Web product and production thereof

Abstract

The invention relates to a single- or multi-layer web product, more particularly a covering web for a construction region, such as a roof, basement, basin, consisting of or containing a cover web with at least a first filler, which consists of or contains comminuted heterogeneous domestic and / or industrial waste materials.

Description

[0001] Description

[0002] Web-shaped product and production of such

[0003] The invention relates to a single-layer or multi-layer sheet-like product, in particular a covering sheet for a building area, such as a roof, basement, pool, consisting of or containing a polymer and / or plastic-containing covering sheet with at least one first filler.

[0004] The invention also relates to a method for producing a web-shaped product, in particular a covering sheet for a building area, such as a roof, basement, pool, consisting of or containing a polymer and / or plastic-containing covering sheet with at least one first filler.

[0005] Fields of application for the cover sheets mentioned are listed in the well-known application standards DIN 18531, DIN 18532, DIN 18533, DIN 18534 and DIN 18535.

[0006] A web-like product in the form of a cover layer system can be found, for example, in EP 3 744 519 A1. The cover layer system comprises a single- or multi-layer cover sheet, a nonwoven layer bonded to it, and a bituminous adhesive layer covering the cover layer. The cover layer contains polyvinyl chloride as the plastic, a plasticizer, which can be a polymeric plasticizer or a monomeric plasticizer or a mixture thereof, as well as color pigments, UV stabilizers, fungicides, thermal stabilizers, and other additives, as well as fillers such as chalk and / or talc.

[0007] In general, fillers are used to reduce the proportion of matrix in the finished product and thus save costs

[0008] A web-like product in the form of a sealing membrane is described in WO 2018 / 210667 A1. Its cover layer, defined by a combination carrier insert, contains a base polymer with a PVC content of 45% to 57% by weight, a low-molecular-weight plasticizer with a content of 25% to 45% by weight, and processing aids such as antioxidants, UV stabilizers, color pigments, titanium dioxide, flame retardant additives, and a filler with a content of up to 20% by weight. Chalk and / or talc are used as fillers.

[0009] Corresponding sheet-like products, used in the manufacture of roofing membranes, for example, are subject to increasing requirements for sustainable business practices. Therefore, in the manufacture of new products, emphasis is placed on the careful use of resources and the reduction of CO2 emissions. To meet these requirements, it is well known that raw materials from old products can be recycled to reduce the use of new ones.

[0010] In the flat roof sector, it is therefore already common practice to remove the bitumen or plastic waterproofing membranes laid on the roof during renovation and to recycle them. This allows bitumen and plastics to be reused in the production of new roofing membranes. However, considering that it usually takes more than 50 years before a flat roof is renovated, the use of recycled material is limited. Furthermore, it is common practice during renovation to leave old roofing membranes on the roof substructure and cover them with a new layer of roofing membranes. Due to the long lifetime of the roofing membranes, only a very limited amount of roofing membranes is available for the recycling process. Another disadvantage is that old products contain substances that are no longer permitted to be used under current law.

[0011] A covering membrane consisting of residue particles combined with bitumen, which is intended for road construction and industrial floors, can be found in DE 44 26 752 A1.

[0012] According to DE 32 43 361 A1, dried sewage sludge is used to produce films to achieve damping properties.

[0013] DE 24 34 487 A1 describes a process for producing potting compounds, films, or rollable material webs using composted waste as a filler. A composite material is known from US Pat. No. 4,013,616 A. Pyrolyzed municipal waste is used as a filler.

[0014] A floor covering with a carrier layer made of recycled material is known from DE 699 03 764 T2.

[0015] The object of the present invention is to further develop web-shaped products, in particular cover sheets for a building area, such as roofs, basements, pools, in such a way that a saving of new raw material is achieved without having to accept disadvantages, in particular with regard to the physical properties, compared to conventionally manufactured products.

[0016] To solve the problem, with regard to the web-shaped product itself, it is essentially proposed that the first filler consists of or contains shredded heterogeneous waste materials from household and / or industry.

[0017] The waste materials should at least contain or consist of renewable raw materials or parts thereof and / or minerals or products consisting of or containing materials such as rock, minerals or salts.

[0018] According to the invention, waste which is essentially available in unlimited quantities and which is generated particularly in households but also in industry, provided that it is not hazardous waste, is used for the sustainable production of web-like products.

[0019] The first filler can replace the polymer of the cover sheet matrix.

[0020] For example, in the case of a cover sheet containing a polymer matrix, the otherwise present filler made of inorganic or mineral material, such as in particular chalk and / or talc and / or kaolin, is completely or at least partially replaced by the filler according to the invention.

[0021] In other words, the first filler can be a polymer-replacing filler. Regarding the term "cover sheet," it should be noted that this can be single-layer or multi-layered. In a multi-layer cover sheet, at least one layer contains the first filler according to the invention.

[0022] Examples of waste from private households (household waste) are: - residual waste - organic waste, such as food and kitchen waste, - old glass - waste paper - packaging (Green Dot) - electronic waste - hazardous waste - bulky waste - metal bulky waste - garden waste such as green waste, roots, trunks and stumps - textiles (old clothing collection) - pollutants from households.

[0023] Other types of waste that usually require disposal in waste containers include: - Construction and demolition waste - Building rubble, mixed construction waste, broken concrete, screed, gypsum, drywall, aerated concrete, stones - Garden waste and green waste - Roots, trunks and stumps - Excavated earth (soil and stones) - Wood, untreated and treated - Contaminated waste such as - Hazardous waste - Building materials containing asbestos - Roofing felt containing tar and bitumen - Contaminated excavated earth. Waste is essentially defined as materials and substances used by humans that no longer serve an immediate purpose. Waste materials include organic waste, waste paper, lightweight packaging, used glass, hygiene products, plastics, but also inert materials such as stone and sand and old textiles.

[0024] From a legal perspective, waste in Germany is categorised as a five-stage waste hierarchy under the Circular Economy Act, which came into force on 1 June 2012 - Act to Promote the Circular Economy and Ensure the Environmentally Sound Management of Waste (Circular Economy Act, KrWG) - in Section 6: - Prevention, - Preparation for Reuse, - Recycling, - Other recovery, in particular energy recovery and backfilling, - Disposal

[0025] Based on this principle, the waste management measure that best ensures the protection of people and the environment must be selected. Technical, economic and social aspects must be taken into account. The waste hierarchy is specified in the basic obligations in Sections 7 and 8. With regard to the newly included recovery options (preparation for reuse - recycling - other recovery), Section 8 Paragraph 2 stipulates that the priority or equal status of a recovery measure and requirements for the high quality of recovery for certain types of waste are to be determined by legal order. The so-called calorific value clause in Paragraph 3 (old version) was repealed by the Act amending the Closed Substance Cycle and Waste Management Act of March 27, 2017. As a result of the repeal, the fundamental priority of material recovery (recycling) over energy recovery applies regardless of the calorific value of the waste in accordance with Section 6 Paragraph 1. Furthermore, Section 9 Paragraph 2 states:2 - with a few exceptions - a ban on mixing hazardous waste.

