Recycled Polyethylene Composition Gel Content Optimization
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Solution Overview
Problem
The use of recycled polymer materials, particularly crosslinked polyethylene, in manufacturing often results in poor mechanical properties and processing challenges, limiting their application in higher-value products due to compatibility issues and increased costs.
Innovation Solution
A polyethylene composition comprising a base resin with a combination of crosslinked polyethylene from recycled waste and virgin or recycled polyethylene, along with an inorganic mineral filler, which improves mechanical properties and processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If recycled crosslinked polyethylene is used in manufacturing, then cost is reduced and ecological footprint is lowered, but mechanical properties deteriorate and processing becomes difficult
Solution Approach 1:
The patent applies parameter changes by controlling the gel content of crosslinked polyethylene within 5-80% and optimizing the ratio between crosslinked and non-crosslinked polyethylene components. This parameter optimization resolves the contradiction by finding the sweet spot where sufficient crosslinking provides mechanical strength while limited crosslinking maintains processability and ductility.
Solution Approach 2:
The patent creates a composite material system combining crosslinked polyethylene (for strength and stability) with non-crosslinked polyethylene (for ductility and processability). This composite approach resolves the contradiction by integrating materials with complementary properties, where the crosslinked fraction provides reliability and the thermoplastic fraction ensures ease of manufacture.
2Strength
If high crosslinked content recycled waste is used, then material cost is reduced, but mechanical properties and processing speed deteriorate
Solution Approach 1:
The patent optimizes the gel content parameter to 5-80%, preventing excessive crosslinking that would cause processing difficulties. This parameter control ensures that the material maintains adequate mechanical strength while preserving sufficient thermoplastic character for efficient processing at practical speeds.
Solution Approach 2:
The patent applies local quality by creating a heterogeneous structure where crosslinked regions (providing strength) are distributed within a continuous thermoplastic matrix (enabling processing). This local differentiation allows the material to exhibit both high strength and good processability simultaneously.
3Object-generated harmful factors
If recycled polyethylene is used instead of virgin material, then cost and ecological impact are improved, but mechanical properties and compatibility deteriorate
Solution Approach 1:
The patent creates a composite system combining recycled crosslinked polyethylene with recycled or virgin non-crosslinked polyethylene. This composite structure resolves the contradiction by using the crosslinked fraction for structural strength and the thermoplastic fraction for ductility and compatibility, achieving mechanical properties comparable to virgin materials while maintaining environmental benefits.
Solution Approach 2:
The patent achieves homogeneity by carefully controlling the compatibility between crosslinked and non-crosslinked polyethylene phases through optimization of their ratio and molecular characteristics. This homogeneous integration ensures consistent mechanical properties throughout the material, closing the gap with virgin polyethylene performance.
4Stability of the object's composition
If crosslinked fractions are used in high amount, then material stability is improved, but adhesion and compatibility with thermoplastic matrix deteriorate
Solution Approach 1:
The patent optimizes the gel content parameter to 5-80%, preventing excessive crosslinking that would create large, incompatible particles. This parameter control ensures that crosslinked regions remain sufficiently small and numerous to maintain good interfacial adhesion with the thermoplastic matrix while still providing the desired material stability and strength.
Data Source
AI summary
The invention is related to a polyethylene composition characterized in that it comprises a base resin and an inorganic mineral filler which is present in the composition in an amount of 1 to 50 wt % in respect to the weight of composition, wherein said base resin comprises: a) a first crosslinked polyethylene (PEX) having a gel content (measured according to ASTM D 2765:2006) in the range of 5% to 80% in respect to the weight of crosslinked polyethylene (PEX), said crosslinked polyethylene (PEX) being obtained from recycled wastes and b) a second polyethylene (PE) selected from virgin polyethylene and recycled polyethylene, or mixtures thereof. The invention is further related to a process for production of said polyethylene composition, and use of the polyethylene composition.