Method for recovering sealing profile and window, door and facade structure

Abstract

The invention relates to a method for recovering EPDM-sealing profiles of windows, doors and / or facade structures; and a window, door or facade structure; the method comprises the following steps: a. Providing (101) a used EPDM-sealing profile, b. Comminuting (102), in particular grinding the sealing profile, c. Wetting (103) the comminuted material with a wetting agent in order to provide a recycled material premix (1) and feeding (105) a new material (2) to the comminuted material, and d. Shaping (106) the comminuted material, in particular in the form of an element (3) of a window, door and / or facade structure, wherein the shaping (106) is carried out in a co-extrusion manner; and a window, door or facade structure.

Description

Technical Field

[0001] This invention relates to a method for recycling sealing profiles. It includes a method for recycling EPDM-sealing profiles from windows, doors, and / or facade structures, as well as the windows, doors, and / or facade structures themselves. Background Technology

[0002] Window, door, or facade profile structures are mostly post-treated separately after their lifespan. However, while the materials for hollow profiles, such as aluminum or plastic, can mostly be treated in a completely or largely pure manner, rubber seals in this field exhibit a wide range of variations in hardness, crosslinking type, formulation details, and foaming.

[0003] Furthermore, elastomers and / or EPDM, for example, are not as fusible as aluminum or plastics due to the chemical cross-linking of their polymer chains, making their processing more costly. Therefore, they are generally classified as non-recyclable.

[0004] US2009 / 0289396A1 discloses a processing of a rubber component comprising EPDM from a tire, a pad as filler, and / or a reinforcing material dispersed in a matrix material. US2017 / 0218137A1 discloses a comparable processing of rubber materials from tires, etc.

[0005] US2018 / 0186974A1 discloses a method for reusing used cross-linked or vulcanized waste rubber by mixing it with new materials. In particular, a microencapsulation process can be employed. For molding, the material mixture can be extruded.

[0006] The aforementioned documents do not disclose the molding of seals for window, door, or facade structural applications. Instead, all of these documents assume that they will be integrated into the blend. Co-extrusion and the resulting surface variations (e.g., different surface roughness due to differences in the local distribution of recycled and virgin materials) are not mentioned in these documents. Summary of the Invention

[0007] Despite the aforementioned problems, the present invention aims to overcome the aforementioned technical biases while providing a simple method for using seals as raw materials and starting materials.

[0008] The present invention achieves this objective by means of a method having the features of claim 1 and by means of a window, door or facade structure having the features of claim 11.

[0009] The method according to the invention recycles EPDM-sealing profiles for windows, doors, and / or facade structures. Unlike hollow profiles, which are optionally made of plastic or metal, especially aluminum, EPDM-sealing profiles represent high costs in their processing and have been uneconomical to date. This method provides a solution to this problem and includes at least the following steps:

[0010] a. Provide used EPDM sealing profiles

[0011] Used EPDM seals can be seals of varying degrees of newness and condition. Therefore, for example, used EPDM seals can also be understood as residues cut from previously new rolls of material, i.e., so-called "pre-consumer waste." The use of these seal profiles is essentially the cutting of these materials.

[0012] However, most sealing profiles consist of so-called "post-use waste," which are sealing profiles that have been exposed to the environment for a long time, especially climates such as sunlight, cold and / or rain.

[0013] b. Crushing, especially grinding, sealing profiles

[0014] In the second step, the used sealing profile can be pulverized. This can be done, in particular, by grinding. The smaller the average particle size of EPDM particles, the larger the reactive surface area. However, fine dust should not be generated during the pulverization process.

[0015] c. Wet the pulverized material with a wetting agent to provide a recycled premix and to supply new material to the pulverized material, and

[0016] In the third step, the pulverized material is wetted with a wetting agent, and new material is supplied to the pulverized material. These two method features can be performed sequentially in time. In addition to the wetting agent, other crosslinking agents, crosslinking accelerators, and other auxiliaries can be added. In this case, the wetting agent, crosslinking agent, and auxiliaries are the same types as the starting material, thus allowing for further recycling.

