Method for producing resin composition

Abstract

In this method for producing a resin composition, a soft polyvinyl chloride resin composition is produced using, as a raw material, a resin profile having rigid polyvinyl chloride as a main component. The method for producing a resin composition includes: a crushing step of crushing a resin profile to form a crushed material; a mixing step in which a master batch mixture obtained by mixing rigid polyvinyl chloride, a stabilizer, and a plasticizer, a powder material having calcium carbonate as the main component, and the crushed material are mixed while being heated to obtain a mixture; and a mixing step in which the kneaded product and the master batch formulation are kneaded while being heated, thereby producing a resin composition in which the kneaded product and the master batch formulation are mixed. The purpose of the present invention is to easily produce a soft polyvinyl chloride resin composition by recovering a resin profile having rigid polyvinyl chloride as the main component.

Description

Technical Field

[0001] The present invention relates to a method for producing a resin composition for producing a soft polyvinyl chloride resin composition. Background Art

[0002] Resin profiles with rigid polyvinyl chloride as the main component are used in doors and windows such as resin windows. The resin profile is manufactured by heating a rigid polyvinyl chloride resin material to melt it and extruding the molten resin material. When such a resin profile is recovered to manufacture a soft polyvinyl chloride resin composition, for example, the scraps obtained by crushing the resin profile are mixed with a liquid plasticizer, and the plasticizer is used to soften the rigid polyvinyl chloride in the scraps to manufacture a soft polyvinyl chloride resin composition.

[0003] However, in the manufactured resin profile, the resin particles are deformed due to extrusion molding, and the voids in the resin particles that existed before extrusion molding almost disappear. Therefore, during the mixing process of the crushed materials of the resin profile and the plasticizer, it is difficult for the plasticizer to penetrate into the crushed materials, and the crushed materials also become easy to slide against each other due to the plasticizer. Therefore, the crushed materials of the resin profile and the plasticizer are difficult to be mixed, and the rigid polyvinyl chloride of the crushed materials is difficult to be softened by the plasticizer. In this regard, the existing known method for manufacturing a soft vinyl chloride resin composition is to use a mixer to mix the crushed material with a particle size of less than 3 mm obtained after the rigid vinyl chloride resin molded product is crushed, the plasticizer, and the filling material to manufacture the soft vinyl chloride resin composition (reference patent document 1).

[0004] In the existing method for producing a soft vinyl chloride resin composition described in Patent Document 1, a filler is used to absorb a plasticizer, and the plasticizer is mixed into a pulverized product together with the filler. However, since the plasticizer is mainly mixed into the pulverized product in an amount absorbed by the filler, the amount of plasticizer added is limited, which may make it difficult to produce a soft, soft vinyl chloride resin composition. Moreover, since the amount of plasticizer added depends on the type of filler, etc., the design of the soft vinyl chloride resin composition is sometimes limited. Therefore, from the perspective of easily producing a soft vinyl chloride resin composition, the existing method for producing a soft vinyl chloride resin composition still has room for improvement.

[0005] Patent Document 1: Japanese Patent No. 5446105 Summary of the invention

[0006] The present invention has been made in view of the above-mentioned conventional problems, and an object of the present invention is to easily produce a resin composition of soft polyvinyl chloride by recycling a resin shape material containing hard polyvinyl chloride as a main component.

[0007] The present invention is a method for producing a resin composition, which uses a resin profile with hard polyvinyl chloride as a main component as a raw material to produce a soft polyvinyl chloride resin composition, and comprises:

[0008] A crushing step of crushing the resin profile to form crushed materials;

[0009] a mixing step of mixing a masterbatch prepared by mixing rigid polyvinyl chloride, a stabilizer and a plasticizer, a powder material mainly composed of calcium carbonate, and the crushed material while heating to obtain a mixed material; and

[0010] The mixing step kneads the kneaded product and the master batch formulation while heating to produce the resin composition obtained by mixing the kneaded product and the master batch formulation.

[0011] According to the present invention, a resin material mainly composed of hard polyvinyl chloride can be recovered to easily produce a resin composition of soft polyvinyl chloride. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 This is a flow chart showing the production process of the soft polyvinyl chloride resin composition according to the present embodiment.

[0013] Figure 2 It is a figure which shows typically the state of each stage of the manufacturing process of the soft polyvinyl chloride resin composition which concerns on this embodiment.

[0014] Figure 3 This is a diagram showing an example of crushed materials for producing a kneaded material according to the present embodiment.

[0015] Figure 4 This is a diagram showing another example of the resin shape material according to the present embodiment.

[0016] Explanation of symbols

[0017] 10Resin profiles

[0018] 11 Main body

[0019] 12. Subsidiary Department

[0020] 20 Crushed materials

[0021] 30First Powder Material

[0022] 40 Second powder material

[0023] 50Plasticizer

[0024] 60 Masterbatch formulation

[0025] 70 Third Powder Material

[0026] 71 Calcium carbonate

[0027] 80 Mixed

[0028] 81 pellets

[0029] RMaximum size DETAILED DESCRIPTION

[0030] One embodiment of the method for producing a resin composition of the present invention will be described with reference to the drawings.

[0031] In the method for producing a resin composition of the present embodiment, a resin profile having hard polyvinyl chloride as a main component is used as a raw material to produce a soft polyvinyl chloride resin composition. Thus, the resin profile produced once is reused and recycled into the resin composition to produce a new resin composition.

