Polymer Composite Separation via Solvent Absorption and Thermal Blistering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional recycling methodologies face difficulties in separating polymers bonded to different substrates within composite structures, leading to a significant diversion of these materials to landfills rather than recycling.
Innovation Solution
A method involving the absorption of an organic solvent composition within the polymer and substrate, followed by contact with a liquid at a temperature higher than the solvent's boiling point to induce internal pressure and separation, combined with shear or comminution to isolate the polymer from the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional recycling methodologies are used, then physical separation of polymer from substrate is attempted, but separation fails and polymer composite structures end up in landfill
Solution Approach 1:
The patent applies preliminary action by first absorbing an organic solvent composition into the polymer composite structure before thermal processing. This pre-solvation step swells the polymer and weakens adhesion to the substrate, enabling subsequent easy separation when hot liquid is applied. The preliminary solvent absorption prepares the material for effective separation that would otherwise be impossible with conventional methods alone.
Solution Approach 2:
The patent utilizes parameter changes by transforming the physical state of the organic solvent from liquid (absorbed in step 1) to vapor (in step 2 when exposed to liquid above its boiling point). This phase change generates internal pressure within the polymer matrix, causing bubbling and blistering that physically separates the polymer from the substrate. The temperature parameter is also changed to exceed the solvent's boiling point to drive this separation mechanism.
2Loss of substance
If polymer composite structures are landfilled instead of recycled, then separation difficulty is avoided, but resource waste and environmental harm increase
Solution Approach 1:
The patent converts the strong adhesion between polymer and substrate, which initially prevents separation, into a benefit through controlled solvent absorption. The solvent penetrates and swells the polymer, creating internal stress and weakening bonds. When hot liquid is applied, rapid vaporization generates pressure that exploits the softened polymer-substrate interface, transforming the previously problematic bonded structure into easily separable components, thereby enabling recovery and eliminating landfill disposal.
3Manufacturing precision
If bulk sorting and comminution are used, then polymer streams are sorted by density or weight, but residual contamination remains and clean polymer streams are not achieved
Solution Approach 1:
The patent applies extraction by removing the polymer from its composite structure through selective separation. The organic solvent is absorbed preferentially into the polymer phase, and subsequent thermal processing extracts the polymer as separated bubbles or blisters from the substrate. This extraction mechanism achieves clean polymer separation at the source, before any sorting or comminution, eliminating residual contamination that would otherwise require complex multi-stage processing.
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 method effectively separates polymers from substrates within composite structures, enabling the recycling of materials that were previously difficult to process, such as laminated polyester/polyvinyl chloride structures, by causing the polymer to bubble, blister, or foam and subsequently being isolated using known separation techniques.
Implementation Method 1
absorbing a composition comprising organic solvent within one or both of the polymer and substrate
Implementation Method 2
contacting the resulting polymer composite structure with liquid having a temperature higher than the boiling point of the composition
Implementation Method 3
causing the polymer to bubble, blister, or foam
Implementation Method 4
induce internal pressure and separation
Data Source
Figure 1~2
Figure 3
AI summary
The present invention provides a method of promoting separation of polymer bonded to a substrate of different material, which collectively form at least part of a polymer composite structure, the method comprising: (1) contacting the polymer composite structure with a composition comprising organic solvent which is absorbed within one or both of the polymer and substrate, wherein the composition comprising organic solvent does not dissolve either the polymer or the substrate, and (2) contacting the polymer composite structure provided in step (1) with liquid (i) having a temperature higher than the boiling point of the composition comprising organic solvent used in step (1), and (ii) that does not dissolve either the polymer or the substrate, the action of which promotes separation between the polymer and the substrate.