Composite Polymer Separation With Vacuum Solvent Circulation
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Solution Overview
Problem
Larger composite polymer objects, such as boat hulls and windmill blades, are difficult to recycle due to their size, often ending up in landfills where they break down into microplastics over hundreds of years.
Innovation Solution
A method and system involving a flexible bag and solvent circulation under vacuum to separate embedded fibers or fillers from the polymer matrix, using a solvent infusion system with a flow netting and pumps to facilitate chemical breakdown without physical cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional recycling facilities are used, then small-scale composite polymer objects can be recycled, but larger composite polymer objects cannot be recycled due to their size
Solution Approach 1:
The patent replaces mechanical cutting and shredding systems with a chemical solvent-based system. The solvent circulates through the composite polymer object, chemically breaking down the polymer matrix and separating embedded fibers and fillers. This chemical approach eliminates the size limitations of mechanical recycling facilities, enabling the recycling of large objects like boat hulls and windmill blades without requiring physical cutting or specialized equipment.
Solution Approach 2:
The patent changes the state of the polymer matrix from solid to dissolved by introducing a chemical solvent. The solvent transforms the polymer matrix into a soluble state, allowing it to be separated from embedded components. This parameter change from solid to dissolved enables the recycling process to handle objects of any size, as the chemical breakdown occurs throughout the entire object regardless of its dimensions.
2Ease of manufacture
If large composite polymer objects are sent to landfills, then they can be disposed of, but they break down into microplastics over hundreds of years
Solution Approach 1:
The patent converts the harmful persistence of large polymer objects in landfills into a beneficial recycling opportunity. Instead of allowing them to degrade slowly into microplastics over hundreds of years, the chemical solvent process rapidly breaks down the polymer matrix in a controlled manner, separating it from embedded fibers and fillers. This transforms the long-term degradation problem into a short-term chemical processing solution, eliminating microplastic formation while enabling material recovery and reuse.
3Productivity
If solvent circulation is used to separate embedded components, then chemical breakdown occurs, but solvent volume requirements increase
Solution Approach 1:
The patent employs a hydraulic circulation system where a pump forces the solvent through the composite polymer object. The solvent is circulated under pressure through the object, allowing efficient penetration and chemical breakdown of the polymer matrix. This hydraulic approach enables thorough solvent contact with minimal volume requirements, as the pumped circulation ensures complete solvent distribution throughout the object without requiring excessive quantities of solvent.
Solution Approach 2:
The patent implements a continuous circulation system where the solvent is constantly pumped through the composite polymer object and recovered. The solvent circulates repeatedly, maintaining continuous chemical breakdown action. This continuous action maximizes separation efficiency while minimizing solvent consumption, as the same solvent volume is reused multiple times through cyclic circulation and recovery processes.
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
Enables the recycling of large-scale composite polymer objects efficiently, reducing solvent volume requirements and minimizing material handling, allowing for the recovery of embedded components for reuse.
Implementation Method 1
the solvent circulates along the surface of the composite polymer object and separates, cleaves, or breaks down the embedded fibers or fillers (such as carbon fibers, glass fibers, wood filler, etc.) from the polymer matrix part
Implementation Method 2
The circulating pump pulls the solvent out of the flexible bag and recirculates the solvent back to the inlet (typically via the reservoir)
Implementation Method 3
A positive displacement pump creates a vacuum to pull the solvent into the flexible bag
Data Source
AI summary
Various embodiments are described herein for a system and method for breaking down a composite polymer object. The method for breaking down a composite polymer object can comprise: sealing the composite polymer object inside a flexible bag, the composite polymer object comprising an embedded component (such as fibers or fillers) and a polymer matrix component (such as resin); wherein the embedded component and polymer matrix component are chemically bonded; circulating a solvent through the flexible bag, the solvent having a chemical reaction with the composite polymer object that frees the embedded component from the thermoset polymer matrix component, the flexible bag being degradation resistant to the solvent; and recovering the embedded component from the polymer matrix component.