[0032] Figure 1 This is a flow chart showing the production procedure (process) of the soft polyvinyl chloride resin composition according to the present embodiment. Figure 2 It is a figure which shows typically the state of each stage of the manufacturing process of the soft polyvinyl chloride resin composition which concerns on this embodiment.

[0033] As shown in the figure, the useless resin profile 10 (reference Figure 2 A)( Figure 1 S101). The resin profile 10 is a profile (extruded profile) formed by extruding a resin. The resin is rigid polyvinyl chloride, and the resin profile 10 is a rigid polyvinyl chloride profile made of rigid polyvinyl chloride. Rigid polyvinyl chloride is polyvinyl chloride (PVC) without a plasticizer, and other components (for example, various stabilizers, improvers) may be mixed in the polyvinyl chloride. In addition, Figure 2 A shows a cross section of the resin profile 10 perpendicular to the longitudinal direction.

[0034] Here, the resin profile 10 is a resin-made molded product (resin molded product) for a resin window used as a door and window. The resin window has a window frame (resin window frame) and a window sash made of resin, and the window sash includes a frame (resin frame) made of resin, and the resin window frame and the resin frame are respectively formed by the resin profile 10. In addition, as the resin profile 10, the scrap material of the resin profile 10 of the resin window is recycled. The scrap material of the resin profile 10 is, for example, the scrap material of the manufacturing site of the resin window, or the scrap material recycled as market waste. In contrast, the resin profile 10 can also be a discarded resin profile 10.

[0035] Next, the recycled resin profile 10 is crushed by a crusher to form a scrap 20 of the resin profile 10 (see Figure 2 B)( Figure 1S102). The pulverizer is, for example, an impact crusher as an impact crusher. When the resin profile 10 is long or large, before being pulverized by the pulverizer, the resin profile 10 is first formed into a size that can be pulverized by the pulverizer, for example, by cutting the resin profile 10. In addition, the resin profile 10 can also be pulverized in two stages. In this case, after the resin profile 10 is pulverized roughly by the pulverizer for coarse pulverization in the first stage, the coarse pulverized material 20 is pulverized into fine pulverized material 20 by the pulverizer for fine pulverization in the second stage. In this way, the pulverized material 20 obtained by pulverizing the resin profile 10 is generated.

[0036] The resin profile 10 is a part of the raw material of the resin composition of soft polyvinyl chloride. Soft polyvinyl chloride is polyvinyl chloride mixed with a plasticizer, and contains a plasticizer. In addition, the resin composition is a composition with soft polyvinyl chloride as the main component, and becomes the raw material of the molded product of soft polyvinyl chloride. The plasticizer is an additive that gives softness to hard polyvinyl chloride, and softens the hard polyvinyl chloride.

[0037] Plasticizers include, for example, phthalate plasticizers such as dibutyl phthalate (DBP), diisodecyl phthalate (DIDP), di(2-ethylhexyl) phthalate (DOP), butyl benzyl phthalate (BBP), and diisononyl phthalate (DINP); aliphatic dibasic acid ester plasticizers such as tri(2-ethylhexyl) trimellitate (TOTM), di(2-ethylhexyl) adipate (DOA), diisononyl adipate (DINA), diisodecyl adipate (DIDA), and dibutyl sebacate (DBS); phosphate ester plasticizers such as tri(2-ethylhexyl) phosphate (TOP) and triphenyl phosphate (TPP); or polyester plasticizers such as epoxidized soybean oil.

[0038] Before using the scraps 20 of the resin profile 10 as a raw material to produce a soft polyvinyl chloride resin composition (refer to Figure 2 C), firstly, a powder material (first powder material 30) mainly composed of rigid polyvinyl chloride, a powder material (second powder material 40) composed of a stabilizer, and a liquid plasticizer 50 are kneaded by a mixer. Thus, the first powder material 30, the second powder material 40, and the plasticizer 50 are mixed to generate a masterbatch formulation 60 (reference Figure 2 D)( Figure 1 The mixer is, for example, a ribbon mixer having ribbon-shaped blades, and the first powder material 30, the second powder material 40, and the plasticizer 50 are mixed by the rotating blades.

[0039] The first powder material 30 is a powder of hard polyvinyl chloride (hard polyvinyl chloride powder) formed into a powder, and is a powder (fine powder) smaller than the scrap 20. In addition, the first powder material 30 is unused hard polyvinyl chloride powder or recycled hard polyvinyl chloride powder. When the recycled hard polyvinyl chloride powder is used as the first powder material 30, the resin profile 10 is crushed into a powder smaller than the scrap 20 by a crusher to generate the hard polyvinyl chloride powder (first powder material 30) obtained by crushing the resin profile 10. In this way, the first powder material 30 is formed from the resin profile 10.

[0040] The second powder material 40 is a powder of a stabilizer (stabilizer powder) formed into a powder, and is a powder (fine powder) smaller than the crushed material 20. The stabilizer is, for example, a heat stabilizer for suppressing the thermal decomposition of a soft polyvinyl chloride resin composition, stabilizing the resin composition to suppress the degradation of the resin composition. In addition, the stabilizer is, for example, a barium-zinc (Ba-Zn) stabilizer, a calcium-zinc (Ca-Zn) stabilizer, or a tin (Sn) stabilizer.

