JP2024052648A - Resin molded product, manufacturing method for resin molded product, resin extrusion molded product, and manufacturing method for resin extrusion molded product - Google Patents

Abstract

[Problem] To provide a resin molded product that can achieve high quality while containing recycled resin, a manufacturing method for a resin molded product, a resin extrusion molded product, and a manufacturing method for a resin extrusion molded product. [Solution] The resin molded product 1 is a resin molded product 1 that contains a recycled material containing resin, and has a base material 2 and a surface layer 3 formed on a surface 2a of the base material 2, the base material 2 contains a matrix resin and foreign matter contained in the matrix resin and consisting of a component derived from the recycled material, the component being a resin or metal different from the matrix resin, the particle size of the foreign matter being 355 μm or less, and the thickness of the surface layer 3 being 0.2 mm to 0.5 mm. [Selected Figure] Figure 2

Description

This disclosure relates to resin molded products, methods for manufacturing resin molded products, resin extrusion molded products, and methods for manufacturing resin extrusion molded products.

A large amount of used building waste materials, such as fittings such as windows and doors, fences, decks, etc., are discarded. Most of this waste material is processed into the form of waste plastic or mixed waste and is landfilled at final disposal sites. This waste material includes many resin components, such as resin frames for fittings such as windows, and resin decks. In recent years, technology to recycle waste materials containing resin is desired in order to reduce environmental burdens, including the 2050 Carbon Neutral Declaration. For example, Patent Document 1 discloses a technology for manufacturing hollow window frames using a resin material containing recycled polyvinyl chloride resin recovered from waste materials.

JP 2020-079531 A

After dismantling the parts, recycled resin materials are crushed and sorted by material. However, because waste contains a variety of resin and metal materials, even after sorting, it is common for different materials such as tiny metal pieces to be mixed in. When window frames are manufactured using recycled resin mixed with different materials, as in the technology disclosed in Patent Document 1, foreign matter appears on the surface of the molded product. Resin frames with such foreign matter exposed do not meet the quality standards for window frames and other building materials.

The present disclosure has been made in consideration of the above circumstances, and aims to provide a resin molded product that can achieve high quality while containing recycled resin, a manufacturing method for a resin molded product, a resin extrusion molded product, and a manufacturing method for a resin extrusion molded product.

A resin molded product according to one embodiment of the present disclosure is a resin molded product that includes a recycled material containing resin, and has a base material and a surface layer formed on the surface of the base material, the base material containing a matrix resin and a foreign matter that is contained in the matrix resin and is composed of a component derived from the recycled material, the component being a resin or metal different from the matrix resin, the particle size of the foreign matter being 355 μm or less, and the thickness of the surface layer being 0.2 mm or more and 0.5 mm or less.

FIG. 2 is a schematic diagram showing one surface of a resin molded product according to an embodiment. FIG. 1 is a cross-sectional view showing a resin molded product according to an embodiment. FIG. 4 is a schematic diagram showing a foreign object in a resin molded product according to an embodiment; 3 is a flowchart of a method for manufacturing a resin molded product according to an embodiment. FIG. 1 is a cross-sectional view showing a resin extrusion molded product according to one embodiment. FIG. 1 is a cross-sectional view showing a resin extrusion molded product according to one embodiment. 2 is a flowchart of a method for producing a resin extrusion molded product according to one embodiment.

(Resin molded products)
Hereinafter, an embodiment of a resin molded product, a manufacturing method for a resin molded product, a resin extrusion molded product, and a manufacturing method for a resin extrusion molded product will be described with reference to the drawings. Fig. 1 is a schematic diagram showing one side of a resin molded product according to an embodiment of the present disclosure. Fig. 2 is a cross-sectional view along the thickness direction of the resin molded product according to an embodiment of the present disclosure. Fig. 3 is a schematic diagram showing a foreign object in a resin molded product according to an embodiment of the present disclosure.

As shown in Figures 1 and 2, the resin molded product 1 has a base material 2 and a surface layer 3 formed on the surface 2a of the base material 2. The resin molded product 1 includes a foreign matter 4. More specifically, the base material 2 includes the foreign matter 4.

The substrate 2 is composed of a resin molded body containing virgin resin raw material and recycled materials. The unused, newly produced resin raw material is called "virgin resin raw material." The material obtained from processed resin components is called "recycled material."

Recycled materials are resin materials that are collected and separated from the collected materials, such as resin products contained in waste building materials after use, waste resin products generated during the manufacturing process at factories, and waste generated at construction sites.

The molding material prepared to obtain the base material 2 includes virgin resin raw materials and recycled materials. In addition to the main agent, the molding material includes at least one of an impact resistance modifier, a weathering material, a heat stabilizer, a processing aid, a filler, a lubricant, or a pigment. The main agent is, for example, polyvinyl chloride resin (hereinafter referred to as "PVC resin"). The raw material blending ratio of the molding material is adjusted according to the components and blending amount of the recycled material. The recycled material is mainly added as a raw material for the main agent. Therefore, the content of virgin resin raw materials is determined according to the amount of the main agent contained in the recycled resin material. Details will be described later.

The substrate 2 is obtained by molding a material obtained by kneading the above-mentioned molding materials. The matrix resin of the substrate 2 is a resin containing, for example, polyvinyl chloride, ABS, high-density polyethylene, low-density polyethylene, polypropylene, polystyrene, or nylon.

The substrate 2 contains foreign matter 4 derived from recycled materials. The foreign matter 4 is made of a resin or metal different from the matrix resin. The foreign matter 4 is mixed in with the matrix resin of the substrate 2. In addition, the foreign matter 4 present on and in the vicinity of the surface 2a of the substrate 2 is exposed on and in the vicinity of the surface 2a of the substrate 2, as shown in FIG. 1. The vicinity of the surface 2a of the substrate 2 refers to the region on the surface 2a side of the substrate 2 in the cross section of the substrate 2 in the thickness direction. In other words, the vicinity of the surface 2a of the substrate 2 refers to the surface layer of the substrate 2.

