FORM NO 2
THE PATENTS ACT, 1970 (39 OF 1970) & The Patents Rules, 2003 COMPLETE SPECIFICATION [See sections 10 and Rule 13]

1. 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

2. APPLICANT(S) THE SUPREME INDUSTRIES LIMITED
3. PREAMBLE TO THE DESCRITION
PROVISIONAL
The following spec describes invention ification COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed

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 were 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, effort was spent on upgrading the processing and equipment to produce blended compositions containing the recycled resins. It became 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 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 during the manufacturing of foam. 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 compatibilizer. The efforts to blend reprocess cross linked polyethylene foam and recycle low density polyethylene without any compatibilizer are hampered because the reprocess cross linked polyethylene foam converting it 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 the melting temperature is lowered 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 used in the same way as ordinary thermoplastic materials along with reprocess low density polyethylene in cushioning foam as well as 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 any 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.

Yet another objective is a preparation for forming low cost good aesthetically appealing cushioning foam products with constant weight of sheet in compression molding press.
PROBLEM TO BE SOLVED
The industry needs a solution for difficulties caused 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 sheet preparation. The present invention is a solution for both the above problems.
BRIEF DESCRIPTION OF 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 discloses a composition which is processable into a product which is a 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 process that includes
blending of recycled crosslinked polyethylene foam, preferably
a waste, alongwith reprocess low density polyethylene and
adding a Dicumyl peroxide (DCP) cross linking agent and
Azodicarbamide (ADC) chemical blowing agent, a
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. The said polymer composition is mixed in a kneader, whose shaft is specially designed to improve the processibility at 6-7 kg/cm2 pressure & 130- 135 degree temperature for 20-24 minutes. After the formation of lumps, the said mixture is then mixed on a two roll mill for 5-10 minutes at 100-115 (degree Celsius) temperature. When mixing of melt composition has been completed on two roll mill, the said mixture is then transferred on a sheeting machine at 100-115 (degree Celsius) degree temperature for the sheet preparation. This

formed sheet is then filled in the mold with the weight being around 11.50 kg to 12.5 kg. The mold is then transferred to a press at a pressure in the range of 170-190 kg/cm2, steam pressure shall be around 5.0-5.5 Bar for a duration of about 40 - 45 mins. This is the final process that forms the main composition. The 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/cm which 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 un cross linked polyethylene which when tested for the tensile strength and hardness showed results which made it compatible for use in various applications.

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 in nature.
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.