[0041] The particle size of the first powder material 30 and the particle size of the second powder material 40 are both 500 μm or less. Here, the particle size is the particle size after sieving using a sieve with a nominal mesh size according to Japanese Industrial Standards (JIS Z 8801-1: 2019), and the particle size of 500 μm or less refers to the particle size that can pass through the sieve with a nominal mesh size of 500 μm. The first powder material 30 and the second powder material 40 with a particle size of 500 μm or less are mixed with the plasticizer 50 to generate a masterbatch formulation 60 prepared by the first powder material 30, the second powder material 40, and the plasticizer 50.

[0042] When generating the masterbatch formulation 60, since the rigid polyvinyl chloride and the stabilizer are powders (the first powder material 30 and the second powder material 40), the rigid polyvinyl chloride and the stabilizer can be efficiently mixed. In addition, the plasticizer 50 is easily absorbed by the first powder material 30, and the plasticizer 50 can be efficiently mixed into the first powder material 30. While the plasticizer 50 is absorbed by the first powder material 30, the first powder material 30, the second powder material 40, and the plasticizer 50 are completely mixed.

[0043] The masterbatch formulation 60 is a formulation in which the concentration of a specific component in the components contained in the soft polyvinyl chloride resin composition is prepared to be higher than the concentration (target concentration) in the resin composition. Here, the masterbatch formulation 60 contains: the hard polyvinyl chloride contained in the first powder material 30, the stabilizer contained in the second powder material 40, and the plasticizer 50, and the concentration of the plasticizer 50 is higher than the target concentration. In this way, the masterbatch formulation 60 is a formulation prepared by preparing hard polyvinyl chloride, the stabilizer and the plasticizer 50, and the concentration of the plasticizer 50 is prepared to be higher than the target concentration.

[0044] In the masterbatch formulation 60, when the first powder material 30 is set to 100 parts by weight (phr), the plasticizer 50 is 150 parts by weight or more and 250 parts by weight or less. In this way, relative to 100 parts by weight of the first powder material 30, 150 parts by weight or more and 250 parts by weight of the plasticizer 50 are added, and the first powder material 30 of rigid polyvinyl chloride, the second powder material 40 of the stabilizer, and the plasticizer 50 are mixed to generate the masterbatch formulation 60. At this time, the rigid polyvinyl chloride contained in the first powder material 30, the stabilizer contained in the second powder material 40, and the plasticizer 50 are mixed (mixed), and the rigid polyvinyl chloride contained in the first powder material 30 is softened by the plasticizer 50, thereby generating a masterbatch formulation 60 that is softer than the resin composition of soft polyvinyl chloride. The generated masterbatch formulation 60 is a liquid (paste) object with a high viscosity and can be easily deformed.

[0045] Next (reference Figure 2 E), the masterbatch formulation 60, the powder material (third powder material 70) with calcium carbonate as the main component, and the crushed material 20 of the resin profile 10 are mixed while being heated by a heating mixer ( Figure 1 Thus, the masterbatch formulation 60, the third powder material 70, and the crushed material 20 are mixed to obtain a mixed product 80 (see S104) obtained by mixing the masterbatch formulation 60, the third powder material 70, and the crushed material 20. Figure 2 F). The heating kneading machine is, for example, a Banbury mixer, a kneader, or a Brabender mixer, and applies shear force to the masterbatch formulation 60, the third powder material 70, the crushed material 20, and the kneaded product 80 during the kneading process. The heating kneading machine heats the masterbatch formulation 60, the third powder material 70, the crushed material 20, and the kneaded product 80 to a predetermined temperature and kneads them.

[0046] The third powder material 70 is a powder of calcium carbonate (calcium carbonate powder) formed into a powder, and is a powder (fine powder) smaller than the crushed material 20. The particle size of the third powder material 70 is 500 μm or less, similar to the first powder material 30 and the second powder material 40. The third powder material 70 having a particle size of 500 μm or less is kneaded with the masterbatch formulation 60 and the crushed material 20 to generate a kneaded product 80 of the masterbatch formulation 60, the third powder material 70, and the crushed material 20.

[0047] Figure 3 This is a diagram showing an example of the crushed material 20 for producing the kneaded material 80 according to the present embodiment.

[0048] As shown in the figure, by crushing the resin profile 10, the crushed materials 20 of various shapes and maximum dimensions R are formed. The maximum dimension R of the crushed materials 20 is the dimension of the largest dimension of the outer shape of each crushed material 20. The maximum dimension R of the crushed materials 20 used to generate the kneaded material 80 is 15 mm or less. Therefore, when crushing the resin profile 10, the resin profile 10 is crushed in such a way that the maximum dimension R of the crushed materials 20 is 15 mm or less. Alternatively, after crushing the resin profile 10, the crushed materials 20 with a maximum dimension R greater than 15 mm are separated and removed using a separation device, etc., and the crushed materials 20 with a maximum dimension R of 15 mm or less are screened out. The crushed materials 20 with a maximum dimension R of 15 mm or less are mixed with the masterbatch formulation 60 and the third powder material 70 to generate the kneaded material 80.

[0049] In the kneaded product 80, when the crushed material 20 is set to 100 parts by weight, the master batch formulation 60 is 30 parts by weight or more and 60 parts by weight or less, and the third powder material 70 is 5 parts by weight or more and 50 parts by weight or less. In this way, when the kneaded product 80 is generated, 30 parts by weight or more and 60 parts by weight of the master batch formulation 60 are added to 100 parts by weight of the crushed material 20, and 5 parts by weight or more and 50 parts by weight of the third powder material 70 are added. In addition, the master batch formulation 60, the third powder material 70, and the crushed material 20 are heated from the temperature at the start of kneading (for example, room temperature) to a temperature in the range of 160° C. or more and 190° C. or less by a heating kneading machine, and the master batch formulation 60, the third powder material 70, the crushed material 20, and the kneaded product 80 are kneaded at the same time, and then the kneading of the kneaded product 80 is terminated.

