Académique Documents
Professionnel Documents
Culture Documents
003381
Figure 1. Simulated hopper design 1. (a) Simulation of compound ow from hopper (top) to extruder (bottom). (b) Example of bridging (ow stopped unexpectedly). (c) Top view of the hopper after bridging.
are more suitable or efcient to run with high regrind loadings. Our results showed that higher loadingsup to 85% of regrindcould be used for relatively simple (cross-section) prole extrusion. For more complex proles, lower regrind loadings should be considered. We also believe that the heat-stabilizer and lubricant package should be modied further when extruding very complex proles with high regrind loadings, such as PVC window proles. Thus, we developed a formulation with a lubricant and stabilizer package that has strong metal-release properties (it reduces the shear heat created between extruder and melt) as well as strong internal lubrication characteristics (it reduces the shear heat created between the polymer particles). This formulation allowed us to incorporate up to 70% of regrind in the compound. Using the proper hopper setup (see Figure 2), we were able to extrude proles with excellent mechanical properties and good surface nishes compared with using virgin material. Currently, we have both been able to use all of our manufacturing scrap and also purchase recycled PVC. We found that the hopper design of certain extruders plays a significant role in improving the extrusion process when using regrind. In
Author Information Hong Chang Gossen Corp. Milwaukee, WI Hong Chang is a research and development scientist with Gossen and an adjunct professor at the University of Wisconsin-Milwaukee. Nidal Abu-Zahra Materials Department University of Wisconsin-Milwaukee Milwaukee, WI Nidal Abu-Zahra, associate professor and chair of the materials department of the College of Engineering and Applied Science, holds a PhD in industrial engineering and MS and BS degrees in mechanical engineering. He is also a lean-manufacturing consultant at Gossen Corp.
References 1. Peter Mapleston, K 2010: just one word: sustainability, Plast. Eng. 66, pp. 1224, 2010. 2. Hong Chang and Nidal Abu-Zahra, One step forward to a sustainable green solution of extruded-foam PVC building products, J. Vinyl Add. Technol. In press.
Figure 2. Simulated hopper design 2. (a) Simulation of compound ow from hopper (top) to extruder (bottom). (b) All compounds transported through the hopper without interruption.
addition, the appropriate stabilizer and lubricant package is key to a lower melting temperature when high loadings of regrind are used in a compound. We concluded that the geometry of the prole may also impact the amount of regrind that could be effectively used in extrusion. Our future research will focus on development of tooling that will further improve the ability to use high loadings of recycled PVC regrind, especially for more complex proles. As more and more recycled PVC can be used to make high-quality proles, manufacturers will become signicant contributors to sustainable, green solutions for PVC applications. In addition, because of PVCs low thermal conductivity and light weight, it will become more prevalent in Leadership in Energy and Environmental Design certication and applications.