The thickness of the substrate 2 is preferably 0.5 mm or more and 4 mm or less, and more preferably 1 mm or more and 3 mm or less. If the thickness of the substrate 2 is less than the lower limit, the molding material does not flow easily and molding is difficult. If the thickness of the substrate 2 exceeds the upper limit, cooling after molding takes a long time, productivity decreases, and the amount of molding material used increases, resulting in the use of more material than necessary.

The base material 2 may contain additives. Examples of additives include polymer processing aids. By including additives in the base material 2, the tensile elongation of the resin molded product 1 is improved, and the resin molded product 1 has sufficient strength (resistance to breakage) for use as a building fixture.

The content of the additive relative to the total weight (100% by weight) of the base material 2 is preferably 0.05% by weight to 3% by weight, more preferably 0.5% by weight to 1.5% by weight. If the content of the additive is less than the lower limit, the effect of the tensile breaking elongation cannot be obtained. If the content of the additive exceeds the upper limit, the maximum value of the tensile breaking elongation will not change, resulting in the addition of unnecessary material.

Foreign matter 4 has various shapes, originating from foreign matter that was mixed in the recycled material. Foreign matter 4 appears in an irregular shape that differs from the design shape of the molding process. Examples of foreign matter 4 include an uneven shape that includes a portion that protrudes slightly from surface 2a of substrate 2, and an example of foreign matter 4 that exists near surface 2a of substrate 2 and does not protrude from surface 2a of substrate 2, but appears as a change in color, etc.

The foreign matter 4 has an irregular shape. The size of the foreign matter 4 exposed on the surface 2a of the substrate 2 and in its vicinity can be measured by a microscope, image processing, or the like. Specifically, as shown in FIG. 3, the linear distance between the edges of the foreign matter 4 detected by a microscope or the like is measured. The length L of the point where the linear distance between the edges is the longest is defined as the longest part of the foreign matter 4. The largest dimension of the diameter along the direction intersecting the longest part L is the minimum diameter y, and this minimum diameter y is the particle size of the foreign matter 4. The minimum diameter y of the foreign matter 4 is 355 μm or less, and preferably 250 μm or less. As a result of the minimum diameter y of the foreign matter 4 being 355 μm or less, it is difficult to notice in appearance, and even if the resin molded product 1 is manufactured using recycled resin material, it can withstand practical use. Furthermore, if the minimum diameter y of the foreign matter 4 is 250 μm or less, the foreign matter 4 cannot be visually recognized on the surface 2a of the substrate 2 even if the thickness of the surface layer 3 is thin (0.25 mm to 0.3 mm).

The foreign matter 4 includes an organic material or a thermosetting resin with a higher melting point than the matrix resin (e.g., polyvinyl chloride), or a metal. The foreign matter 4 is a component other than the virgin resin raw material and additives used during manufacturing. The material of the foreign matter 4 can be detected, for example, by a method in which the exposed foreign matter 4 is cut off from the surface 2a of the substrate 2 and its vicinity and the components are analyzed. The material of the foreign matter 4 present inside the substrate 2 can be detected, for example, by a method in which the resin molded product 1 is cut, the exposed foreign matter 4 on the cut surface is cut off, and the components are analyzed. For example, if no exposed foreign matter 4 is found, an arbitrary position of the resin molded product 1 is cut out and the components are analyzed.

The lead content VPB of resin molded product 1 is 0% by weight < VPB ≦ 3% by weight. Virgin resin raw materials do not contain lead. Lead removal is performed in the process of obtaining recycled materials, so the lead contained in the waste is removed. However, because recycled resin materials are obtained from waste, there is a possibility that they may contain trace amounts of lead. Resin molded product 1 is manufactured using recycled materials and lead-free virgin resin raw materials.

It is preferable that the resin molded product 1 has an average of 6 or less foreign matter 4 present per unit area on the surface 2a of the substrate 2. The foreign matter 4 exposed on the surface 2a of the substrate 2 can be detected by various methods, such as visual inspection, microscopy, light irradiation, and image processing. The surface of the resin molded product 1 (surface 2a of the substrate 2) can be measured by such methods to count the number of foreign matter 4. When the average number of foreign matter 4 present per unit area on the surface 2a of the substrate 2 is 6 or less, the number of foreign matter 4 exposed on the surface 2a of the substrate 2 is extremely small. As a result, even a resin molded product 1 manufactured using recycled resin materials can withstand practical use.

The surface layer 3 contains an acrylic resin. Examples of acrylic resins include polymethyl methacrylate resin, ASA (Acrylate Sthene Acrylonitrile) resin, and acrylonitrile-ethylene-styrene copolymer (AES) resin. These may be used alone or in combination of two or more types.

The thickness of the surface layer 3 is preferably 0.2 mm to 0.5 mm, and more preferably 0.3 mm to 0.5 mm. If the thickness of the surface layer 3 is less than the lower limit, the foreign matter 4 will be visible. If the thickness of the surface layer 3 exceeds the upper limit, the mechanical strength will decrease, resulting in the unnecessary addition of acrylic.

The resin molded product 1 described above can be used as at least one of the molded parts of, for example, a door or window frame, a building material for outdoor installation, and a paving material. Examples of the door or window frame include sashes and doors. For example, the resin molded product 1 can be suitably used for the resin frame of a sash or the resin frame of a shoji screen. Examples of the building material for outdoor installation include wood decks, building materials for sunrooms, drainage pans, and covers for air intake/exhaust ports. Examples of the paving material include paving materials for roads, such as materials for temporary roads, parks, and sidewalks. The resin molded product 1 may be a reinforcing material that is not exposed to the outside after installation and is buried in soil, resin, concrete, or wall coating materials.