[0026] The invention proposes using waste as the first filler, thereby achieving a higher-value utilization. Thus, waste is recycled instead of being sent for thermal recycling or used as backfill. Due to the inventive recycling of waste, energy and pollutant emissions, as well as storage capacity, for example, in landfills, are significantly reduced.

[0027] Therefore, it is particularly provided that the first filler consisting of or containing the waste material contains at least one material or several materials from the group of biowaste, such as food and kitchen waste, hygiene products such as diapers, and plastic.

[0028] Waste containing pollutants, construction and demolition waste, are not intended for use according to the invention.

[0029] Household waste in Germany was used as an example in a final report published by the Federal Office “Comparative analysis of municipal residual waste from representative regions in Germany to determine the proportion of problematic substances and recyclable materials”, published in June 2020. Here, reference is made to the fact that there are essentially five different main material groups that can be found here: - 39.3 wt.% native organic waste - 27.6 wt.% dry materials - 26.3 wt.% residual waste - 6.3 wt.% fine waste (0-10 mm core size) - 0.5 wt.% problematic and pollutant substances

[0030] Native organic waste is mainly summarized as kitchen and food waste, garden waste, other organic waste and filled or partially emptied food packaging.

[0031] Dry recyclable materials are mainly waste paper, waste glass, plastics, waste textiles and wood / cork, as well as waste electrical and electronic equipment.

[0032] The residual waste that must be disposed of with household waste in almost all municipalities in Germany according to separate waste separation regulations consists largely of hygiene products. Organic and mineral fine waste also includes residual waste such as garbage and ash.

[0033] The problematic and harmful substances are also classified as part of the group of pharmaceuticals and medicines, which in many municipalities in Germany can also be disposed of with household waste in accordance with separation requirements for citizens.

[0034] Used batteries and accumulators are also included in this main substance group.

[0035] Furthermore, there are clear differences in the amount of waste and the proportions in terms of settlement structure; there are differences in rural, densely populated rural and urban areas.

[0036] In order to be able to use appropriately shredded heterogeneous waste for a web-shaped product, in particular the outer layer or ply of a covering sheet, such as a roofing sheet, the waste materials should preferably have grain sizes of ≤ 1 mm, particularly preferably ≤ 250 pm.

[0037] In particular, the waste to be used as the first filler contains fibers, which are generally divided into natural fibers and synthetic fibers (also called chemical fibers). Both groups are used in everyday products—for example, in textile products such as clothing and fabrics, as reinforcement inserts in industry, as reinforcement inserts in plastic products, and in construction products.

[0038] Natural fibers include: - Plant fibers, a collective term for fibers of plant origin, which include: - Seed fiber - Cotton fiber (CO) - Kapok (KP) - Akon - Poplar fluff bast fiber

[0039] Bamboo fiber

[0040] Fiberglass boiler

[0041] Hemp fiber (HA)

[0042] Siberian hemp hemp

[0043] Jute (JU)

[0044] Urena (JR)

[0045] flax fiber

[0046] Ramie fiber (RA)

[0047] Kenaf fiber (KE)

[0048] Roselle fiber (JS)

[0049] Fiber of the Sunn (SN)

[0050] Abutilon

[0051] Punga

[0052] Castor oil plant

[0053] Bluish Dogbane

[0054] leaf fiber

[0055] Sisal (SI)

[0056] Abaca (Manila hemp) (AB)

[0057] Curauä

[0058] Fibre from agaves

[0059] Ixtle fiber

[0060] Arenga fiber

[0061] Afrik or palm fiber

[0062] Henequen fiber (HE)

[0063] Fique (FI) leaf fiber

[0064] Phormium

[0065] Alfa (AL)

[0066] Maguey

[0067] yucca

[0068] Pita

[0069] Fruit fiber

[0070] Coconut fiber (CC)

[0071] As replacement fibers can be used e.g. fibers from: broom

[0072] hop

[0073] Cattail reed

[0074] Willow bast

[0075] Fiber from spinning glands

[0076] Tussah silk (ST)

[0077] Muga silk

[0078] Eriseid

[0079] Anapheseide

[0080] Spider silk Byssus silk Fiber from silkworm glands Fibers from hair follicles

[0081] Sheep wool (WO)

[0082] Alpaca (WP), llama (WL), vicuna (WG), guanaco (GU) camel hair (WK)

[0083] Angora (WA)

[0084] Kashmir (WS)

[0085] Mohair (World Cup)

[0086] Yak (HY)

[0087] Goat hair (HZ)

[0088] Cattle hair (HR) Horsehair (HS) Fiber plaster

[0089] Wollastonite.

[0090] Synthetic or chemical fibers:

[0091] Man-made fibers are all fibers that are artificially produced by chemical-technical processes from natural or synthetic polymers as well as from inorganic substances, predominantly in the form of filaments (monofilaments, multifilaments) and further processed into filament yarns or processed into staple fibers (staple fibers) by cutting or tearing and then spun into yarns by secondary spinning processes or processed directly into textile fabrics, for example, by nonwoven manufacturing processes. Due to their artificial origin, they are still also referred to as

[0092] Synthetic fibers.

[0093] Chemical fibers are described in the DIN EN ISO 2076 standard for the designation of chemical fibers, which was published in 2014. The generic names are usually used together with the word "fiber," for example, the generic names viscose are used as viscose fiber and glass as glass fiber.

[0094] Fibers made from natural polymers

[0095] Fibers made from regenerated cellulose

[0096] Viscose (CV)

[0097] Modal (CMD)

[0098] Lyocell (CLY)

[0099] Cupro (CUP)

[0100] Fibers made from cellulose esters

[0101] Acetate (CA)

[0102] Triacetate (CTA)

[0103] Protein fibers

[0104] Regenerated protein fibers (PR)

[0105] Modified soybean protein fiber (MSP)

[0106] Zein, fiber from corn protein.

