Effects of a Twin-Screw Extruder Equipped with a Molten Resin Reservoir on the Mechanical Properties and Microstructure of Recycled Waste Plastic Polyethylene Pellet Moldings

Each year, increasing amounts of plastic waste are generated, causing environmental pollution and resource loss. Recycling is a solution, but recycled plastics often have inferior mechanical properties to virgin plastics. However, studies have shown that holding polymers in the melt state before extrusion can restore the mechanical properties; thus, we propose a twin-screw extruder with a molten resin reservoir (MSR), a cavity between the screw zone and twin-screw extruder discharge, which retains molten polymer after mixing in the twin-screw zone, thus influencing the polymer properties. Re-extruded recycled polyethylene (RPE) pellets were produced, and the tensile properties and microstructure of virgin polyethylene (PE), unextruded RPE, and re-extruded RPE moldings prepared with and without the MSR were evaluated. Crucially, the elongation at break of the MSR-extruded RPE molding was seven times higher than that of the original RPE molding, and the Young’s modulus of the MSR-extruded RPE molding was comparable to that of the virgin PE molding. Both the MSR-extruded RPE and virgin PE moldings contained similar striped lamellae. Thus, MSR re-extrusion improved the mechanical performance of recycled polymers by optimizing the microstructure. The use of MSRs will facilitate the reuse of waste plastics as value-added materials having a wide range of industrial applications.