(Method of manufacturing resin molded product)
As shown in Fig. 4, the method for producing a resin molded product includes a step (S3) of further secondarily crushing a primary powder obtained by crushing a recycled material containing a resin to obtain a recycled raw material finer than the primary powder, a step (S4) of mixing the virgin resin raw material and the recycled raw material to obtain a mixed resin raw material, a step (S5) of extrusion molding using the mixed resin raw material and an acrylic resin, and a step (S6) of obtaining a resin molded product. Furthermore, the method for producing a resin molded product includes a waste recovery step (S1) and a step (S2) of primary crushing the waste to obtain a primary powder in order to obtain a recycled material.

First, a method for obtaining primary powder will be described. For example, resin products contained in waste from used building materials, waste from resin products generated during the manufacturing process at a factory, and waste generated at a construction site are collected (S1). Waste collection is not limited to a method of collecting waste independently, and may be a method of obtaining waste collected by a waste collection business operator. Next, the collected waste is separated into resin parts and non-resin parts. The separated resin parts are crushed with a crusher, hammer, etc. to obtain a mixed crushed product. Impurities such as metals, metals, and soft resins are removed from the obtained mixed crushed product to obtain primary powder. The primary powder may be further sorted by a wind sorting method, a color-distinguishing sorting method, or the like to determine the type of resin contained in the primary powder. The process of obtaining primary powder from waste may be performed as a series of steps in a resin molding method, or primary powder processed by a recycling business operator or the like may be obtained in advance.

When manufacturing a resin frame for a sash as the resin molded product 1, it is more preferable to separate the waste of the resin frame for the sash during waste collection (S1) to obtain primary powder (S2). There are many resins in common between the molding material for obtaining the resin molded product 1 and the resin components contained in the recycled resin, which can increase recycling efficiency and manufacturing efficiency.

Next, the primary powder is subjected to secondary pulverization (S3). In the secondary pulverization, the primary powder is further subjected to secondary pulverization to obtain a recycled raw material having a smaller particle size than the primary powder. For example, the same pulverizer as the primary pulverization is used for the secondary pulverization. The recycled raw material may be processed into a fine powder finer than the particle size of the main agent pellets of the virgin resin raw material. Specifically, after obtaining a pulverized product having a minimum diameter of 2 mm to 15 mm square by the primary pulverization, the recycled raw material is obtained as a pulverized product having a minimum diameter of less than 355 μm by the secondary pulverization. In addition to the method of obtaining a recycled raw material having a minimum diameter of less than 355 μm only by the secondary pulverization process, a sieving process may be performed after the secondary pulverization to obtain a recycled raw material having a minimum diameter of less than 355 μm. For example, after removing particles having a minimum diameter larger than 355 μm by the sieving process, a pulverization process may be performed to obtain a fine recycled raw material while suppressing the variation in particle size. The particle size of the recycled raw material may be less than the average particle size of the main raw material of the virgin resin raw material. By further subjecting the primary powder to secondary crushing to obtain fine recycled raw material, the appearance of foreign matter 4 can be suppressed. By obtaining fine recycled raw material, the physical properties of the resin molded product 1 can be maintained at a high level. In the case of sieving, a powder with a particle size of 355 μm or less is obtained. However, during sieving, particles with short sides less than 355 μm and long sides of 355 μm or more may not be classified and may be mixed into the recycled raw material. It is more preferable that the minimum diameter is 250 μm or less. In this case, if the primary crushing produces crushed material with a minimum diameter of less than 10 mm, recycled raw material with a minimum diameter of 250 μm or less can be obtained more efficiently after secondary crushing.

Next, the virgin resin raw material and the recycled raw material are mixed to obtain a molding material (S4). The molding material is, for example, a mixed resin raw material containing PVC resin and various other materials. The content of recycled raw materials in the molding material is, for example, 10% by weight or more. By including 10% by weight or more of recycled raw materials in the molding material, the recycling rate of the resin is improved. As a result of including 10% by weight or more of recycled raw materials in the molding material, a resin molded product 1 that can withstand practical use can be manufactured even if the usage rate of recycled materials is high.

For example, when the resin molded product 1 is used as a non-exposed part that is not exposed to the outside, there is no need to consider the deterioration of the design due to the appearance of the foreign matter 4. In this case, for example, the content of recycled raw materials contained in the molding material is 10% by weight or more. Since the resin molded product 1 of the present disclosure uses recycled raw materials processed into fine powder, it is less susceptible to the deterioration of physical properties caused by the presence of the foreign matter 4. Specifically, by using recycled raw materials with small particle size, the surface area of the recycled resin material increases, making it easier for the recycled material to melt and maintaining good extrusion performance. As a result, the deterioration of physical properties caused by the foreign matter 4 can be suppressed. When the resin molded product 1 is used as a non-exposed part, the content of recycled materials can be further increased.

Next, extrusion molding is performed (S5). A conventional method is used for extrusion molding. When the resin molded product 1 is manufactured as a resin frame for a sash, the part exposed to the outside with the resin frame installed, that is, the exposed part visible from the outside, is molded with a material containing virgin resin raw material and recycled raw material together with a material forming a surface layer, or is molded only with virgin resin raw material, and the non-exposed part not visible from the outside is molded with a composite material formed with a material containing virgin resin raw material and recycled raw material. Note that the recycled raw material of the recycled material may be a mixture of multiple types, for example, recycled raw material made of waste materials from resin fittings and waste materials generated in factories, or recycled raw material made of resin fittings, waste materials generated in factories, and other waste materials. The base material 2 and surface layer 3 of the resin molded product 1 are molded by two-color molding. The exposed part and the non-exposed part may also be molded by two-color molding.

After this, a finishing process is performed to turn the resin molded product 1 into a product (S6). During the finishing process, the externally exposed surface of the resin molded product 1 may be painted with a pigment or the like. The surface may also be covered with a resin sheet.