[0107] Casein fibers (also casein fibers)

[0108] Artificial spider fiber

[0109] Polylactide (PLA)

[0110] Alginate (ALG)

[0111] Chitin (CHT)

[0112] Elastodien (ED)

[0113] Bio-based polyamides (PA 4.10 / PA 6.10 / PA 10.10 / PA 10.12 / PA 11)

[0114] Fibers made from synthetic polymers

[0115] Polyester (PES)

[0116] Polyamide (PA) (USA Nylon)

[0117] Polyimide (PI)

[0118] Polyamideimide (PAI)

[0119] Aramid (AR) 11

[0120] Polyacrylic (PAN)

[0121] Modacrylic (MAC)

[0122] Polytetrafluoroethylene (PTFE)

[0123] Polyethylene (PE)

[0124] Polypropylene (PP)

[0125] Polychloride (CLF)

[0126] Elastane (EL)

[0127] Polybenzoxazole (PBO)

[0128] Polybenzimidazole (PBI)

[0129] Polyurea

[0130] Melamine (MEL)

[0131] Polyphenylene sulfide (PPS)

[0132] Trivynil

[0133] Elastolefin (EOL)

[0134] Elastomultiester (ELE)

[0135] Polyvinyl alcohol (PVA or PVAL)

[0136] Vinylal (PVAL)

[0137] Polycarbonate (PC)

[0138] Polystyrene (PST, PS)

[0139] Fibers made from inorganic materials

[0140] Ceramic fibers

[0141] Quartz fiber, silica fiber

[0142] Fiber optic (GF)

[0143] Basalt fiber

[0144] Carbon fiber (CF)

[0145] Boron fiber

[0146] Crystal fibers

[0147] Photonic crystal fibers (Photonic-crystal fiber PCF).

[0148] slag fiber

[0149] Nanotube fibers

[0150] Metal fibers (MTF, ME / MET).

[0151] The fibers contained in the first filler, regardless of whether they are synthetic or natural, should be as short as possible. Technically, a distinction is generally made between different groups of fiber lengths – especially for fiber-reinforced plastics: - Short fibers L = 0.1 to 1 mm - Long fibers L = 1 to 50 mm - Continuous fibers L > 50 mm

[0152] For processing as a first filler, the fiber lengths should be in the short fiber range, i.e., 0.1 to 1.0 mm. The first filler produced from the heterogeneous waste materials, which replaces the filler chalk and / or talc present in the prior art, should preferably have a density p of 1.0 g / cm 3 ≤ p ≤ 1.6 g / cm 3 have.

[0153] Preferably, the composition of the waste materials should be such that the ignition residue of the first filler at 750 °C is 7.75% to 7.90%, in particular 7.80% to 7.85%.

[0154] Preferably, the first filler contains renewable raw materials, such as biological fibers from bananas, wood fibers, plants, silica, and metallic particles, such as aluminum foil sections.

[0155] The first filler can also contain composite materials. Composite materials are understood as a combination of different materials – e.g., metal / plastic composites or a combination of different material classes – e.g., in the plastics sector: plastic packaging consisting of multiple layers, which in turn are based on different types of plastic. Fiber composites consisting of a resin matrix and a reinforcing mesh are also possible. The composite materials can be separated, if necessary, e.g., by applying energy, such as heating.

[0156] In particular, it is intended that the first filler material consists of or contains unsorted waste. However, it is particularly possible that the heterogeneous waste materials are pre-sorted waste materials.

[0157] In particular, the pre-sorted waste materials should be pre-sorted in such a way that they comply with the European Union's REACH Regulation. In particular, it is also intended that the pre-sorted waste materials be pre-sorted in such a way that contaminated waste, especially asbestos-containing building materials, tar and bitumen-containing building materials, and contaminated excavated earth, is excluded.

[0158] In particular, it is also envisaged that the first filler contains waste from known recycling processes in the manufacture of sheet materials, such as roofing membranes. Corresponding production waste intended for recycling arises, for example, from the edge trim - so-called edge strips - or when starting up production, i.e. material that accumulates until the machine parameters finally correspond to the specification of the sheets to be manufactured and these can be produced. This can be homogeneous or heterogeneous materials. The latter are, for example, multi-layer sheets that contain reinforcing inserts, e.g. made of glass or polyester. Production waste that can be used as the first filler also includes production waste that occurs when a changeover has to be made during the manufacture of sheets, for example when there is a change in color or recipe.

[0159] The first filler used offers, among other things, the advantage of reducing the proportion of the matrix in a finished product and thus saving costs.

[0160] It is noteworthy, and equally inventive, that the cover membrane contains, in addition to the first filler, a second filler, which is typically used in polymer and / or plastic-containing cover membranes or layers used to manufacture multi-layer products, such as roofing membranes or other waterproofing membranes. The second filler is selected from the group of inorganic and / or mineral fillers and / or carbon black. Of particular note is a product selected from the group of chalk, talc, kaolin, and carbon black.

[0161] The proportion of the second filler in wt.% should preferably be approximately the proportion of the first filler in wt.% of the cover sheet.

[0162] In a further embodiment, the content of the second filler can also be significantly lower than that of the first filler, for example ratios of first to second filler of 4:1, 3:1, 2:1. If a first and a second filler are used, with each filler being combined with a carrier material to produce granules which together result in hybrid granules, it is particularly provided that the shape of the granules is standardized, for example by using sieves or melt filters, so that processing and dosing options are improved. This enables better homogenization, i.e. even distribution of the hybrid granules in the cover sheet, to be achieved during the extrusion step, i.e. during the production of the cover sheet, which can also be referred to as a film or layer.

[0163] Fillers are generally used to improve the following properties: - Optimization and increase of stiffness

[0164] - Reduction of shrinkage and improvement of surface appearance. - Targeted increase in thermal or electrical conductivity - Environmental sustainability - Elastic modulus - Heat resistance

[0165] - the continuous use temperature - the tendency to shrink is significantly reduced - the increase in hardness properties.

[0166] The technical challenge here is to ensure good incorporation and distribution in the carrier material matrix, the fineness and distribution of the filler particles, and to avoid excessive dosage, as the following properties can otherwise be negatively affected: a higher mass, significant deterioration of the tensile strength and elongation at break

[0167] The combination of the first filler from waste materials and the second filler, which can be inorganic, mineral fillers or carbon black, does not result in any deterioration of these properties. These properties are even partially improved by different grain size and fineness distributions of the first and second fillers. It is noteworthy and inventive that the first filler is covered by layers of the web-shaped product, in particular, encapsulated by the layers that do not contain any of the first filler, but may contain a conventional filler (second filler), such as chalk and / or talc and / or kaolin, and / or carbon black.

