JP2016216558A - Method for producing resin-made sash - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technology of being capable of recycling a used resin-made sash containing polyvinyl chloride as a main component.SOLUTION: A method for producing a resin-made sash includes: collecting a used resin-made sash containing polyvinyl chloride as a main component; pulverizing the used resin-made sash to produce recycled powder; evaluating characteristics of the recycled powder; determining an additive added to the recycled powder on the basis of the result of the characteristic evaluation; mixing the recycled powder and the additive to produce a kneaded product; and extrusion molding the kneaded product.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a technology capable of recycling a resin sash mainly composed of polyvinyl chloride.

  Polyvinyl chloride is widely used as a resin sash for holding window glass because it is excellent in mechanical strength, weather resistance, heat insulation and the like. Since polyvinyl chloride is white, the resin sash can be made into various colors by coloring it with a pigment, for example. For this reason, the use of polyvinyl chloride makes it possible to produce a resin sash having a high design and rich in color variations.

  Resin sashes are typically manufactured by cutting and joining profile extruded polyvinyl chloride. For this reason, at the time of manufacture of the resin sash, the cut end material of the resin sash is generated. By recycling such resin sash trims and manufacturing a new resin sash, it is possible to save resources and reduce costs.

  However, the end material of such a resin sash contains various subcomponents according to the specifications of the resin sash. For example, the end material of the resin sash is colored with a pigment or is covered with a protective film. When such a resin sash mill is recycled as it is, it is difficult to adjust the color, and the weather resistance may be deteriorated due to the presence of subcomponents.

  Patent Document 1 discloses a technique for manufacturing a new resin sash by recycling the scrap material generated during the manufacture of the resin sash. In the technique according to Patent Document 1, a recycled powder obtained from the end material of a resin sash and an unused polyvinyl chloride powder (virgin powder) are used in combination. More specifically, the outer layer of the resin sash is formed of virgin powder, and the inner layer of the resin sash is formed of recycled powder.

  In the resin sash according to Patent Document 1, by forming the outer layer that appears in the appearance with virgin powder, design characteristics and weather resistance comparable to a resin sash produced without using recycled powder can be obtained.

Japanese Patent No. 3420527

  Several decades have passed since the commercialization of resin sashes mainly composed of polyvinyl chloride. For example, many used resin sashes that have deteriorated or damaged due to aging have been discarded, such as when rebuilding or demolishing buildings. It is becoming Therefore, by recycling such a used resin sash, more effective resource saving and cost reduction are realized.

  However, in the case of a used resin sash, there is a case where a component changes due to aging, unlike an end material generated at the time of manufacturing the resin sash. In addition, the used sash may have a different kind and amount of additive from the end material generated when the resin sash is manufactured. For this reason, the resin sash produced by recycling the used resin sash as it is may not provide sufficient physical properties such as mechanical strength.

  In view of the circumstances as described above, an object of the present invention is to provide a technology capable of recycling a used resin sash mainly composed of polyvinyl chloride.

In order to achieve the above object, in a method for producing a resin sash according to an embodiment of the present invention, a used resin sash mainly composed of polyvinyl chloride is collected.
The used resin sash is pulverized to produce a recycled powder.
Characteristic evaluation of the recycled powder is performed.
An additive to be added to the recycled powder is determined based on the result of the characteristic evaluation.
A kneaded product is prepared by mixing the recycled powder and the additive.
The kneaded product is extruded.
In this configuration, physical properties that are insufficient for the recycled powder obtained from the used resin sash can be supplemented by the additive. For this reason, good physical properties can be obtained in a resin sash that is newly produced by recycling a used resin sash.

A polyvinyl chloride virgin powder may be used as the additive.
The amount of the virgin powder added may be 30% by weight or less based on the total amount of the recycled powder and the virgin powder.
In this configuration, the physical properties of the resin sash can be easily improved by using the recycled powder and the polyvinyl chloride virgin powder together.

In the above characteristic evaluation, the impact resistance of a molded body obtained from the recycled powder may be evaluated.
When the impact resistance is insufficient, a reinforcing agent may be used as the additive.
Thereby, the resin sash excellent in impact resistance can be manufactured.

In the characteristic evaluation, the thermal stability of the molded body obtained from the recycled powder may be evaluated.
When the thermal stability is insufficient, a thermal stabilizer may be used as the additive.
As the heat stabilizer, at least one of a lead stabilizer and a calcium / zinc stabilizer may be used.
By these, the resin sash excellent in thermal stability can be manufactured.

