WO2017033201A1 - Manufacturing process for block foam by blending of recycle cross linked low density poly ethylene (ldpe) foam and uncross linked reprocess ldpe without any compatibilizer for making same. - Google Patents

Manufacturing process for block foam by blending of recycle cross linked low density poly ethylene (ldpe) foam and uncross linked reprocess ldpe without any compatibilizer for making same. Download PDF

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Publication number
WO2017033201A1
WO2017033201A1 PCT/IN2016/000088 IN2016000088W WO2017033201A1 WO 2017033201 A1 WO2017033201 A1 WO 2017033201A1 IN 2016000088 W IN2016000088 W IN 2016000088W WO 2017033201 A1 WO2017033201 A1 WO 2017033201A1
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WO
WIPO (PCT)
Prior art keywords
foam
low density
reprocess
ldpe
cross linked
Prior art date
Application number
PCT/IN2016/000088
Other languages
French (fr)
Inventor
Amit Kumar Ghosh
Piyush YADAV
Shailesh GUPTA
Gourishanker Jha
Original Assignee
The Supreme Industries Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by The Supreme Industries Limited filed Critical The Supreme Industries Limited
Publication of WO2017033201A1 publication Critical patent/WO2017033201A1/en

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/24—Crosslinking, e.g. vulcanising, of macromolecules
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/09—Carboxylic acids; Metal salts thereof; Anhydrides thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/10—Esters; Ether-esters
    • C08K5/101—Esters; Ether-esters of monocarboxylic acids
    • C08K5/103—Esters; Ether-esters of monocarboxylic acids with polyalcohols
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/14—Peroxides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2300/00—Characterised by the use of unspecified polymers
    • C08J2300/30—Polymeric waste or recycled polymer
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/04—Homopolymers or copolymers of ethene
    • C08J2323/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2423/04—Homopolymers or copolymers of ethene
    • C08J2423/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C08K2003/2296—Oxides; Hydroxides of metals of zinc
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24—Acids; Salts thereof
    • C08K3/26—Carbonates; Bicarbonates
    • C08K2003/265—Calcium, strontium or barium carbonate
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2207/00—Properties characterising the ingredient of the composition
    • C08L2207/20—Recycled plastic
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2312/00—Crosslinking

