A METHOD FOR PRODUCING SCOOP PROTECTIVE PLUGS FROM RECYCLED METALLIZED, PEARLIZED, AND COATED FILM WASTE, AND THE PRODUCT OBTAINED BY THIS METHOD.

Abstract

The invention relates to a method for producing protective caps (2) for spools (7) without additional primary (virgin) plastic raw materials by recycling scrap films generated in the production processes of coated film, pearlized film and metallized film used in the flexible packaging sector, and to the product obtained by this method. Within the scope of the method, the aforementioned scraps are collected and separated, then subjected to crushing and granulation processes to obtain a granule (1) that is entirely (100%) recycled; this granule (1) is dried and then shaped into a protective cap (2) by injection molding, cooled and removed from the mold. The resulting protective cap (2) contains a cylindrical body (5), a flange area (4) and radial reinforcement wings (3) and, when placed at the ends of the spool (7), it evenly withstands the axial and radial loads to which the film coil (8) is subjected during storage, transport and use, thus preventing deformation.

Description

1 TARIFF FROM RECYCLED METALLIZED, PEARLIZED AND COATED FILM WASTE A METHOD FOR PRODUCING PROTECTIVE PLUGS FOR WHEEL SCREWS AND THIS... PRODUCT OBTAINED BY THE METHOD Technical Area 5 The invention is a spool protector made from recycled metallized, pearlized and coated film waste. It relates to a method for producing plugs and the product obtained using this method. State of the Art BOPP (biaxially oriented polypropylene) and BOPET are produced in the flexible packaging sector. (biaxially oriented polyethylene terephthalate), metallized and various coated films, production 10 After the completion of the process, they are usually placed in cardboard or composite spools. It is wound into coils, stored, transported, and shipped to end users. The weight of these reels depends on the type of film used, its thickness, and the reel dimensions. Depending on the situation, significant values ​​can be reached, which also affects storage and transportation. During the processes, the bobbins are subjected to intense mechanical loads, especially at their ends. 15 This leads to the bearing of the spools under the aforementioned loads, resulting in crushing and ovalization. Various types of deformation can occur, such as warping; these deformations distortion of the bobbin geometry, consequently during winding and unwinding processes. This can lead to operational disruptions and a decrease in the quality of the final product. In order to prevent such deformations, 20 in current practices Mechanical strength is applied to both ends of the bobbins to prevent bobbin deformation. Plastic protective plugs are installed to provide protection. These are used in known solutions. The stoppers are designed to help the spool maintain its shape during transport, storage, and use. generally from primary (virgin) plastic raw materials or commercial plastic granules It is produced by injection molding method. However, this approach requires 25% raw material. this leads to high costs and increased primary plastic consumption. is happening. On the other hand, metallization occurs due to the nature of the process flow in film production facilities. film scraps, faulty production reels, waste materials from the beginning and end of production. Waste such as these cannot be recycled in most existing processes. Especially 30 Metallized coated films, due to the metal layer in their structure, are not traditionally recycled. 2 It is technically difficult to incorporate into transformation systems; similarly, various functional Films with coatings can also be directly reproduced due to their high-quality layered structure. is not suitable for use today. Therefore, the aforementioned waste materials are not suitable for use today. In their applications, they are generally sold to recycling companies at low prices, thus reducing energy consumption. They are either directed to recycling facilities or disposed of directly. This 5 This situation results in both economic losses and inefficient resource management for manufacturing businesses. This results in an environmental disadvantage due to its unusability. In current technology, the raw materials used in the production of bobbin protection elements... The fact that it is largely sourced from primary plastics is a major factor increasing production costs. It stands out as one of the elements. Furthermore, these 10 require high mechanical strength. Solutions that allow the use of alternative raw materials in these types of applications are limited. This is because some products made from recycled materials have mechanical properties. The inadequacy of these properties means that these materials require a high load-bearing capacity. This is why it is not preferred in protective plug applications. The spools... under the axial and radial loads it is subjected to during transport and storage, the necessary 15 In plugs that do not demonstrate sufficient strength, deformation may occur over time, affecting the plug and the spool. If the geometric compatibility between them is insufficient, the loads will not be distributed homogeneously. They cannot be distributed properly, and localized crushing may occur at the ends of the bobbins. In current practices, metallized and coated film is produced during manufacturing. 20 aimed at directly converting waste into high-strength technical products. There is no integrated system. The production of raw materials required for plug manufacturing. a system that ensures the continuous and sustainable supply of goods within the facility It is not available; this situation makes businesses dependent on external raw material procurement. This leads to deformations occurring in the bobbins. resulting in coil geometry distortion, followed by winding unraveling, printing, 25 additional operational problems may arise in processes such as lamination and slicing. This is the reason. In the current technique, the structural components contained in metallized film, pearlized film, and coated film wastes and by taking advantage of mechanical properties, it has high rigidity and compressive strength. There is no solution for the production of protective plugs. Spool protection 30 In existing applications, in order to ensure the necessary mechanical strength in the components This usually requires the use of new raw materials, which increases both costs and... This creates a disadvantage in terms of sustainability. Therefore, the known aspects of the technique... 3 In this case, it both improves the bobbin protection performance and prevents damage during production. Metallized, pearlized and coated film wastes are placed in protective plugs with sufficient mechanical strength. a new production method that can transform and is economically and environmentally sustainable The need is clearly evident. In conclusion, due to the drawbacks described above and the current solutions regarding topic 5 Due to its shortcomings, an improvement is needed in the relevant technical field. It has been made. Purpose of the Invention The invention was created by drawing inspiration from existing situations and overcoming the aforementioned drawbacks. It aims to solve it. 10 The purpose of the invention is to utilize BOPP, BOPET, used in the plastics and flexible packaging industry. A new production method for recycling metallized and similar polymer-based films. The goal is to provide the products obtained as a result of this method. The purpose of the invention is to utilize metallized, pearlized and coated scrap materials generated during film production processes. 