JP6726078B2 - Method of manufacturing resin sash - Google Patents

Description

The present invention relates to a technique of recycling a resin pipe containing polyvinyl chloride as a main component as a resin sash.

Polyvinyl chloride is widely used as a resin sash for holding a window glass because it has excellent mechanical strength, weather resistance, and heat insulating properties. Since polyvinyl chloride is white, the resin sash can be made into various colors by coloring it with a pigment, for example. Therefore, by using polyvinyl chloride, it is possible to manufacture a resin sash having a wide variety of colors and high designability.

Resin sashes are typically manufactured by cutting and joining profile extruded polyvinyl chloride. Therefore, when the resin sash is manufactured, the scraps of the cut resin sash are generated. By recycling a scrap material of such a resin sash to manufacture a new resin sash, resource saving and cost reduction can be achieved.

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 may be colored with a pigment or may be covered with a protective film. When the scrap material of such a resin sash is recycled as it is, it may be difficult to adjust the color and the weather resistance may be deteriorated due to the presence of the subcomponent.

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

In the resin sash according to Patent Document 1, by forming the outer layer that appears in the external appearance with virgin powder, it is possible to obtain the design and weather resistance comparable to those of the resin sash manufactured without using the recycled powder.

Japanese Patent No. 3420527

Polyvinyl chloride is widely used as a resin pipe, and many used resin pipes that have been deteriorated or damaged due to use have been discarded. Therefore, if such a used resin pipe can be recycled as a resin sash, more efficient resource saving and cost reduction can be realized.

However, the resin sash and the resin pipe are common in that they contain polyvinyl chloride as a main component, but the required physical properties and extrusion moldability are different. For example, a resin sash is required to have high mechanical strength, whereas a resin pipe is required to have a certain degree of rigidity. Moreover, since the resin sash has a more complicated shape than the resin pipe, the resin sash is required to have higher extrusion moldability than the resin pipe.

Therefore, if the resin pipe is to be recycled as it is as a resin sash, the physical properties required for the resin sash may not be obtained, and the resin sash having a desired shape may not be obtained.

In view of the above circumstances, an object of the present invention is to provide a technique for recycling a resin pipe containing polyvinyl chloride as a main component as a resin sash.

In order to achieve the above object, in the method for manufacturing a resin sash according to one embodiment of the present invention, a used resin pipe containing polyvinyl chloride as a main component is recovered.
The used resin pipe is crushed to produce recycled powder having an average particle size of 3 mm or less.
A kneaded product is prepared by mixing the recycled powder and the additive.
The kneaded product is extruded.
With this configuration, by setting the average particle size of the recycled powder to 3 mm or less, a kneaded product in which the recycled powder and the additive are uniformly mixed can be obtained. The kneaded product thus obtained can be satisfactorily extruded. Moreover, it is possible to adjust the components suitable for the resin sash by adding an additive to the recycled powder.

As the additive, at least one of a reinforcing agent, a processing aid, and a lubricant may be used.
By using a reinforcing agent as an additive, the mechanical strength of the resin sash can be improved. By using a processing aid or a lubricant as an additive, it becomes possible to improve the extrusion moldability of the resin sash.

You may create a molded object using the said recycled powder.
The compounding amount of the reinforcing agent may be determined based on the Charpy impact value obtained by the Charpy impact test of the molded body.
With this configuration, a resin sash having an appropriate mechanical strength can be obtained.

A technique for recycling a resin pipe containing polyvinyl chloride as a main component as a resin sash can be provided.

It is a top view of the window which concerns on one Embodiment of this invention. FIG. 2 is a partial cross-sectional view of the window taken along the line AA′ in FIG. 1. 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.

[Structure 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 has a frame material 20 and a cover material 30 which contain polyvinyl chloride as a main component.

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

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

The joining method of the members 20a, 20b, 20c, 20d of the frame member 20 and the joining method of the members 30a, 30b, 30c, 30d of the cover member 30 are not limited to welding and fitting, and known methods can be adopted as appropriate. Is.

2 is a partial sectional view of the window 1 taken along the line AA′ in FIG. 1, and FIG. 3 is an enlarged sectional view of the frame member 20 of the resin sash 10. The frame material 20 and the cover material 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 has two glasses 41a and 41b facing each other, and a spacer 41 that hermetically seals the outer edge portions of the glasses 41a and 41b. The window glass 40 is configured as a double-layer glass in which a space between the glasses 41a and 41b is filled with argon gas. The window glass 40 having such a configuration can exhibit high heat insulation.