In the above characteristic evaluation, the gelation time of the recycled powder may be evaluated.
When the gelation time is shorter than the first range, a lubricant may be used as the additive.
When the gelation time is longer than the first range, a torque improver may be used as the additive.
With this configuration, the gelation time of the kneaded product of the recycled powder and the additive becomes appropriate, and a well kneaded melt kneaded product can be obtained. The melt-kneaded product obtained in this way can be well extruded by an extruder.

In the above characteristic evaluation, the gelation initial torque of the recycled powder may be evaluated.
When the gelation initial torque is higher than the second range, a lubricant may be used as the additive.
When the gelation initial torque is lower than the second range, a torque improver may be used as the additive.
With this configuration, the initial gelation torque of the kneaded product of the recycled powder and the additive becomes appropriate, and a well kneaded melt kneaded product can be obtained. The melt-kneaded product obtained in this way can be well extruded by an extruder.

As the torque improver, an oxidized polyethylene wax having an acid value of 15 or more and 18 or less may be used.
With this configuration, the effect of shortening the gelation time and the effect of increasing the gelation initial torque can be obtained better.

  A technique capable of recycling used resin sashes mainly composed of polyvinyl chloride can be provided.

It is a top view of the window concerning one embodiment of the present invention. It is a fragmentary sectional view in alignment with the AA 'line of FIG. 1 of the said window. It is an expanded sectional view of the frame material of the resin sash of the said window. It is a flowchart which shows the recycling method of the said resin sash.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[Configuration of Resin Sash 10]
FIG. 1 is a plan view of a resin sash 10 according to an embodiment of the present invention. The resin sash 10 is configured as an outer frame of the rectangular window 1 and holds the outer edge portion of the window glass 40. The resin sash 10 includes a frame material 20 and a cover material 30 mainly composed of polyvinyl chloride.

  The frame material 20 has members 20a, 20b, 20c, and 20d formed by profile extrusion molding. The members 20a and 20b constitute long side members that face each other, and the members 20c and 20d constitute short side members that face each other. The members 20a, 20b, 20c, and 20d are joined to each other by welding to form a rectangular shape.

  The cover material 30 has members 30a, 30b, 30c, and 30d formed by profile extrusion. The members 30a and 30b constitute long side members that face each other, and the members 30c and 30d constitute short side members that face each other. The members 30a, 30b, 30c, and 30d are joined to each other by fitting to form a rectangular shape.

  The method for joining the members 20a, 20b, 20c, and 20d of the frame material 20 and the method for joining the members 30a, 30b, 30c, and 30d of the cover material 30 are not limited to welding, and known methods can be appropriately employed.

  2 is a partial cross-sectional view of the window 1 taken along line AA ′ of FIG. 1, and FIG. 3 is an enlarged cross-sectional view of the frame material 20 of the resin sash 10. The frame member 20 and the cover member 30 of the resin sash 10 are formed in a hollow structure and sandwich the outer edge portion of the window glass 40.

  The window glass 40 includes two glasses 41a and 41b facing each other, and a spacer 41 that seals the outer edges of the glasses 41a and 41b in a secret manner. The window glass 40 is configured as a multi-layer glass in which argon gas is sealed in a space between the glasses 41a and 41b. The window glass 40 having such a configuration can exhibit high heat insulation.

  In addition, the structure of the window glass 40 is arbitrary. For example, the gas sealed in the window glass 40 may not be argon gas, and may be, for example, krypton gas, dry air, or the like. Moreover, the window glass 40 may not be a double layer glass, and may be a triple glass or a single plate glass. Further, the glasses 41a and 41b can be arbitrarily selected from known glasses, and may be configured with a surface coating.

  As shown in FIG. 3, the frame member 20 includes a holding surface 22 that holds the end surface of the window glass 40, a first fitting portion 21 provided adjacent to the holding surface 22, and a substantially vertical position from the holding surface 22. And a first sandwiching portion 23 that extends. The first fitting part 21 and the first clamping part 23 are arranged on opposite sides of the holding surface 22.

  As shown in FIG. 2, the cover member 30 includes a second fitting part 31 and a second clamping part 32. The 2nd fitting part 31 is comprised so that fitting to the 1st fitting part 21 of the frame material 20 is possible. That is, the cover member 30 is attached to the frame member 20 by fitting the second fitting portion 31 to the first fitting portion 21. The second clamping part 32 of the cover material 30 attached to the frame material 20 extends from the second fitting part 31 so as to face the first clamping part 23 of the frame material 20.

