Bio-Based Calcium Carbonate Filler for Polymer Reinforcement
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Solution Overview
Problem
The challenge is to develop a calcium carbonate-comprising material with a high content of bio-based carbon that can be effectively used in polymers, particularly in bio-based polymers, while maintaining sufficient mechanical, rheological, and processing stability.
Innovation Solution
A calcium carbonate-comprising material is developed with specific properties, including a weight median particle size of ≤60 μm, a top cut particle size of ≤500 μm, and a residual total moisture content of ≤1.0 wt.-%. This material has a bio-based carbon content of at least 50 wt.-%, based on the total weight of carbon, and can be based on eggshells, seashells, and/or oystershells. Additionally, the material may be treated with surface-treatment agents to enhance its properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If calcium carbonate is added to polymer compositions to improve mechanical properties, then the mechanical properties are improved, but the bio-based carbon content decreases
Solution Approach 1:
The patent applies parameter changes by carefully controlling the particle size distribution (d50: ≤60 μm, d98: ≤500 μm) and moisture content (≤1.0 wt.%) of the calcium carbonate filler to optimize its performance in bio-based polymer compositions. These parameter adjustments enable the inorganic filler to enhance mechanical properties while minimizing the reduction of bio-based carbon content, achieving a balance between reinforcement and sustainability.
2Ease of manufacture
If calcium carbonate filler is used in bio-based polymers to achieve economical viability, then the economical viability is improved, but the bio-based carbon content decreases
Solution Approach 1:
The patent optimizes the particle size parameters (d50: ≤60 μm, d98: ≤500 μm) and moisture content (≤1.0 wt.%) of calcium carbonate to enhance its reinforcement efficiency. By adjusting these parameters, the filler provides superior mechanical properties at lower loadings, improving the economical viability of bio-based polymer products while preserving as much bio-based carbon content as possible.
3Stability of the object's composition
If calcium carbonate with specific particle size is used to improve processing stability, then the processing stability is improved, but the bio-based carbon content decreases
Solution Approach 1:
The patent specifies precise particle size parameters (d50: ≤60 μm, d98: ≤500 μm) and moisture content (≤1.0 wt.%) for the calcium carbonate filler to optimize processing stability in bio-based polymer formulations. These controlled parameters ensure consistent flow characteristics and processing behavior, enabling stable production while maintaining high bio-based carbon content through efficient filler utilization.
Data Source
AI summary
The present invention relates to a calcium carbonate-comprising material having a content of bio-based carbon determined according to DIN EN 16640:2017 of at least 50 wt.-%, based on the total weight of carbon in the calcium carbonate-comprising material, a process for the preparation of the calcium carbonate-comprising material, a polymer formulation comprising the calcium carbonate-comprising material, an article formed from the polymer formulation, a process for preparing the article as well as the use of the calcium carbonate-comprising material in a polymer formulation