bases and seats|
    US9888785B2|2014-04-21|2018-02-13|Casper Sleep Inc.|Mattress|FR3111091A1|2020-06-04|2021-12-10|Societe Plymouth Francaise|Process for recycling a polymer foam, material obtained and uses|
    EP3957453A1|2020-08-20|2022-02-23|Covestro Deutschland AG|Method and system for separating waste polyurethane foams|
    EP3957454A1|2020-08-20|2022-02-23|Covestro Deutschland AG|Method and system for separating waste polymers|
    法律状态:
    2019-11-25| PLFP| Fee payment|Year of fee payment: 2 |
    2020-05-22| PLSC| Publication of the preliminary search report|Effective date: 20200522 |
    2020-11-25| PLFP| Fee payment|Year of fee payment: 3 |
    2021-11-25| PLFP| Fee payment|Year of fee payment: 4 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1871674A|FR3088558B1|2018-11-21|2018-11-21|PROCESS FOR MANUFACTURING RECYCLED FOAM TAPES|
    FR1871674|2018-11-21|FR1871674A| FR3088558B1|2018-11-21|2018-11-21|PROCESS FOR MANUFACTURING RECYCLED FOAM TAPES|
    EP19210248.1A| EP3656525A1|2018-11-21|2019-11-20|Method for manufacturing recycled foam sheets.|
    [返回顶部]