Graphene Masterbatch Composition for Bottle ESCR and PCR Use
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Solution Overview
Problem
Blow molded plastic bottles are susceptible to environmental stress cracking (ESC), which reduces their utility and safety over time, especially due to factors like UV light exposure and temperature changes, and there is a need for compositions that are highly resistant to ESC while incorporating post-consumer resin (PCR).
Innovation Solution
A masterbatch composition comprising graphene and a carrier resin, along with optional waxes, is added to a base resin to form a blend that improves ESC resistance, allowing for the production of plastic containers with enhanced durability and higher PCR content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If blow molded bottles are made from conventional plastic materials, then manufacturing is simple and cost-effective, but they are susceptible to environmental stress cracking which reduces utility and safety over time
Solution Approach 1:
The patent applies composite materials by combining graphene nanoparticles with polyethylene resin to create a blended composition. The graphene particles (1-2 μm size, 0.2-0.3 g/cm³ bulk density) are dispersed in the resin matrix to form a composite material that exhibits enhanced environmental stress cracking resistance while maintaining processability for blow molding applications
2Reliability
If graphene is added to improve ESC resistance, then durability and safety are enhanced, but manufacturing precision and dispersion control become more difficult
Solution Approach 1:
The patent applies parameter changes by optimizing specific parameters of the graphene material: particle size is controlled at 1-2 μm and bulk density at 0.2-0.3 g/cm³. These parameter specifications ensure proper dispersion in the resin matrix during manufacturing while achieving the desired ESC resistance enhancement
3Adaptability or versatility
If post-consumer resin is incorporated to promote sustainability, then environmental impact is reduced, but ESC resistance may be compromised
Solution Approach 1:
The patent uses composite materials to combine graphene-enhanced resin with post-consumer resin in a layered structure. The graphene-containing masterbatch is dispersed in the base resin to create a composite system that maintains ESC resistance even when incorporating up to 7% post-consumer resin, thus achieving both sustainability and reliability
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 masterbatch composition enhances the ESC resistance of plastic containers, promoting sustainability by increasing PCR usage and extending the shelf-life and safety of the containers.
Implementation Method 1
a masterbatch composition is provided for use in manufacturing a plastic container having improved environmental stress cracking resistance (ESCR)
Data Source
AI summary
The present disclosure relates to a masterbatch composition comprising 10 to 30 wt % of a graphene component and 60 to 90 wt % a carrier resin, wherein the graphene component has a particle size of 1 to 2 uM and a bulk density of 0.2 to 0.3 g/cm3.