Here is an example of a recycled resin product using recycled materials including recycled raw materials. For example, the recycled resin product is a recycled resin product that includes a first resin molded part formed of a first resin material containing recycled raw materials of the recycled resin, and a second resin molded part formed of a second resin material having a lower content of recycled resin material containing recycled raw materials than the first resin molded part or not containing recycled materials, and the exposed part that is exposed when in use is composed of the second resin molded part, and the non-exposed part that is located inside the exposed part and is not exposed when in use is composed of the first resin molded part. Although foreign matter 4 may be exposed on the surface 2a of the base material part 2 in the resin molded product 1, the number of exposed foreign matter 4 is extremely small, and sufficient physical strength is obtained. With such a recycled resin product, the exposed part has the same appearance as a non-recycled product, and the recycling rate of the resin material can be increased.

(Resin extrusion moldings)
FIG. 5 is a cross-sectional view of a resin extrusion molded product according to an embodiment of the present disclosure. This resin extrusion molded product is a cross-sectional view of a longitudinal frame constituting a shoji door of a door fitting (sliding door) cut in the short direction. In FIG. 5, the upper side is the outdoor side, and the lower side is the indoor side. As shown in FIG. 5, the resin extrusion molded product 10 has a surface layer portion (outdoor side portion) 11, an intermediate portion 12, and a surface layer portion (indoor side portion) 15. The surface layer portion (outdoor side portion) 11 has a substrate portion 13 made of a first resin material and a surface layer 14 formed on the surface of the substrate portion 13. The substrate portion of the intermediate portion 12 is formed of the first resin material and does not have a surface layer. The substrate portion of the surface layer portion (indoor side portion) 15 is formed of a second resin material made only of virgin resin raw material, and does not have a surface layer. The surface layer portion (outdoor side portion) 11 is a portion exposed to the outdoor side when the resin extrusion molded product 10 is a resin sash. The intermediate portion 12 is a portion that is continuous with the surface layer portion (outdoor side portion) 11 and is not exposed to the surface, and the surface layer portion (indoor side portion) 15 is a portion that is exposed to the indoor side. The glass 100 is placed in the recess on the right side of the resin extrusion molding 10. The glass 100 is inserted between the surface layer portion (outdoor side portion) 11 and the surface layer portion (indoor side portion) 15, and is fixed by inserting a press edge into the recess 16 at the glass side end of the surface layer portion (indoor side portion) 15. The glass 100 is fixed by the upper frame, lower frame, and right vertical frame at the outer peripheral end in the same configuration as the left frame. The substrate portion 2 of the surface layer portions 11 and 15 may be formed only from recycled raw materials of recycled resin, and a surface layer 3 may be provided. The substrate portion of the intermediate portion 12 may be formed only from recycled raw materials of recycled resin, and the surface layer 3 may not be provided.

The surface layer 11 is made of the resin molded product 1 described above.

The surface layer (indoor side) 15 is made only of the virgin resin material mentioned above.

(Other examples)
FIG. 6 is a cross-sectional view showing a resin extrusion molded product according to an embodiment of the present disclosure. This resin extrusion molded product is a cross-sectional view of a longitudinal frame constituting a shoji screen of a fitting (sliding window) cut in the short direction. The top of FIG. 6 is the outdoor side, and the bottom is the indoor side. As shown in FIG. 6, the resin extrusion molded product 20 has a surface layer portion (outdoor side portion) 21, an intermediate portion 22, and a surface layer portion (indoor side portion) 25. The surface layer portion (outdoor side portion) 21 has a substrate portion 23 made of a first resin material and a surface layer 24 formed on the surface of the substrate portion 23. The substrate portion of the intermediate portion 22 is formed of the first resin material and does not have a surface layer. The substrate portion of the surface layer portion (indoor side portion) 25 is formed only from a virgin resin raw material and does not have a surface layer. The surface layer portion (outdoor side portion) 21 is a portion exposed to the outdoor side when the resin extrusion molded product 20 is a resin sash. The intermediate portion 22 is a portion that is continuous with the surface layer portion (outdoor side portion) 21 and is not exposed to the surface. This shows the left vertical frame of the resin extrusion molded product 20, with glass 100 placed in the recess on the right side. The glass 100 is inserted between the surface layer (outdoor side portion) 21 and the surface layer (indoor side portion) 125, and is fixed by inserting a press edge into the recess 26 at the glass side end of the surface layer (outdoor side portion) 21. The glass 100 is also fixed by the upper frame, lower frame, and right vertical frame at the outer periphery end in a structure similar to that of the left frame.

The surface layer 21 is made of the resin molded product 1 described above.

The surface layer (indoor side) 25 is made only of the virgin resin raw material described above, but a surface layer may be provided on the base material layer, as with the surface layer (outdoor side) 21.

(Method for manufacturing resin extrusion molded products)
As shown in Fig. 7, the manufacturing method of the resin extrusion molding includes a step (S13) of obtaining a finer recycled raw material than the primary powder by further crushing the primary powder obtained by crushing the recycled material containing the resin, a step (S14) of obtaining a mixed resin raw material by mixing the virgin resin raw material and the recycled raw material, a step (S15) of extruding a first surface layer portion having a base material portion and a surface layer formed on the surface of the base material portion using the mixed resin raw material and an acrylic resin, and extruding an intermediate portion made of the mixed resin raw material and continuous with the first surface layer portion, and extruding a second surface layer portion continuous with the intermediate portion using the virgin resin raw material, and a step (S16) of obtaining a resin extrusion molding. Furthermore, the manufacturing method of the resin extrusion molding includes a waste recovery step (S11) and a step (S12) of obtaining a primary powder by crushing the waste to obtain a recycled material. The first surface layer portion becomes the surface layer portion (outside the room), and the second surface layer portion becomes the surface layer portion (inside the room).