[0050] When generating the kneaded product 80, the calcium carbonate contained in the third powder material 70 and the hard polyvinyl chloride contained in the scrap 20 are mixed with the polyvinyl chloride containing the stabilizer and the plasticizer 50, that is, the master batch formulation 60. The master batch formulation 60 and the scrap 20 are both polyvinyl chloride, so they are easily compatible with each other and can be easily mixed (kneaded). Therefore, the plasticizer 50 contained in the master batch formulation 60 can be easily mixed with the scrap 20. By mixing the plasticizer 50 contained in the master batch formulation 60 with the hard polyvinyl chloride contained in the scrap 20, the hard polyvinyl chloride contained in the scrap 20 is softened by the plasticizer 50, and soft polyvinyl chloride is generated.

[0051] The kneaded product 80 is an intermediate mixture obtained by mixing the masterbatch formulation 60, the third powder material 70, and the scraps 20, and is produced in the intermediate stage of manufacturing the soft polyvinyl chloride resin composition as the final mixture. In addition, the kneaded product 80 has soft polyvinyl chloride as a main component and contains a stabilizer, calcium carbonate, and a plasticizer 50. The masterbatch formulation 60, the third powder material 70, and the scraps 20 are completely mixed to generate the kneaded product 80 of soft polyvinyl chloride containing a stabilizer and calcium carbonate.

[0052] When the masterbatch formulation 60, the third powder material 70, and the crushed material 20 are mixed (refer to Figure 2 G), the solid calcium carbonate 71 (for example, crystals of calcium carbonate) contained in the third powder material 70 is sunk into the crushed material 20. And, due to the calcium carbonate 71, the crushed material 20 is hooked on the masterbatch formulation 60, and the crushed materials 20 are hooked with each other. As a result, the friction between the crushed material 20 and the masterbatch formulation 60, and the friction between the crushed materials 20 are large, and the crushed material 20 and the masterbatch formulation 60 are easily mixed. As a result, the mixing of the crushed material 20 and the masterbatch formulation 60 can be promoted. At the same time, since the calcium carbonate is a powder (the third powder material 70), the calcium carbonate can be efficiently mixed into the masterbatch formulation 60 and the mixed material 80. Therefore, the mixed material 80 can be easily mixed.

[0053] After the kneading of the mixture 80 is completed, the mixture 80 of the masterbatch formulation 60, the third powder material 70, and the crushed material 20 is processed to form a pellet 81 of the mixture 80 (refer to Figure 2 H)( Figure 1 The pellets 81 are pellets of the kneaded material 80 formed into granules, and are mainly composed of soft polyvinyl chloride and contain a stabilizer and calcium carbonate. The pellets 81 are formed from the kneaded material 80 by the molding process of the pellets 81.

[0054] In the forming process of the pellets 81, the kneaded material 80 in a molten state is discharged from the heating kneading machine and passed between rollers arranged side by side. At this time, the kneaded material 80 is compressed by passing between the outer peripheral surfaces of two or more rollers facing each other. Then, the kneaded material 80 is extruded by an extrusion molding machine, and the kneaded material 80 after extrusion molding is cut in sequence to form pellets 81 of the kneaded material 80.

[0055] Next, the kneaded product 80 and the master batch formulation 60 are kneaded while being heated by a heating kneading machine to produce a soft polyvinyl chloride resin composition ( Figure 1 At this time, the particles 81 of the kneaded product 80 and the masterbatch formulation 60 are kneaded while being heated, so that the particles 81 are mixed with the masterbatch formulation 60. The heating mixer applies shear force to the kneaded product 80 (particles 81), the masterbatch formulation 60, and the resin composition during the kneading process. The heating mixer heats the kneaded product 80, the masterbatch formulation 60, and the resin composition to a predetermined temperature and kneads them to generate a resin composition.

[0056] In the resin composition of soft polyvinyl chloride, when the kneaded product 80 (particles 81) is set to 100 parts by weight, the masterbatch formulation 60 is more than 0 parts by weight and less than 100 parts by weight. In this way, when the resin composition is generated, more than 0 parts by weight and less than 100 parts by weight of the masterbatch formulation 60 are added relative to 100 parts by weight of the kneaded product 80. In addition, the kneaded product 80 and the masterbatch formulation 60 are heated from the temperature at the beginning of kneading (for example, room temperature) to a temperature in the range of 120°C to 165°C, and at the same time, the kneaded product 80, the masterbatch formulation 60, and the resin composition are kneaded, and then the kneading of the resin composition is terminated.

[0057] When the soft polyvinyl chloride resin composition is manufactured (generated), the components contained in the kneaded product 80 are mixed with the components contained in the master batch formulation 60. The kneaded product 80 and the master batch formulation 60 are both polyvinyl chloride, so they are easily compatible with each other and can be easily mixed (kneaded). In addition, the soft polyvinyl chloride contained in the kneaded product 80 is further softened by the plasticizer 50 contained in the master batch formulation 60.

[0058] The soft polyvinyl chloride resin composition is a final mixture obtained by mixing the kneaded product 80 (pellets 81) with the masterbatch formulation 60. The resin composition has soft polyvinyl chloride as a main component and contains a stabilizer, calcium carbonate, and a plasticizer 50. The kneaded product 80 and the masterbatch formulation 60 are completely mixed to produce a soft polyvinyl chloride resin composition containing a stabilizer and calcium carbonate.