[0017] d. To shape crushed materials, especially into components for windows, doors and / or facade structures.

[0018] Finally, the pulverized and moistened material provided in step c is shaped into elements for windows, doors, or facade structures.

[0019] Depending on the type of EPDM-sealing profile used, the element may have particular properties, especially surface properties, which will be discussed below, and may vary depending on the duration of use. Therefore, it is not to be said that all sealing profiles prepared according to the method of the invention, including those made from recycled EPDM-sealing profile materials, possess the properties described below.

[0020] EPDM materials are generally considered climate-stable; however, climate has an influence on EPDM formation. Typically, EPDM is crosslinked by peroxidation or via sulfur bridging until a certain degree of crosslinking is achieved. Post-crosslinking can be achieved through climate, such as heat, humidity, or radiation. It is well known that a higher degree of crosslinking results in higher hardness compared to virgin material. Correspondingly, the surface roughness of composites composed of recycled, pulverized EPDM sealing profiles and virgin material differs, comparable to sandpaper. Such EPDM composites composed of EPDM with different hardnesses are not known to date. They can, for example, advantageously prevent or at least reduce displacement of the sealing profile within the groove of a hollow profile.

[0021] In terms of process, the method according to the invention is also advantageous because it not only creates the aforementioned novel materials, but also provides the cost-effective possibility of converting large quantities of EPDM materials with different hardness into new products.

[0022] Advantageous embodiments of the invention are the subject of the dependent claims.

[0023] If grinding is used to provide EPDM powder, an average particle size between 0.1 and 0.8 mm is preferred to obtain the optimal size for further processing. The average particle size includes a certain range of variation for individual particles. The average particle size can be determined using commercially available particle size analyzers, such as those based on laser diffraction.

[0024] Wetting agents can advantageously be added to the milled EPDM powder in an amount of 1-10% by weight. Adding a wetting agent within this range allows for optimal preparation of the surface so as to bond particularly tightly with the subsequently metered addition of new material.

[0025] In addition to wetting the pulverized material, a crosslinking agent, preferably sulfur and / or peroxide, can be added to the pulverized material of the recycled premix. The crosslinking agent can also be supplied as part of the new material. However, it is also desirable to form bonds between the recycled EPDM material and the new material, so that the recycled mixture may already contain a crosslinking agent, such as peroxide and / or sulfur.

[0026] In addition to crosslinking agents, zinc oxide can also be added to the pulverized material of the recycled premix to further control the crosslinking process.

[0027] It is also advantageous to add the accelerator to the pulverized material of the recycled premix. This can also be included in the new material; however, the reaction kinetics are better when the accelerator is already included in the recycled premix, i.e., as a mixture of pulverized EPDM sealant, wetting agent, and optional additional additives and reagents.

[0028] Advantageously, the mixing of the new material and the recycled premix can be carried out to such an extent that, based on the total amount, the proportion of the pulverized used EPDM material is at least 10% by weight, preferably at least 20% by weight, and particularly preferably at least 50% by weight. Thus, a very large amount of used EPDM can be converted in the method.

[0029] Molding can be performed using established methods, such as co-extrusion. Therefore, the method according to the invention can be implemented using existing manufacturing machines and can be carried out on suitable process equipment.

[0030] Apart from molding, all steps of the method can be carried out at temperatures below 50°C, preferably below 40°C, in an energy- and material-saving manner. This enables better control of the kinetic reaction.

[0031] Providing used EPDM seals includes providing a mixture of seals composed of different EPDM materials, which is further processed into components. Therefore, EPDM seals of varying ages, properties, and chemical compositions can be processed together using the method according to the invention.

