Method for recycling furniture materials, in particular mattress, bed base, and seat materials, sheet of material obtained by such a method and related recycling facility

Abstract

The invention relates to a method for recycling furniture materials, in particular mattress, bed base, and seat materials, the method comprising the following steps: a breakup step, in which base materials are obtained by breaking up the bedding element; a sorting step ( 18 ), in which the base materials are separated into a plurality of families of materials according to the nature of the base materials; a step ( 20 ) for grinding the different families of materials; a mixing step ( 22 ), in which a mixture is prepared, the mixture comprising a predetermined amount of at least one family of ground materials; a step ( 24 ) for forming a sheet of non-woven unconsolidated material from the mixture; a step ( 27 ) for consolidating the non-woven unconsolidated sheet of material; a step for calendering the non-woven consolidated sheet of material.

1 . A method for recycling furniture products, notably mattresses, bed bases ( 46 ) and seats, the method comprising the following steps:
 a breakup step, in which base materials are obtained by breaking up the bedding product;   a sorting step ( 18 ), in which the base materials are separated into a plurality of families of materials, according to the nature of the base materials;   a step ( 20 ) for grinding the different families of materials;   a mixing step ( 22 ), in which a mixture is prepared, the mixture comprising a predetermined amount of at least one family of ground material;   a step ( 24 ) for forming a sheet of non-woven unconsolidated material from the mixture;   a step ( 27 ) for consolidating the non-woven unconsolidated material sheet;   a step for calendering the non-woven consolidated material sheet.   
     
     
         2 . The method according to  claim 1 , characterized in that, in the sorting step ( 18 ), the base materials are sorted so as to separate at least first and third families of materials, the first family of materials grouping the base materials which both do not contain textile fibers but in majority contain polyurethane, and the third family of materials grouping the base materials containing textile fibers. 
     
     
         3 . The method according to  claim 1 , characterized in that, in the sorting step ( 18 ), the base materials are sorted so as to separate at least one second family of materials, grouping the base materials in majority containing latex. 
     
     
         4 . The method according to  claim 1 , characterized in that it comprises a step ( 14 ) for disinfecting the elements to be treated, before the breakup step ( 18 ). 
     
     
         5 . The method according to  claim 4 , characterized in that the disinfection of the elements to be treated is carried out via a chemical route by spraying a disinfectant on an external surface of the bedding elements, or by exposing the bedding elements to microwave radiation. 
     
     
         6 . The method according to  claim 1 , characterized in that, in the step ( 24 ) for forming the non-woven unconsolidated material sheet, the mixture is carried away and dispersed by an air flow and deposited in a chamber, according to the method known as the air lay method. 
     
     
         7 . The method according to  claim 1 , characterized in that, in the consolidation step ( 26 ), the non-woven unconsolidated material sheet is thermally consolidated. 
     
     
         8 . The method according to  claim 2 , characterized in that the mixture comprises by weight, between 40% and 80% of the first family of materials, between 15% and 45% of the third family of material, and between 5% and 20% of a mixture of bicomponent fibers. 
     
     
         9 . The method according to  claim 3 , characterized in that the mixture comprises by weight, between 30% and 70% of the first family of materials, between 5% and 25% of the second family of materials, between 10% and 30% of the third family of materials and between 5% and 25% of a mixture of bicomponent fibers. 
     
     
         10 . The method according to  claim 3 , characterized in that the mixture comprises by weight between 20% and 60% of the first family of materials, between 15% and 35% of the second family of materials, between 5% and 25% of the third family of materials, and between 10% and 30% of a mixture of bicomponent fibers. 
     
     
         11 . The method according to  claim 1 , characterized in that it comprises, before the breakup step, a step for detecting in the element to be treated a plurality of predetermined chemical compounds. 
     
     
         12 . A non-woven material sheet obtained by the method according to  claim 1 , the sheet including a mixture of a bicomponent fiber mixture and of at least one of the following families of materials: a first family of materials in majority containing polyurethane foam, a second family of materials in majority containing latex; a third family of materials containing textile fibers. 
     
     
         13 . The sheet according to  claim 12 , characterized in that said mixture comprises by weight, between 60% and 90% of polyurethane foam, between 2% and 15% of textile fibers, and between 5% and 20% of the mixture of bicomponent fibers. 
     
     
         14 . The sheet according to  claim 12 , characterized in that said mixture comprises by weight, between 45% and 75% of polyurethane foam, between 5% and 25% of latex, between 1% and 10% of textile fibers, and between 5% and 25% of the mixture of bicomponent fibers. 
     
     
         15 . The sheet according to  claim 9 , characterized in that said mixture comprises by weight, between 35% and 65% of polyurethane foam, between 15% and 35% of latex, between 1% and 8% of textile fibers, and between 10% and 30% of the mixture of bicomponent fibers. 
     
     
         16 . A facility for recycling bedding elements, mattresses, bed bases and seats, the facility comprising:
 a breakup device, in which the base materials are obtained by breaking up the furniture product;   a sorting device, in which the base materials are separated into several families of materials, depending on the nature of the base materials;   a device ( 58 ,  59 ,  60 ) for grinding the different families of materials;   a mixing device ( 68 ), in which a mixture is prepared, the mixture comprising a predetermined amount of at least one family of ground materials;   a device ( 80 ) for forming a non-woven unconsolidated material sheet from the mixture;   a device ( 84 ) for consolidating the non-woven unconsolidated material sheet;   a device ( 98 ) for calendering the non-woven consolidated material sheet.