  That is, the resin sash 10 with the cover member 30 attached to the frame member 20 forms a recess for receiving the outer edge portion of the window glass 40 by the holding surface 22 and the fitting portions 21 and 31. A glass cradle 50 and airtight materials 51a and 51b are provided in the recess. The glass cradle 50 and the airtight materials 51a and 51b are formed of a resin material.

  The glass cradle 50 holds the end surface of the window glass 40. The airtight member 51 a is sandwiched between the second sandwiching portion 32 of the cover member 30 and the glass 41 a of the window glass 40. The airtight member 51 b is sandwiched between the first sandwiching portion 23 of the frame member 20 and the glass 41 b of the window glass 40. The glass cradle 50 and the airtight materials 51a and 51b improve the airtightness between the window glass 40 and the resin sash 10 and eliminate rattling.

  Further, the frame member 20 is provided with fixing portions 24 and 25 protruding from the outer edge portion thereof. The protruding directions of the fixing portions 24 and 25 are orthogonal to each other, the fixing portion 24 protrudes in the outer peripheral direction, and the fixing portion 25 protrudes in the indoor direction. The fixing portions 24 and 25 are fixed to an opening formed in a wall or roof of a building by a fixing member such as a screw, for example. That is, when the window 1 is installed in the opening of the building, the fixing portions 24 and 25 are fixed to the opening of the building.

[Recycling method of resin sash 10]
FIG. 4 is a flowchart showing a method for recycling the resin sash 10. Hereinafter, the method for recycling the resin sash 10 will be described with reference to FIG.

  In the present embodiment, an example in which a frame material 20 of a similar resin sash 10 is newly manufactured by recycling the used resin sash 10 of the window 1 attached to a building will be described. The cover member 30 of the resin sash 10 can be manufactured in the same manner as the frame member 20.

(Step S10: Recovery of resin sash 10)
In step S10, the resin sash 10 is collected from the building. In step S10, the fixing member which fixes the fixing | fixed part 24 and 25 to the opening part of a building is removed first, and the window 1 is removed from the opening part of a building. At this time, for example, a member such as a sealing material provided between the resin sash 10 and the opening of the building is removed.

  Next, the window 1 removed from the opening of the building is dismantled. That is, the fitting between the second fitting portion 31 of the cover material 30 and the first fitting portion 21 of the frame material 20 is released, and the cover material 30 is removed from the frame material 20. Then, the window glass 40, the glass cradle 50, and the airtight members 51a and 51b are removed from the frame member 20 from which the cover member 30 has been removed. Furthermore, members having components other than polyvinyl chloride such as metal members provided on the frame material 20 and the cover material 30 are removed as necessary. Thus, the resin sash 10 is obtained.

If necessary, in order to reduce impurities other than polyvinyl chloride in the resin sash 10, the following processing may be performed on the resin sash 10.
・ Primary cutting and selection of good parts ・ Secondary cutting to remove highly contaminated parts such as corners ・ Removal of foreign materials such as soft polyvinyl chloride, tape, and rust ・ Waste wiping, high-pressure washing, air blow Dirt removal by etc. ・ Detection and removal of metal parts by metal detector

  Thereby, collection | recovery of the frame material 20 and the cover material 30 which are the recycling raw materials which have a polyvinyl chloride as a main component is completed.

(Step S20: Grinding of resin sash 10)
In step S20, recycled powder is produced by pulverizing the frame material 20 and the cover material 30 collected in step S10. For example, a twin-screw crusher or a high-speed vortex crusher can be used for step S20. In order to perform mixing well in step S50 described later, the average particle size of the recycled powder is preferably 300 μm or less.

  In step S20, for example, the frame material 20 and the cover material 30 can be pulverized in two stages. That is, in the first stage, the frame material 20 and the cover material 30 are coarsely pulverized to obtain a coarsely pulverized powder having a particle diameter of 5 to 10 mm, and in the second stage, the coarsely pulverized powder is finely pulverized to obtain a 1 mm mesh. Can be made into a finely pulverized powder having a particle diameter capable of passing through the.

(Step S30: Evaluation of recycled powder)
In step S30, the recycled powder obtained in step S20 is evaluated. More specifically, in step S30, problems in the case of manufacturing the frame material 20 using the recycled powder obtained in step S20 as it is are clarified. The evaluation method of the recycled powder is not limited to a specific method.

  For example, in step S30, a molded body can be produced using the recycled powder obtained in step S20 as it is. By measuring the physical properties of the molded body, it becomes possible to grasp the physical properties that are insufficient when the resin sash 10 is manufactured using the recycled powder as it is. The molded body of the recycled powder can be produced, for example, by roll kneading and press molding.