[0032] Furthermore, according to the invention, window, door, or facade structures comprise elements of a composite material formed from at least recycled EPDM and virgin materials, wherein the recycled EPDM within the composite material has a higher degree of crosslinking than the virgin material. As previously stated, in the context of the method according to the invention, not every type of recycled EPDM necessarily leads to the aforementioned results in the composite material. However, the degree of crosslinking of the EPDM increases with climate over time. This makes it possible to alter surface properties, particularly surface roughness, thereby enabling better adhesion in hollow profiles.

[0033] Composite materials can advantageously include a matrix material containing novel materials. In the novel material serving as the matrix material, recycled EPDM-materials are arranged and distributed therein, wherein the recycled EPDM-materials have a higher Shore hardness than the matrix material.

[0034] The component can be formed into a molded part, preferably an extruded molded part, which is partially formed entirely of new material, including sections of recycled ECPM material that have a higher surface roughness than sections composed entirely of new material.

[0035] In addition, the component can be formed into a sealing profile, which includes a first end face, such as a stop face or sealing lip, and a sealing foot for a groove, wherein the sealing foot has a surface roughness greater than that of the end face due to the recycled EPDM material distributed in the matrix material. Attached Figure Description

[0036] Further advantages, features, and details of the invention will become apparent from the following description, in which exemplary embodiments of the invention will be explained in more detail with the aid of the accompanying drawings. Those skilled in the art will also readily consider, in their individual considerations the features disclosed in combination in the drawings, description, and claims, and combine them into other meaningful combinations.

[0037] Figure 1 A flowchart illustrating an embodiment variation of the method according to the present invention is shown. Detailed Implementation

[0038] Figure 1 The method shown includes, in its first step, providing a sealing profile for a window, door, or facade profile structure. This provision can be achieved by loosening the sealing profile from a frame profile, such as a plastic or metal frame profile, especially a hollow profile. This can be done, for example, by removing a rubber weatherstripping from a seal groove, or typically by removing the rubber weatherstripping by damaging the profile, for example, by chopping it up. Following this destructive crushing step, the crushed EPDM is separated from the mixture of lightweight crushed fractions by separation.

[0039] In application fields, sealing profiles are also commonly and professionally referred to as sealing rubber. Therefore, in application fields, this refers both to the elastic material and to EPDM-based materials. Sealing profiles containing EPDM are particularly preferred.

[0040] In the second step 102, the sealing profile is preferably pulverized into powder by grinding. The average particle size of the powder (hereinafter also referred to as rubber powder) can be between 0.1 and 0.8 mm.

[0041] However, alternatively, the sealing profile can be cleaned before pulverization. This can be done, in particular, by chemical or purely physical cleaning.

[0042] In the third step 103, a wetting agent is added. In this case, the wetting agent can be added in a preferred range of 1 to 10% by weight based on the powder. The wetting agent is used to improve the reactivity and / or surface adhesion of the powder.

[0043] The pretreated and wetted abrasive sealant powder is then further processed into a recycled premix in another step 104. For this purpose, the sealant powder is mixed with crosslinking chemicals typically used in the field of elastomer and / or EPDM sealant applications. Suitable crosslinking chemicals are one or more zinc oxide compounds, referred to as ZnO in the context of this invention. However, they can also be mixed oxides or zinc in different oxidation states, with zinc(II) oxide being particularly preferred. Preferably, the zinc oxide compound is added in the range of 1-3% by weight, based on the amount of powder.

[0044] In addition to the crosslinking agent, sulfur and / or an accelerator may be added in step 104 to form a recycled premix. Based on the amount of powder, the preferred concentration of sulfur may be between 0.25 and 1.5% by weight.

[0045] In addition to or as a substitute for sulfur, polymerization accelerators and / or crosslinking accelerators may be added to the powder. Based on the weight of the powder used, the preferred concentration of the accelerator may be between 0.5 and 1.5% by weight. Preferably, sulfenamide, preferably N-cyclohexylbenzothiazole-2-sulfenamide, abbreviated as CBS, may be added as an accelerator to the recycled fine powder.

