Recyclable Polymer Structures via Reversible Click Bonds

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Solution Overview

Problem

Existing polymer recycling methods face challenges in efficiently converting and reconfiguring polymer structures due to limitations in breaking and reforming chemical bonds, which restricts the recyclability and reusability of polymer materials.

Innovation Solution

A method involving the use of chemical click bonds to form and re-form polymer structures, where particles with specific functionalities are bonded and separated to create new shapes, allowing for the recycling and reconfiguration of polymer structures by breaking and re-click-bonding, utilizing epoxy particles and polymers like polyimides and polyurethanes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional polymer recycling methods are used, then polymer structures can be recycled, but the recycling process is inefficient and cannot easily reconfigure polymer structures into new shapes

Engineering Contradiction:

Improverecycling efficiencyVSAvoidreconfiguration capability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The polymer structure is divided into discrete particles bonded by reversible click bonds, allowing the material to be segmented into feedstock particles for recycling while maintaining the ability to reassemble into various new shapes and structures

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses reversible chemical bonds (click bonds) that can be broken and reformed under controlled conditions, enabling the polymer to transition between structured and feedstock states. The use of diels-alder reactions allows bonding at lower temperatures and debonding at elevated temperatures, providing controllable parameter changes for efficient recycling and reconfiguration

Inventive Principle:

Principle #35Parameter changes

2Loss of substance

If chemical bonds are broken to recycle polymer structures, then material reuse is enabled, but the process is complex and energy-intensive

Engineering Contradiction:

Improvematerial reuseVSAvoidrecycling process complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The invention replaces traditional mechanical recycling methods with chemical bond-based recycling. The reversible click bonds (diels-alder reactions) enable controlled debonding through chemical mechanisms rather than mechanical force, reducing process complexity and energy requirements while enabling complete material recovery

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The recycling process utilizes thermal phase transitions to control the reversible bonding. Heating above the glass transition temperature enables bond breaking, while cooling facilitates bond reforming, providing a simple thermally-driven mechanism for recycling without complex equipment

Inventive Principle:

Principle #36Phase transitions

3Reliability

If polymer structures are designed for recyclability, then environmental sustainability improves, but the structural strength and rigidity are compromised

Engineering Contradiction:

Improvestructural strengthVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The invention creates composite polymer structures where particles are bonded through reversible click bonds. This composite architecture maintains structural strength through the bonding network while enabling recyclability through the reversible nature of the bonds. The particles themselves can be crosslinked for strength while the inter-particle bonds remain reversible

Inventive Principle:

Principle #40Composite materials

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 efficient recycling and reconfiguration of polymer structures, allowing for repeated use and adaptation of materials, such as in space missions, by converting used polymer structures into feedstock and re-forming them into new shapes, enhancing material reuse and reducing waste.

Implementation Method 1

Breaking the click bonds may optionally include heating the particles

Methodology Applied

Scientific EffectThermal energy input: Heating

Implementation Method 2

the feedstock particles are chemically click-bonded together to form a second polymer structure

Methodology Applied

Scientific EffectChemical bonding: Chemical Bonding

Data Source

PatentUS11649337B2Recycle feedstocks for on-demand article manufacturing

Publication Date: 2023.05.16 UNITED STATES OF AMERICA AS REPRESENTED BY THE ADMINISTRATOR NAT AERONAUTICS & SPACE ADMINISTRATION

AI summary

A method of recycling a polymer structure includes converting a first polymer structure into feedstock. The first polymer structure comprises particles that are bonded to one another by chemical click bonds to form a first shape. The first polymer structure is converted into feedstock particles by breaking the click bonds. The feedstock particles are formed into a second shape, and the feedstock particles are chemically click-bonded together to form a second polymer structure having a second shape. Breaking the click bonds may include heating the particles. The structures may be formed by causing first particles having dienes to chemically bond to dienophiles of second particles.