Recycled Polymer Tile Composition with Flame Retardants
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Solution Overview
Problem
Current methods for recycling plastic waste into tile compositions lack effective solutions for achieving low flammability, high UV stability, high durability, long-term thermal stability, extended shelf life, and low environmental impact, while also reusing polymer waste and being easily prepared.
Innovation Solution
Developing tile compositions comprising at least 40 wt.% recycled polymer, such as HDPE, LDPE, or polypropylene, combined with additives like mold releasing agents, flame retardants, light stabilizers, and stabilizer additives, with no virgin polymer, to create tiles that are aesthetically pleasing, durable, and environmentally friendly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic waste is recycled into tile compositions using conventional methods, then polymer waste is reused, but the tiles lack low flammability, high UV stability, high durability, and long-term thermal stability
Solution Approach 1:
The patent applies composite materials by combining recycled polymer particles with specific additives including flame retardants, UV stabilizers, and mold releasing agents in a master batch composition. This composite approach enables the tile to achieve multiple performance requirements (flammability resistance, UV stability, durability) simultaneously while using recycled materials, resolving the contradiction between reliability and ease of manufacture.
Solution Approach 2:
The patent changes the chemical and physical parameters of the recycled polymer through the addition of functional additives. By modifying the composition parameters (adding flame retardants, stabilizers, and processing aids), the tile achieves improved flammability resistance, UV stability, and thermal stability without changing the fundamental recycled polymer base material, thus maintaining ease of manufacture while enhancing reliability.
2Object-affected harmful factors
If tile compositions are made with 100% recycled polymer, then environmental impact is reduced and virgin polymer use is eliminated, but the tiles exhibit poor aesthetic appearance and reduced performance
Solution Approach 1:
The patent applies local quality by adding specific functional additives at controlled concentrations (0.1-10 wt% each) to the recycled polymer matrix. Each additive provides a localized function: flame retardants for fire resistance, UV stabilizers for color retention, and mold releasing agents for manufacturing. This allows the tile to maintain 100% recycled polymer content (low environmental impact) while achieving required performance and aesthetic properties through targeted local modifications.
Solution Approach 2:
By creating a composite material system where recycled polymer particles are combined with functional additives in a master batch, the patent achieves both environmental sustainability and performance requirements. The composite structure allows the recycled polymer to form the bulk material (reducing environmental impact) while the embedded additives provide the necessary functional properties (flammability resistance, UV stability, appearance).
3Loss of substance
If conventional plastic recycling methods are used, then plastic waste is processed, but substantial waste including organic waste, metal waste, water waste, and carbon dioxide is generated
Solution Approach 1:
The patent extracts and removes contaminants from the recycled polymer stream through filtration and separation processes before incorporating the cleaned polymer particles into the tile composition. This extraction of impurities (organic waste, metal waste, water waste) reduces substance loss and environmental harm while maintaining recycling productivity by ensuring the polymer material is suitable for reuse without generating substantial waste byproducts.
Solution Approach 2:
The patent converts the potential harm of using recycled polymer (which may contain impurities and degraded properties) into a benefit by systematically addressing and eliminating contaminants through the master batch composition process. The recycling process, which could generate waste, is transformed into a beneficial closed-loop system where polymer waste is converted into high-performance tile material with reduced substance loss.
4Ease of manufacture
If recycled polymer particles are used directly without additives, then the manufacturing process is simple, but the tiles lack flammability resistance, UV stability, and extended shelf life
Solution Approach 1:
The patent applies preliminary action by pre-mixing the recycled polymer particles with functional additives (flame retardants, UV stabilizers, mold releasing agents) in a master batch composition before tile manufacturing. This preliminary incorporation of protective agents ensures that the recycled polymer is pre-equipped with flammability resistance, UV stability, and processing performance, eliminating the need for complex post-processing steps while extending the tile's shelf life and stability.
Solution Approach 2:
The patent changes the chemical composition parameters of the recycled polymer by incorporating functional additives at optimized concentrations. This parameter modification enhances the polymer's inherent properties (adding flammability resistance, UV stability, and extended shelf life) while maintaining manufacturing simplicity, as the modified polymer can be processed using standard tile manufacturing techniques without requiring complex additional steps.
Data Source
AI summary
The present disclosure provides compositions comprising a tile and methods for preparing the tile. The tile may be a floor tile, a wall tile, or a decorative tile used commercially or residentially.