15 film waste is recycled into granular raw material through a controlled recycling process. transformation and injection molding of the resulting granules into film in the production of protective caps attached to the ends of bobbins used in winding The goal is to establish a system and process that makes evaluation possible. Another aim of the invention is plastic recycling, waste management technologies, sustainable production systems, circular economy practices, packaging production 20 a viable solution in the technical fields of packaging technologies and auxiliary equipment by giving economic value to waste materials generated during production. to enable their conversion and simultaneously to transport the bobbins and The aim is to prevent deformation during storage processes. Another aim of the invention is to utilize scrap metallized films generated during film production processes, 25 Following the collection and classification of pearlized films and coated films, this the recycling process of materials, the results obtained from recycling the conversion of the obtained material into granular form, the aforementioned granular raw material Used in injection molding processes for the production of protective plugs. evaluation and placement of the produced plugs onto the ends of the bobbins in 30 coils The goal is to provide an integrated process flow that includes its use. 4 Another aim of the invention is to utilize metallized films, pearlized films, and coated film wastes only. not only is it limited to recycling, but these wastes also require high mechanical strength. The aim is to transform it into an auxiliary packaging equipment. In this regard, the invention... Its purpose is to produce from recycled metallized, pearlized and coated film granules. axial and 5-fold damage to which plugs and spools are subjected during transport, storage and use By ensuring that it is structured to withstand radial loads, it prevents damage that occurs at the ends of the bobbin. The aim is to prevent potential negative effects such as crushing, ovalization, and deformation. Another objective of the invention is to analyze the metallized layer and its structure within the metallized films. layered film structure, granular material obtained after recycling By taking advantage of the fact that it positively contributes to their mechanical properties, sufficient 10 in plug products. The goal is to achieve rigidity, compressive strength, and shape stability. Another purpose of the invention is to protect the bobbins from deformation, coil protection. preserving its geometry and preventing damage during transport and storage The aim is to reduce damage. In addition, the purpose of the invention is to reduce damage caused by the production of plugs. reducing the amount of primary plastic raw materials and the waste generated during production. bringing materials back into the production cycle and thus reducing costs. The goal is to create a cost-effective and sustainable production structure. In order for the invention to provide the aforementioned technical solution; metallized films, pearlized The use of a recycled granule obtained from films and coated film waste, this controlled recycling in a way that preserves the mechanical properties of the granules and 20 The application of the granulation process results in a plug with load-bearing capacity. Geometry creation, connection and centering suitable for the inner diameter of the bobbin. ensuring the structure and designing a plug that exhibits resistance to deformation. The aim is to improve it. In this way, the problems encountered in the current state of the art will be overcome. raw material costs, inability to utilize waste, and insufficient mechanical strength are among the 25 Problems are being addressed through an integrated and sustainable production method. The structural and characteristic features and all the advantages of the invention are given in the figures below. This becomes clearer thanks to the detailed explanation written with references to these figures. This will be understood, and therefore the evaluation should also take these forms and detailed explanations into consideration. It needs to be done by taking precautions. 30 Figures that will help understand the invention. Figure 1 shows the procedural steps of the method described in the invention. Figure 2 shows a side view of the product that is the subject of the invention. Figure 3 shows the front view of the product that is the subject of the invention. Description of Part References 5 1 Granule 2 Protective plugs 3 Radial reinforcement fins 4 Flange areas Cylindrical body 10 6 Center openings 7 Bobbins 8 Film reels Detailed Description of the Invention This detailed description outlines the preferred configurations of the method and product that constitute the invention, 15 This explanation is provided solely to facilitate a better understanding of the subject. The present invention covers scrap generated during the production processes of coated film, pearlized film, and metallized film. by recycling the films, without using additional primary (virgin) plastic raw materials, that is, a completely (100%) recycled granule (1) with a protective cap (2) It relates to a production method for producing something and the product obtained by this method. Invention 20 granules (1), coated film, pearlized film and metallized film scraps used within the scope It can be obtained by recycling it individually or together. In the first stage of the method described in the invention, the coated film resulting from the production processes, Pearlized film and metallized film scraps are collected from the production line and sorted according to material type. They are separated according to the regulations. At this stage, the aforementioned scrap materials are purified from foreign materials and recycled. 25 It is made suitable for the conversion process. This process involves the recycled granules (1) This ensures that a homogeneous structure is obtained and improves the efficiency of subsequent production steps. This increases the amount of scrap metal, paper, wood, and similar materials that will enter the recycling process. The quality of the granule (1) obtained is ensured by being free from foreign materials. It has a direct impact. 