Polymer composition for coating a polyolefin fabric substrate
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Solution Overview
Problem
Current polymer-coated textile materials, particularly those made from polyolefins, face challenges in recycling due to the inability to separate and reuse non-polyolefin materials like polyurethane and PVC, which are not environmentally sustainable and lack desirable properties such as stiffness and flame retardance when using recycled materials.
Innovation Solution
A polymer composition for coating polyolefin fabric substrates is developed, comprising 5-35% recycled coated polyolefin fabric substrate and 65-95% virgin polyolefin composition, specifically using ethylene and propylene based plastomers with defined density and MFR ranges, along with a flame retardant, to achieve good mechanical and flame retardant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If non-polyolefin materials (polyurethane, PVC) are used for polymer coated textile materials, then coating flexibility and softness are improved, but recyclability and separability deteriorate
Solution Approach 1:
The patent applies homogeneity by using polyolefin material for both the fabric substrate and the coating layer, ensuring material compatibility and uniform chemical properties throughout the coated textile structure. This homogeneous polyolefin composition enables effective recycling and separation while maintaining the desired coating softness and flexibility.
2Reliability
If recycled materials are used in the coating composition, then sustainability is improved, but mechanical properties (tensile strength, stiffness) deteriorate
Solution Approach 1:
The patent applies composite materials by creating a multi-component polyolefin coating composition that combines recycled coated fabric substrate (5-35 wt.%) with virgin polyolefin composition (65-95 wt.%). This composite structure integrates the sustainability benefits of recycled materials with the mechanical strength of virgin polyolefin, achieving both environmental and performance objectives.
Solution Approach 2:
The patent applies parameter changes by precisely controlling the compositional ratio of recycled to virgin polyolefin materials (5-35% recycled, 65-95% virgin) and specifying particular polyolefin composition parameters (ethylene vinyl acetate content, density, melt flow rate). These parameter optimizations ensure the coating maintains adequate tensile strength and stiffness while incorporating sufficient recycled content for sustainability.
3Reliability
If recycled coated fabric substrate is used in higher proportions, then sustainability is improved, but coating performance and mechanical properties worsen
Solution Approach 1:
The patent applies parameter changes by establishing an optimized compositional range (5-35 wt.% recycled coated fabric substrate, 65-95 wt.% virgin polyolefin composition) and controlling specific material parameters (ethylene vinyl acetate content of 5-40%, density of 0.85-0.95 g/cm³, melt flow rate of 0.5-30 g/10 min). These controlled parameters ensure consistent coating performance, adhesion, and mechanical properties while maximizing sustainable recycled content within the proven effective range.
Data Source
AI summary
The present invention relates to a polymer composition suitable for coating a polyolefin fabric substrate comprising the following components: A) 5 to 35 wt.-% based on the overall weight of the polymer composition of a recycled polyolefin fabric substrate; wherein said fabric substrate is coated with a polyolefin composition comprising the following components: a1) an ethylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.857 to 0.915 g/cm3 and a MFR2 (190° C. 2.16 kg) determined according to ISO 1133 in the range of 0.5 to 30 g/10 min; and a2) a propylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.850 to 0.910 g/cm3 and a MFR2 (230° C. 2.16 kg) determined according to ISO 1133 in the range of 0.01 to 30 g/10 min; B) 65 to 95 wt.-% based on the overall weight of the polymer composition of a virgin polyolefin composition comprising the following components: b1) an ethylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.857 to 0.915 g/cm3 and a MFR2 (190° C. 2.16 kg) determined according to ISO 1133 in the range of 0.5 to 30 g/10 min; and b2) a propylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.850 to 0.910 g/cm3 and a MFR2 (230° C. 2.16 kg) determined according to ISO 1133 in the range of 0.01 to 30 g/10 min. Furthermore, the present invention relates to use of component A) for coating a virgin or recycled polyolefin fabric substrate, to a process for coating a polyolefin fabric substrate, to a polyolefin fabric substrate coated with the composition according to the invention and to an article comprising at least one component formed from the coated polyolefin substrate.