[0168] Encapsulation, in particular, ensures that the first filler, consisting of the crushed or ground heterogeneous waste materials, cannot absorb liquid. Furthermore, interactions with media or direct contact with underlying substrates are avoided.

[0169] Particularly good results can be achieved if the proportion in wt.% of the first filler in the cover sheet or the layer of the cover sheet containing the first filler is between 0.1 and 10, in particular between 3 and 5.

[0170] The sheet-like product is, in particular, a product that can be described as a plastic product, such as a plastic roofing membrane, where the product material contains a polymer matrix and at least the following components in wt.%. The material of the polymer matrix is ​​mentioned first: - PVC-P (reference according to DIN SPEC 20000-201): PVC ≥ 40, plasticizer ≤ 40, other materials ≤ 20 containing the first filler or - TPE (reference according to DIN SPEC 20000-201): TPE ≥ 50, other materials ≤ 50 containing the first filler or - ECB (reference according to DIN SPEC 20000-201): Butylacrylate copolymer ≥ 25, bitumen ≥

[0171] 25, other materials ≤ 30 containing the first filler or - EVA (or EVAC (reference according to DIN SPEC 20000-201 )): Ethylene-vinyl acetate (EVA)

[0172] ≥ 25, Polyvinyl chloride (PVC) ≤ 50, other materials ≤ 30 containing the first filler or - FPO (reference according to DIN SPEC 20000-201): Flexible polyolefin (FPO) ≥ 30, other

[0173] Materials ≤ 70 containing the first filler or - PIB (reference according to DIN SPEC 20000-201): High molecular weight polyisobutylene (PIB) ≥ 30, further materials ≤ 80 containing the first filler or - EPDM (reference according to DIN SPEC 20000-201): EPDM elastomer ≥ 30, further materials ≤ 75 containing the first filler.

[0174] For PVC-P, the plasticizers used can be a monomeric plasticizer, a polymeric plasticizer, a linear plasticizer, a bio-based plasticizer or a combination of these.

[0175] The first filler should in particular contain at least one material from the group of thermoplastics or thermoplastics, such as synthetic polyolefin, such as polyethylene, hard polyethylene (HDPE), soft polyethylene (LDPE), linear low-density polyethylene (LLPE), polypropylene (PP), polystyrene (PS), such as high-impact polystyrene (HIPS), polyvinyl chloride (PVC), hard PVC, soft PVC, polyurethane (PU), polyamide (PA), ethylene-vinyl alcohol copolymers (EVOH), acrylonitrile-butadiene-styrene (ABS).

[0176] If, in particular, the cover sheet is a plastic sheet with a polymer matrix, the teaching of the invention also encompasses a cover sheet containing bitumen. Polymers such as APP (atactic polypropylene) or IPP (isotactic polypropylene) are replaced by the first filler.

[0177] Consequently, the teaching according to the invention is also used in a cover sheet having bitumen as a matrix, replacing the polymer of the matrix with the filler according to the invention in order to produce a cover sheet in particular more cost-effectively.

[0178] The invention is therefore also characterized by the use of the filler according to the invention made from shredded heterogeneous waste materials from household and / or industry as a replacement for polymer of the matrix of the cover sheet.

[0179] In particular, it is also provided that the first filler is not used in powder form, but in the form of granules. A method for producing a sheet-like product, in particular a covering sheet for a building area, such as a roof, basement, pool, consisting of or containing a covering sheet with at least one first filler, in particular with one or more of the features explained above, comprises at least the method steps a) mixing at least heterogeneous waste materials from household and / or industry, b) preferably heating and drying the mixture, c) producing granules to form a first material, d) if necessary, grinding the granules of the first material, e) if necessary.Sieving the first material f) Mixing the first material with a second material comprising a plurality of substances which together form the product material, and g) Extruding the product material in order to subsequently provide the web-shaped product or a layer thereof, in particular by calendering.

[0180] A dry blend is produced through process steps a) to f) or a), b), c) and f).

[0181] Process steps d) and e) can also be used additionally before process step c). This results in an even more compact granulate shape and an even better size distribution of the particles contained in the resulting granulate.

[0182] Process steps d) and e) can also be carried out before process step c) instead of after it, thereby achieving an even more compact form of the granulate or an even better size distribution of the particles contained in the produced granulate.

[0183] In particular, the invention proposes a method for producing a web-shaped product, in particular a covering sheet for a building area, such as a roof, basement, pool, consisting of or containing a covering sheet containing a polymer and / or plastic with at least one first filler, in particular with some or more of the features explained above, comprising at least the method steps

[0184] A) Mixing of at least heterogeneous waste materials from household and / or industry,

[0185] B) preferably heating and drying the mixture, C) producing a granulate to form a first material,

[0186] D) if necessary, grinding the granules of the first material,

[0187] E) if necessary, sieve the first material

[0188] F) mixing the first material with a carrier material compatible with the polymer matrix, in particular plastic, and granulating, in particular extruding or compounding and subsequent granulating to produce a masterbatch granulate,

[0189] G) Mixing the masterbatch granules with a third material containing several substances which together form the product material, and

[0190] H) Extruding the product material in order to subsequently provide the web-shaped product or a layer thereof, in particular by calendering.

[0191] The production of granules as mentioned under c) or c) and the grinding and sieving if necessary results in the waste being available in a form that can be easily dosed in order to be incorporated into a material in accordance with the recipe specifications.

[0192] In particular, it is provided that before process step f) or G) a hybrid granulate is produced which contains the first filler and the second filler.

[0193] After process step F), the masterbatch granules are mixed with granules containing the second filler, which, as a carrier material, consists of a material that is also compatible with the polymer matrix. The granules thus produced are referred to as hybrid granules, which, according to process step G), are then mixed with a third material containing several substances that together form the product material.

[0194] Accordingly, before mixing the first material according to process step f), the first material is mixed with a granulate consisting of or containing the second filler. This hybrid material thus produced is then mixed with the second material comprising several substances that together form the product material.

[0195] The grinding of the granulate mentioned in the process can be carried out on standard grinding systems, such as planetary ball mills, which are ideal for the micro-comminution of hard, medium-hard, soft, brittle, tough, and moist materials. The material to be ground is primarily crushed by the high-energy impact of grinding balls in rotating grinding chambers. Cutting mills with a knife system or fine mills with an impact disc system can also be used.

[0196] The screening process referred to in the process can be carried out on standard screening systems, such as tumbler screens, vibrating screens, circular screens, ultrasonic screens, and / or mills with a plansifter and / or combinations of the individual processes. The advantage of screening is that overly large particles are removed from the heterogeneous material and are not transported further in the production flow.

