Blow Molding Polymer Composition from Waste Battery Separator
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Solution Overview
Problem
The recycling of waste secondary battery separators, especially those with ceramic coatings, is challenging due to poor physical properties such as low elongation, flexural strength, and impact resistance, which hinder their processability and integration into polymer compositions for blow molding.
Innovation Solution
A polymer composition for blow molding is developed that includes a waste high-density polyethylene material from a waste separator with an inorganic coating, along with a new high-density polyethylene. The inorganic content from the coated separator is adjusted to 3-20 wt% of the total composition, ensuring excellent mechanical properties and processability without the need for additional pre-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic coating is applied to waste separators to improve thermal resistance, then thermal resistance is improved, but physical properties such as elongation and impact strength are greatly decreased
Solution Approach 1:
The patent changes the inorganic content parameter from 0% (virgin material) to a controlled range of 1-10 wt% in the recycled composition. This parameter adjustment allows the composition to maintain adequate thermal resistance from the ceramic coating while improving elongation and impact strength by optimizing the balance between coated and uncoated separator materials.
Solution Approach 2:
The patent creates a composite polymer composition that combines recycled separator material containing ceramic coating with additional polymers and inorganic additives. This composite structure allows the ceramic-coated waste separator to be integrated into a new material system where the ceramic provides thermal stability while the composite matrix restores mechanical properties like elongation and impact strength.
2Device complexity
If ceramic-coated waste separator is recycled directly without pre-processing, then process complexity is reduced, but physical properties such as elongation and impact strength are greatly decreased
Solution Approach 1:
The patent extracts the ceramic coating from the problem-solving approach by accepting it as an inevitable component rather than attempting to remove it through pre-processing. Instead of separating the ceramic from the polymer matrix (which would add complexity), the invention takes out the need for ceramic removal entirely and works with the coated material directly, adjusting other composition parameters to compensate for the ceramic's impact on mechanical properties.
Solution Approach 2:
The patent changes the compositional parameters by controlling the inorganic content within 1-10 wt% and adjusting polymer ratios to achieve optimal mechanical properties. This parameter optimization allows direct recycling of ceramic-coated separators without pre-processing while maintaining adequate elongation and impact strength through compositional balancing.
3Object-generated harmful factors
If high content of waste high-density polyethylene is used in polymer composition, then environmental friendliness is improved, but melt flow index and mechanical properties are deteriorated
Solution Approach 1:
The patent optimizes the waste HDPE content parameter within specific ranges (20-60 wt% or 30-50 wt% in different embodiments) rather than using maximum possible amounts. This parameter control, combined with adjusting inorganic content to 1-10 wt% and selecting appropriate new HDPE with specific melt flow indices, allows the composition to achieve both high environmental friendliness and adequate melt flow index for blow molding processability.
Data Source
AI summary
Provided is a polymer composition for blow molding which includes a high-density polyethylene recovered from a secondary battery separator and has excellent mechanical properties. The polymer composition having excellent processability may be prepared by recycling a secondary battery separator, and may be molded to manufacture an environmental a molded article manufactured by blow molding which has excellent mechanical properties such as flexural strength, elongation, and impact strength in a large temperature range and has excellent processing moldability.