The configuration of the window glass 40 is arbitrary. For example, the gas sealed in the window glass 40 may not be argon gas, but may be krypton gas, dry air, or the like. Further, the window glass 40 does not have to be double glazing, and may be triple glass or single plate glass. Further, the glasses 41a and 41b can be arbitrarily selected from known glasses, and may be formed by 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 direction from the holding surface 22. And a first sandwiching portion 23 that extends. The first fitting portion 21 and the first holding portion 23 are arranged on the opposite sides of the holding surface 22.

As shown in FIG. 2, the cover material 30 has a second fitting portion 31 and a second holding portion 32. The second fitting portion 31 is configured to be fittable with the first fitting portion 21 of the frame member 20. That is, the cover material 30 is attached to the frame material 20 by fitting the second fitting portion 31 into the first fitting portion 21. The second holding portion 32 of the cover material 30 attached to the frame material 20 extends from the second fitting portion 31 so as to face the first holding portion 23 of the frame material 20.

That is, the resin sash 10 having the cover material 30 attached to the frame material 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 pedestal 50 and airtight members 51a and 51b are provided in the recess. The glass pedestal 50 and the airtight materials 51a and 51b are made of a resin material.

The glass pedestal 50 holds the end surface of the window glass 40. The airtight material 51a is sandwiched between the second sandwiching portion 32 of the cover material 30 and the glass 41a of the window glass 40. The airtight material 51b is sandwiched between the first sandwiching portion 23 of the frame material 20 and the glass 41b of the window glass 40. The glass pedestal 50 and the airtight materials 51a and 51b improve 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 projecting directions of the fixing parts 24 and 25 are orthogonal to each other, the fixing part 24 projects in the outer peripheral direction, and the fixing part 25 projects in the indoor direction. The fixing portions 24 and 25 are fixed to an opening formed in a wall or a roof of a building with a fixing member such as a screw. 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 for resin pipes]
FIG. 4 is a flowchart showing a method of recycling the resin pipe as the resin sash 10. Hereinafter, a method of recycling the resin pipe as the resin sash 10 will be described with reference to FIG.

In this embodiment, an example of manufacturing the frame material 20 of the resin sash 10 by recycling the resin pipe will be described. The cover material 30 of the resin sash 10 can be manufactured similarly to the frame material 20.

(Step S10: Recovery of Resin Pipe)
In step S10, the resin pipe containing polyvinyl chloride as a main component is recovered. The resin pipe collected in step S10 is not limited to a particular type.

Examples of such resin pipes include hard polyvinyl chloride pipes (VP, VM, VU, etc.), impact resistant hard polyvinyl chloride pipes (HIVP), hard polyvinyl chloride pipes for construction drainage (IDVP), buried Examples thereof include a rigid polyvinyl chloride pipe (ISVP) for drainage and a rigid polyvinyl chloride pipe (IWVP) for water transportation.

Further, in step S10, a portion containing polyvinyl chloride as a main component may be taken out from the resin pipe in which polyvinyl chloride is partially used. Examples of the resin pipe in which polyvinyl chloride is partially used include a recycled rigid polyvinyl chloride three-layer pipe (RS-VU), a recycled three-layer rigid vinyl chloride pipe for sewer (RS-VU), and the like. ..

The polyvinyl chloride contained in the resin pipe collected in step S10 preferably has a degree of polymerization of 1000. With a resin pipe whose main component is polyvinyl chloride having a degree of polymerization of 1000, it is easy to obtain appropriate fluidity when molding the frame material 20, and the frame material 20 can be molded well.

Further, since the tin stabilizer softens polyvinyl chloride and reacts with lead to turn black, the resin pipe collected in step S10 does not include a resin pipe containing the tin stabilizer. Is preferred.
When recovering a plurality of types of resin pipes, a resin pipe containing a tin-based stabilizer may be used within a range that does not adversely affect the frame material 20. In this case, the amount of the resin pipe containing the tin-based stabilizer is preferably 10% by mass or less with respect to the entire resin pipe to be recovered.