[0197] During extrusion, it is advantageous to use a melt filter to filter out overly large particles from the filler or material. In an example film extrusion, a slot die is used to shape or form a layer, film, or roofing membrane. The layer thicknesses of the individual layers, films, or sheets can be adjusted via the adjusted die gap. If the polymer melt in the die contains particles that are too large for the set roller gap, this could lead to undesirable effects in the layer, film, or roofing membrane, such as uneven thickness distribution or visible defects such as sink marks or burnt spots.

[0198] Furthermore, good incorporation of the filler according to the invention is demonstrated via a process step of granulating a masterbatch (step F). Any masterbatch is produced from a base material, primarily a thermoplastic, which is compatible with and homogenizable with the actual material of the granulate to be subsequently mixed in. For example, for a PVC-P sheet, PVC or EVA is selected as the polymer matrix or carrier material of the masterbatch, or for a TPE or FPO sheet, PE or PP types are selected as the polymer matrix (carrier material). Due to the heterogeneous structure of the filler according to the invention, filler contents of the masterbatch of up to 30 wt. %, preferably up to 20 wt. %, particularly preferably up to 15 wt. % can be achieved.

[0199] It is possible that after the product material has been manufactured, it is extruded to form a first layer, wherein the first layer is covered on the underside by a second layer and on the top side by a third layer and optionally completely encapsulated by the second and third layers.

[0200] The first layer can be combined with the second and third layers, for example by coextrusion in the calendering process or by coating.

[0201] In particular, it is provided that the heterogeneous waste materials or the granulate produced from them is ground in such a way that the grain size of the ground waste materials is ≤ 1 mm, particularly preferably ≤ 250 pm.

[0202] Preferably, the first material is milled at a temperature T i with T1 < 80 °C. Cooled systems, e.g., at temperatures at room temperature or below 60 °C, also contribute to improvement.

[0203] The mixing of the first material with the second material or of the masterbatch granulate with the third material takes place in particular in an extruder, wherein a temperature T2 of 160 °C ≤ T2 ≤ 200 °C, preferably between 175 °C and 195 °C, is preferred during the process.

[0204] In the case of PVC-P, the first filler according to the invention can also be added during dry blend production. It is possible to add either the produced waste granulate or the ground and sieved waste mixture to the dry blend process. Addition after the plasticizer addition, i.e., at temperatures > 80 °C, is recommended to prevent migration of the plasticizer into the first filler. Furthermore, there are no restrictions, and mixing should be carried out at temperatures of 110 °C ≤ T ≤ 130 °C to obtain a homogeneous, non-gelled dry blend.

[0205] When adding the first filler, prior drying at temperatures between 40°C and 80°C, preferably 50°C and 70°C, can provide an advantage with regard to processability, compounding, or extrusion of the cover sheet. The first filler can thus absorb any residual moisture that may occur, for example, during transport. Preventing water absorption by the first filler can only be achieved with great certainty if water vapor-impermeable layers, such as aluminum foil—here with a layer thickness of at least 8 μm—are used.

[0206] According to the invention, the first filler is only added to the mixture of plastic and plasticizer and, if applicable, other formulation components when the plasticizer has been completely absorbed by the plastic (drying point).

[0207] Extrusion or calendering should be carried out at a temperature T3 of 160 °C ≤ T3 ≤ 200 °C, preferably between 175 °C and 195 °C.

[0208] Furthermore, the heated mixture of heterogeneous waste materials should be compacted before the granulate is produced.

[0209] Corresponding process steps are also applied if the second filler is used in addition to the first filler.

[0210] According to the invention, the filler commonly used for the production of sheet-like products, which is in particular chalk and / or talc, is replaced by heterogeneous waste materials derived from waste, be it domestic waste, industrial waste, or a combination thereof. The sheet-like product is in particular the covering or covering membrane of a covering system used in the construction sector, with roofing membranes being preferred.

[0211] A corresponding cover or covering sheet can be applied to a reinforcing layer, such as a combination carrier insert consisting of glass fleece and / or glass reinforcement or a fleece layer, in accordance with the prior art, as can be seen, for example, from EP 3 744 519 A1 or WO 2018 / 021667 A1, the disclosures of which are expressly incorporated by reference, while the side not covered by the sheet-like product according to the invention is covered by an adhesive layer, which can be strip-shaped. Of course, it is also possible for the sheet-like product according to the invention to be directly connected to an adhesive layer or adhesive strips in order to be attached to a building structure, such as a roof substructure. An insert or reinforcement made of, for example, glass and / or polyester can also run between the layer containing the first filler and a layer covering it and located away from the building structure.

[0212] Conventional household waste, for example, is used as a raw material for the filler. However, industrial waste can also be used, provided the components can be formed into granules in a technically and energetically viable manner. These granules are then ground to achieve grain sizes similar to those known from fillers used in the state of the art, such as chalk and / or talc.

[0213] The use of such waste as a starting point has the advantage that a dedicated collection system is not required, and municipal and industrial waste disposal companies can be used. In particular, processed waste can also be used, as can be seen in EP 1 863 620 B1, WO 2012 / 007949 A1, or WO 2010 / 082202 A2, the disclosures of which are expressly incorporated by reference and which constitute a supplementary disclosure with respect to the claimed waste materials.

[0214] In particular, the invention is characterized by a single-layer or multi-layer sheet-like product, in particular a covering sheet for a building area, such as a roof, basement, pool, consisting of or containing a covering sheet with at least one first filler, wherein the first filler consists of or contains shredded heterogeneous waste materials from household and / or industry.

[0215] In particular, it is provided that the cover sheet contains at least one polymer and / or a plastic.

[0216] The invention is also characterized by a method for producing a web-shaped product or a layer thereof, in particular a covering sheet for a building area, such as a roof, basement, pool, consisting of or containing a covering sheet with at least one first filler, comprising at least the method steps a) mixing at least heterogeneous waste materials from household and / or industry, containing at least biowaste, b) heating and drying the mixture, c) producing a granulate to form a first material, d) optionally grinding the granulate of the first material, e) optionally sieving the first material f) mixing the first material with a second material comprising a plurality of substances which together form the product material, and g) extruding the product material in order to subsequently provide the web-shaped product or a layer thereof, in particular by calendering.

[0217] The cover sheet can contain a polymer matrix or a bitumen matrix.

[0218] In particular, the invention is characterized by a multi-layer web-shaped product, in particular a covering sheet for a building area, such as a roof, basement, pool, comprising a covering sheet with at least one first filler which consists of or contains shredded heterogeneous waste materials from household and / or industry, wherein the covering layer is covered by two layers and encapsulated by these.

