Melt Filter Plastic Separation Viscosity
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Solution Overview
Problem
Current recycling methods fail to economically separate pure plastic materials from complex mixtures, such as multilayer films and polymer blends, leading to incineration or landfill disposal due to the inability to efficiently differentiate and extract individual types of plastics based on their properties.
Innovation Solution
The method involves melting the material mixture and utilizing melt filters to separate plastics based on their specific melt viscosities, with adjustable filter stages and additional energy or chemical influences to optimize separation, allowing for the use of commercially available extrusion systems and filters to achieve high-purity recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional recycling methods are used to process mixed plastic materials, then processing can be performed on the mixture, but the plastic recyclate cannot be obtained with high purity
Solution Approach 1:
The patent changes the physical parameter of viscosity by melting the plastic mixture and utilizing the different melt viscosities of various plastic types. Melt filters with specific pore sizes are used to separate plastics based on their melt viscosity, allowing high-purity recovery of individual plastic types from complex mixtures that were previously不可回收
Solution Approach 2:
The patent replaces conventional mechanical separation methods with a viscosity-based separation system using melt filters. Instead of relying on density or mechanical sorting, the system uses the differential flow behavior of melted plastics through filters with controlled pore sizes, achieving separation based on rheological properties
2Manufacturing precision
If mixed plastic materials are processed without separation, then processing is simpler, but the plastic recyclate is contaminated and unsuitable for high-quality applications
Solution Approach 1:
The patent segments the separation process into multiple stages using a series of melt filters with progressively smaller pore sizes. Each filter stage targets specific plastic types based on their melt viscosity, allowing systematic separation of complex plastic mixtures into pure components through a modular filter cascade system
Solution Approach 2:
The patent employs a universal melt filter system that can handle various types of plastic mixtures and composite materials. The same basic filter technology works across different applications by adjusting filter pore size and arrangement, providing a multi-functional solution for separating plastics, removing contaminants, and recovering pure recyclates
3Manufacturing precision
If melt filters are used to separate plastics based on melt viscosity, then high-purity plastic separation is achieved, but the process requires melting which consumes energy
Solution Approach 1:
The patent utilizes the phase transition of plastics from solid to molten state to enable separation. By controlling the melting process and utilizing the distinct melt viscosities of different plastics, the system achieves efficient separation. The phase change is reversible, allowing the separated molten plastics to be cooled and recovered as solid recyclates
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
This approach enables efficient and cost-effective separation of individual plastic types from complex mixtures, achieving high recycling quality and enabling the reuse of previously non-recyclable materials, including composite materials and non-plastic components.
Implementation Method 1
separating one or more types of plastic contained in the melted part of the material mixture from the material mixture based on the specific melt viscosity of the respective melted type of plastic
Implementation Method 2
Melting at least part of the material mixture
Data Source
Figure 1
AI summary
The invention relates to a method for separating different types of plastic from or within a material mixture. Furthermore, the invention relates to the use of melt filters in a method according to the invention, as well as a device for carrying this out.