[0059] The hardness of the soft polyvinyl chloride resin composition changes according to the concentration (e.g., mass percentage concentration) of the plasticizer 50 contained, and becomes a hardness corresponding to the concentration of the plasticizer 50. The weight parts of the master batch formulation 60 added to the scraps 20 and the weight parts of the master batch formulation 60 added to the kneaded product 80 are adjusted based on the weight parts of the plasticizer 50 formulated in the master batch formulation 60, thereby adjusting the concentration of the plasticizer 50 contained in the soft polyvinyl chloride resin composition and the hardness of the resin composition. The concentration of the plasticizer 50 contained in the resin composition is adjusted to the target concentration, and the hardness of the resin composition is adjusted to the target hardness.

[0060] After the production of the soft polyvinyl chloride resin composition is completed, the resin composition in a molten state is discharged from the heating kneading machine and the resin composition is passed between rollers arranged side by side ( Figure 1 At this time, the resin composition is passed between the outer peripheral surfaces of two or more rollers facing each other to be compressed. Then, the resin composition is extruded by an extrusion molding machine, and the extruded resin composition is cut in sequence to form soft polyvinyl chloride particles ( Figure 1 Then, the soft polyvinyl chloride pellets are used to form a soft polyvinyl chloride molded product ( Figure 1 S109). Soft polyvinyl chloride molded products are, for example, airtight materials and gaskets for doors and windows.

[0061] In the case of manufacturing a soft polyvinyl chloride resin composition by kneading the masterbatch formulation 60, the third powder material 70, and the scraps 20 in a single kneading, the total amount of the plasticizer 50 contained in the masterbatch formulation 60 kneaded in a single kneading increases. Therefore, the amount of the plasticizer 50 kneaded with the scraps 20 increases, making it difficult for the plasticizer 50 to be kneaded with the scraps 20. In addition, the viscosity of the kneaded body made of the masterbatch formulation 60, the third powder material 70, and the scraps 20 decreases, which may make it difficult to knead the kneaded body. As a result, it is difficult for the scraps 20 to be kneaded with the masterbatch formulation 60.

[0062] In contrast, in the method for producing the resin composition described above, after the masterbatch formulation 60, the third powder material 70, and the scrap 20 are kneaded to generate the kneaded product 80, the kneaded product 80 is kneaded with the masterbatch formulation 60 to produce the soft polyvinyl chloride resin composition. In this way, by performing the kneading with the masterbatch formulation 60 twice, the plasticizer 50 contained in the masterbatch formulation 60 can be easily kneaded with the scrap 20 during the first kneading, and the masterbatch formulation 60 can be easily kneaded with the kneaded product 80 during the second kneading. In addition, during the first kneading, the calcium carbonate 71 contained in the third powder material 70 can promote the kneading of the scrap 20 with the masterbatch formulation 60. Therefore, the rigid polyvinyl chloride contained in the scrap 20 is uniformly softened by the plasticizer 50.

[0063] When generating the mixed product 80, the masterbatch formulation 60 and the scrap 20 are both polyvinyl chloride, so they are easy to mix. In addition, when generating the soft polyvinyl chloride resin composition, the mixed product 80 and the masterbatch formulation 60 are both polyvinyl chloride, so they are easy to mix. Therefore, the plasticizer 50 contained in the masterbatch formulation 60 can also be easily mixed into the scrap 20 and the mixed product 80 respectively. Therefore, the time required for mixing the mixed product 80 and the resin composition can be shortened. In addition, the plasticizer 50 contained in the masterbatch formulation 60 is easy to be compatible with the scrap 20 and the mixed product 80 respectively, and the addition amount of the plasticizer 50 added to the resin composition can also be increased.

[0064] Therefore, the resin profile 10 with hard polyvinyl chloride as the main component can be recovered to easily manufacture the resin composition of soft polyvinyl chloride. Moreover, the concentration of the plasticizer 50 in the resin composition can be increased to expand the hardness range of the resin composition that can be manufactured. It is also possible to manufacture a soft resin composition. Even if the addition amount of calcium carbonate is increased, the concentration of the plasticizer 50 can still be increased to reduce the hardness of the resin composition. Thus, the performance reduction of the resin composition can be suppressed. Therefore, the addition amount of calcium carbonate can be increased, thereby reducing the material cost of the resin composition. By using the scraps 20 that can be formed relatively easily to manufacture the resin composition, the resin profile 10 can also be efficiently recovered.

[0065] The pellets 81 are formed from the kneaded product 80, and the pellets 81 of the kneaded product 80 are kneaded with the masterbatch formulation 60. Therefore, during the kneading process, the pellets 81 of the kneaded product 80 can be dispersed in the masterbatch formulation 60, so that the kneaded product 80 and the masterbatch formulation 60 are smoothly kneaded.