Definitions

  • the present invention relates to the preparation of a composition by blending of recycle cross-linked Low- density poly ethylene (LDPE) foam and uncross linked reprocess LDPE for making block foam with compositions and methods for making foam.
  • LDPE Low- density poly ethylene
  • the present invention provides for the suitable shearing and heating during the thermoplaticizing process for breakdown of the three dimensional structure and decreases its molecular weight, producing a recycled material that has a sufficient thermoplastic property to allow it to be reused in foam products without any adverse affect on the quality. Since the recycled crosslinked polyethylene can be melted down and use in the same way as ordinary thermoplastic materials along with reprocess low density polyethylene in cushioning foam and expansion joint products it has the advantage that it can be reused without additional material. By using this recycled cross linked LDPE and reprocess LDPE in our foam products, getting free from any cracks, blow hole, pin hole or other defects.
  • LDPE recycle cross linked low density polyethylene
  • Yet another objective of the present invention is to provide a method for producing a polyethylene composition of reprocess cross linked low density polyethylene and recycled crosslinked polyethylene by blending together in a kneader process for sheet preparation without any compatibilizer s.
  • Yet another objective is a preparation forming low cost good aesthetically appeal cushioning foam products with constant weight of sheet in compression molding press.
  • the industry needs a solution for difficulties in using cross linked LDPE for recyclable applications, during foam manufacturing. There also remains a need for a cost effecting process with economic benefit of process and method which provides for composition and reprocess methodology for a sheet preparation.
  • the present invention is a solution for both the above problems.
  • Fig. 1 is a test report that depicts a graph which shows the TEAR TEST Report of the invented polymer product which portrays the properties of the invented product as well within the range of the normal conventional products.
  • Fig. 2 is a test report that depicts a graph which shows the TENSILE STRENGTH Report of the invented polymer product which portrays the properties of the invented product as well within the range of the normal conventional products.
  • the present Invention relates a composition which is processable into a product low density foam from about 5.0% to 40.0% by weight of a recycled cross linked polyethylene wastage, 5.0% to 40% by weight of a reprocess low density polyethylene and an effective amount of a Dicumyl peroxide (DCP) (0.3- 1.0%) comprising blowing agent (2.0-6.0%), Calcium carbonate filler (5.0- 20%), zinc oxide (1.0 - 1.5%), stearic acid (0.1-0.2%) and glycerol monostearate (0.5- 1.0).
  • DCP Dicumyl peroxide
  • It is also relates to method of the processing includes blending recycle of crosslinked polyethylene foam, preferably a waste, together with reprocess low density polyethylene and adding a Dicumyl peroxide (DCP) cross linking agent and Azodicarbamide (ADC) chemical blowing agent, combination of calcium carbonate filler, zinc oxide (ZnO), stearic acid and glycerol monostearate to the composition.
  • DCP Dicumyl peroxide
  • ADC Azodicarbamide
  • This additive system shows compatibility during blending with reprocess cross linked polyethylene.
  • Polymer composition is mixed in kneader, which shaft specially design to improve the processibility at 6-7 kg/cm 2 pressure & 130- 135 degree temperature for 20-24 min.
  • Initial block foam thickness is 50 mm to 55 mm, density is 68 kg/m 3 to 82 kg/m 3 , shore hardness is 15 to 25, minimum elongation at break should be 45%, minimum tensile strength at break should 4.2 kg/ cm 2 and tear strength is 1.5 ⁇ 0.3 kg/cmwhich can be used for making low cost, good and aesthetically appealing cushioning foam and expansion joint applications.
  • the existing product also decreases the carbon footprint as there is no use of any virgin polymers for the production of the foam.
  • the manufactured cross linked poly ethylene foam from recycled cross linked polyethylene foam and reprocessed cross linked polyethylene which when tested for the tensile strength and hardness showed results which made it compatible for use for various applications.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Processes Of Treating Macromolecular Substances (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)

Abstract

The present invention discloses a process which comprises of blending of cross linked recycled low density poly ethylene and uncross linked reprocess low density poly ethylene without the use of a compatibilizer to produce a polymer product that can be used commercially.

