Filler Recovery from Polymer via Step-Heating and Elutriation

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Solution Overview

Problem

Current methods for recovering filler materials from polymer matrices are energy-intensive, produce significant pollution, and require harsh chemicals, leading to resource wastage and undesirable waste.

Innovation Solution

A step-heating process followed by elutriation and filtering to separate filler materials from polymer matrices, eliminating the need for deagglomeration and harsh acids, using a system comprising a heater, elutriation, and filtering systems to efficiently recover filler materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If CO2 heating, high energy deagglomeration, and harsh acids are used for leaching and purification, then filler material can be recovered, but energy consumption increases and pollution is produced

Engineering Contradiction:

Improvefiller material recoveryVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the thermal parameters by using step-heating with specific temperature ranges (first temperature below decomposition point, second temperature at decomposition point) to selectively vaporize polymer matrix while preserving filler material, eliminating the need for harsh chemicals and high-energy deagglomeration processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces mechanical deagglomeration and chemical leaching systems with a thermal vaporization system followed by condensation, substituting high-energy mechanical and chemical processes with controlled thermal processing that achieves separation without pollution

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If CO2 heating, high energy deagglomeration, and harsh acids are used for leaching and purification, then filler material can be recovered, but pollution is produced

Engineering Contradiction:

Improvefiller material recoveryVSAvoidpollution

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the polymer matrix from a harmful contaminant requiring harsh chemical removal into a beneficial vaporizable component that separates naturally through controlled heating, with the vaporized polymer being condensed and removed as useful byproduct

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces temperature control as an intermediary mechanism that mediates between the filler material and polymer matrix, using differential thermal properties to achieve clean separation without direct contact between filler material and harsh chemicals

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If high energy deagglomeration is used, then filler material can be separated from polymer matrix, but resource input increases

Engineering Contradiction:

Improvefiller material separationVSAvoidresource input

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent extracts the polymer matrix from the composite material through selective vaporization at controlled temperatures, leaving the filler material intact and easily separable, eliminating the need for resource-intensive deagglomeration of the entire composite

Inventive Principle:

Principle #2Taking out (Extraction)

4Reliability

If polymer material is heated to high temperature to pyrolyze, then filler material can be separated, but filler material may overharden and require intense deagglomeration

Engineering Contradiction:

Improvefiller material separationVSAvoidpyrolysis temperature control

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent segments the heating process into distinct stages with different temperature levels - first heating below decomposition temperature to vaporize polymer, then controlled heating to decomposition temperature to complete pyrolysis - preventing over-hardening of filler material throughout the process

Inventive Principle:

Principle #1Segmentation

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 reduces energy consumption and pollution, enabling cost-effective and resource-efficient recovery of filler materials by preventing over-hardening and allowing for simple separation without intense deagglomeration or harsh chemicals.

Implementation Method 1

heating the polymer material to a first temperature; heating the polymer material to a second temperature higher than the first temperature to produce a pyrolyzed material

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 2

elutriating the pyrolyzed material to obtain a separated mixture

Methodology Applied

Scientific EffectDensity-based separation: Density Gradient

Implementation Method 3

filtering the separated mixture to separate the filler material from the remainder of the separated mixture

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS11465084B2Method and system for recovering filler material

Publication Date: 2022.10.11 HONEYWELL FEDERAL MANUFACTURING & TECHNOLOGIES LLC

AI summary

A method of recovering filler material from a polymer material comprises (a) heating the polymer material to a first temperature; (b) heating the polymer material to a second temperature higher than the first temperature resulting in a pyrolyzed material; (c) elutriating the pyrolyzed material to obtain a separated mixture; and (d) filtering the separated mixture to obtain the filler material.