[0219] The invention is also characterized by a single-layer or multi-layer sheet-like product, in particular a covering sheet for a building area, such as a roof, basement, pool, consisting of or containing a covering sheet with at least one first filler which consists of or contains shredded heterogeneous waste materials from household and / or industry, wherein the waste materials are pre-sorted, wherein asbestos-containing building materials, tar- and bitumen-containing building materials, contaminated excavated earth are sorted out.

[0220] Although the teaching of the invention preferably relates to a cover sheet containing a polymer matrix, the teaching of the invention also applies to a cover sheet with a bitumen matrix.

[0221] The invention is also characterized in that the first filler has a density ρ of 1.0 g / cm 3 ≤ ρ ≤ 1 .6 g / cm 3and / or that the proportion in wt.% of the first filler in the cover sheet or in the layer in which the first filler is contained is between 0.1 and 10, in particular between 3 and 5.

[0222] If the cover sheet is multi-layered, the weight percentage refers to the layer containing the first filler.

[0223] It is particularly noteworthy that the cover sheet or layer contains the first filler and a second filler in the form of an inorganic or mineral filler or carbon black, in particular chalk and / or kaolin and / or talc and / or carbon black. In other words, the layer contains both the first and second fillers.

[0224] The invention also relates to the use of the first filler according to one or more of the above-mentioned characterizations as a filler instead of a filler that replaces the polymer of the matrix of a cover sheet or layer of a sheet-like product.

[0225] Further details, advantages and features of the invention emerge not only from the claims and the features derived therefrom - individually and / or in combination - but also from the following description of preferred examples, wherein features described in combination are also inventive in themselves.

[0226] Fig. 1 shows a cover layer system 10 in the form of a laminated, self-adhesive roofing membrane, which consists of a cover layer 12, which in the exemplary embodiment is multi-layered and consists of a top layer 24, a reinforcement layer 26 in the form of an insert or reinforcement made of glass and / or polyester, a middle layer 20, and a bottom layer 22. The cover layer system 10 further comprises a nonwoven layer 14, an adhesive layer 16, which in turn is covered by a protective film 18. The reinforcement layer 26 is not mandatory.

[0227] The middle layer 20 containing the first filler according to the invention, which can have a composition of the type described above, in particular corresponding to the formulation of a PVC-P, TPE, ECB, EVA, FPO, PIB or EPDM sheet, can be covered, i.e. encapsulated, not only on the top and bottom sides, but also at its edges by the second and third layers, i.e. the bottom layer 22 and the top layer 24, in order to prevent penetration of moisture into the middle layer 20, which is to be referred to as the first layer.

[0228] An example illustration can be seen in Fig. 2.

[0229] The first filler of the first layer or middle layer 20 is based on heterogeneous household and / or industrial waste materials, which preferably contain at least plastic and at least one or more materials from the group of biowaste, such as food, kitchen waste, and hygiene products such as diapers. Biowaste also includes renewable raw materials such as organic banana fibers, as well as wood fibers. Furthermore, it is particularly intended that the first layer 20 contains silicon dioxide, metallic particles, such as aluminum foil sections, or textile fibers.

[0230] The heterogeneous waste materials used can originate from pre-sorted waste, whereby pollutants that are particularly subject to the REACH Regulation of the European Union or metal particles that make energetically efficient processing into granules impossible or difficult have been removed.

[0231] To produce the first layer 20, the heterogeneous waste materials are heated, compacted, granulated and then ground to obtain a grain size of ≤ 1 mm, particularly preferably ≤ 250 pm.

[0232] Existing fibers have lengths that are in the range of short fibers, i.e. 0.1 to 1.0 mm.

[0233] The ground first material, i.e., the heterogeneous waste, is mixed in the manner described above—optionally after a previously produced masterbatch—with the other substances used for the middle layer and then extruded using an extruder, with processing temperatures ranging between 160°C and 200°C, preferably between 175°C and 195°C. The extruded material can then be surrounded or encapsulated by the second and third layers 22, 24 in a calendering process, with the material of the layers 22, 24 also being extruded. Optionally, the layers 20, 22, 24 or the starting materials for them can be formed by coextrusion. The proportion of the first filler according to the invention in the first layer 20 should be a maximum of 10 wt.%.

[0234] The second and third layers 22, 24, corresponding to a PVC-P membrane, can have PVC as their main component, with the proportion being between 40 and 57 wt.%. Furthermore, the material of the second and third layers contains a plasticizer, particularly a low-molecular plasticizer, in a proportion of 25 to 45 wt.%. The other substances have a maximum proportion of 20 wt.%.

[0235] Suitable materials for the upper layer 24 and the lower layer 22 are those known for covering sheets according to the application rules mentioned above.

[0236] In order to determine the extent to which the first filler according to the invention, which consists of heterogeneous waste materials, influences the properties of a covering sheet for a building area, comparative tests were carried out.

[0237] A first sample consisted of the components listed in Table 1 (Sample 1). A second sample (Sample 2) was prepared using the same recipe ingredients as Sample 1, with the exception that ground heterogeneous waste materials were used instead of chalk. The weight proportions were identical, as shown in Table 1.

[0238] Table 1 :

[0239] The ground heterogeneous waste materials, hereinafter referred to as the primary filler, had a purity level defined by the European Union's REACH regulation. The components of the primary filler were determined using differential scanning calorimetry, vibrational spectroscopy (FT-IR, Fourier transform infrared), ashing / ignition residue at 750 °C, followed by SEM (EDX) observation, microscopy, and XRF analysis.

[0240] Various types of PE and PP were found and detected as plastic components. Other chemical elements such as aluminum, sodium, magnesium, calcium, chlorine, magnesium, carbon, silicon, and oxygen were identified, which indicate, for example, chalk (CaCO3), quartz and / or silica (SiCh), and aluminum foil / sheet. Furthermore, fibers of biological origin from banana peels and wood fibers, textile fibers, acetaldehyde, acetone, and pentanal were identified. The first filler was provided as granules, which were first pre-dried for a period of approximately 2 hours at a temperature of approximately 60°C. The granules were then ground to obtain particle sizes of ≤ 1 mm.

[0241] The ground first filler was added to the PVC mixture at a temperature > 80 °C during the dry-blend process in a hot mixer, during which the other components were also added to the mixture. The resulting powder mixture or dry-blend mixture was then mixed at temperatures < 130 °C.

[0242] The mixture was then cooled to temperatures below 55 °C. The dry blend provided was then processed in an extruder at temperatures between 170 °C and 195 °C, and the mass was subsequently extruded through a slot die and calendered.