The waste recovery process (S11), the process of obtaining primary powder (S12), the process of obtaining recycled raw materials (S13), and the process of obtaining mixed resin raw materials (S14) are the same as the waste recovery process (S1), the process of obtaining primary powder (S2), the process of obtaining recycled raw materials (S3), and the process of obtaining mixed resin raw materials (S4) described above.

Next, extrusion molding is performed (S15). A conventional method is used for extrusion molding. When the resin extrusion molding product 10 is manufactured as a resin frame for a sash, the first surface layer of the exposed part, i.e., the exposed part that is visible from the outside when the resin frame is installed, has a surface layer and is molded from a composite material formed from a material containing virgin resin raw material and recycled raw material, and the second surface layer of the exposed part is molded only from virgin resin raw material, and the non-exposed part that is not visible from the outside when the resin frame is installed is molded from a composite material formed from a material containing virgin resin raw material and recycled raw material. Note that the recycled raw material of the recycled material may be a mixture of multiple types, for example, recycled raw material made from waste materials of resin fittings and recycled raw material made from waste materials generated in factories, or recycled raw material made from waste materials of resin fittings and factories, or other waste materials. The base material part 13 and surface layer 14 of the resin extrusion molding product 10 and the surface layer part 11 are molded by two-color molding. Additionally, the surface layer 11, the middle portion 12, and the surface layer 15 are molded using two-color molding.

After this, a finishing process is performed to produce the resin extrusion molded product 10 (S16). During the finishing process, the surface layer 11 of the resin extrusion molded product 10 may be painted with a pigment or the like, or may be covered with a resin sheet.

In the above-mentioned method for producing a resin extrusion molded product, a case has been described in which a first surface layer portion having a base portion and a surface layer formed on the surface of the base portion is extruded using a mixed resin raw material and an acrylic resin, but the method for producing a resin extrusion molded product of the present disclosure is not limited to this. In the method for producing a resin extrusion molded product of the present disclosure, after the base portion is extruded using the mixed resin raw material, an acrylic resin may be applied to the surface of the base portion to form a surface layer.

In the case of a molded product that includes recycled materials, in order to manufacture the product without any foreign matter being mixed in, it is necessary to remove all the foreign matter from the recycled material. However, it takes a lot of effort to remove all the foreign matter from the recycled material. In contrast, the resin molded product 1 of the present disclosure can minimize the deterioration of quality caused by the foreign matter 4 while allowing the inclusion of the foreign matter 4. One example of the deterioration of quality caused by the foreign matter 4 is the deterioration of the external design. For example, the resin frame of a sash is a part that is easily noticeable to people in terms of appearance, and is a part that is used for a long time. Therefore, the design is deteriorated when a large number of irregularities due to the foreign matter 4 appear on the surface 2a of the base material part 2 of the resin molded product 1, or when a large foreign matter appears. In contrast, the resin molded product 1 of the present disclosure can suppress the number of irregularities due to the foreign matter 4 that appear on the surface 2a of the base material part 2, and suppress the impact on the external design. As a result of suppressing the number of foreign matters 4 that appear on the surface 2a of the base material part 2, the occurrence rate of defective resin molded products 1 is suppressed. In the resin molded product 1 of the present disclosure, the particle size of the foreign matter 4 appearing on the surface 2a of the base material 2 and in its vicinity can be suppressed to a small size of 355 μm or less, making the foreign matter 4 less noticeable in appearance. Another example of quality degradation caused by the foreign matter 4 is a deterioration in physical properties. In the resin molded product 1 of the present disclosure, the size of the foreign matter 4 can be reduced by secondary crushing. As a result, the deterioration in physical properties of the resin molded product 1 caused by the foreign matter 4 can be suppressed. Since the exposed foreign matter 4 can be made less noticeable in appearance, the deterioration in quality of the resin molded product 1 can be suppressed.

The resin molded product 1 of the present disclosure can suppress the particle size of the foreign matter 4 appearing on the surface 2a of the base material 2 and in its vicinity to a small size of 250 μm or less, so that even if the thickness of the surface layer 3 is thin, the foreign matter 4 can be made less noticeable in appearance.

The resin molded product 1 of the present disclosure has a surface layer thickness of 0.2 mm or more and 0.5 mm or less, so that foreign matter 4 is not recognized on the surface 2a of the base material portion 2. In addition, the tensile elongation of the resin molded product 1 is 50% or more, so that the resin molded product 1 has sufficient strength (resistance to breakage) for use as a building fixture.

The resin molded product 1 of the above embodiment is made of virgin resin raw material and recycled material. The resin molded product 1 has an average of 6 or less foreign matter 4 present per ⁵ cm2 on the surface 2a of the base material 2 and in the vicinity thereof, and the number of exposed foreign matter 4 is extremely small. Even if the resin molded product 1 contains foreign matter 4, the quality of the appearance is not deteriorated and the product can withstand practical use.

The matrix resin of the resin molded product 1 is a resin containing polyvinyl chloride. The resin molded product 1 can be used, for example, to manufacture resin frames for sashes. By using the resin molded product 1 to manufacture resin frames for sashes, the rate of use of recycled materials from waste materials can be improved in the manufacture of building materials, and the effect of carbon neutrality can be achieved.

According to the resin molded product 1 of the above embodiment, the foreign matter 4 may be a material other than inorganic matter such as an organic material or a thermosetting resin having a higher melting point than the matrix resin, or may contain a metal material. Since the resin molded product 1 is obtained by extrusion molding using a thermoplastic resin as the main raw material, if the material contains a thermosetting resin, the thermosetting resin will remain in the resin molded product 1 and will easily become a foreign matter. Similarly, if a material with a higher melting point than the matrix resin is included, it will easily become a foreign matter in the resin molded product 1 without melting. However, since the resin molded product 1 uses recycled raw materials processed into fine particles, the size of the foreign matter 4 caused by the recycled raw materials is suppressed. As a result, even if an organic material or a thermosetting resin having a higher melting point than the matrix resin, which is a material that is easily exposed as a foreign matter 4, is mixed in, the impact on the quality of the resin molded product 1 is small.

