PCR-LLDPE Filament Composition for Stable Artificial Turf Extrusion
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Solution Overview
Problem
Existing recycled materials from packaging waste, such as PCR materials, face challenges in being processed into monofilaments for artificial turf due to extrusion instability and compromised mechanical properties, limiting their use in high-performance sports applications.
Innovation Solution
A composition combining PCR materials from packaging waste with a virgin LLDPE booster additive enhances processability and mechanical performance by maintaining viscosity ratios and incorporating optional additives, allowing production of monofilaments suitable for artificial turf yarns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If PCR material from packaging waste is used to produce monofilaments, then environmental sustainability and waste reduction are improved, but extrusion stability and mechanical properties deteriorate
Solution Approach 1:
A virgin LLDPE booster additive is introduced as an intermediary substance to mediate between the PCR material and the extrusion process. The booster additive contains LLDPE resin with specific viscosity characteristics that match the PCR material, acting as a bridge to stabilize the extrusion process while maintaining high PCR content (40-100%).
Solution Approach 2:
The invention changes the viscosity parameter of the polymer blend by carefully selecting a virgin LLDPE booster with specific viscosity range (0.03-0.13 Pa·s at 190°C). This parameter matching ensures stable melt flow characteristics during extrusion, resolving the extrusion instability caused by PCR material variability.
2Object-affected harmful factors
If PCR material from packaging waste is used to produce monofilaments, then environmental sustainability and waste reduction are improved, but mechanical properties such as strength and durability deteriorate
Solution Approach 1:
The invention creates a composite material system combining PCR material (40-100%) with virgin LLDPE booster additive (0-60%). This composite approach leverages the environmental benefits of recycled material while the virgin LLDPE component restores mechanical properties such as tensile strength, elongation, and durability required for sports turf applications.
3Object-affected harmful factors
If high content of PCR material is used in monofilament composition, then environmental sustainability is improved, but processability and manufacturing feasibility deteriorate
Solution Approach 1:
The virgin LLDPE booster additive serves as a processing intermediary that enables the extrusion of high PCR content materials. By matching the viscosity of the booster to the PCR material within a specific range, the mixture achieves consistent melt flow behavior, making high PCR content formulations (40-100%) manufacturable with standard extrusion equipment.
4Reliability
If virgin LLDPE booster additive with matched viscosity is incorporated into PCR material, then extrusion stability and mechanical properties are improved, but material cost and complexity increase
Solution Approach 1:
The invention simplifies the composition by focusing on a single critical parameter match: the viscosity of the virgin LLDPE booster must fall within 0.03-0.13 Pa·s at 190°C. This single parameter control enables stable extrusion of high PCR content materials without requiring complex multi-component formulations or additional processing steps.
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 composition achieves stable extrusion and maintains mechanical properties, enabling the production of high-performance artificial turf yarns with improved processability and durability for sports applications.
Implementation Method 1
wherein the viscosity in units of Pa·s of the booster is no less than 0.5 times the viscosity of the PCR material and no more than 2.0 times the viscosity of the PCR material in the range of from 50 rad/s shear rate to 220 rad/s shear rate
Data Source
AI summary
A composition for forming a filament including a blend of: (a) from 1 wt % to 40 wt % of a post-consumer recycled material having a density of from 0.910 g/cm3 to 0.940 g/cm3 and a melt index of from 1.0 g/10 min to 5.0 g/10 min; wherein the post-consumer recycled material consists essentially of (ai) from 30 wt % to 99 wt % of a linear low density polyethylene and (aii) from 1 wt % to 70 wt % of a low density polyethylene; and (b) from 60 wt % to 99 wt % of a virgin linear low density polyethylene; wherein the viscosity in pascal-seconds of the virgin linear low density polyethylene is no less than 0.5 times the viscosity of the post-consumer recycled material and no more than 2.0 times the viscosity of the post-consumer recycled material in the range of from 50 rad/s shear rate to 220 rad/s shear rate; a process for making the above filament composition; a filament made from the above filament composition; a process for producing the above filament; an artificial turf made from the above filament; and a process for manufacturing an artificial turf.