[0066] When the amount of the plasticizer 50 is less than 150 parts by weight relative to 100 parts by weight of the first powder material 30, the amount of the plasticizer 50 contained in the masterbatch formulation 60 is too small, and therefore, the effect of softening the scraps 20 (rigid polyvinyl chloride) and the kneaded product 80 by the masterbatch formulation 60 may be affected. Furthermore, when the amount of the plasticizer 50 is more than 250 parts by weight relative to 100 parts by weight of the first powder material 30, the first powder material 30 may not be able to completely absorb the plasticizer 50, and the plasticizer 50 may remain in a liquid state. In contrast, when the amount of the plasticizer 50 is within a range of 150 parts by weight or more and 250 parts by weight or less relative to 100 parts by weight of the first powder material 30, the plasticizer 50 can be absorbed by the first powder material 30 without causing waste, and the effect of softening the scraps 20 and the kneaded product 80 by the masterbatch formulation 60 can be ensured. More preferably, the plasticizer 50 is 170 parts by weight or more and 230 parts by weight or less relative to 100 parts by weight of the first powder material 30. Thus, the plasticizer 50 is smoothly absorbed by the first powder material 30, and the masterbatch formulation 60 can surely soften the scraps 20 and the kneaded product 80.

[0067] When the masterbatch formulation 60 is less than 30 parts by weight relative to 100 parts by weight of the scraps 20, the amount of the plasticizer 50 of the masterbatch formulation 60 mixed with the scraps 20 is too small, and thus the effect of softening the scraps 20 (rigid polyvinyl chloride) by the masterbatch formulation 60 may be affected. Furthermore, when the masterbatch formulation 60 is more than 60 parts by weight relative to 100 parts by weight of the scraps 20, the masterbatch formulation 60 is too much, and thus it is difficult to mix the masterbatch formulation 60 with the scraps 20, and the softening of the scraps 20 may be uneven. On the other hand, when the weight of the masterbatch formulation 60 is within the range of 30 parts by weight or more and 60 parts by weight or less relative to 100 parts by weight of the scraps 20, the masterbatch formulation 60 can be easily mixed with the scraps 20, and the scraps 20 can be stably softened by the plasticizer 50 contained in the masterbatch formulation 60. More preferably, the masterbatch formulation 60 is 35 parts by weight or more and 55 parts by weight or less relative to 100 parts by weight of the scraps 20. Thus, the masterbatch formulation 60 can be smoothly kneaded with the scraps 20, and the plasticizer 50 contained in the masterbatch formulation 60 can be surely softened.

[0068] The hardness of the soft polyvinyl chloride resin composition is adjusted to the target hardness by adjusting the addition amount of the masterbatch formulation 60 relative to 100 parts by weight of the kneaded product 80 within a range of more than 0 parts by weight and less than 100 parts by weight. On the other hand, when the masterbatch formulation 60 is more than 100 parts by weight relative to 100 parts by weight of the kneaded product 80, the masterbatch formulation 60 is too much, so it is difficult to knead the masterbatch formulation 60 with the kneaded product 80, and the kneading of the masterbatch formulation 60 and the kneaded product 80 may be uneven. In addition, the proportion of the scraps 20 used to manufacture the soft polyvinyl chloride resin composition is reduced, so the amount of recycled resin profiles 10 is reduced, which may affect the material cost of the resin composition. When the weight of the masterbatch formulation 60 is greater than 0 parts by weight and less than 100 parts by weight relative to 100 parts by weight of the kneaded product 80, the masterbatch formulation 60 can be easily kneaded with the kneaded product 80 while adjusting the hardness of the soft polyvinyl chloride resin composition, and the recovery amount of the resin profile 10 can be ensured. More preferably, the masterbatch formulation 60 is greater than 0 parts by weight and less than 80 parts by weight relative to 100 parts by weight of the kneaded product 80. Thus, the masterbatch formulation 60 can be smoothly kneaded with the kneaded product 80, and the recovery amount of the resin profile 10 can be reliably ensured.

[0069] When the third powder material 70 is less than 5 parts by weight relative to 100 parts by weight of the scrap 20, the solid calcium carbonate 71 contained in the third powder material 70 may affect the effect of promoting the mixing of the scrap 20 and the masterbatch formulation 60. In addition, when the third powder material 70 is more than 50 parts by weight relative to 100 parts by weight of the scrap 20, the concentration of calcium carbonate in the soft polyvinyl chloride resin composition is too high, and therefore, the performance (e.g., elongation characteristics) of the resin composition may be affected. In contrast, when the weight of the third powder material 70 is within the range of more than 5 parts by weight and less than 50 parts by weight relative to 100 parts by weight of the scrap 20, the mixing of the scrap 20 and the masterbatch formulation 60 can be promoted, and the performance of the resin composition can be ensured. More preferably, the third powder material 70 is more than 15 parts by weight and less than 40 parts by weight relative to 100 parts by weight of the scrap 20. This can reliably promote the kneading of the scraps 20 and the masterbatch formulation 60 and ensure the performance of the resin composition.

[0070] When the maximum size R of the crushed material 20 is greater than 15 mm, the crushed material 20 is too large, and therefore, it may be difficult to mix the crushed material 20 with the masterbatch formulation 60 and the third powder material 70. In contrast, when the maximum size R of the crushed material 20 is 15 mm or less, the crushed material 20 can be dispersed during the mixing process, so that the crushed material 20 can be easily mixed with the masterbatch formulation 60 and the third powder material 70. More preferably, the maximum size R of the crushed material 20 is 8 mm or less. Thus, the crushed material 20 can be smoothly mixed with the masterbatch formulation 60 and the third powder material 70.

[0071] The softening temperature of a resin refers to the temperature (softening point) at which the resin begins to soften and deform. The softening temperature of the crumbs 20 mainly composed of hard polyvinyl chloride is different from the softening temperature of the mixed material 80 (pellets 81) mainly composed of soft polyvinyl chloride. The softening temperature of the hard polyvinyl chloride and the crumbs 20 is higher than the softening temperature of the soft polyvinyl chloride and the mixed material 80.