According to the resin molded product 1 of the above embodiment, the minimum diameter of the foreign matter is 355 μm or less, so even if the foreign matter 4 appears on the surface of the resin molded product 1, it is not noticeable in appearance and can maintain a design that is suitable for practical use.

The tensile elongation at break of the resin molded product 1 is 25% or more. Therefore, even if the resin molded product 1 is made of recycled materials and contains foreign matter 4, it has physical properties that can withstand practical use.

According to the resin molded product 1 according to the above embodiment, the base material 2 contains an additive, which improves the tensile elongation of the resin molded product 1 and gives the resin molded product 1 sufficient strength (resistance to breaking) for use as a building material. In addition, the content of the additive relative to the total weight (100% by weight) of the base material 2 is 0.05% by weight or more and 3% by weight or less, so that the effect of tensile breaking elongation is obtained.

According to the above-mentioned manufacturing method for resin molded products, the recycled materials are subjected to secondary crushing to obtain fine regenerated raw materials, so even if foreign matter 4 is mixed in, the foreign matter 4 is unlikely to be visible on the outside of the resin molded product, and a high-quality resin molded product can be provided.

The above-mentioned manufacturing method for resin molded products obtains recycled raw materials with a minimum particle diameter of 355 μm or less, thereby reducing the appearance of foreign matter 4 on the surface 2a of the base material 2 and its vicinity. The above-mentioned manufacturing method for resin molded products obtains recycled raw materials with a minimum particle diameter of 355 μm or less, thereby reducing the size of foreign matter 4 appearing on the surface 2a of the base material 2 and its vicinity, thereby making the foreign matter 4 less noticeable in appearance.

According to the manufacturing method of the resin molded product, the recycled raw material is subjected to secondary crushing so that the average particle size of the recycled raw material is less than the average particle size of the main raw material of the virgin resin raw material. As a result, during the manufacturing process, the resin components derived from the recycled material are easily melted and well mixed with the virgin resin raw material, reducing the appearance of foreign matter 4 on and near the surface 2a of the substrate portion 2 of the resin molded product 1.

According to the above-mentioned manufacturing method for resin molded products, the virgin resin raw material contains polyvinyl chloride. The resin molded product 1 can be used, for example, to manufacture resin frames for sashes. By using the resin molded product 1 to manufacture resin frames for sashes, the utilization rate of recycled raw materials from waste materials can be improved in the manufacture of building materials, and the effect of carbon neutralization can be achieved.

The recycled raw materials described above do not contain large particles, so large foreign matter 4 is unlikely to appear when extrusion molded products are produced, making them suitable as materials for molded products.

According to the manufacturing method of the resin molded product, waste resin fittings are used as recycled materials. The manufacturing method of the resin molded product can be used, for example, in the manufacture of resin sash frames. In the manufacture of the resin molded product 1, such as resin sash frames, the utilization rate of recycled raw materials from waste can be improved. As a result, the reuse of resin materials can be promoted and the use of virgin resin raw materials can be reduced, so that the manufacturing method of the resin molded product can achieve the effect of carbon neutralization in the manufacture of resin sash frames.

The above embodiment provides a resin molded product that contains recycled resin and yet achieves high quality, as well as a method for manufacturing the resin molded product.

The resin extrusion molded product 10 of the present disclosure has surface layers 11, 15 and an intermediate portion 12, and since the surface layer 11 is made of the resin molded product 1 of the present disclosure, even if the foreign matter 4 appears on the surface of the substrate portion 13 of the surface layer 11 or in its vicinity, it is not noticeable in appearance and can maintain a design that can withstand practical use.

According to the above-mentioned manufacturing method for resin extrusion molded products, the recycled materials are subjected to secondary crushing to obtain fine regenerated raw materials, so even if foreign matter is mixed in, it is difficult for the foreign matter to be visible on the outside of the resin molded product, and a high-quality resin extrusion molded product can be provided.

The above-mentioned manufacturing method for resin extrusion molded products obtains recycled raw materials with a minimum particle diameter of 355 μm or less, thereby reducing the appearance of foreign matter on the surface of the substrate 13 of the surface layer 11 and its vicinity. The above-mentioned manufacturing method for resin extrusion molded products obtains recycled raw materials with a minimum particle diameter of 355 μm or less, thereby reducing the size of foreign matter appearing on the surface of the substrate 13 and its vicinity, thereby making the foreign matter less noticeable in appearance.

According to the above-mentioned manufacturing method for resin extrusion molded products, the recycled raw materials can be secondary crushed so that the average particle size is 355 μm or less. As a result, the surface area of the resin components derived from the recycled materials increases during the manufacturing process, making them easier to melt and mix well with the virgin resin raw materials, reducing the appearance of foreign matter on the surface of the substrate portion 13 of the surface layer portion 11 of the resin extrusion molded product 10 and in its vicinity.

According to the manufacturing method of the resin extrusion molded product described above, the virgin resin raw material contains polyvinyl chloride. The resin extrusion molded product 10 can be used, for example, in the manufacture of resin frames for sashes. By using the resin extrusion molded product 10 for resin frames for sashes, the utilization rate of recycled raw materials from waste materials can be improved in the manufacture of building materials, and the effect of carbon neutrality can be achieved.

The recycled raw materials described above do not contain large particles, so large foreign matter is unlikely to appear when extrusion moldings are produced, making them suitable as materials for moldings.

According to the manufacturing method of the resin extrusion molded product, waste resin fittings are used as recycled material. The manufacturing method of the resin extrusion molded product can be used, for example, in the manufacture of resin sash frames. In the manufacture of the resin extrusion molded product 10 for the manufacture of resin sash frames, the utilization rate of recycled materials from waste can be improved. As a result, the reuse of resin materials can be promoted and the use of virgin resin raw materials can be reduced, so that the manufacturing method of the resin extrusion molded product can achieve the effect of carbon neutralization in the manufacture of resin sash frames.

