Adhesive Composition Using Recycled Resin and Ethylene-Acrylic Acid Copolymer
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Solution Overview
Problem
The recycling of post-consumer polyethylene resins is hindered by their lower physical properties and processability, as well as the difficulty in distinguishing between high-quality grade A and low-quality grade C resins, which affects the uniform mixing with ethylene-acrylic acid copolymers and results in deteriorated adhesive properties.
Innovation Solution
An adhesive composition comprising an ethylene-acrylic acid copolymer and a post-consumer recycled resin (PCR) with specific melt index ranges, where the PCR is characterized using a capillary rheometer to ensure low foreign matter content and excellent miscibility, allowing for the differentiation of grade A resins and improving adhesive strength and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polyethylene PCR resin is mixed with ethylene-acrylic acid copolymer, then adhesive composition can be produced, but uniform mixing is difficult due to foreign matter and poor miscibility
Solution Approach 1:
The patent applies parameter changes by controlling the melt index of both the ethylene-acrylic acid copolymer and PCR resin within specific ranges (1-30 g/10 min and 1-10 g/10 min respectively), and maintaining their ratio within 0.33-3.0. This parameter optimization ensures compatible flow characteristics and viscosity, enabling uniform mixing while maintaining adhesive properties despite the presence of foreign matter in recycled resin.
Solution Approach 2:
The patent applies local quality by differentiating between grade A PCR resin (with low foreign matter content suitable for mixing) and grade C PCR resin (with high foreign matter content). By selectively using grade A resin and controlling the mixing process, the patent achieves uniform local distribution of components, which is essential for consistent adhesive performance.
2Object-affected harmful factors
If PCR resin is used to reduce waste and greenhouse gas emissions, then environmental benefit is achieved, but physical properties and processability deteriorate
Solution Approach 1:
The patent applies composite materials by creating a blended system of ethylene-acrylic acid copolymer and PCR resin. This composite approach allows the incorporation of recycled resin (providing environmental benefit) while the ethylene-acrylic acid copolymer component compensates for the deteriorated physical properties, achieving a balance between sustainability and performance.
Solution Approach 2:
The patent applies parameter changes by optimizing the melt index parameters of both components and their mixing ratio. By controlling these parameters, the patent improves processability (enabling continuous extrusion) while maintaining the physical properties necessary for adhesive performance, thus resolving the contradiction between environmental benefit and material quality.
3Measurement precision
If grade A and grade C PCR resins are differentiated using ICP elemental analysis or TGA pyrolysis analysis, then resin quality can be identified, but analysis cost is high
Solution Approach 1:
The patent applies this principle by replacing expensive, complex analytical instruments (ICP elemental analysis, TGA pyrolysis analysis) with a simple, low-cost melt index measurement method. The melt index test provides sufficient discrimination between grade A and grade C PCR resins at minimal cost, making quality identification economically viable for routine applications.
Solution Approach 2:
The patent applies this principle by extracting the essential quality differentiation capability from complex analytical methods and implementing it through a simplified melt index measurement approach. This extraction retains the core function of quality identification while eliminating the need for expensive equipment and complex procedures.
Data Source
AI summary
Provided is an adhesive composition including an ethylene-acrylic acid copolymer and a post-consumer recycled resin (PCR), wherein the ethylene-acrylic acid copolymer has a melt index (190° C., 2.16 kg, ASTM D1238) of 1 to 30 g/10 min, and the PCR has a melt index (190° C., 2.16 kg, ASTM D1238) of 1 to 10 g/10 min, and a preparation method thereof, which can have excellent processability, low gel content, and excellent adhesive strength by easily distinguishing a certain level of PCR resin by a capillary rheometer and mixing the PCR resin with an ethylene-acrylic acid copolymer.