Depolymerized Wax Tack Coats for Recycled Plastic Miscibility

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Solution Overview

Problem

The use of recycled plastics in asphalt paving, particularly in tack coats, is limited by poor miscibility, microplastic evolution, inconsistent feedstock, and unpredictable performance, leading to inadequate bonding and premature pavement deterioration.

Innovation Solution

Employing depolymerized waxes derived from recycled plastics in tack coat formulations, which are created via catalytic depolymerization processes, to enhance bonding strength, reduce viscosity, and allow lower application temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If recycled plastics are used directly in tack coat formulations, then sustainability is improved, but miscibility deteriorates leading to asphalt phasing

Engineering Contradiction:

ImprovesustainabilityVSAvoidmiscibility

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The patent applies parameter changes by transforming the chemical structure of recycled plastics through depolymerization to change their molecular weight and chemical properties. This transformation improves miscibility with asphalt while maintaining sustainability benefits, resolving the contradiction between using recycled materials and achieving proper formulation stability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system by combining depolymerized plastic products with asphalt and other tack coat components. This composite approach allows the recycled plastic to be integrated into the asphalt matrix, improving both sustainability and formulation stability through proper material composition.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If recycled plastics are used in tack coats, then sustainability is improved, but performance predictability deteriorates due to inconsistent feedstock

Engineering Contradiction:

ImprovesustainabilityVSAvoidperformance predictability

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The depolymerization process standardizes the chemical properties of recycled plastic feedstock by transforming it into a controlled product with consistent molecular weight and composition. This parameter transformation improves performance predictability while maintaining the sustainability advantages of using recycled materials.

Inventive Principle:

Principle #35Parameter changes

3Strength

If traditional waxes are used in tack coats, then bonding is improved, but environmental harm increases due to petroleum extraction

Engineering Contradiction:

Improvebonding strengthVSAvoidenvironmental harm

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful environmental impact of petroleum extraction into a beneficial process by using depolymerized recycled plastics as the wax source. This transforms a harmful resource extraction approach into a sustainable recycling approach, maintaining bonding strength while eliminating environmental harm.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the source and chemical properties of the wax from petroleum-based to recycled plastic-based through depolymerization. This parameter change maintains the functional properties needed for bonding while eliminating the environmental harms associated with petroleum extraction.

Inventive Principle:

Principle #35Parameter changes

4Quantity of substance

If higher application temperatures are used, then viscosity is reduced for better application, but energy consumption increases

Engineering Contradiction:

Improveapplication rateVSAvoidenergy consumption

Core Design Contradiction:

Quantity of substanceVSUse of energy by moving object

Solution Approach 1:

The patent changes the chemical composition of the tack coat formulation by incorporating depolymerized plastic products that modify the temperature-viscosity relationship. This allows the formulation to achieve proper application characteristics at lower temperatures, reducing energy consumption while maintaining acceptable application rates.

Inventive Principle:

Principle #35Parameter changes

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

The use of depolymerized waxes increases bond strength by 20%, reduces application rates by 50%, and eliminates the need for environmentally harmful solvents, improving sustainability and safety in tack coat applications.

Implementation Method 1

Methodology Applied

Scientific EffectViscosity reduction:

Implementation Method 2

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

The waxes are created from the depolymerization of plastics, including recycled plastics, including but not limited to polyethylene and/or polypropylene.

Methodology Applied

Scientific EffectCatalytic depolymerization: Catalysis

Data Source

PatentUS20260008937A1Tack Coat Formulations Containing Products Derived from Depolymerized Polymers

Publication Date: 2026.01.08 GREENMANTRA RECYCLING TECH

AI summary

Tack coat formulations can include an amount of a depolymerized wax. In some embodiments, the depolymerized wax is a polypropylene-based wax. In some embodiments, the depolymerized wax is a polyethylene-based wax. In some embodiments, the tack coat formulation is a hot applied tack coat. In some embodiments, the tack coat formulation is polymer modified tack coat. In some embodiments, the tack coat formulation is a cutback bitumen tack coat. In some embodiments, the tack coat formulation is an asphalt emulsion tack coat. In some embodiments, the tack coat is a trackless tack coat.