[0072] When the kneaded product 80 is generated, the masterbatch formulation 60, the third powder material 70, and the scraps 20 are heated to a temperature in the range of 160° C. or higher and 190° C. or lower. Thus, the scraps 20 are softened, and the viscosity of the scraps 20 is adjusted to a viscosity suitable for kneading, so that the scraps 20 are easily kneaded with the masterbatch formulation 60 and the third powder material 70. The temperature at which the masterbatch formulation 60, the third powder material 70, and the scraps 20 are heated is more preferably in the range of 170° C. or higher and 180° C. or lower. Thus, the viscosity of the scraps 20 can be prevented from being too high or too low, and the scraps 20 can be smoothly kneaded with the masterbatch formulation 60 and the third powder material 70.

[0073] When the soft polyvinyl chloride resin composition is produced, the kneaded product 80 and the master batch formulation 60 are heated to a temperature in the range of 120° C. to 165° C. In this way, the kneaded product 80 is softened, and the viscosity of the kneaded product 80 is adjusted to a viscosity suitable for kneading, so that the kneaded product 80 and the master batch formulation 60 can be easily kneaded. The temperature at which the kneaded product 80 and the master batch formulation 60 are heated is more preferably in the range of 130° C. to 155° C. In this way, the viscosity of the kneaded product 80 can be prevented from being too high or too low, and the kneaded product 80 and the master batch formulation 60 can be smoothly kneaded.

[0074] When the particle size of the first powder material 30 is greater than 500 μm, the absorption of the plasticizer 50 by the first powder material 30 may be affected. On the other hand, when the particle size of the first powder material 30 is less than 500 μm, the plasticizer 50 is easily absorbed by the first powder material 30, and the first powder material 30 can efficiently absorb the plasticizer 50. As a result, the masterbatch formulation 60 can be easily generated.

[0075] In addition, any one or both of unused rigid polyvinyl chloride powder and recycled rigid polyvinyl chloride powder can be used as the first powder material 30. And, it is also possible not to form particles 81 by the mixed material 80, but to mix the mixed material 80 after mixing with the masterbatch formulation 60. In the case of coloring the soft polyvinyl chloride resin composition, the addition and mixing of the pigment are carried out at any stage (for example, the stage of generating the resin composition) from the generation of the mixed material 80 to the generation of the resin composition. When the resin profile 10 as the raw material of the resin composition is the scrap material of the resin profile 10 (here, the resin profile 10 of the resin window), the scrap material of the resin profile 10 can be effectively recycled and the cost of the resin composition is reduced.

[0076] Figure 4 This is a diagram showing another example of the resin shape 10 according to the present embodiment, and shows a cross section of the resin shape 10 perpendicular to the longitudinal direction.

[0077] As shown in the figure, here, the resin profile 10 has a main body 11 mainly composed of hard polyvinyl chloride and an appendage 12 mainly composed of soft polyvinyl chloride. The appendage 12 is a soft part attached to the main body 11 as a hard part, formed smaller than the main body 11, and protruding from the main body 11. When the resin profile 10 is crushed ( Figure 1 In S102), the attachment 12 is not removed from the main body 11, but the resin profile 10 to which the attachment 12 is attached is crushed to form scraps 20 of the resin profile 10.

[0078] The formed scraps 20 include scraps 20 of only the main body 11, scraps 20 of only the appendage 12, and scraps 20 containing both the main body 11 and the appendage 12. The scraps 20 are kneaded with the masterbatch formulation 60 and the third powder material 70 to obtain a kneaded product 80. In this way, the resin profile 10 can be easily recovered without separating the appendage 12 made of soft polyvinyl chloride and the main body 11 made of hard polyvinyl chloride of the resin profile 10.

[0079] In the above, the resin profile 10 is described as an example of a scrap material of the resin profile 10 of a resin window, but the resin profile 10 is not limited to the resin profile 10 of the resin window, and may be other resin profiles 10. Other resin profiles 10 are, for example, a rigid polyvinyl chloride profile (PVC profile) used as other than a resin window, a rigid polyvinyl chloride profile with an attached portion of soft polyvinyl chloride used other than a resin window (a profile with soft PVC), a heat-resistant rigid polyvinyl chloride profile (heat-resistant PVC profile), a rigid polyvinyl chloride profile laminated with acrylic resin (acrylic laminated PVC profile), and a rigid polyvinyl chloride profile with a resin laminate sheet (for example, a polyolefin resin sheet) bonded to the surface (a profile with a laminate sheet).

[0080] Next, an example of a method for producing a soft polyvinyl chloride resin composition is described, but the present invention is not limited to the following example. Figure 1 The flow chart shown is for producing a soft polyvinyl chloride resin composition.

[0081] Table 1

[0082]

[0083] Table 1 shows the weight parts of each material in each stage of the examples.

[0084] When generating the masterbatch formulation 60, 200 parts by weight of the plasticizer 50 and 2.5 parts by weight of the second powder material 40 are added to 100 parts by weight of the first powder material 30. The plasticizer 50 is diisononyl phthalate (DINP), and the second powder material 40 is a barium-zinc (Ba-Zn) stabilizer. When generating the mixed material 80, 45 parts by weight of the masterbatch formulation 60 and 25 parts by weight of the third powder material 70 are added to 100 parts by weight of the scrap 20. When generating the resin composition of soft polyvinyl chloride, 24 parts by weight of the masterbatch formulation 60 are added to 100 parts by weight of the mixed material 80. In the embodiment, the resin profile 10 is recycled to produce a resin composition of soft polyvinyl chloride.