According to the above embodiment, it is possible to provide a resin extrusion molded product that can achieve high quality while containing recycled resin, and a method for manufacturing the resin extrusion molded product.

The above-mentioned embodiment is illustrative and is not limited to the scope of the above disclosure. The above-mentioned embodiment can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the gist of the disclosure. These embodiments and their modifications are included in the scope of the claims and their equivalents. For example, although primary and secondary crushing are performed, crushing may be performed so that the minimum particle diameter in one crushing is 355 μm or less, and sieving after secondary crushing may not be required.

In the above embodiment, an example was given in which polyvinyl chloride is the main material of the matrix resin, but the matrix resin is not limited to this example. For example, the matrix resin may be ABS, high-density polyethylene, low-density polyethylene, polypropylene, polystyrene, nylon, etc.

The present invention will be explained in more detail below with reference to examples, but the present invention is not limited to the following examples.

Example 1
An example of a resin molded product obtained by the above-mentioned manufacturing method for a resin molded product will be described. The molding material includes, for example, PVC resin, acrylic rubber, titanium oxide, calcium, zinc-based metal soap, high molecular weight modified acrylic, calcium carbonate, polyol ester, polyethylene wax, and color pigment. The resin material including PVC resin is a virgin resin raw material. The raw material for PVC resin is in powder form. Virgin materials are also used for the other materials.

The recycled resin material was obtained from waste sash resin frames. The waste resin frames were made mainly of PVC resin. The waste resin frames were removed and crushed to obtain a mixed crushed product. Metal, soft resin, and other parts remaining in the mixed crushed product were removed to obtain a primary powder. Next, the primary powder was subjected to secondary crushing using a crusher. After secondary crushing, particles with a minimum diameter of more than 250 μm were sieved to obtain recycled raw material with a minimum diameter of 250 μm or less. As shown in FIG. 3, the direction having a diameter that is most likely to pass through a sieve when it is assumed to pass through a sieve is called the minimum direction X. The maximum particle diameter is the largest dimension of the diameters along the direction intersecting the minimum direction X, called the minimum diameter y. The maximum length D refers to the maximum length in the direction D in which it is most difficult to pass through the sieve. The length L of the longest part and the maximum length D may not be the same.

The obtained recycled raw material was mixed with PVC resin pellets, which is a virgin resin raw material, and other materials to obtain a molding material. The content of recycled resin material in the molding material was 10% by weight. In addition, acrylic resin (product name: AM10, manufactured by Techno UMG) was used as the material for the surface layer (surface layer molding material). The molding material and the surface layer molding material were extrusion molded to obtain a resin molded product having a base part containing recycled resin material and a surface layer formed on the surface of the base part and made of acrylic resin. The thickness of the surface layer was set to 0.35 mm to 0.40 mm.

Example 2
A recycled raw material was obtained in the same manner as in Example 1. In Example 2, a recycled raw material with a minimum diameter y of more than 250 μm and not more than 300 μm was obtained. The obtained recycled raw material was mixed under the same conditions as in Example 1 to obtain a molding material. The obtained molding material and the above-mentioned surface layer molding material were extrusion molded under the same conditions as in Example 1 to obtain a resin molded product having a base part containing a recycled resin material and a surface layer formed on the surface of the base part and made of acrylic resin.

Example 3
The recycled raw material was obtained in the same manner as in Example 1. In Example 3, a recycled raw material with a minimum diameter y exceeding 300 μm and not exceeding 355 μm was obtained. The obtained recycled raw material was mixed under the same conditions as in Example 1 to obtain a molding material. The obtained molding material and the above-mentioned surface layer molding material were extrusion molded under the same conditions as in Example 1 to obtain a resin molded product having a base part containing a recycled resin material and a surface layer formed on the surface of the base part and made of acrylic resin.

(Comparative Example 1)
The recycled raw material was obtained in the same manner as in Example 1. In Comparative Example 1, a recycled raw material with a minimum diameter y exceeding 355 μm and not exceeding 425 μm was obtained. The obtained recycled raw material was mixed under the same conditions as in Example 1 to obtain a molding material. The obtained molding material and the above-mentioned surface layer molding material were extrusion molded under the same conditions as in Example 1 to obtain a resin molded product having a base part containing a recycled resin material and a surface layer formed on the surface of the base part and made of acrylic resin.

(Comparative Example 2)
The recycled raw material was obtained in the same manner as in Example 1. In Comparative Example 2, a recycled raw material with a minimum diameter y of more than 425 μm and less than 500 μm was obtained. The obtained recycled raw material was mixed under the same conditions as in Example 1 to obtain a molding material. The obtained molding material and the above-mentioned surface layer molding material were extrusion molded under the same conditions as in Example 1 to obtain a resin molded product having a base part containing a recycled resin material and a surface layer formed on the surface of the base part and made of acrylic resin.

Example 4
A resin molded product having a base material containing a recycled resin material and a surface layer made of an acrylic resin and formed on the surface of the base material was obtained in the same manner as in Example 1, except that the thickness of the surface layer was set to 0.25 mm to 0.30 mm.

Example 5
A resin molded product having a base material containing a recycled resin material and a surface layer made of an acrylic resin formed on the surface of the base material was obtained in the same manner as in Example 2, except that the thickness of the surface layer was set to 0.25 mm to 0.30 mm.

Example 6
A resin molded product having a base material containing a recycled resin material and a surface layer made of an acrylic resin and formed on the surface of the base material was obtained in the same manner as in Example 3, except that the thickness of the surface layer was set to 0.25 mm to 0.30 mm.