30 6 The separated scrap materials undergo crushing, washing, drying, melting, and other processes in the second stage of the method. A granule suitable for injection molding is obtained by undergoing granulation processes. (1) is converted into raw materials. At this stage, the scrap is first crushed in a crushing machine. The material is reduced to suitable sizes and fed into the granulation line. The material is then extruded. Ideally within a temperature range of 190–210 °C, but usable within 170–230 °C. It is melted and homogenized. Keeping the temperature below the specified range will result in the desired outcome. While exceeding the range can negatively affect the quality of the granule (1), polymer This can lead to thermal decomposition in its structure. The molten material is passed through a mold. It is cooled and cut using a granule cutting system, making it suitable for injection molding. Recycled granule (1) raw material is obtained. In this way, low economic 10 Valuable production waste is transformed into a new high value-added engineering raw material. It is being transformed. The resulting granules (1) are then subjected to a moisture content reduction in the next stage of the method. For this purpose, it is preferably dried in a silo-type dryer and then injected. It is transferred to the feed hopper of the molding machine. The drying process is carried out by the flow of the granules (1) 15 by improving its characteristic, complete filling of the mold and the protective plug (2) It ensures that the geometry of the dried granule (1) is formed correctly. The continuous and homogeneous feeding of the product into the injection molding machine ensures the resulting product. This is important in terms of quality continuity. During the shaping stage of the method, the dried granules (1) are injected into the injection machine 20 The preferred temperature inside the cylinder is 205–215 °C, but the usable temperature is 195–225 °C. It is melted within the range of 850–1000 bar. The molten material is preferably used at this temperature. It is injected into a closed mold by applying an injection pressure of 700–1200 bar. and thus the mold cavity is completely filled by the protective plug (2) The geometric dimensions and surface quality are achieved at the desired values. Mold 25 After the filling is complete, shrinkage voids form on the product. To prevent leakage and ensure dimensional stability, preferably 500–700 bar pressure can be used. A holding pressure of 400–800 bar is applied; this pressure is preferably applied for 8–12 seconds. The process is continued for 5–15 seconds while usable. Then the product is placed inside the mold. Mold 30, preferably 30–40 °C, usable 25–50 °C with the help of cooling channels. at the temperature, preferably for 20–30 seconds, usable for 15–40 seconds, under control. It is cooled in this way. When the protective plug (2) reaches sufficient mechanical strength, the mold The mold opens and the product is automatically removed from the mold with the help of an injector system. Total production encompasses injection, holding pressure, cooling, and product extraction processes. 7 Cycle time is preferably 50–70 seconds, but usable between 30–90 seconds. It is being completed. The dimensional measurements, surface integrity and protective plug (2) removed from the mold must be checked. It is checked whether the radial reinforcement fins (3) are fully formed; product It is ensured that there are no cracks, incomplete fillings, collapses, or deformations on the surface. 5 The aforementioned protective plug (2) consists of a cylindrical body (5), around this cylindrical body (5). radial reinforcement wings (3), flange area (4) located at one end of the fuselage and has a structure consisting of a central opening (6) located in the center of the temple. The cylindrical body (5) fits tightly onto the inner surface of a spool (7) with the protective plug (2). While ensuring placement by the method, the flange area (4) is precisely 10 to the end of the spool (7). By sitting, they contribute to resisting axial loads. Radial reinforcement fins (3) are positioned at specific intervals on the fuselage (5) for storage, transport and Axial and radial loads generated during use are balanced along the core (7) to ensure that it is distributed in such a way that it can prevent the spool (7) ends from becoming unusable. It prevents crushing, ovalization and deformations. Center opening (6), 15 The protective plug (2) helps both to reduce material usage and during assembly. It allows alignment with the axis of the bobbin (7). The fundamental novelty of the invention is that the entire protective plug (2), i.e. 100%, is covered with film. from the granular (1) raw material obtained from pearlized film and metallized film scraps produced and without using any additional primary plastic raw materials, spool (7) 20 The goal is to ensure the mechanical strength required to perform the protective function. According to the findings, the metallized layer and multilayer film are present in the structure of metallized films. its structure has a positive effect on the mechanical properties (1) of the granule obtained after recycling. It contributes to providing sufficient rigidity and compressive strength in protective plug (2) products. and shape stability can be achieved. 25 Protective plugs (2) produced by the invention method, on which film coils (8) are wound By a tight fit method to both ends of the bobbins (7), no additional connecting elements It is installed mechanically without the use of tools. During assembly, the protective plug (2) must be aligned with the axis of the spool (7). 30 placement and ensuring the flange area (4) fits perfectly onto the end of the spool (7) This ensures that any issues that may arise during storage, transportation, and use are avoided. Axial and radial loads are met in a balanced manner, occurring at the ends of the core (7). Any crushing, ovalization and deformations that may occur are prevented, and the film reel (8) 8 Geometric integrity is preserved and reliability of use is increased. Thus... A circular economy approach by reintroducing production waste into the production cycle. It is supported. Within the scope of the invention, the granule (1) used in the production of the protective plug (2) is obtained. In the process, coated film, pearlized film and metallized film scraps, individually or together, 5 It is possible to use them; the usage rates of the aforementioned film scraps are obtained. It can be modified depending on the desired mechanical properties. A preferred aspect of the invention... In its application, the protective plug (2) is produced by injection molding method, different molding suitable for shaping recycled thermoplastic granules (1) It is also possible to use the methods. In addition, the protective plug (2) will be used 10 depending on the inner diameter of the bobbin (7), the weight of the film reel (8) and the operating conditions different outer diameter, cylindrical body (5) length, flange area (4) diameter and radial reinforcement wing (3) can be produced to have geometries such that such geometric changes are the invention It does not change the basic working principle. The protective plugs mentioned (2) are only Other industrial windings used on bobbins (7) but not on plastic film reels (8) 15 It is also applicable in systems, and such applications are also the basic technical purpose of the invention. and is evaluated within the scope of its working principles.