[0046] Optionally, an activator, preferably less than 2% by weight, may be provided based on the total amount of the recycled mixture. As an activator, EPDM-terpolymers, such as, in particular, the commercially available Trilene 67, may be used. Alternatively or additionally, rubber, particularly polyoctene rubber or Vestamer 8012, may be used as an accelerator.

[0047] Other optional components of the recycled premix are desulfurizing agents, crosslinking systems, and / or additives. As desulfurizing agents, Struktol A89 and / or Struktor H107 and / or Struktol H107 can be used. As crosslinking systems, mixtures of liquid polymers and Vestammer 8012 can be used. Additionally, Deoflow F and / or DeoVulc TP4-75V can be used as additives. Based on the total amount of the recycled premix, the other optional components can be provided preferably in amounts less than 2% by weight.

[0048] The recycled premix is ​​preferably present in granular or strip form at the end of step 104. It may have an average particle diameter in the granular form or an average cross-section relative to the longitudinal axis in the strip form, between 1 mm and 5 mm, preferably between 2 and 4 mm.

[0049] Finally, in step 105, a mixture typically used as a starting material for EPDM-based materials is incorporated into the recycled premix. This mixture is also referred to below as the virgin material mixture. It may contain EPDM, carbon black, accelerators, and crosslinking agents, as well as optional plasticizers and optional one or more additives. Other solids, such as chalk, may also be provided in the virgin material mixture as a substitute for or supplement to carbon black. In this case, the recycled premix and the virgin material mixture are mixed in a ratio between 1:4 and 4:1. Particularly preferably, the proportion of recycled material mixed with the virgin material mixture is between 20-60% by weight. Steps 105 and 106 may also be performed simultaneously, for example, in the case of layered application during the formation of a molded article. In this case, a layer of virgin material mixture may be provided on top of a layer of molten recycled premix. In this case, the layers that melt together are non-uniform mixtures.

[0050] To form new EPDM-based molded articles, the mixture is processed into molded articles in another step 106 of the molding method. As the molding method, an extrusion method, such as a co-extrusion method, can be preferably used, thereby enabling the production of new sealing profiles.

[0051] Particularly preferred, the mixture containing recycled EPDM can be processed into a sealing profile by co-extrusion, wherein a layer of recycled premix is ​​covered by one or more layers of new material to provide a very smooth surface of the molded article.

[0052] In step 106, a Coex sealing profile may also be prepared, wherein the sealing foot for engagement in the groove receiving portion of the hollow cavity profile is made of a mixture of recycled materials with relatively rough surfaces, such that it engages in the groove with reduced force through the rough surfaces.

[0053] Although the aforementioned steps, especially steps 103 and / or 104 and / or 105, can be performed at a normal room temperature between 10-35°C, the molding method is performed at a temperature between 70°C and 250°C.

[0054] The invention is characterized in that, even in the case of conventional molding with new materials, the material of the used sealing profile does not undergo any further thermochemical transformation, but is instead pulverized in a relatively energy-efficient manner by grinding the sealing profile.

[0055] Furthermore, when using multiple sealing profiles, there is no need for costly separation of different EPDM types. This would require identifying the EPDM type and thus performing analysis. These aspects are now redundant.

[0056] Furthermore, different EPDM types can be supplied to the process individually or, in particular, as mixtures, wherein the differences between the EPDM types lie in their different hardness, porosity (e.g., dense rubber or foam rubber), different colors, production type (e.g., as extruded profiles), and their chemical composition, especially whether they are peroxide-crosslinked and / or sulfur-crosslinked EPDM types.

[0057] In the processing according to the invention, the newly prepared molded part may contain a high proportion of recycled materials, greater than 10% by weight, preferably greater than 20% by weight, and particularly preferably greater than 50% by weight.

