Recycled PC/ABS Computer Chassis Composition
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Solution Overview
Problem
The mechanical recycling of polycarbonate-based plastics for electronic devices results in degraded mechanical properties due to energy input during the melting process, limiting the amount of recycled material that can be used, and traditional solutions to enhance properties often increase costs and environmental concerns.
Innovation Solution
A polymeric composition combining post-consumer recycled ITE waste-derived PC/ABS blend with non-ITE derived post-consumer recycled resin, fillers, and renewable source-derived flame retardants, achieving high recycle and renewable content without compromising mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If mechanical recycling is used to recycle polycarbonate-based plastics, then recycle content is increased, but mechanical properties (tensile strength, tensile modulus) degrade
Solution Approach 1:
The patent creates a composite polymer composition by combining mechanically recycled polycarbonate-based plastic with a polymeric additive composition. This additive composition contains stabilizers, lubricants, and other functional materials that compensate for the degradation caused by mechanical recycling. The composite structure allows the recycled plastic to maintain its mechanical properties while achieving high recycle content (up to 70-100% recycled material).
Solution Approach 2:
The patent modifies the physical and chemical parameters of the recycled plastic by incorporating specific additives at controlled concentrations. The additive composition includes stabilizers that prevent chain scission, lubricants that improve processing, and other functional materials that restore mechanical properties. By adjusting the concentration and type of additives, the patent maintains tensile strength, tensile modulus, and other mechanical properties despite high recycled content.
2Strength
If additives are introduced to counteract reduced mechanical properties of recycled polymer, then mechanical properties are improved, but costs increase and environmental sustainability decreases
Solution Approach 1:
The patent employs self-service by using the recycled plastic itself as the base material and adding only the necessary functional components. The additive composition is designed to work synergistically with the recycled polycarbonate-based plastic, allowing the recycled material to serve as both the structural component and the basis for the additive formulation. This reduces the need for external virgin materials while maintaining mechanical properties.
Solution Approach 2:
The patent recovers and reuses the recycled plastic that would otherwise be discarded or downcycled. By capturing the value in the recycled material and formulating it into a composite composition with appropriate additives, the patent recovers the mechanical properties and functional performance. This approach maximizes the utilization of recycled content (up to 70-100%) while minimizing the need for additional virgin materials, thereby improving sustainability.
Data Source
AI summary
Polymeric compositions, methods of making the compositions, and composites, such as computer chassis containing the compositions are described. The polymeric compositions can contain 10 wt. % to 70 wt. % of a post-consumer recycled information technology and telecommunications equipment (ITE) waste derived PC/ABS blend; 5 wt. % to 30 wt. % of a filler, wherein at least a portion of the fillers are obtained from a post-consumer recycled ITE waste; and 5 wt. % to 30 wt. % of a flame retardant obtained from a renewable source. In some instances, the polymeric compositions have a total recycled content of 50 wt. % to 90 wt. %.