If necessary, in order to reduce impurities other than polyvinyl chloride in the recovered resin pipe, the resin pipe may be subjected to the following treatments.
・Primary cutting and selection of good parts ・Secondary cutting to remove dirty parts such as edges ・Removal of soft polyvinyl chloride, tape, rust and other deposits ・Wipe with a waste cloth, high pressure cleaning , Removal of dirt by air blow, etc. ・Detection and removal of metal members with metal detector

As a result, the recovery of the resin pipe, which is a recycled raw material containing polyvinyl chloride as a main component, is completed.

(Step S20: Crush resin pipe)
In step S20, the recycled powder is produced by crushing the resin pipe collected in step S10. For example, a twin-screw crusher or a high-speed vortex crusher can be used in step S20.

In step S20, if the resin pipe before crushing is large or long, crushing by the crusher becomes difficult. In this case, the resin pipe is cut in advance to a predetermined size or smaller. For example, a resin pipe is first cut into a ring and then cut into smaller pieces.

The crushing of the resin pipe can be performed in two steps. For example, in the first stage, the resin pipe is roughly pulverized to obtain a coarsely pulverized powder having a particle size that allows passage through a 10 to 15 mm mesh, and in the second stage, the coarsely pulverized powder is finely pulverized so that the particles can pass through a 5 mm mesh. It can be a finely pulverized powder having a diameter. By carrying out such two-step crushing, it is possible to surely make powder having an average particle diameter of 3 mm or less, which is preferable.

The average particle diameter of the recycled powder needs to be 3 mm or less.
Since the smaller the average particle size of the recycled powder, the larger the surface area, the additive easily penetrates into the recycled powder when the recycled powder and the additive are mixed in step S40 described later. As a result, a uniform kneaded body can be obtained.

On the other hand, if the average particle size of the recycled powder is larger than 3 mm, it becomes difficult to obtain sufficient impact resistance for use in the molded body obtained by extrusion molding in step S50 described later. Further, if the average particle size of the recycled powder is larger than 3 mm, the additive tends to be unevenly distributed in the kneaded product, stable production becomes difficult, and the dimensional accuracy of the molded product obtained by extrusion molding of step S50 described later is deteriorated. Resulting in. Further, if the average particle size of the recycled powder is larger than 3 mm, gelation is less likely to proceed during extrusion molding, and the frame material 20 that is an extrusion molded body has irregularities, making it difficult to obtain a smooth surface.
Particularly, from the viewpoint of impact resistance in a molded product obtained by extrusion molding, and from the viewpoint that a uniform kneaded product can be obtained in mixing with an additive, the average particle diameter of the recycled powder is preferably 1 mm or less, In particular, it is more preferably 0.5 mm or less.

The average particle size of the recycled powder can be measured by a low-tap type automatic sieve using a JIS Z8801 standard sieve.

(Step S30: Blending of additives)
In step S30, an additive is mixed with the obtained recycled powder. In step S30, an additive effective for overcoming the problems when the frame material 20 is manufactured by using the recycled powder as it is is mixed with the recycled powder. As the additive, a plurality of kinds may be used in combination as necessary.

As the additive, for example, a reinforcing agent, a heat stabilizer, an ultraviolet stabilizer, an internal lubricant, an external lubricant, a torque improver, a colorant, a plasticizer, a filler, a processing aid, titanium oxide, calcium carbonate, etc. can be selected. Is. The type and amount of the additive added to the recycled powder can be determined from the type and amount of the components that are not contained in the resin pipe among the components necessary for the frame material 20.

In particular, by using the reinforcing agent as an additive, the rigidity derived from the resin pipe can be overcome, and the frame material 20 having high mechanical strength can be obtained. Further, by using a processing aid or a lubricant as an additive, it is possible to overcome the low extrusion moldability derived from the resin pipe, and it is possible to extrude the frame material 20 having a complicated shape.

The internal lubricant has a polar group and is compatible with polyvinyl chloride to reduce the kneading torque. The external lubricant is a hydrocarbon chain incompatible with polyvinyl chloride and improves the lubricity between polyvinyl chloride and the mold.

The internal lubricant and the external lubricant can be selected from, for example, the LOXIOL (registered trademark) series manufactured by Emery Oleochemical. As the internal lubricant, for example, G60, G32 or the like can be selected. As the external lubricant, for example, VPN963, VPN233, G21 or the like can be selected.

