Reclaimed PVC Substrate Manufacturing via Thermal Compression

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Solution Overview

Problem

The recycling of reclaimed poly(vinyl chloride) (PVC) is challenging due to processing difficulties caused by unknown additives and fillers, limiting its reuse in future applications, as conventional melt processing is ill-suited for handling the variability in reclaimed PVC materials.

Innovation Solution

A method for continuous manufacture of poly(vinyl chloride) and reclaimed poly(vinyl chloride) substrates using a continuous double belt press, which thermally compresses particulate PVC compounds to form substrates with controlled features like lower density, surface coloration, and cupping without requiring precise melt state properties, enabling the reuse of reclaimed PVC materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional melt processing is used for reclaimed PVC, then processing is simple and equipment is standard, but the variability in reclaimed PVC materials causes processing difficulties and limits reuse

Engineering Contradiction:

Improveprocessing simplicityVSAvoidprocessing reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the processing parameters from melt-state processing to particle-board pressing conditions. By controlling moisture content (6-12%), pressing temperature (80-120°C), and pressing pressure (0.5-2.0 MPa), the process accommodates reclaimed PVC variability without requiring precise melt state control, thus resolving the contradiction between ease of manufacture and processing reliability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional melt processing (thermal-mechanical extrusion) with a particle-board pressing system. This substitution uses moisture control and mechanical pressing rather than melt flow control, enabling reliable processing of reclaimed PVC with unknown additives and fillers

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Quantity of substance

If reclaimed PVC with unknown additives and fillers is processed, then material availability increases, but processing difficulties arise due to feedstock variability

Engineering Contradiction:

Improvereclaimed PVC availabilityVSAvoidprocessing ease

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent changes the processing approach from melt-state parameters to particle-board pressing parameters (moisture content, pressing temperature, pressing pressure). This allows processing of reclaimed PVC with variable composition including unknown additives and fillers, increasing material availability while maintaining processing ease

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent achieves homogeneous pressing conditions across the reclaimed PVC material by controlling moisture content uniformly (6-12%) and applying consistent pressing pressure (0.5-2.0 MPa). This homogenizes the processing of heterogeneous reclaimed PVC feedstock, making manufacturing easier despite material variability

Inventive Principle:

Principle #33Homogeneity

3Productivity

If high fraction of reclaimed PVC is used, then cost-effectiveness and sustainability improve, but conventional processing methods become ill-suited and commercial utility is limited

Engineering Contradiction:

Improvecost-effectivenessVSAvoidcommercial utility

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent changes from melt processing parameters to particle-board pressing parameters, enabling high fractions of reclaimed PVC (up to 100%) to be processed effectively. The controlled moisture content (6-12%), temperature (80-120°C), and pressure (0.5-2.0 MPa) parameters make high-reclaimed-content products commercially viable for applications like ceiling tiles and flooring

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces melt extrusion machinery with particle-board pressing equipment, enabling cost-effective processing of high fractions of reclaimed PVC. This substitution removes the limitations of conventional processing methods and opens commercial utility for reclaimed PVC in various building materials applications

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 allows for the cost-effective reclamation and reuse of large amounts of PVC, producing substrates with desirable mechanical and aesthetic characteristics suitable for various applications, such as building materials and flooring, while maintaining rigidity and reducing material costs.

Implementation Method 1

thermally compressed to form a continuous panel of desired flatness

Methodology Applied

Scientific EffectThermal compression: Heating

Implementation Method 2

thermal compression bonding of poly(vinyl chloride) compounds and reclaimed poly(vinyl chloride) compounds to form rigid substrates

Methodology Applied

Scientific EffectThermal compression bonding: Heating

Data Source

PatentUS10543626B2Poly(vinyl chloride) substrates and method for producing the same

Publication Date: 2020.01.28 INTERFACIAL CONSULTANTS LLC

AI summary

Articles and methods of manufacture of poly(vinyl chloride)-based substrates are described. The substrates may be utilized in various consumer, industrial, transportation, building and construction, and agricultural applications and may include reclaimed poly(vinyl chloride).