An example of a method for measuring physical properties of a molded article effective in step S30 will be described below.
-Charpy impact test-Thermal decomposition time measurement-Tensile yield stress measurement-Bending elastic modulus measurement These measurements can be performed in accordance with, for example, non-plastic polyvinyl chloride building material JISA5558.

  In Step S30, by evaluating the gelation characteristics of the recycled powder, it is possible to grasp the physical properties that are insufficient for kneading the recycled powder in Step S50 described later. The gelation property can be evaluated using, for example, a blast graph. Examples of gelation characteristics that can be evaluated by blast graph include gelation time, gelation initial torque, and thermal decomposition time.

(Step S40: Determination of additives)
In step S40, an additive to be added to the recycled powder is determined based on the evaluation result obtained in step S30. That is, an additive that is effective for overcoming the problems in manufacturing the resin sash 10 using the recycled powder as it is is determined. As an additive, you may use it in combination of multiple types as needed.

  Additives can be selected from reinforcing agents, heat stabilizers, UV stabilizers, internal lubricants, external lubricants, torque improvers, colorants, plasticizers, fillers, processing aids, etc., according to the evaluation result of step S30. It is.

  For example, if the impact resistance of the recycled powder compact is insufficient by the Charpy impact test in step S30, a reinforcing agent can be used as an additive. As the reinforcing agent, for example, an acrylic reinforcing agent can be used.

  Further, when the thermal stability of the recycled powder compact is insufficient by the thermal decomposition time measurement in step S30, a thermal stabilizer can be used as an additive. The heat stabilizer is preferably at least one of a lead stabilizer and a calcium / zinc stabilizer. A tin stabilizer is not preferable because it softens polyvinyl chloride and reacts with lead to blacken.

  About the gelation characteristic in step S30, it is preferable to preset beforehand the gelation conditions which can be knead | mixed favorably in step S50 mentioned later. When the gelling conditions are not satisfied, an additive that is effective for satisfying the gelling conditions can be selected.

  For example, a first range of gelation time and a second range of gelation initial torque can be set as the gelation conditions. That is, when the gelation time is outside the first range, an additive that is effective for keeping the gelation time within the first range can be selected. In addition, when the gelling initial torque is out of the second range, an additive that is effective for keeping the gelling initial torque within the second range can be selected.

  Specifically, when the gelation time is shorter than the first range or when the gelation initial torque is higher than the second range, a lubricant can be used as an additive. The lubricant can be arbitrarily selected, and for example, LOXIOL (registered trademark) G60 and LOXIOL (registered trademark) G32 (both are product names of Emery Oleochemical Co., Ltd.) can be used.

  Further, when the gelation time is longer than the first range or when the gelation initial torque is lower than the second range, a torque improver can be used as an additive. As a torque improver, what has the effect | action which shortens gelatinization time and the effect | action which raises gelation initial stage torque can be selected suitably.

  As the torque improver, for example, an oxidized polyethylene wax having an acid value of 15 to 18 can be used. As such an oxidized polyethylene wax, for example, LOXIOL (registered trademark) VPG1631 (product name of Emery Oleochemical Co., Ltd.) can be mentioned.

  The addition amount of each additive can be determined as appropriate. As an example, with respect to 100 parts by weight of recycled powder, the addition amount of the reinforcing agent is 5 parts by weight or less, the addition amount of the heat stabilizer is 4 parts by weight or less, the addition amount of the lubricant is 2 parts by weight or less, and the torque improver Can be added to 1 part by weight or less, and the amount of processing aid added can be 2 parts by weight or less.

  Moreover, as needed, an unused polyvinyl chloride powder (virgin powder) can be used as an additive. By using virgin powder as an additive, the physical properties of the resin sash 10 can be easily improved. However, from the viewpoint of resource saving and cost reduction, the amount of virgin powder added is preferably within 30% by weight with respect to the entire polyvinyl chloride powder composed of recycled powder and virgin powder.

(Step S50: Mixing of recycled powder and additives)
In step S50, the recycled powder obtained in step S20 and the additive determined in step S30 are mixed to produce a kneaded product. Mixing of the recycled powder and the additive can be performed, for example, by hot blending at 120 to 140 ° C.

(Step S60: extrusion molding)
In step S60, members 20a, 20b, 20c, and 20d of the frame material 20 are produced by profile extrusion molding of the kneaded material obtained in step S50. Specifically, the members having a cross-sectional shape shown in FIG. 3 are continuously extruded and cut for each of the members 20a, 20b, 20c, and 20d.

