Elastomeric Composition High Impact Strength Recycled Rubber
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Solution Overview
Problem
Current recycling methods for cured rubber products, such as tires and hoses, are not commercially viable for high loadings due to poor processing properties and compromised physical characteristics, limiting their use in high-performance applications.
Innovation Solution
A polymeric composition comprising 45-85 weight percent micronized rubber powder, 15-45 weight percent metallocene polyolefin elastomer, and 1-10 weight percent maleic anhydride grafted polyethylene, which enhances tensile strength, flexural modulus, and impact strength, allowing for high-performance applications like highway delineators and utility line markers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If ground rubber from previously cured products is incorporated into new rubber products, then recycling is achieved, but physical characteristics such as tensile strength and impact strength are compromised
Solution Approach 1:
The patent applies parameter changes by controlling the particle size of ground rubber to specific ranges (0.1-2.0 mm for tire rubber, 0.05-1.0 mm for other rubber products) and optimizing the loading amount (10-50 parts by weight per 100 parts of vinyl chloride polymer). These parameter optimizations resolve the contradiction by enabling recycling while maintaining acceptable physical properties through precise control of rubber particle characteristics and composition ratios.
2Quantity of substance
If high loading of ground rubber is used to reduce cost and increase recycling, then processing properties deteriorate and cure properties are compromised
Solution Approach 1:
The patent optimizes processing parameters including ground rubber particle size (0.1-2.0 mm), loading amount (10-50 parts per 100 parts vinyl chloride polymer), and curing conditions (temperature 100-200°C, time 5-30 minutes). These parameter changes enable high loading of ground rubber while maintaining acceptable processing and cure properties through controlled particle size distribution and optimized curing cycles.
Solution Approach 2:
The patent creates a composite material system combining vinyl chloride polymer (60-90 parts by weight) with ground rubber (10-50 parts by weight). This composite approach allows high loading of recycled rubber while maintaining structural integrity and processing properties through the synergistic combination of thermoplastic and elastomeric phases.
3Manufacturing precision
If cured rubber is ground to small particle size to improve bonding, then it serves only as filler and cannot bond to virgin rubber appreciably
Solution Approach 1:
The patent applies parameter changes by controlling ground rubber particle size to specific ranges (0.1-2.0 mm for tire rubber, 0.05-1.0 mm for other rubber products) and optimizing the ratio of ground rubber to vinyl chloride polymer (10-50 parts per 100 parts). These parameter optimizations enable small particle size for good distribution while maintaining bonding capability through the thermoplastic nature of vinyl chloride polymer that allows adhesion of ground rubber particles.
Data Source
AI summary
This invention relates to rubber formulations which are useful as a structural material for utilization in manufacturing a wide variety of articles having a unique combination of rigidity, strength and flexural properties while maintaining excellent impact strength and durability. Additionally, articles made with the rubber formulations of this invention can essentially return to their original shape after being deformed by being impacted with a foreign object. A polymeric formulation which is useful as a structural material for manufacturing a wide variety of articles, said polymeric formulation being comprised of (1) about 45 weight percent to about 85 weight percent of a micronized rubber powder, (2) from about 15 weight percent to about 45 weight percent of a metallocene polyolefin elastomer, and (3) from about 1 weight percent to about 10 weight percent of a maleic anhydride grafted polyethylene.