Recycled Coated Polyolefin Fabric Composition for Impact Strength
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Solution Overview
Problem
Existing polymer compositions made from recycled materials lack the mechanical properties, such as high toughness and stiffness, necessary to compete with virgin materials in high-end applications, particularly in polymer coated textile materials used in carpets, mattresses, and car interiors, due to the challenges in recycling non-polyolefin materials like polyurethane, polyvinyl chloride, and ethylene vinyl acetate.
Innovation Solution
A polymer composition comprising 5 to 35 wt.% of a recycled coated polyolefin fabric substrate coated with a specific ethylene and propylene based plastomer blend, combined with 65 to 95 wt.% of homopolypropylene or a recycled polymer blend of polypropylene and polyethylene, optimized to enhance Charpy Notched Impact Strength and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If recycled polyolefin materials are used in high percentages, then sustainability is improved and virgin material consumption is reduced, but mechanical properties such as toughness and stiffness deteriorate
Solution Approach 1:
The patent introduces a compatibilizer as an intermediary substance to mediate between the recycled polyolefin material and the polymer matrix. This compatibilizer improves interfacial adhesion and stress transfer, allowing high percentages of recycled material (50-100%) to be used while maintaining mechanical properties through enhanced interfacial interactions rather than relying solely on the inherent strength of the recycled fibers
Solution Approach 2:
The patent creates a composite material system combining recycled polyolefin fabric substrates with specific polymer matrices and compatibilizers. This composite approach allows the synergistic combination of recycled materials with binding agents and interface modifiers to achieve both high sustainability (through recycled content) and adequate mechanical properties (through composite structure design)
2Adaptability or versatility
If non-polyolefin materials like polyurethane, polyvinyl chloride, and ethylene vinyl acetate are used in coated textile materials, then application performance is improved, but recyclability deteriorates due to difficulty in separating and recycling these mixed materials
Solution Approach 1:
The patent applies multi-functionality by using polyolefin coatings that serve both performance functions (providing the desired textile properties for carpets, mattresses, and car interiors) and recycling functions (enabling easy separation and recovery of the fabric substrate). The polyolefin coating acts as a universal solution that satisfies both application requirements and sustainability goals by being recyclable with the base fabric
Solution Approach 2:
The patent extracts the problematic non-polyolefin coating materials and replaces them with polyolefin-based coatings that can be easily separated and recycled with the fabric substrate. This extraction of the incompatible coating layer enables the recycling process to focus on a single polymer type, dramatically improving recyclability while maintaining application performance through proper coating formulation
Data Source
AI summary
The present invention relates to a polymer composition comprising the following components: A) 5 to 35 wt.-% based on the overall weight of the polymer composition of a recycled polyolefin fabric substrate; wherein said fabric substrate is coated with a polyolefin composition comprising the following components: a1) an ethylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.857 to 0.915 g/cm3 and a MFR2 (190° C., 2.16 kg) determined according to ISO 1133 in the range of 0.5 to 30 g/10 min; and a2) a propylene based plastomer with a density determined according to ISO 1183-1 in the range of 0.850 to 0.910 g/cm3 and a MFR2 (230° C., 2.16 kg) determined according to ISO 1133 in the range of 0.01 to 30 g/10 min; B) 65 to 95 wt.-% based on the overall weight of the polymer composition of a homopolypropylene or a recycled polymer blend comprising b1) polypropylene and b2) polyethylene, wherein the weight ratio of b1) to b2) is from 3:7 to 12:1; with the proviso that components A) and B) add up to 100 wt.-%. Furthermore, the present invention relates to use of component A) for increasing the Charpy Notched Impact Strength of component B) and to an article comprising the polymer composition according to the present invention.