Reversible Crosslinked 3D Loop Material for Heat-Resistant Recycling
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Solution Overview
Problem
Existing 3D loop cushions made with thermoplastic resins lack sufficient heat resistance for transportation applications and cannot be recycled via melt processing due to conventional crosslinking methods.
Innovation Solution
A three-dimensional random loop material (3DRLM) composed of crosslinked ethylene-based polymers and 2,2,6,6-tetramethyl-4-piperidyl methacrylate disulfide (BiTEMPS methacrylate) linkages, allowing for high heat resistance and recyclability through melt processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional crosslinking is used to improve heat resistance, then heat resistance is improved, but recyclability via melt processing is lost
Solution Approach 1:
The patent applies dynamic covalent chemistry by using disulfide bonds that can reversibly break and reform. The crosslinked network transitions from a static permanent structure to a dynamic reversible structure, allowing the material to be recyclable through melt processing while maintaining heat resistance during service. The disulfide bonds break at processing temperatures enabling reprocessing, then reform upon cooling to restore crosslinking and heat resistance.
Solution Approach 2:
The patent changes the chemical parameter of the crosslink bonds from permanent covalent bonds to reversible disulfide bonds. This parameter change allows the material to exhibit different properties at different temperatures: heat resistance at service temperatures due to crosslinking, and melt processability at elevated temperatures when disulfide bonds break reversibly.
2Ease of manufacture
If thermoplastic resins are used to enable recyclability, then recyclability is improved, but heat resistance is insufficient
Solution Approach 1:
The patent creates a composite material system combining thermoplastic polyolefin matrix with reversible crosslinked network formed by disulfide bonds. This composite structure provides both the recyclability of thermoplastics (through melt processing when crosslinks break) and the heat resistance of crosslinked materials (when crosslinks are intact at service temperatures).
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
The 3DRLM achieves high heat resistance suitable for transportation applications while maintaining recyclability, addressing the limitations of existing materials.
Implementation Method 1
each continuous strand composed of a crosslinked composition formed from starting materials comprising (i) an ethylene-based polymer, and (ii) 2,2,6,6-tetramethyl-4-piperidyl methacrylate disulfide (BiTEMPS methacrylate)
Implementation Method 2
heating a first article to a reprocessing temperature... heating the coating to a reprocessing temperature, and forming, at the reprocessing temperature, the coating into a re-processable ethylene-based polymer composition
Data Source
AI summary
The present disclosure provides an article. In an embodiment, the article a three-dimensional random loop material (“3DRLM”) composed of a web structure of a multitude of winding continuous strands melt-bonded together at a multitude of contact points to form a multitude of loops. Each continuous strand is composed of a crosslinked composition formed from starting materials comprising (i) an ethylene-based polymer, and (ii) 2,2,6,6-tetramethyl-4-piperidyl methacrylate disulfide (BiTEMPS methacrylate). This yields a 3DRLM that is composed of a crosslinked composition comprising (i) an ethylene-based polymer, and (ii) linkages having a Structure (2) below (I)