Shredded Plastic Composite Products With Low-Temperature Curing
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Solution Overview
Problem
Existing methods for manufacturing plastic products from virgin materials are inefficient and environmentally impactful, lacking effective utilization of recycled plastic waste.
Innovation Solution
A method involving the use of shredded plastic particles, primarily composed of PET or PETE, HDPE, PVC, LDPE, PP, PS, PC, or PMMA, mixed with an uncured resin, cured at temperatures below 110°C to form a plastic product with a cured matrix, where the particles remain distinct and dispersed within the matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If shredded plastic particles are used as raw material, then environmental impact is reduced and recycling is promoted, but manufacturing process complexity increases
Solution Approach 1:
The patent changes the physical state parameters of the plastic particles by controlling particle size (0.1-2.0 mm) and using low-temperature curing processes. This allows direct processing of shredded plastic waste without extensive pre-treatment, reducing manufacturing complexity while maintaining environmental benefits
Solution Approach 2:
The patent creates composite materials by combining shredded plastic particles with uncured resin matrix. This composite approach allows direct utilization of mixed plastic waste streams without pre-sorting, as the resin matrix binds different particle types together, simplifying the manufacturing process while promoting recycling
2Use of energy by moving object
If low curing temperature is used, then energy costs are reduced, but curing process effectiveness may be compromised
Solution Approach 1:
The patent selects specific resin systems that cure effectively at low temperatures (below 110°C). By changing the chemical parameters of the curing agents and resins, the process achieves complete curing at reduced temperatures, lowering energy costs while maintaining curing effectiveness
Solution Approach 2:
The patent replaces thermal-mechanical curing processes with chemical curing mechanisms that operate at low temperatures. The uncured resin undergoes chemical reactions to form the cured matrix, substituting high-temperature thermal processing with low-temperature chemical transformation, thereby reducing energy consumption while ensuring complete curing
3Ease of manufacture
If shredded plastic particles of mixed types are used, then pre-sorting requirements are eliminated, but material homogeneity decreases
Solution Approach 1:
The patent creates a composite material system where shredded plastic particles of different types are embedded in a resin matrix. The matrix acts as a binding phase that accommodates particle heterogeneity, allowing direct use of mixed plastic waste without pre-sorting while maintaining overall material stability and product performance
Solution Approach 2:
The patent applies local quality by having the resin matrix provide a uniform binding environment around heterogeneous plastic particles. Each particle region maintains its own properties while the surrounding matrix ensures overall structural homogeneity and stability, allowing mixed particle types to coexist without compromising material consistency
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 enhances product strength, simplifies manufacturing, reduces energy costs, and promotes recycling by utilizing post-consumer waste without the need for pre-sorting or cleaning, thus minimizing environmental impact.
Implementation Method 1
curing the uncured matrix within the mixture at a temperature that is less than 110 degrees Celsius. Curing the uncured matrix within the mixture may form a cured matrix that comprises a cured resin
Data Source
AI summary
A plastic product includes shredded plastic particles disposed within a cured matrix. The cured matrix includes a cured resin. The shredded plastic particles are distinct from the cured matrix of the plastic product. The plastic product is manufactured by forming a mixture by mixing shredded plastic particles with an uncured matrix. The uncured matrix includes an uncured resin. The mixture is injected or poured into a mold. The uncured matrix within the mixture is cured at a temperature that is less than 110 degrees Celsius.