[0243] Table 2 shows the mechanical property measurements of calendered sheets produced from samples 1 and 2. It can be seen that replacing the chalk filler with ground heterogeneous waste materials did not significantly change the mechanical properties and even led to improved results in terms of dimensional stability.

[0244] Color deviations were observed between the samples. To compensate for these, appropriately modified pigment mixtures can be used.

[0245] Table 2:

[0246] Examination overview

[0247] The QUV test reproduces the damage caused by sunlight, rain and dew.

[0248] Regarding the weight loss, it should be noted that this was lower for Sample 1 than for Sample 2, which contained the filler according to the invention. This suggests that the filler according to the invention was less leached from the sample than the chalk in Sample 1.

[0249] In a further study, the materials of Sample 1 and Sample 2 were welded together using a Leister Varimat V2 and standard settings of 520°C, 2.1 m / min to verify the joint strength and the influence of the use of the inventive filler. The results showed a problem-free weld: a) Shear strength of the joint (EN 12317-2) - Ø 796 N / 50 mm, tear outside the joint b) Peel strength of the joint (EN 12316-2) - Ø 236 N / 50 mm, material destruction

[0250] The results show no negative influence compared to the welded sheets of Sample 1 and Sample 2 as described in Table 2.

[0251] In a further test, multi-layer roofing membranes 100 (Fig. 3) were produced, each with a thickness of 1.5 mm, consisting of a top layer 120, a reinforcing insert 140 made of a glass fabric, and a bottom layer 160. A waterproofing membrane (sample 3) had the following composition with respect to the top and bottom layers:

[0252] Table 3:

[0253] A roofing membrane corresponding to Sample 4 had the same structure and composition as Sample 3 with regard to the top layer and reinforcement insert. The bottom layer was formed according to the teachings of the invention and thus included the first filler according to the invention and, in addition, the second filler in the form of chalk.

[0254] To produce the filler mixture consisting of the first and second fillers, a masterbatch material was produced from the first filler and a PVC carrier material. A second granulate was produced from the second filler, chalk, and also PVC as the carrier material. The masterbatch granulate and the second granulate were then mixed to form hybrid granules. A uniform granule shape was achieved by sieving the hybrid granules. The hybrid granules were mixed with the other formulation components forming the base layer and then extruded onto the reinforcement insert (middle layer).

[0255] As can be seen from Table 3, no differences were found between sample 3 and sample 4. Table 4: The welding conditions for the peel strength and shear strength tests were 520 °C, 3.3 m / min, and Varimat V2 was used as the welding machine in the tests.

[0256] Scanning electron microscope (SEM) images revealed that the fillers in Sample 3 and Sample 4 were distributed evenly, meaning there was no chemical or physical interaction with the polymer matrix. The images also show that the first filler according to the invention is not washed out. In contrast, in some applications, fillers from the chalk and kaolin group are washed out.

Claims

Patent claims Web-shaped product and its manufacture 1. Single- or multi-layered web-shaped product (10), in particular a covering membrane for a building area, such as roof, basement, pool, consisting of or containing a covering membrane (20) or layer with at least one first filler, characterized in that the first filler consists of or contains crushed heterogeneous waste materials from household and / or industry.

2. Web-shaped product according to claim 1, characterized in that the cover web (20) or layer contains a polymer matrix.

3. Web-shaped product according to claim 1, characterized in that the cover sheet (20) or layer contains a bitumen matrix.

4. Web-shaped product according to at least one of the preceding claims, characterized in that the cover sheet (20) or layer contains the first filler as well as a second filler in the form of an inorganic or mineral filler or carbon black, in particular chalk and / or kaolin and / or talc and / or carbon black.

5. Web-shaped product according to at least one of the preceding claims, characterized in that the first filler consisting of or containing the waste material contains at least one material, preferably several materials, from the group consisting of native organic waste, dry materials, residual waste, fine waste (particle size preferably ≤ 10 mm).

6. Web-shaped product according to at least one of the preceding claims, characterized in that the first filler consisting of or containing the waste material contains at least one material or several materials from the group consisting of biowaste, such as food and kitchen waste, hygiene products, such as diapers, and plastics.

7. Balm-shaped product according to at least one of the preceding claims, characterized in that the waste material has a particle size ≤ 1 mm, preferably ≤ 250 pm.

8. Web-shaped product according to at least one of the preceding claims, characterized in that the waste material contains fibers of a length in the range of short fibers ≤ 1 mm, in particular more than 90% of the fibers have a corresponding length.

9. Web-shaped product according to at least one of the preceding claims, characterized in that the first filler has a density ρ of 1.0 g / cm³ 3 ≤ ρ ≤ 1.6 g / cm³ 3 exhibits.

10. Web-shaped product according to at least one of the preceding claims, characterized in that the residue on ignition of the first filler at 750 °C is 7.75% to 7.90%, in particular 7.80% to 7.85%.

11. Web-shaped product according to at least one of the preceding claims, characterized in that the first filler contains renewable raw materials, such as biological fibers, preferably from bananas, wood fibers, silica and optionally metallic particles, such as aluminum foil sections.

12. Web-shaped product according to at least one of the preceding claims, characterized in that the first filler consists of or contains unsorted waste.

13. Web-shaped product according to at least one of the preceding claims, characterized in that the web-shaped product (10, 12) consists of several layers (20, 22, 24), that the layer containing the first filler is covered by at least one layer (22, 24), in particular covered by two layers and encapsulated by these.

14. Web-shaped product according to at least one of the preceding claims, characterized in that the proportion in wt.% of the first filler in the cover web (20) is between 0.1 and 10, in particular between 3 and 5.

15. A web-shaped product according to at least one of the preceding claims, characterized in that the first filler containing or consisting of the heterogeneous waste materials at least partially replaces the filler present in covering layers in the construction area, in particular in the form of chalk and / or talc and / or kaolin and / or soot.

16. A web-shaped product according to at least one of the preceding claims, characterized in that the heterogeneous waste materials contain or consist of several materials from the group consisting of biowaste, hygiene products, plastics, fine waste, waste paper, waste glass, composite materials, stones, sand, textiles, and metals.

17. Web-shaped product according to at least one of the preceding claims, characterized in that the heterogeneous waste materials are pre-sorted waste materials.

18. Single- or multi-view web-shaped product according to at least one of the preceding claims, characterized in that the pre-sorted waste materials are pre-sorted in such a way that the waste materials comply with the REACH Regulation of the European Union.