  For extruding the kneaded product, for example, a 60 mmφ conical twin screw extruder can be used. In this case, the temperature of the cylinder can be set to 170 to 210 ° C, the temperature of the adapter can be set to 180 to 200 ° C, and the temperature of the mold can be set to 185 to 205 ° C. The resin melting temperature at the mold outlet is preferably about 195 to 205 ° C.

  Then, the frame material 20 is completed by welding each member 20a, 20b, 20c, 20d obtained at step S60.

[Other Embodiments]
As mentioned above, although embodiment of this invention was described, this invention is not limited only to the above-mentioned embodiment, Of course, a various change can be added.

  For example, the recycling method according to the above embodiment is not limited to the resin sash 10 according to the above embodiment, and any used resin sash can be used. Further, a plurality of types of used resin sashes may be pulverized together to form a recycled powder. Also in these cases, a resin sash having good physical properties can be newly produced by evaluating the recycled powder in step S30 and determining an appropriate additive in step S40.

  Further, in the recycling method according to the above embodiment, not only the resin sash 10 according to the above embodiment but also a resin sash having a wide variety of configurations can be newly manufactured.

  Furthermore, a resin sash produced by recycling is configured as a composite of a recycled composition molded using recycled powder and a virgin composition molded using only virgin powder without using recycled powder. May be. Such a resin sash can be molded by separately coextruding the recycled composition and the virgin composition.

  As an example, in the resin sash 10 having a hollow structure, the inner layer can be a recycled composition and the outer layer can be a virgin composition. In other words, by using the virgin composition for the outer layer that appears in the appearance of the resin sash 10, the same appearance as when the recycled composition is not used can be obtained. On the other hand, by using an inner layer that does not affect the design of the resin sash 10 as a recycled composition, resource saving and cost reduction are possible. It should be noted that recycled powder can be added to the virgin composition within a range that does not affect the color tone.

  In addition, if necessary, a coating layer may be provided on the surface of the resin sash obtained in the above embodiment. For example, a resin film or coating, or a metal cover such as aluminum may be provided on the surface of the resin sash. The resin sash may be painted with various paints.

DESCRIPTION OF SYMBOLS 1 ... Window 10 ... Frame material 20 ... Cover material 30 ... Window glass 50 ... Glass cradle 51a, 51b ... Airtight material 100 ... Resin sash

Claims (8)

Collect used resin sashes mainly composed of polyvinyl chloride,
The used resin sash is crushed to produce a recycled powder,
Characterize the recycled powder,
Determining an additive to be added to the recycled powder based on the result of the characteristic evaluation;
Mixing the recycled powder and the additive to produce a kneaded product,
A method for producing a resin sash, in which the kneaded product is extruded. It is a manufacturing method of the resin sash of Claim 1,
Using polyvinyl chloride virgin powder as the additive,
The amount of the virgin powder added is 30% by weight or less based on the total amount of the recycled powder and the virgin powder. A method for producing a resin sash according to claim 1 or 2,
In the characteristic evaluation, the impact resistance of the molded body obtained from the recycled powder is evaluated,
A method for producing a resin sash, wherein a reinforcing agent is used as the additive when the impact resistance is insufficient. A method for producing a resin sash according to any one of claims 1 to 3,
In the characteristic evaluation, the thermal stability of the molded body obtained from the recycled powder is evaluated,
A method for producing a resin sash, wherein a thermal stabilizer is used as the additive when the thermal stability is insufficient. It is a manufacturing method of the resin sash of Claim 4,
A method for producing a resin sash, wherein at least one of a lead stabilizer and a calcium / zinc stabilizer is used as the heat stabilizer. A method for producing a resin sash according to any one of claims 1 to 5,
In the characteristic evaluation, the gelation time of the recycled powder is evaluated,
When the gelation time is shorter than the first range, using a lubricant as the additive,
A method for producing a resin sash, wherein a torque improver is used as the additive when the gelation time is longer than the first range. A method for producing a resin sash according to any one of claims 1 to 6,
In the characteristic evaluation, the gelation initial torque of the recycled powder is evaluated,
When the gelation initial torque is higher than the second range, using a lubricant as the additive,
A method for producing a resin sash, wherein a torque improver is used as an additive when the gelation initial torque is lower than the second range. A method for producing a resin sash according to claim 6 or 7,
A method for producing a resin sash, wherein an oxidized polyethylene wax having an acid value of 15 or more and 18 or less is used as the torque improver.

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