Description

TITLE
Manufacturing Process For Block Foam By Blending Of Recycle Cross Linked Low Density Poly Ethylene (LDPE) Foam And Uncross Linked Reprocess LDPE Without Any Compatibilizer For Making Same.
FIELD OF THE INVENTION
The present invention relates to the preparation of a composition by blending of recycle cross-linked Low- density poly ethylene (LDPE) foam and uncross linked reprocess LDPE for making block foam with compositions and methods for making foam.
BACKGROUND
Until recently the uncross linked and cross linked low density polyethylene resin are used for many purposes including the manufacture of foam products which were useful as cushioning materials and films for converting to packaging material, known as air filled bubble wrap. Although cross linking has many advantages, the same can not be reprocessed back even through melting. As the desire for higher level of recycled cross linked resin in commodity plastics increased, lots of effort was being spent on upgrading processing and equipment to produce blended compositions containing the recycled resins. It was difficult to use the recycled three dimensional structure of cross linked LDPE due to its high melting point and processing issues. It is known that the structural difference in cross linked polyethylenes due to three dimensional structure results in notable property differences. However the three-dimensional lattice structure produced by crosslinked polyethylene makes it impossible to melt it down again for molding/ others applications. This causes the processing difficulties and quality problems due difficulties in the melting in cross linked polyethylene. The melting problems causes porosity and melt fracture on the final product. This difficulty becomes more pronounced in the during the foam manufacture.
In the past attempts have been made to incorporate a recycling wastage of cross linked polyethylene, such as that obtained from cross linked polyethylene foam and reprocess low density polyethylene resins used to make it from expanded low density polyethylene foam by using compatibilizers. The efforts to blend reprocess cross linked polyethylene foam and recycled low density polyethylene without any compatibilizer are hampered because the reprocess cross linked polyethylene foam converting in to thermoplastics polyethylene by thermoplasticizing process occurs at a higher shear rate. By suitable heating and shearing to cross linked polyethylene foam, it decreases its molecular weight, and lowers the melting temperature to produce a recycled material that is sufficiently thermoplastic in nature to allow it to be reused in finished products in place of virgin material.
The present invention provides for the suitable shearing and heating during the thermoplaticizing process for breakdown of the three dimensional structure and decreases its molecular weight, producing a recycled material that has a sufficient thermoplastic property to allow it to be reused in foam products without any adverse affect on the quality. Since the recycled crosslinked polyethylene can be melted down and use in the same way as ordinary thermoplastic materials along with reprocess low density polyethylene in cushioning foam and expansion joint products it has the advantage that it can be reused without additional material. By using this recycled cross linked LDPE and reprocess LDPE in our foam products, getting free from any cracks, blow hole, pin hole or other defects.
OBJECT OF INVENTION
It is the object of the present invention to provide a suitable composition of recycle cross linked low density polyethylene (LDPE) together with reprocess low density polyethylene without a compatibilizer for making aesthetically appealing low density foam products which can be used as cushioning materials for use in the packaging industry and expansion joint applications.
Yet another objective of the present invention is to provide a method for producing a polyethylene composition of reprocess cross linked low density polyethylene and recycled crosslinked polyethylene by blending together in a kneader process for sheet preparation without any compatibilizer s.
Yet another objective is a preparation forming low cost good aesthetically appeal cushioning foam products with constant weight of sheet in compression molding press. PROBLEM TO BE SOLVED
The industry needs a solution for difficulties in using cross linked LDPE for recyclable applications, during foam manufacturing. There also remains a need for a cost effecting process with economic benefit of process and method which provides for composition and reprocess methodology for a sheet preparation. The present invention is a solution for both the above problems.
BRIEF DESCRIPTION OP THE DRAWINGS
Fig. 1 is a test report that depicts a graph which shows the TEAR TEST Report of the invented polymer product which portrays the properties of the invented product as well within the range of the normal conventional products.
Fig. 2 is a test report that depicts a graph which shows the TENSILE STRENGTH Report of the invented polymer product which portrays the properties of the invented product as well within the range of the normal conventional products.
DESCRIPTION OF THE INVENTION
The present Invention relates a composition which is processable into a product low density foam from about 5.0% to 40.0% by weight of a recycled cross linked polyethylene wastage, 5.0% to 40% by weight of a reprocess low density polyethylene and an effective amount of a Dicumyl peroxide (DCP) (0.3- 1.0%) comprising blowing agent (2.0-6.0%), Calcium carbonate filler (5.0- 20%), zinc oxide (1.0 - 1.5%), stearic acid (0.1-0.2%) and glycerol monostearate (0.5- 1.0).
It is also relates to method of the processing includes blending recycle of crosslinked polyethylene foam, preferably a waste, together with reprocess low density polyethylene and adding a Dicumyl peroxide (DCP) cross linking agent and Azodicarbamide (ADC) chemical blowing agent, combination of calcium carbonate filler, zinc oxide (ZnO), stearic acid and glycerol monostearate to the composition. This additive system shows compatibility during blending with reprocess cross linked polyethylene. Polymer composition is mixed in kneader, which shaft specially design to improve the processibility at 6-7 kg/cm2 pressure & 130- 135 degree temperature for 20-24 min. After formation of lumps and then mixed on a two roll mill for 5- 10 minute at 100- 115 (degree Celsius) temperature. After proper mixing of melt composition on two roll mill then transfer on sheeting machine at 100- 1 15 (degree Celsius) degree temperature for sheet preparation. Green sheet fill in mold with 1 1.50 kg to 12.5 kg then mold transfer in to press at 170- 190 kg/ cm2 pressure, steam pressure 5.0-5,5 Bar and time 40-45 min. After processing, the main composition is formed. Initial block foam thickness is 50 mm to 55 mm, density is 68 kg/m3 to 82 kg/m3, shore hardness is 15 to 25, minimum elongation at break should be 45%, minimum tensile strength at break should 4.2 kg/ cm2 and tear strength is 1.5 ± 0.3 kg/cmwhich can be used for making low cost, good and aesthetically appealing cushioning foam and expansion joint applications.
The existing product also decreases the carbon footprint as there is no use of any virgin polymers for the production of the foam.
SAMPLE TEST RESULTS:
The manufactured cross linked poly ethylene foam from recycled cross linked polyethylene foam and reprocessed cross linked polyethylene which when tested for the tensile strength and hardness showed results which made it compatible for use for various applications.