Claims

9 REQUESTS 1. A protective plug (2) is a production method and its characteristic is;  Collection of coated film, pearlized film and metallized film scraps and separation,  The separated scrap materials are crushed and subjected to a granulation process to form a 5 obtaining the granules (1),  drying of the granules (1),  a protective plug (2) by injection molding of the dried granules (1) shaping in this form,  Cooling of the shaped protective plug (2), 10  removal of the cooled protective plug (2) from the mold It includes the steps of the process.

2. The method conforming to Claim 1 is characterized by the granulation process taking place at a temperature of 170–230 °C. It is carried out within this period.

3. A protective plug (2) whose feature is; 15  a cylindrical body (5) suitable for placement on the inner surface of a spool (7),  a flange area (4) located at one end of the cylindrical body (5),  Radial reinforcement wings (3) located on the cylindrical body (5) It includes protective plug (2), coated film, pearlized film and metallized film obtained by recycling scrap materials individually or in combination, and any 20 a fully (100%) recycled product containing no additional primary plastic raw materials. It is made of granules (1).

4. Method that conforms to claim 1 or 2 and has the characteristic of being the shaping step of the granule (1) melting at a cylinder temperature of 195–225 °C and melting of the granule (1) 700–1200 by injecting into a mold using a pressure of 25 bar. It is the realization of.

5. A method suitable for any of the previous requirements, characterized by its mold filling. after completion, a holding pressure of 400–800 bar for 5–15 seconds It is the implementation.

6. A method that complies with any of the previous requirements and whose characteristic is; the cooling step The process is carried out at a mold temperature of 25–50 °C for a duration of 15–40 seconds.

7. A method suitable for any of the previous requirements, characterized by: demolding. This step is performed using an ejector system.

8. Protective plug (2) in accordance with claim 3, its feature is that there is a 5 in the center of the protective plug (2). It includes a central opening (6).

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