[0058] The inherent advantages of EPDM, especially its processability through extrusion, can also be applied to EPDM materials with recycled components.

[0059] Used EPDM seals can be processed into sealing profiles, corner connection profiles, sealing parts, molded sealing parts, sealing frames, frame profiles, and frames or components for window, door, and / or facade systems within the scope of this method. In this case, molded parts, such as sealing corners or sealing frames, and extruded sealing profiles can be realized within the scope of the method according to the invention.

[0060] Figure Labels

[0061] 1. Recycled premix

[0062] 2 new materials

[0063] 3 components

[0064] 101 provides sealing profiles for window, door, or facade profile structures.

[0065] 102. Crush the sealing profile into powder.

[0066] 103 Add wetting agent

[0067] 104 Further processing

[0068] 105 Supply of new material mixtures

[0069] 106 Molding Method

Claims

1. A method for recycling EPDM-sealing profiles for windows, doors, and / or facade structures, characterized by the following steps: a. Provide (101) used EPDM sealing profiles, b. Crushing (102), especially grinding sealing profiles, c. Wet the pulverized material with a wetting agent (103) to provide a recycled premix (1) and supply (105) new material (2) to the pulverized material, and d. Molding the pulverized material (106), particularly molding it into elements (3) of windows, doors and / or facade structures, wherein the molding (106) is carried out by co-extrusion.

2. The method according to claim 1, characterized in that, The EPDM powder is prepared by grinding, and preferably, the average particle size of the EPDM powder is between 0.1 and 0.8 mm.

3. The method according to claim 1 or 2, characterized in that, The wetting agent is added to the ground EPDM powder at a ratio of 1-10% by weight.

4. The method according to any one of the preceding claims, characterized in that, A layer of recycled premix is ​​covered by one or more layers of new material to provide a very smooth surface for the molded body.

5. The method according to any one of the preceding claims, characterized in that, The co-extruded sealing profile is manufactured in such a way that the sealing foot of the co-extruded profile used for engagement in the groove receiving portion of the hollow profile is made of a recycled mixture with relatively rough surfaces, so that it engages in the groove with reduced force through the rough surfaces.

6. The method according to claim 4 or 5, characterized in that, The accelerator is added to the pulverized material of the recycled premix (1).

7. The method according to any one of the preceding claims, characterized in that, The mixing of the new material (2) and the recycled premix (1) is carried out to such an extent that, based on the total amount, the proportion of the pulverized used EPDM material is at least 10% by weight, preferably at least 20% by weight, and particularly preferably at least 50% by weight.

8. The method according to any one of the preceding claims, characterized in that, Except for molding (106), all steps of the method are carried out at temperatures below 50°C, preferably below 40°C.

9. The method according to any one of the preceding claims, characterized in that, The provision of (101) used EPDM seals includes providing a mixture of seals composed of different EPDM materials, which are further processed into elements (3).

10. A window, door, or facade structure, particularly manufactured by the method according to any one of the preceding claims, comprising an element as a composite material formed of at least recycled EPDM-material and new material (2), wherein the recycled EPDM-material within the composite material has a higher degree of crosslinking than the new material (2), and wherein the element (3) is molded, preferably co-extruded molded, which is partially formed entirely of the new material (2), including a segment of recycled EPDM-material having a higher surface roughness than a segment composed entirely of the new material (2).

11. The window, door, or facade structure according to claim 10, characterized in that, The composite material has a matrix material comprising a novel material (2) and a recycled EPDM material distributed therein, the recycled EPDM material having a higher Shore hardness than the matrix material.

12. The window, door, or facade structure according to any one of the preceding claims, characterized in that, The element (3) is formed into a sealing profile, the sealing profile including a first end face and a sealing foot for a groove, wherein the sealing foot has a surface with a surface roughness greater than that of the end face due to the recycled EPDM material distributed in the matrix material.

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