Recycled HDPE HFFR Cable Jacketing With Mechanical and Flame Balance
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Solution Overview
Problem
Existing recycled polyolefin materials exhibit poor mechanical properties and are not suitable for high-quality applications due to cross-contamination with non-polyolefin materials, limiting their recycling and reuse in products like jacketing materials.
Innovation Solution
A halogen-free flame retardant (HFFR) post-consumer recycled (PCR)-derived polymer composition is developed, comprising 10.0 to 45.0 wt% of specific thermoplastic PCR polymer made from high density polyethylene (HDPE) polymer, combined with other components like ethylene butyl acrylate copolymer, silicon fluid, calcium and magnesium carbonate, carbon black, and additives to enhance mechanical and flame retardant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If recycled polyolefin materials are used, then environmental impact is reduced and recyclability is improved, but mechanical properties deteriorate due to cross-contamination and degradation
Solution Approach 1:
The patent applies parameter changes by carefully controlling the melt flow rate (MFR) of the PCR-HDPE within 0.10 to 0.80 g/10min and density within 0.940 to 0.980 g/cm³. These parameter specifications ensure that the recycled material maintains adequate mechanical properties while preserving recyclability. The controlled parameters prevent excessive degradation that would occur with higher MFR values while still allowing sufficient recycled content (10-45 wt%) to be used.
Solution Approach 2:
The patent creates a composite material system by combining PCR-HDPE with specific flame retardant additives and other polymers in defined proportions. This composite approach allows the recycled base material to provide recyclability while the added components compensate for mechanical property losses and provide flame retardancy. The synergistic combination enables the use of degraded recycled material while achieving required performance levels.
2Strength
If large amounts of virgin materials are added to improve mechanical properties, then mechanical strength is improved, but environmental impact worsens and recyclability decreases
Solution Approach 1:
The patent optimizes the proportion of PCR-HDPE to be between 10.0 to 45.0 wt% of the total composition, with the remaining portion being other components. This parameter optimization allows maximum use of recycled material (up to 45%) while maintaining adequate mechanical properties. By precisely defining this range, the patent avoids the need to add excessive virgin material, thus minimizing environmental impact while achieving required performance.
Solution Approach 2:
The patent applies local quality by specifying different requirements for different components: the PCR-HDPE component has specific MFR and density ranges to ensure adequate base properties, while flame retardant additives and other components have their own specifications. This differentiated approach allows each component to contribute optimally to the overall performance, enabling high recycled content while maintaining mechanical properties through targeted component selection rather than blanket use of virgin material.
3Object-affected harmful factors
If flame retardant additives are incorporated, then safety and flame retardant properties are improved, but mechanical properties may deteriorate
Solution Approach 1:
The patent controls the MFR of the PCR-HDPE within 0.10 to 0.80 g/10min, which is a lower range than typical recycled materials. This lower MFR (higher viscosity) compensates for the mechanical property reduction caused by flame retardant additives. The controlled viscosity maintains adequate mechanical strength even with 10-45 wt% recycled content and flame retardant formulations, resolving the contradiction between flame safety and mechanical properties.
Solution Approach 2:
The patent formulates a composite system where flame retardant additives are combined with PCR-HDPE of specifically controlled properties. The composite structure allows the flame retardant components to provide safety functionality while the controlled PCR-HDPE matrix maintains mechanical integrity. This composite approach enables both flame retardancy and adequate mechanical properties to coexist without requiring excessive virgin material addition.
Data Source
AI summary
The present invention provides a novel halogen-free flame retardant (HFFR) post-consumer recycled (PCR)-derived polymer composition suitable for flame retardant layer of a wire or cable, preferably as a flame retardant jacketing layer, which comprises of from 10.0 to 45.0 wt% of a specific thermoplastic PCR polymer comprised of high density polyethylene (HDPE) polymer showing favorable to excellent mechanical properties combined with favorable to excellent flame retardant and safety properties.