Method for decomposing polymer material, method for producing recycled resin, and method for recovering inorganic filler

Patent metadata

Field	Value
Publication number	US-9822209-B2
Application number	US-201514740569-A
Country	US
Kind code	B2
Filing date	Jun 16, 2015
Priority date	Sep 12, 2008
Publication date	Nov 21, 2017
Grant date	Nov 21, 2017

Abstract

The present invention is a method for decomposing a polymer material by chemically decomposing a polymer material containing a first monomer and a second monomer in a mixture of the polymer material with the first monomer or a derivative of the first monomer to produce a chemical raw material. A relationship between a proportion of number of molecules of the second monomer to number of molecules of the first monomer in a reaction system for decomposing the polymer material and the molecular weight of the chemical raw material produced in the reaction system is acquired in advance (S 101 ). Subsequently, an addition mount of the derivative of the first monomer to be added to the polymer material is determined based on the above relationship (S 102 ). The first monomer in the addition amount determined is then mixed with the polymer material (S 103 ).

First claim

The invention claimed is:

1. A method for producing a recycled resin, comprising:
providing a polymer material containing a resin component composed of a first monomer which is a phenolic compound, and a second monomer which is an aldehyde compound;
providing a plurality of recycled resin samples, each of which is produced by chemically decomposing the resin component in a mixture of said polymer material with said first monomer or a derivative of said first monomer, and mixing the decomposed resin component with said second monomer or a derivative of said second monomer, in which said providing the plurality of recycled resin samples, the plurality of recycled resin samples has a different second/first monomer ratio from each other, the second/first monomer ratio being a molar ratio of an amount of the second monomer or the derivative of said second monomer derived from said polymer material and the mixed second monomer or the derivative of said second monomer to an amount of the first monomer or the derivative of said first monomer derived from said polymer material and the mixed first monomer or the derivative of said first monomer, in a reaction system for producing said recycled resin samples;
acquiring a relationship in advance between the second/first monomer ratio and a physical property of said recycled resin samples;
acquiring data of a correlation between said physical property of said recycled resin samples and the second/first monomer ratio;
determining a first range of the second/first monomer ratio in which when the second/first monomer ratio becomes small, said physical property of said recycled resin samples becomes small;
determining a second range of the second/first monomer ratio which is smaller than and adjacent to the first range of the second/first monomer ratio, in which when the second/first monomer ratio becomes small, said physical property of said recycled resin samples substantially does not change;
determining a threshold value as a boundary value between the first range of the second/first monomer ratio and the second range of the second/first monomer ratio;
determining an addition amount of said first monomer or the derivative of said first monomer to be added to said polymer material based on said data of the correlation and so that the second/first monomer ratio is not less than the threshold value; and
producing said recycled resin by chemically decomposing the resin component in the mixture of said polymer material with said first monomer or the derivative of said first monomer, and mixing said second monomer or the derivative of said second monomer in said addition amount determined with said decomposed resin component.

2. The method for producing a recycled resin according to claim 1 , in which said physical property is a measurement value obtained by one or more methods selected from any of a method of measuring physical properties, a method for separation and analysis, spectrum analysis, electromagnetic analysis and thermal analysis.

3. The method for producing a recycled resin according to claim 2 , in which a molecular weight of said recycled resin is calculated from said physical property.

4. The method for producing a recycled resin according to claim 1 , in which, at determining said addition amount of said second monomer or the derivative of said second monomer to be added is that said addition amount of said second monomer or the derivative of said second monomer to be added to said decomposed resin component is determined by selecting said proportion corresponding to said physical property to be desired from said relationship.

5. The method for producing a recycled resin according to claim 1 , in which the method further comprises separating said decomposed resin component from the mixture of said polymer material with said first monomer or the derivative of said first monomer, and said recycled resin is produced by adding said second monomer or the derivative of said second monomer in said addition amount or the derivative of said second monomer to a decomposition product of said separated resin component.

6. The method for producing a recycled resin according to claim 1 , in which said phenolic compound is one or more kinds selected from phenol, o-cresol, m-cresol and p-cresol.

7. The method for producing a recycled resin according to claim 1 , in which said aldehyde compound is one or more kinds selected from formaldehyde, paraformaldehyde, trioxane and hexamethylenetetramine.

8. The method for producing a recycled resin according to claim 1 , in which said polymer material contains a crosslinked polymer.

9. The method for producing a recycled resin according to claim 8 , in which said crosslinked polymer is a phenol resin, a melamine resin, a urea resin or an epoxy resin.

10. The method for producing a recycled resin according to claim 1 , wherein, determining an addition amount of said second monomer or the derivative of said second monomer to be added to said decomposed resin component based on said relationship is performed and so that the second/first monomer ratio is less than 1.0.

11. The method for producing a recycled resin according to claim 1 , wherein, the threshold value is 0.4.

12. The method for producing a recycled resin according to claim 1 , wherein said physical property reflects a molecular weight of said recycled resin samples produced in said reaction system.

Assignees

• Sumitomo Bakelite Co

Inventors

• Goto Junya
• Ishikawa Masaki
• Orihara Tamotsu
• Koide Taichi

Classifications

• C08J11/14

  by treatment with steam or water · CPC title

• C08J11/16

  by treatment with inorganic material (C08J11/14 takes precedence) · CPC title

• D01F9/12

  Carbon filaments; Apparatus specially adapted for the manufacture thereof · CPC title

• C08G8/28 Primary

  Chemically modified polycondensates · CPC title

• C08K7/06

  Elements · CPC title