Melt-Processed Polymer Composition With Recycled PEX Filler
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Solution Overview
Problem
Recycling of cross-linked polyethylene is challenging due to its thermoset properties, which make it difficult to remelt and combine with thermoplastic materials, resulting in low compatibility and impaired melt processing, leading to limited recycling options and high ash residues during combustion.
Innovation Solution
Finely ground cross-linked polyethylene is mixed with thermoplastic polymers to form a composition that can be melt-processed, allowing for higher loadings of PEX as a filler, improving mechanical properties and weldability, and reducing the need for mineral fillers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cross-linked polyethylene is used in high proportions in polymer blends, then recycling efficiency improves, but melt processing capability deteriorates due to poor compatibility with thermoplastic materials
Solution Approach 1:
The patent changes the particle size parameter of cross-linked polyethylene from conventional large particles to fine powder form. This parameter change enables the cross-linked polyethylene to be evenly dispersed and compatibilized with thermoplastic matrices, allowing high proportions (30-80 wt%) to be used while maintaining melt processing capability through conventional extrusion and injection molding techniques.
Solution Approach 2:
The patent creates a composite material system where fine powder cross-linked polyethylene is combined with thermoplastic polymers to form a homogeneous blend. This composite approach allows the thermoset cross-linked polyethylene to function as a filler within the thermoplastic matrix, achieving both high recycling content and processability through standard thermoplastic processing methods.
2Reliability
If cross-linked polyethylene is ground to fine powder and mixed with thermoplastic polymer, then compatibility and weldability improve, but the complexity of the processing procedure increases
Solution Approach 1:
The patent applies preliminary action by pre-grinding cross-linked polyethylene into fine powder before blending with thermoplastic polymers. This pre-processing step ensures proper particle size for compatibility and dispersion, but the subsequent processing uses standard extrusion and molding equipment, so the overall complexity increase is minimal while weldability is significantly improved.
3Strength
If conventional mineral fillers are replaced with cross-linked polyethylene, then mechanical properties and strength improve, but ash residues during combustion increase
Solution Approach 1:
The patent converts the harmful thermoset nature of cross-linked polyethylene (which normally prevents recycling) into a beneficial filler material. By grinding it to fine powder and blending with thermoplastics, the cross-linked polyethylene becomes a strength-enhancing filler that replaces mineral fillers, thereby reducing combustion ash residues while improving mechanical properties.
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 enables cost-effective recycling of cross-linked polyethylene waste, enhances the strength and weldability of polymer products, and reduces ash residues during combustion by incorporating PEX as a filler in thermoplastic matrices, offering improved mechanical properties and reduced material weight.
Implementation Method 1
cross-linked polyethylene is mixed with at least one thermoplastic matrix polymer to form a polymer composition which is melt-processed
Implementation Method 2
a polymer composition which is melt-processed
Data Source
AI summary
A method and composition of making polymer products from thermoplastic polymers by melt processing. Cross-linked polyethylene are mixed with at least one thermoplastic matrix polymer to form a polymer composition which is melt-processed. The cross-linked polyethylene is formed by a finely divided powder with particles having a screened size of less than 600 μm and a D50 of 200 to 400 μm. Cross-linked polyolefin can be used in a cost-effective and simple manner so that products generally considered a waste, such as scrapped cross-linked polyethylene pipes or unused cross-linked polyethylene discarded in e.g. pipe making processes, can be recycled and used as a starting material for polymer products.