19. Single- or multi-viewed web-shaped product according to at least one of the preceding claims, characterized in that the pre-sorted waste materials are pre-sorted in such a way that asbestos-containing building materials, tar- and bitumen-containing building materials, and contaminated excavated soil are sorted out.

20. Web-shaped product according to at least one of the preceding claims, characterized in that the product material, with the exception of the first filler, contains at least one Materials from the group consisting of PVC (polyvinyl chloride), TPE (thermoplastic elastomer), TPO (thermoplastic olefin-based elastomer) or FPO (flexible polyolefin), TPV (thermoplastic vulcanizate), EPDM (ethylene propylene diene monomer rubber), EVA (ethylene vinyl acetate), fluoropolymers or other common materials as specified, for example, in DIN SPEC 20000-201 :2015-08.

21. Web-shaped product according to at least one of the preceding claims, characterized in that the product material from which the cover layer (12) or a layer (20) thereof consists contains at least in wt.% at PVC-P as polymer matrix: PVC ≥ 40, plasticizer ≤ 40, other materials ≤ 20 containing the first filler or TPE as polymer matrix: TPE ≥ 50, other materials 50 containing the first filler or ECB as polymer matrix: Butyl acrylate copolymer ≥ 25, bitumen 25, further Materials ≤ 30 containing the first filler or EVA (or EVAC) as polymer matrix: Ethylene vinyl acetate (EVA) ≥ 25, polyvinyl chloride (PVC) ≤ 50, other materials ≤ 30 containing the first filler or FPO as polymer matrix: Flexible polyolefin (FPO) ≥ 30, other materials ≤ 70 containing the first filler or PIB as polymer matrix: High molecular weight polyisobutylene (PIB) ≥ 30, other materials ≤ 80 containing the first filler or EPDM as polymer matrix: EPDM elastomer ≥ 30, other materials ≤ 75 containing the first filler.

22. Web-shaped product according to at least one of the preceding claims, characterized in that the plasticizer is a monomeric plasticizer, a bio-based plasticizer, a linear plasticizer, a polymeric plasticizer or a combination thereof.

23. Web-shaped product according to at least one of claims 1 to 22, characterized in that the heterogeneous waste materials contain at least one material from the group of thermoplastics or thermoplastic plastics such as synthetic polyolefin, such as high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLPE), polypropylene (PP), polystyrene (PS), such as high-impact polystyrene (HIPS), polyvinyl chloride (PVC), rigid PVC, flexible PVC, polyurethane (PU), polyamide (PA), ethylene-vinyl alcohol copolymers (EVOH), acrylonitrile butadiene styrene (ABS).

24. Method for producing a web-shaped product (10) or a layer (20) thereof, in particular a covering membrane for a building area, such as a roof, basement, or pool, consisting of or containing a covering membrane with at least one first filler, in particular according to at least one of the preceding claims, comprising at least the process steps of: a) mixing at least heterogeneous waste materials from households and / or industry for use as the first filler; b) preferably heating and drying the mixture. c) Producing granules to form a first material, d) optionally grinding the granules of the first material, e) optionally sieving the first material, f) mixing at least the first material with a second material comprising several substances, which together form the product material, and g) extruding the product material to subsequently provide, in particular by calendering, the web-shaped product or a layer thereof.

25. Method according to claim 24, characterized in that, prior to process step f), the first material is mixed with a second filler in the form of an inorganic or mineral filler, in particular chalk and / or kaolin and / or talc, and / or carbon black.

26. Method according to claim 24 or 25, characterized in that the second material used is one which contains a polymer matrix.

27. Method for producing a web-shaped product (10) or a layer (20) thereof, in particular a covering membrane for a building area, such as a roof, basement, or pool, consisting of or containing a covering membrane with at least one first filler, in particular according to at least one of the preceding claims, comprising at least the process steps A) Mixing at least heterogeneous waste materials from households and / or industry for use as the first filler, B) preferably heating and drying the mixture, C) Production of granules to form a first material, D) if necessary, grinding the granules of the first material, E) possibly seven of the first material F) Mixing the first material with a carrier material, in particular plastic, and granulating, in particular extrusion or compounding and subsequent granulation, to produce a masterbatch granulate, G) Mixing the masterbatch granules with a third material containing several substances, which together form the product material, H) Extruding the product material to subsequently provide the web-shaped product or a layer thereof, in particular by calendering.

28. The method of claim 27, characterized in that, prior to process step G), a further granulate is produced or that a further granulate is used which contains a second filler in the form of an inorganic or mineral filler or carbon black, in particular chalk and / or kaolin and / or talc and / or carbon black, and is then mixed with the masterbatch granulate to produce a hybrid granulate, and that in process step G), the hybrid granulate is mixed with the third material.

29. The method of claim 24, characterized in that the third material contains a polymer matrix and a carrier material compatible with the polymer matrix is ​​used. 30.A method according to at least claim 24 or 27, characterized in that a first layer (20) of the web-shaped product (12) is formed from the product material and is preferably covered by at least one further layer (22, 24). A method according to at least claim 30, characterized in that the first layer (20) is covered by both a top layer (24) and a bottom layer (22).

32. A method according to at least claim 30, characterized in that the first layer (20) is a middle layer which is joined to the top layer (24) and the bottom layer (22) by coextrusion, calendering, or coating.

33. A method according to at least one of claims 24 to 32, characterized in that the middle layer (20) is surrounded by the top layer (24) and the bottom layer (22) such that the middle layer is fully encapsulated.

34. A method according to at least one of claims 24 to 33, characterized in that the granules of the first material or hybrid granules are milled to a particle size ≤ 1 mm, in particular ≤ 250 pm.

35. A method according to at least claim 34, characterized in that the granules or hybrid granules are milled at a temperature T1 < 80 °C.

36. Method according to at least one of claims 24 to 35, characterized in that the first material orHybrid granules are mixed with the second material at a temperature T2 of 170 °C ≤ T2 ≤ 195 °C, particularly in an extruder.

37. A method according to at least one of claims 24 to 36, characterized in that the product material is calendered at a temperature T3 of 170 °C ≤ T3 ≤ 195 °C.

38. A method according to at least one of claims 24 to 37, characterized in that the heterogeneous waste materials are compacted before granulation.

39. A method according to at least one of claims 24 to 38, characterized in that the first material is mixed with the second or third material only after the plasticizer present in the second or third material has been absorbed by the plastic present in the second or third material.

40. Use of the first filler according to at least one of the preceding claims. Claims as a filler in place of a filler that replaces the polymer of the matrix of a cover sheet (20) or layer of a web-shaped product (10).

Images