[0085] As described above, in the present embodiment, a method for producing a resin composition as described in the following (1) to (6) is disclosed.

[0086] (1) A method for producing a resin composition, wherein a resin profile having hard polyvinyl chloride as a main component is used as a raw material to produce a soft polyvinyl chloride resin composition, and the method comprises:

[0087] A crushing step of crushing the resin profile to form crushed materials;

[0088] a mixing step of mixing a masterbatch prepared by mixing rigid polyvinyl chloride, a stabilizer and a plasticizer, a powder material mainly composed of calcium carbonate, and the crushed material while heating to obtain a mixed material; and

[0089] The mixing step kneads the kneaded product and the master batch formulation while heating to produce the resin composition obtained by mixing the kneaded product and the master batch formulation.

[0090] In the method for producing a resin composition described in (1), a resin material containing hard polyvinyl chloride as a main component can be recovered to easily produce a resin composition of soft polyvinyl chloride.

[0091] (2) A method for producing a resin composition according to (1),

[0092] The method comprises the step of processing the kneaded material to form particles of the kneaded material, and

[0093] In the mixing step, the pellets of the kneaded product and the masterbatch formulation are kneaded while being heated.

[0094] In the method for producing a resin composition according to (2), particles of the kneaded product can be dispersed in the masterbatch formulation, and the kneaded product and the masterbatch formulation can be smoothly kneaded.

[0095] (3) A method for producing a resin composition according to (1) or (2),

[0096] The method comprises the following steps: adding 150 parts by weight or more and 250 parts by weight or less of the plasticizer to 100 parts by weight of a powder material mainly composed of rigid polyvinyl chloride, thereby generating the masterbatch formulation.

[0097] In the method for producing a resin composition described in (3), the plasticizer can be absorbed by the powder material mainly composed of rigid polyvinyl chloride without being wasted, and the effect of softening the crumbs and the kneaded product by the masterbatch formulation can be ensured.

[0098] (4) The method for producing a resin composition according to any one of (1) to (3), wherein

[0099] In the kneading step, 30 parts by weight or more and 60 parts by weight or less of the masterbatch formulation are added to 100 parts by weight of the crushed material.

[0100] In the mixing step, the masterbatch formulation is added in an amount of more than 0 parts by weight and not more than 100 parts by weight relative to 100 parts by weight of the kneaded product.

[0101] In the method for producing a resin composition described in (4), the masterbatch formulation can be easily kneaded with the scraps, and the scraps can be stably softened by the plasticizer contained in the masterbatch formulation. In addition, the masterbatch formulation can be easily kneaded with the kneaded material while adjusting the hardness of the soft polyvinyl chloride resin composition, and the recovery amount of the resin profile can be ensured.

[0102] (5) The method for producing a resin composition according to any one of (1) to (4), wherein

[0103] In the kneading step, 5 parts by weight or more and 50 parts by weight or less of a powder material containing calcium carbonate as a main component are added to 100 parts by weight of the crushed material.

[0104] In the method for producing a resin composition according to (5), kneading of the crumbs and the masterbatch formulation can be promoted and the performance of the soft polyvinyl chloride resin composition can be ensured.

[0105] (6) The method for producing a resin composition according to any one of (1) to (5), wherein

[0106] In the kneading step, the maximum size of the crushed material is 15 mm or less.

[0107] In the method for producing a resin composition described in (6), the crumbs can be dispersed and the crumbs can be easily kneaded with the masterbatch formulation and the powder material containing calcium carbonate as a main component.

Claims

1. A method for producing a resin composition, wherein a resin profile having hard polyvinyl chloride as a main component is used as a raw material to produce a soft polyvinyl chloride resin composition, characterized in that: include: A crushing step of crushing the resin profile to form crushed materials; A mixing step, mixing a masterbatch prepared by mixing rigid polyvinyl chloride, a stabilizer and a plasticizer, a powder material mainly composed of calcium carbonate, and the crushed material while heating to obtain a mixed material; as well as The mixing step kneads the kneaded product and the master batch formulation while heating to produce the resin composition obtained by mixing the kneaded product and the master batch formulation.

2. The method for producing a resin composition according to claim 1, wherein The method comprises the step of processing the kneaded material to form particles of the kneaded material; and In the mixing step, the pellets of the kneaded product and the masterbatch formulation are kneaded while being heated.

3. The method for producing a resin composition according to claim 1 or 2, characterized in that: The method comprises the following steps: adding 150 parts by weight or more and 250 parts by weight or less of the plasticizer to 100 parts by weight of a powder material mainly composed of rigid polyvinyl chloride, thereby generating the masterbatch formulation.

4. The method for producing a resin composition according to claim 1 or 2, characterized in that: In the kneading step, 30 parts by weight or more and 60 parts by weight or less of the masterbatch formulation are added to 100 parts by weight of the crushed material. In the mixing step, the masterbatch formulation is added in an amount of more than 0 parts by weight and not more than 100 parts by weight relative to 100 parts by weight of the kneaded product.

5. The method for producing a resin composition according to claim 1 or 2, characterized in that: In the kneading step, 5 parts by weight or more and 50 parts by weight or less of a powder material containing calcium carbonate as a main component are added to 100 parts by weight of the crushed material.

6. The method for producing a resin composition according to claim 1 or 2, characterized in that: In the kneading step, the maximum size of the crushed material is 15 mm or less.

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