The type and amount of the additive added to the recycled powder may be determined based on the evaluation result of the recycled powder. As a result, it is possible to more surely understand the problem when the frame material 20 is manufactured by using the recycled powder as it is. The method for evaluating recycled powder is not limited to a particular method.

For example, in step S30, the recycled powder obtained in step S20 can be used as it is to produce a molded body. By measuring the physical properties of this molded body, it becomes possible to understand the physical properties that are insufficient when the frame material 20 is manufactured using recycled powder as it is. A molded body of recycled powder can be produced, for example, by roll kneading and press molding.

The method for measuring the physical properties of the molded product effective in step S30 will be illustrated below.
-Charpy impact test-Vicat softening temperature-Pyrolysis time measurement-Tensile yield stress measurement-Bending elastic modulus measurement These measurements can be performed in accordance with, for example, unplasticized polyvinyl chloride joinery profile JISA5558.

For example, when the Charpy impact test shows that the molded product of recycled powder has insufficient impact resistance, a reinforcing agent can be used as an additive. As the reinforcing agent, for example, an acrylic reinforcing agent can be used.
As described above, by adding the reinforcing agent, a frame material having high impact resistance and high mechanical strength can be obtained. However, if too much reinforcing agent is added, not only will the effect of improving mechanical strength reach its ceiling, but since the reinforcing agent itself will be expensive, this will lead to higher manufacturing costs for the frame material, thus reducing the cost of using recycled materials. The effect will be reduced. From such a viewpoint, the compounding ratio of the reinforcing agent per 100 parts by mass of the recycled powder is preferably 10 parts by mass or less, and more preferably 7 parts by mass or less.

When the thermal stability of the recycled powder compact is insufficient as a result of thermal decomposition time measurement, a thermal stabilizer can be used as an additive. The heat stabilizer is preferably at least one of a lead-based stabilizer and a calcium/zinc-based stabilizer. Specific examples of the lead-based stabilizer include dibasic lead phosphite, tribasic lead phosphite, and lead stearate. Further, specific examples of the calcium/zinc stabilizer include fatty acid salts such as calcium stearate and zinc stearate, and frothite compounds as co-stabilizers, hydrotalcites, polyols and the like.

Further, in step S30, by evaluating the gelling property of the recycled powder, it becomes possible to grasp the physical properties that are insufficient for kneading the recycled powder in step S50 described later. The gelling property can be evaluated using, for example, a plastograph.

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

A torque improver can be added as an additive in order to adjust the gelling time and the gelling initial torque. As the torque improver, for example, an oxidized polyethylene wax having an acid value of 15 or more and 18 or less can be used. Examples of such oxidized polyethylene wax include LOXIOL (registered trademark) VPG1631 (product name of Emery Oleochemical Co., Ltd.).

If the gelling time becomes shorter than the first range due to the addition of a torque improver or the initial gelling torque becomes higher than the second range, a lubricant is further added as an additive. By adding, the gelling property can be adjusted. The lubricant can be arbitrarily selected, and for example, LOXIOL (registered trademark) G60 or LOXIOL (registered trademark) G32 (both are product names of Emery-Oleochemical Co., Ltd.) and the like can be used.

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

If necessary, unused polyvinyl chloride powder (virgin powder) can be used as an additive. By using virgin powder as the additive, the physical properties of the frame material 20 can be easily improved. However, from the viewpoint of resource saving and cost reduction, it is preferable that the addition amount of the virgin powder is within 30 mass% with respect to the entire polyvinyl chloride powder including the recycled powder and the virgin powder.

(Step S40: Mixing Recycled Powder and Additive)
In step S40, the recycled powder obtained in step S20 and the additive compounded in step S30 are mixed to produce a kneaded product. Mixing of the recycled powder and the additive can be performed by, for example, hot blending at 100 to 140°C.

(Step S50: extrusion molding)
In step S50, the kneaded product obtained in step S40 is profile-extruded to produce the members 20a, 20b, 20c, 20d of the frame material 20. Specifically, a member having a cross-sectional shape shown in FIG. 3 is continuously extruded and cut into each member 20a, 20b, 20c, 20d.

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

Then, the frame member 20 is completed by welding the members 20a, 20b, 20c, and 20d obtained in step S50.

