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@PHDTHESIS{Mnikes:1011683,
author = {Mönikes, Marina},
othercontributors = {Greiff, Kathrin and Dornack, Christina},
title = {{A}nalyse von {A}ufbereitungsmöglichkeiten für mehr
{K}unststoff-{R}ezyklateinsatz in der {E}lektroindustrie},
school = {Rheinisch-Westfälische Technische Hochschule Aachen},
type = {Dissertation},
address = {Aachen},
publisher = {RWTH Aachen University},
reportid = {RWTH-2025-04654},
pages = {1 Online-Ressource : Illustrationen},
year = {2025},
note = {Veröffentlicht auf dem Publikationsserver der RWTH Aachen
University; Dissertation, Rheinisch-Westfälische Technische
Hochschule Aachen, 2025},
abstract = {This dissertation on the analysis of processing
possibilities for the increased use of plastic recyclates
examines the key question of what conditions must be met to
close the plastics loops within production in the electrical
industry. The aim of this work is to demonstrate the
potential for the use of plastic recyclates within the
electrical industry and to show which of the processing
possibilities can be utilized to recycle plastic waste from
the industrial environment to close the loops. The use of
plastics has increased significantly in recent years, in
part due to their material properties. As the processing of
plastics increases, the associated environmental impact and
climate change are also coming into focus. Plastics are
durable, and only degrade very slowly. In addition,
producing plastics generates emissions that have an impact
on the environment and the climate. Within Germany, the
electrical industry is the fourth largest plastics
processing industry. Due to this, the industry is paying
particular attention to how it uses raw materials and to
where secondary materials can be used. However, due to the
high demands on product properties coupled with process
reliability issues, recycled plastics only account for
$4.5\%$ of the entire plastics requirement within the German
electrical industry. The use of plastic recyclates within
the electrical industry is limited by a plethora of
constrictions, including the need for special approvals,
material certifications, and quality standards. As a result
of these constrictions, the secondary material must not have
any significant limitations, such as reduced mechanical
properties, and must be practically equivalent to the
primary material. The potential for recycling has been
analyzed in cooperation with Phoenix Contact GmbH $\&$ Co.
KG and presented as an example for the electrical industry.
The plastics PA 6.6, PBT, PC, LCP, and TPU were selected as
the research materials for the first phase; this selection
reflects the application classes of engineering plastics and
high-performance plastics and is a representative overview
of the materials used in the electrical industry. Production
waste sorted by type in the form of sprues and rejects was
collected during production and processed by a recycling
company into the regrind and regranulate forms of recyclate
as a part of the plastics recyclate analysis. Furthermore,
criteria were defined and a procedure developed for testing
the recyclates for their suitability for use in the
electrical industry. A test and measurement plan was drawn
up for this purpose and an evaluation matrix was developed
to validate the results. The first series of tests involved
analyzing the material of the regrinds and regranulates.
Eight different tests were carried out to document the
color, moisture, degradation processes, grain size,
annealing residue, and flow properties. The material
analysis showed clear differences between the processing
steps of the regrinds and regranulates. A second series of
tests showed how the recyclates behave when primary material
is added and what influence this addition has on component
quality and the injection molding process. For this purpose,
up to three test specimens with admixture proportions of
$25\%,$ $50\%,$ and $100\%$ regrind or regranulate were
tested and compared with a reference measurement of $100\%$
primary plastic. The second series of tests clearly showed
that the use of $100\%$ regrind or regranulate is not
suitable due to the existing material damage, such as the
reduced color quality and/or deterioration of the mechanical
properties. Only the addition of primary material led to
perfect results. The results of the analyses demonstrate
that the technical recyclability of all plastic production
waste in the electrical industry is over $80\%.$ By
recycling production waste and reusing it in internal
company production processes, the current industry-typical
proportion of recycled material of the total plastics
requirement could be increased from $4.5\%$ to over $14\%.$
Prerequisites for this include the separation of production
waste by type, appropriate processing, and compliance with
approval requirements. This could close more loops in the
electrical industry and thus actively support resource
conservation and the circular economy. The insights gained
show the complexity of this field of application and open up
new perspectives for practical implementation and further
research.},
cin = {512110 / 510000},
ddc = {620},
cid = {$I:(DE-82)512110_20140620$ / $I:(DE-82)510000_20140620$},
typ = {PUB:(DE-HGF)11},
doi = {10.18154/RWTH-2025-04654},
url = {https://publications.rwth-aachen.de/record/1011683},
}
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