Composite Material from Textile and Polyethylene Waste
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Solution Overview
Problem
Existing processes for producing composite materials from textile waste and thermoplastic binders struggle with variability in textile composition, requiring meticulous sorting and preparation, which is inefficient and environmentally unfriendly.
Innovation Solution
A process that comminutes textile waste and polyethylene film waste into specific size fractions, separates metal and unwanted plastics, and then mixes and extrudes the materials at controlled temperatures and pressures, without the need for meticulous sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If textile waste is meticulously sorted and prepared before processing, then the physical-chemical properties of the composite material can be controlled, but the process complexity and time consumption increase significantly
Solution Approach 1:
The patent changes the physical state of textile waste from intact fabric to comminuted fragments (reducing size to 0-15mm), which fundamentally alters how the material behaves during processing. This parameter change enables direct mixing with thermoplastic binder without meticulous sorting, as the comminuted state uniformizes the material characteristics regardless of original fiber composition variations.
Solution Approach 2:
The patent performs preliminary comminution of textile waste into small fragments (0-15mm) before mixing with the thermoplastic binder. This preliminary action prepares the material in advance, eliminating the need for subsequent meticulous sorting and preparation steps while maintaining consistent composite material properties.
2Ease of manufacture
If textile waste is comminuted into smaller fragments, then mixing with thermoplastic binder becomes easier and more uniform, but the energy consumption and processing time increase
Solution Approach 1:
The patent segments textile waste into small fragments (0-15mm) through comminution, which dramatically improves mixing ease with thermoplastic binder. The segmented state allows uniform distribution of fibers throughout the matrix without requiring excessive energy for further processing or meticulous manual sorting.
3Productivity
If the textile waste stream is not sorted, then processing speed and productivity increase, but the variability in composite material properties increases
Solution Approach 1:
The patent changes the physical state of textile waste from intact fabric to comminuted fragments (reducing size to 0-15mm), which fundamentally alters how the material behaves during processing. This parameter change enables direct mixing with thermoplastic binder without meticulous sorting, as the comminuted state uniformizes the material characteristics regardless of original fiber composition variations.
4Productivity
If thermoplastic binder is mixed with comminuted textile waste, then composite material production becomes more efficient, but the control over fiber distribution and homogenization becomes more difficult
Solution Approach 1:
The patent changes the physical state of textile waste from intact fabric to comminuted fragments (reducing size to 0-15mm), which fundamentally alters how the material behaves during processing. This parameter change enables direct mixing with thermoplastic binder without meticulous sorting, as the comminuted state uniformizes the material characteristics regardless of original fiber composition variations.
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 process produces composite materials with desired physical-chemical properties while reducing the environmental impact by minimizing CO2 emissions and eliminating the need for extensive waste preparation.
Implementation Method 1
heating the mixture until the thermoplastic material has melted
Implementation Method 2
heating the mixture until the thermoplastic material has melted
Implementation Method 3
the mixture is heated until the thermoplastic material has melted
Data Source
AI summary
The invention relates to a process for the production of a composite material from textile waste and polyethylene film waste, characterized in that it comprises the following steps: a) comminuting the textile waste into the fraction up to 15 mm in size, b) comminuting the polyethylene film into the fraction up to 15 mm in size, c) separating metal parts from the comminuted textiles, d) separating metal parts and unwanted plastics from the comminuted film, e) further comminuting the textiles into the fraction up to 5 mm in size, f) mixing the comminuted textiles with the comminuted film, said textiles constituting 10-50% of the mixture, g) plasticizing, homogenizing and extruding the obtained mixture in an extruder at the temperature of 170-240° C. and under the pressure of 8-15 MPa.