[Other Embodiments]
Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments and various modifications can be made.

For example, in the resin pipe recycling method according to the above-described embodiment, not only the resin sash 10 according to the above-described embodiment, but also various resin sashes having various configurations can be newly manufactured.

Further, the resin sash produced by recycling the resin pipe is a composite of a recycled composition molded using recycled powder and a virgin composition molded using only virgin powder without using recycled powder. It may be configured. Such a resin sash can be molded by separately coextruding the recycled composition and the virgin composition.

As an example, in the hollow resin sash 10, the inner layer may be a recycled composition and the outer layer may be a virgin composition. That is, 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 recycle composition is not used can be obtained. On the other hand, by using a recycled composition for the inner layer that does not affect the design of the resin sash 10, resource saving and cost reduction are possible. Recycled powder may be added to the virgin composition within a range that does not affect the color tone.

Furthermore, 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. Further, the resin sash may be coated with various paints.

Hereinafter, the present invention will be described with reference to examples, but the present invention is not limited to these examples.

[Example 1]
The PVC pipe was roughly crushed by a hammer crusher type crusher, and the crushed powder that passed through the 15 mm mesh was further finely crushed by a rotary type crusher to obtain a recycled powder that passed through the 1 mm mesh. The average particle size of this recycled powder was 0.2 mm. The average particle diameter was measured by a low-tap type automatic sieve using a measurement condition JIS Z8801 standard sieve.

A molded body was produced from the obtained recycled powder by extrusion molding, and a test piece having a length of 1 cm, a width of 8 cm, and a thickness of 2.5 mm was produced from the molded body, and subjected to a Charpy impact test according to JIS A5585. Was 3 KJ/m ² . From the above results, the blending ratio of the kneaded product was determined as follows.
Recycled powder: 100 parts by mass Reinforcing agent: 3 parts by mass of acrylic reinforcing agent External lubricant: 0.2 parts by mass of oxidized polyethylene wax

The obtained kneaded product is extruded by a conical twin-screw extruder under the temperature conditions of a cylinder temperature of 175 to 195° C. and a die temperature of 190 to 200° C. to produce a molded product, and the molded product is 1 cm in length and 8 cm in width , to prepare a test piece having a thickness of 2.5 cm, was subjected to a Charpy impact test based on JISA5558, 20KJ ^/ m 2 at 23 ° C., a 8 kJ / ^{m 2} at -10 ° C., to obtain a molded product satisfying the standard It was

[Example 2]
A kneaded material was prepared using the recycled powder having an average particle diameter of 3 mm in the same amount as in Example 1, and extrusion molding was carried out under the same conditions as in Example 1 to prepare a molded body. From the molded article, the vertical 1 cm, horizontal 8 cm, to prepare a test piece having a thickness of 2.5 cm, was subjected to a Charpy impact test based on JISA5558, at 23 ℃ 15KJ ^/ m 2, at -10 ° C. with 6 kJ / ^{m 2} And a molded product satisfying the standard was obtained.

[Comparative Example 1]
Using a recycled powder having an average particle diameter of 5 mm, a kneaded material was prepared in the same blending amount as in Example 1, and extrusion molding was performed under the same conditions as in Example 1 to prepare a molded body. From the molded article, the vertical 1 cm, horizontal 8 cm, to prepare a test piece having a thickness of 2.5 cm, was subjected to a Charpy impact test based on JISA5558, at 23 ℃ 10KJ ^/ m 2, at -10 ° C. in 4 kJ / ^{m 2} Yes, the obtained molded body did not satisfy the standard.

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

Claims (3)

We collect used resin pipes whose main component is polyvinyl chloride,
The used resin pipe is crushed to produce recycled powder having an average particle diameter of 3 mm or less,
The recycled powder and the additive are mixed to prepare a kneaded product,
A method for producing a resin sash, in which the kneaded product is extrusion-molded. The method of manufacturing a resin sash according to claim 1,
A method for producing a resin sash, wherein at least one of a reinforcing agent, a processing aid, and a lubricant is used as the additive. The method of manufacturing a resin sash according to claim 2,
Create a molded body using the recycled powder,
A method for producing a resin sash, wherein the compounding amount of the reinforcing agent is determined based on the Charpy impact value obtained by the Charpy impact test of the molded body.

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