Claims

Claims :-
1. We claim a composition of a polymer without any compatibilizer which is processable into a product from a recycled cross linked polyethylene wastage, and uncross linked reprocess low density polyethylene incorporating Dicumyl peroxide, a blowing agent, a filler, zinc oxide, stearic acid and glycerol monostearate.
2. A composition of a polymer as claimed in Claim 1 which is obtained by the process of blending without using a compatibilizer.
3. A composition of a polymer as claimed in Claim 1 where the recycled low density polyethylene is in powder form foam and is cross linked in nature whereas the reprocess low density polyethylene is a granule form which is uncrosslinked.
4. As claimed in claim 1, a method of processing low density foam block that includes blending of recycle of crosslinked polyethylene foam, preferably a waste, together with reprocess low density polyethylene and adding Dicumyl peroxide (DCP) which is the cross linking agent and Azodicarbamide (ADC), a chemical blowing agent, including a combination of zinc oxide (ZnO), stearic acid and glycerol monostearate to the composition, whereby this additive system shows compatible benefits.
5. A product as claimed in claim 1 which is environmental friendly in nature; the same being processed from a plurality of waste materials, thereby decreasing the carbon footprint in nature.
6. A process to manufacture cross linked poly ethylene foam by the process of shearing and heating to improve the thermoplasticity properties in the invented material.
7. A composition of a polymer and a method to produce the same as claimed along with the accompanying drawings.
PCT/IN2016/000088 2015-08-25 2016-04-07 Manufacturing process for block foam by blending of recycle cross linked low density poly ethylene (ldpe) foam and uncross linked reprocess ldpe without any compatibilizer for making same. WO2017033201A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN3251/MUM/2015 2015-08-25
IN3251MU2015 IN2015MU03251A (en) 2015-08-25 2016-04-07

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WO2017033201A1 true WO2017033201A1 (en) 2017-03-02

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PCT/IN2016/000088 WO2017033201A1 (en) 2015-08-25 2016-04-07 Manufacturing process for block foam by blending of recycle cross linked low density poly ethylene (ldpe) foam and uncross linked reprocess ldpe without any compatibilizer for making same.

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101870169A (en) * 2010-05-11 2010-10-27 四川大学 Preparation method of waste tire rubber/polyethylene foam material
WO2013137711A1 (en) * 2012-03-13 2013-09-19 Texchem Polymers Sdn Bhd Thermoplastic starch composition derives from agricultural waste

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101870169A (en) * 2010-05-11 2010-10-27 四川大学 Preparation method of waste tire rubber/polyethylene foam material
WO2013137711A1 (en) * 2012-03-13 2013-09-19 Texchem Polymers Sdn Bhd Thermoplastic starch composition derives from agricultural waste
EP2756034A1 (en) * 2012-03-13 2014-07-23 Texchem Polymers Sdn Bhd Thermoplastic starch composition derives from agricultural waste

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