Recycled EPDM Sealing Profiles With Co-Extruded Surface Hardness
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Solution Overview
Problem
Existing methods for recycling EPDM sealing profiles from windows, doors, and facade constructions are complex and costly due to the chemical cross-linking of polymer chains, making them non-recyclable, and lack the ability to create targeted surface variations through co-extrusion.
Innovation Solution
A method involving crushing, wetting, and shaping EPDM sealing profiles with a wetting agent, crosslinking agents, and virgin material to create a composite material with varying degrees of hardness, enabling recycling and co-extrusion into new products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If EPDM sealing profiles are recycled through traditional methods, then recycling is achieved, but the process becomes complex and costly due to chemical cross-linking
Solution Approach 1:
The recycling process is divided into distinct stages: collection of used sealing profiles, crushing/grinding into particles, mixing with virgin material and additives, and extrusion into new profiles. This segmentation allows each stage to be optimized independently, reducing overall process complexity while maintaining recycling effectiveness.
Solution Approach 2:
The patent changes the physical state of EPDM from intact cross-linked profiles to crushed particles, then re-processes them through extrusion. By controlling particle size, moisture content, and mixing parameters, the process achieves simple recycling without complex chemical breakdown, avoiding the need for expensive devulcanization chemistry.
2Quantity of substance
If EPDM sealing profiles are classified as non-recyclable due to cross-linking, then reprocessing complexity is avoided, but material utilization is lost
Solution Approach 1:
The patent converts the harmful effect of cross-linking (which prevents melting and traditional recycling) into a benefit by using the cross-linked structure as-is in the final product. The used cross-linked EPDM profiles are directly incorporated into new sealing profiles through mixing and extrusion, eliminating the need for complex chemical breakdown while achieving high material utilization.
Solution Approach 2:
The patent creates composite sealing profiles by combining used EPDM sealing profile particles with virgin EPDM material and additives. This composite approach allows both recycled and virgin materials to retain their cross-linked structure while achieving successful reprocessing and new product formation, maximizing material utilization without complex chemistry.
3Manufacturing precision
If recycled EPDM material is used without co-extrusion, then processing is simplified, but targeted surface variation and adhesion are compromised
Solution Approach 1:
The patent applies local quality by creating different surface characteristics in different regions of the sealing profile. Through co-extrusion, one surface can have a smoother finish while another has a rougher texture, or different surfaces can have different hardness levels. This allows optimized adhesion and sealing performance in specific locations without requiring complex overall processing.
Solution Approach 2:
The patent performs preliminary actions by pre-crushing and pre-moistening the used EPDM profiles before extrusion. This preliminary preparation ensures uniform distribution of recycled material in the extrusion process, enabling precise control of surface properties in the final product without adding complexity during the extrusion itself.
4Quantity of substance
If used EPDM sealing profiles are ground into fine particles, then reactive surface area increases, but fine dust production increases
Solution Approach 1:
The patent applies partial action by grinding the EPDM profiles to a moderate particle size that provides sufficient reactive surface area for successful reprocessing, but not so fine as to create excessive dust. This optimized intermediate particle size balances the need for surface reactivity with the need to minimize dust loss and handling difficulties.
Solution Approach 2:
The patent uses moisture as an intermediary substance that is added during the grinding process. This moisture acts as a mediator that reduces dust generation while maintaining particle reactivity. The moistened particles are easier to handle and less prone to dust formation, yet still provide sufficient surface area for successful extrusion and bonding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient recycling of EPDM material with different hardnesses, producing composite materials with modified surface properties for improved adhesion and reduced displacement in grooves, while being cost-effective and energy-efficient.
Implementation Method 1
Wetting the crushed material with a wetting agent, providing a recycled premix
Implementation Method 2
the chemical cross-linking of their polymer chains
Data Source
Figure 1
AI summary
A method for recycling EPDM sealing profiles from windows, doors and/or facade constructions, comprising the following steps: a. Providing (101) used EPDM sealing profiles; b. Comminuting (102), in particular grinding, the sealing profiles; c. Wetting (103) the comminuted material with a wetting agent by providing a recycled premix (1) and adding (105) virgin material (2) to the comminuted material; and d. Shaping (106) the comminuted material, in particular into an element (3) of a window, door and/or facade construction, wherein the shaping (106) is carried out by co-extrusion; and a window, door or facade construction.