Recycled Polymer Composite Filtration and Fiber Segmentation
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Solution Overview
Problem
Existing methods for producing fiber-filled polymers face challenges when using recycled polymer waste, as adding fibrous fillers to unmelted polymer waste prevents effective filtration and purification, leading to contamination and equipment blockage.
Innovation Solution
A device and method that involves melting the polymer carrier material in a first extrusion device, cleaning it using a melt processing unit with filters, and then introducing fibrous materials into a second extrusion device downstream, where they are mixed and degassed to produce a high-quality composite material, allowing for the use of up to 100% recycled materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If fibrous fillers are added to unmelted polymer waste, then fiber incorporation is achieved, but filtration and purification become impossible and equipment blocks quickly
Solution Approach 1:
The manufacturing process is divided into two separate extrusion devices: the first extrusion device handles melting and filtration of polymer waste, while the second extrusion device handles fiber incorporation. This segmentation allows each device to perform its specific function effectively without interference, resolving the contradiction between fiber incorporation and filtration capability
Solution Approach 2:
The polymer waste is melted and filtered in the first extrusion device before fiber materials are added in the second extrusion device. This preliminary action of cleaning the polymer melt before fiber addition ensures that filtration can be performed effectively while still achieving fiber incorporation in the final composite material
2Reliability
If fibrous fillers are added to melted polymer, then purification can be performed, but fiber lengths are reduced and breaking occurs
Solution Approach 1:
The process is segmented into two stages: purification in the first extrusion device and fiber incorporation in the second extrusion device. This ensures that fibers are not exposed to the high-shear mixing conditions during the purification stage, protecting fiber length while still achieving purification of the polymer carrier material
Solution Approach 2:
The polymer carrier material is purified in advance in the first extrusion device before fibers are introduced. This preliminary purification action eliminates the need for subsequent filtration that would otherwise be required after fiber addition, thereby preserving fiber length and preventing fiber breaking
3Productivity
If recycled polymer waste is used, then resource efficiency is improved, but contamination and impurities increase
Solution Approach 1:
The first extrusion device is equipped with a filtration system that extracts and removes metal splinters and other solid impurities from the melted polymer waste. This extraction process enables the use of heavily contaminated recycled materials while producing a clean polymer melt suitable for composite material production
Solution Approach 2:
The polymer waste undergoes preliminary melting and filtration in the first extrusion device before fiber addition. This preliminary cleaning action removes contaminants and impurities from recycled materials, enabling high resource efficiency without compromising material quality
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 approach enables the production of a high-quality, resource-saving composite material by ensuring the polymer carrier material is cleaned and fibers are integrated without breaking, maintaining fiber lengths and preventing contamination, thus enhancing the composite's properties and production efficiency.
Implementation Method 1
a first extrusion device (10) for melting the polymeric carrier material (2)
Implementation Method 2
a melt processing device (40) for cleaning the melted polymeric carrier material (2)
Implementation Method 3
a second extrusion device (20) in which the fibrous material (5) is mixed with the cleaned polymeric carrier material (2)
Implementation Method 4
the second extrusion device (20) having at least one degassing device (30)
Data Source
AI summary
Method and apparatus (1) for producing a filled polymeric composite material (7) comprising a polymeric carrier material (2) and a fiber material (5) as filler material, wherein the polymeric carrier material preferably contains a major proportion of recycled polymer waste (3). The apparatus comprises a first extrusion unit (10) with an inlet (11) for the polymeric carrier material and an outlet (12) for the molten polymeric carrier material, a melt purification unit (40) for purifying the molten polymeric carrier material, which is connected to the outlet of the first extrusion unit, and a second extrusion unit (20). The second extrusion unit has a melt inlet (26) connected to the outlet (42) of the melt purification unit and a fiber material inlet (27) for the fiber material, arranged upstream of the melt inlet.The second extrusion unit includes at least one degassing unit (31, 32).