The number of foreign objects appearing on the surface of the substrate per unit area was measured for each resin molded product of Examples 1 to 6 and Comparative Examples 1 and 2. The case where the foreign object had a small impact on the appearance was evaluated as "best", the case where the foreign object had a small impact on the appearance when it was alone but had a large impact on the appearance when multiple foreign objects were gathered together was evaluated as "good", and the case where the foreign object had a large impact on the appearance was evaluated as "poor". The number of foreign objects appearing on the surface of the substrate per unit area was measured visually and with a microscope (Micro Square). Specifically, the number of foreign objects that could be visually confirmed was counted in 10 areas divided into 6 cm x 6 cm in the measurement range, and the average value was calculated. The length of the longest part of the confirmed foreign objects was measured using a microscope. The numerical value of the foreign object with the longest longest part among the multiple foreign objects measured is listed in the table as a representative value.

In the resin molded products of Examples 1 to 3, the number of foreign objects per unit area exposed on the surface of the substrate was kept low. The appearance design was evaluated visually. As a result, the resin molded products of Examples 1 to 3 were good enough to withstand practical use with the presence of foreign objects not noticeable. On the other hand, the resin molded products of Comparative Examples 1 and 2 had a number of foreign objects and large foreign objects that were noticeable, and were evaluated as defective products in the visual evaluation of appearance design. As described above, it was found that the resin molded products of Examples 1 to 3 were able to obtain resin molded products that could withstand practical use despite the high content of recycled resin material. In particular, in Example 1, the number of foreign objects per unit area exposed on the surface of the substrate and the value of the longest length of the foreign objects were kept low. In addition, the resin molded products of Examples 4 to 6 were all able to keep the number of foreign objects per unit area exposed on the surface of the substrate low. The appearance design was evaluated visually. As a result, the resin molded products of Examples 4 to 6 were good enough to withstand practical use with the presence of foreign objects not noticeable. In particular, in Example 4, when the thickness of the surface layer was thin, the number of foreign particles per unit area exposed on the surface of the base material was kept low.

The present disclosure includes the following.
(1) A resin molded product containing a recycled resin material, wherein the matrix resin contains foreign matter derived from the recycled resin material and consisting of components different from those of the matrix resin, and the lead content (VPB) of the resin molded product is 0% by weight < VPB ≦ 3% by weight.
(2) A recycled resin product comprising a first resin molded part formed of a first resin material containing recycled raw materials of recycled resins, and a second resin molded part formed of a second resin material having a lower content of recycled resin material containing the recycled raw materials than the first resin molded part or not containing recycled resin material, wherein an exposed portion that is externally exposed when in use is composed of the second resin molded part, and a non-exposed portion that is located inside the exposed portion and is not externally exposed when in use is composed of the first resin molded part.
(3) A recycled resin product according to (2), wherein the second resin material is a virgin resin material that does not contain the recycled resin material.

1: resin molded product, 2: substrate, 3: surface layer, 4: foreign matter, 10: resin extrusion molded product, 11: surface layer, 12: intermediate part, 13: substrate, 14: surface layer, 15: surface layer, 20: resin extrusion molded product, 21: surface layer, 22: intermediate part, 23: substrate, 24: surface layer, 25: surface layer, 100: glass.

Claims (9)

A resin molded product including a recycled material containing resin,
A substrate and a surface layer formed on the surface of the substrate,
The substrate portion contains a matrix resin and a foreign matter that is contained in the matrix resin and is composed of a component derived from the recycled material,
the component is a resin or a metal different from the matrix resin,
The particle size of the foreign matter is 355 μm or less,
A resin molded product, wherein the thickness of the surface layer is 0.2 mm or more and 0.5 mm or less. The resin molded product according to claim 1, wherein the particle size of the foreign matter is 250 μm or less. The resin molded product according to claim 1, wherein the surface layer contains an acrylic resin. The resin molded product according to claim 1, wherein the matrix resin is a resin containing polyvinyl chloride. The resin molded product according to claim 1, wherein the foreign matter is made of an organic material or a thermosetting resin having a melting point higher than that of the matrix resin, or a metal. The substrate contains an additive,
2. The resin molded product according to claim 1, wherein the content of the additive relative to the total weight of the base portion is 0.05% by weight or more and 0.15% by weight or less. A resin extrusion molded product having a surface layer portion and a lower layer portion continuous with the surface layer portion,
A resin extrusion molded product, wherein the surface layer portion is made of the resin molded product according to any one of claims 1 to 6. A step of crushing the waste resin building materials into a primary powder, and then subjecting the primary powder to secondary crushing to obtain a recycled raw material finer than the primary powder;
A step of mixing a virgin resin raw material and the recycled raw material to obtain a mixed resin raw material;
a step of extruding the mixed resin raw material and an acrylic resin;
Obtaining a resin molded product,
The waste contains foreign matter made of an organic material or a thermosetting resin having a higher melting point than polyvinyl chloride, which is a main material of the resin building materials waste, or a metal,
The method for producing a resin molded product, wherein in the step of obtaining the recycled raw material, the waste is pulverized to produce the recycled raw material having a minimum particle size of less than 600 μm. A step of crushing the waste resin building materials into a primary powder, and then subjecting the primary powder to secondary crushing to obtain a recycled raw material finer than the primary powder;
A step of mixing a virgin resin raw material and the recycled raw material to obtain a mixed resin raw material;
a step of extruding a first surface layer portion having a base portion and a surface layer formed on a surface of the base portion by using the mixed resin raw material and an acrylic resin, extruding an intermediate portion made of the mixed resin raw material and continuous with the first surface layer portion, and extruding a second surface layer portion continuous with the intermediate portion by using the virgin resin raw material;
Obtaining a resin extrusion molded product,
The waste contains foreign matter made of an organic material or a thermosetting resin having a higher melting point than polyvinyl chloride, which is a main material of the resin building materials waste, or a metal,
A method for producing a resin extrusion molding, wherein in the step of obtaining the recycled raw material, the waste is pulverized to produce the recycled raw material having a minimum particle size of less than 600 μm.

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