Micro-pellet Precursors for Recycled Polymer Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional polymer resin manufacturing processes face challenges in reliably incorporating post-consumer recycled content, particularly due to issues with suspension and dissolution of flake form in certain applications, necessitating a more effective method to integrate virgin and recycled materials.
Innovation Solution
The use of micro-pellets as precursors, ranging from 300 to 1200 pieces per gram, which can be suspended in solutions and processed through extruders to create multi-attribute pellets with both virgin and recycled content, allowing for direct integration into virgin manufacturing processes without additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If flake form recycled material is used, then recycled content can be incorporated, but suspension and dissolution problems occur
Solution Approach 1:
The patent changes the physical form parameter of recycled material from flake to micro-pellet shape, and controls size parameters (300-1200 pieces per gram), which fundamentally alters suspension and dissolution characteristics to resolve the reliability issue while maintaining recycled content incorporation
Solution Approach 2:
The recycled material is segmented into micro-pellet form with controlled particle size distribution (300-1200 pieces per gram), which improves suspension properties and dissolution behavior compared to flake form, enabling reliable incorporation into virgin resin manufacturing
2Quantity of substance
If conventional flake form is used, then recycled material can be added, but additional processing is required
Solution Approach 1:
The recycled material is pre-processed into micro-pellet form (300-1200 pieces per gram) before being introduced to the extruder, which eliminates the need for additional processing steps during manufacturing and allows direct integration into virgin resin production processes
3Reliability
If micro-pellets are used as precursors, then suspension properties improve, but manufacturing precision requirements increase
Solution Approach 1:
The patent establishes specific size parameter ranges (300-1200 pieces per gram) for micro-pellets that optimize suspension properties while being achievable through standard manufacturing processes, balancing improved reliability with practical manufacturing precision capabilities
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 the efficient production of multi-attribute pellets with improved suspension properties, enabling higher recycled content incorporation and reducing processing complexities, thereby enhancing the reliability of recycled material utilization in resin manufacturing.
Implementation Method 1
The use of micro-pellets as precursors, ranging from 300 to 1200 pieces per gram, which can be suspended in solutions and processed through extruders
Data Source
AI summary
A precursor for use in forming a multi-attribute pellet that includes virgin and recycled content is disclosed. The precursor may comprise a micro-pellet including recycled content. In embodiments, the micro-pellet may be in the range of about 300 pieces per gram to about 1200 pieces per gram. Embodiments of methods for forming precursors and methods for forming multi-attribute pellets are also disclosed.