Composite Material From Waste Via Incompatible Plastic Removal
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Solution Overview
Problem
Existing composite materials derived from heterogeneous waste face structural weaknesses due to phase separation and incompatibility of certain plastics, such as PVC and PET, and the presence of inorganic impurities, which affect homogeneity and integrity.
Innovation Solution
A composite material is produced by removing incompatible plastics like PVC and PET from waste, and subjecting the waste to heating and mixing under shear forces, resulting in a homogenous blend of non-plastic organic matter, thermoplastic polymers, and inorganic matter, with specific weight percentages and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If heterogeneous waste including incompatible plastics (PVC, PET) is processed into composite material, then the quantity of recyclable material increases, but the homogeneity and mechanical integrity of the composite material deteriorates due to phase separation
Solution Approach 1:
The patent removes incompatible plastics (PVC, PET, and other aryl-containing polymers) from the waste stream before processing. This extraction of harmful components prevents phase separation and maintains compositional homogeneity in the final composite material, while still allowing processing of a large quantity of compatible waste materials.
Solution Approach 2:
The patent changes the compositional parameters of the waste feedstock by defining specific exclusion criteria for incompatible polymers. By controlling the chemical composition parameters (removing aryl-containing plastics), the system achieves both high quantity processing and maintained homogeneity in the output composite material.
2Productivity
If heterogeneous waste including incompatible plastics is processed, then productivity increases, but the manufacturing precision and mechanical properties of the composite material worsen
Solution Approach 1:
By extracting incompatible plastics from the waste stream, the system maintains high productivity through processing of large volumes of compatible materials, while ensuring manufacturing precision through elimination of components that would cause phase separation and mechanical failure.
Solution Approach 2:
The patent converts the potential harm of heterogeneous waste composition into a benefit by using the presence of organic matter (cellulose, hemicellulose, lignin) as a binding matrix that enhances composite material properties, while excluding only the specifically harmful incompatible plastics.
3Quantity of substance
If incompatible plastics like PVC and PET are included in the composite material, then the quantity of processed waste increases, but the thermal stability and mechanical strength of the material deteriorates
Solution Approach 1:
The patent extracts incompatible plastics (PVC, PET) from the waste stream, enabling processing of high quantities of compatible materials while preserving thermal stability and mechanical strength by excluding polymers that would degrade at processing temperatures and compromise material reliability.
Solution Approach 2:
The patent controls the thermal and mechanical reliability by changing the compositional parameters - specifically excluding polymers with degradation temperatures below the processing range (150-200°C) and limiting aryl-containing polymers to less than 10% of the total composite material weight.
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 resulting composite material exhibits improved mechanical properties, including high tensile and flexural strength, thermal stability, and reduced density, making it suitable for injection molding and other applications.
Implementation Method 1
subjecting the sorted heterogeneous waste to heating and mixing under shear forces, such as in an extruder, at a temperature maintained within a range of 150° C. and 200° C.
Implementation Method 2
subjecting the sorted heterogeneous waste to heating and mixing under shear forces, such as in an extruder
Data Source
AI summary
The present disclosure provides a composite material comprising a homogenous blend of (a) at least about 40% w/w of non-plastic organic matter out of a total weight of the composite material, said non-plastic organic matter comprising at least cellulose; (b) between about 5% w/w and about 60% w/w plastic matter out of a total weight of said composite material, said plastic matter comprising a plurality of synthetic thermoplastic polymers; and (c) up to 15% w/w inorganic matter; wherein said composite material comprises aryl containing synthetic polymers in an amount of less than 10% out of the total weight of said composite material; and wherein said composite material is characterized by at least one of the following properties: (i) it has a notched izod impact of at least 15 h/m; and (ii) a sample of said composite material that has been subjected to injection molding has at least one of tensile strength of at least 8 MPa; and flexural strength of at least 15 MPa. Also provided is a method of preparing the composite material, the method involving use of heterogenous intake material that comprises aryl-containing synthetic polymers in an amount of less than 10% out of the total weight of said composite material; and to methods of producing articles of manufacture from the composite material.