Polyethylene terephthalate alloy with talc

Abstract

To provide a PET having better flow, faster crystallization, and higher heat distortion temperature, while maintaining good properties of PET.SOLUTION: A system for forming a polyethylene terephthalate (PET) alloy with talc comprises a feed of the PET / talc mixture (PET / talc feed), a feed of PET (PET feed), a mixer coupled to an outlet of the PET / talc feed and coupled to an outlet of the PET feed, and an output that makes the PET alloy a bimodal PET.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 62 / 648,119, filed March 26, 2018, which is hereby incorporated by specific reference in its entirety. [Background technology]

[0002] Polyethylene terephthalate (PET) is a crystalline polymer, and this crystallization affects many properties of PET products, including clarity, stiffness, and strength. The high molecular weight of commercially available PET leads to poor flowability, preventing the production of thin-walled injection-molded parts using PET. PET's slow crystallization results in long cycle times that are not commercially viable. Furthermore, PET has a low heat distortion temperature (HDT), which means PET products can soften at relatively low temperatures.

[0003] PET polymers that have better flow, faster crystallization, and a higher HDT while maintaining the good properties of PET are desirable. [ka] Summary of the Invention

[0004] In one embodiment, a method for forming a polyalkylene terephthalate (PAT) (e.g., polyethylene terephthalate (PET)) blend containing talc is provided. The method may include providing a feed of PAT (PAT feed), providing a feed of talc (talc feed), mixing the PAT feed and the talc feed in a PAT:talc ratio of about 3:1 to about 1:3 in a mixer to form a PAT / talc blend, and providing the PAT / talc blend as an output.

[0005] In one embodiment, a system for forming a polyalkylene terephthalate (PAT) mixture containing talc is provided, the system comprising a PAT feed (PAT feed), a talc feed (talc feed), and a mixer coupled to an outlet for the PAT feed and an outlet for the talc feed, the mixer being capable of mixing the PAT and the talc in a PAT:talc ratio of about 3:1 to about 1:3 to form a PAT / talc mixture. may include:

[0006] In one embodiment, a method for forming a polyalkylene terephthalate (PAT) alloy with talc is provided. The method may include providing a PAT feed (PAT feed), providing a PAT / talc feed (PAT / talc feed), combining the PAT feed and the PAT / talc feed in a mixer to form a PAT alloy having about 1% (w / w) to about 50% (w / w) talc, and providing the PAT alloy as an output.

[0007] In one embodiment, a system for forming a polyalkylene terephthalate (PAT) alloy with talc is provided. The system can include a mixer coupled to a PAT feed (PAT feed), a PAT / talc feed (talc feed), a PAT feed outlet, and a PAT / talc feed outlet, the mixer capable of mixing the PAT and PAT / talc to form a PAT alloy having about 1% (w / w) to about 50% (w / w) talc.

[0008] In one embodiment, the polyalkylene terephthalate / talc (PAT / talc) mixture can include polyalkylene terephthalate (PAT) with talc in a PAT:talc ratio of about 3:1 to about 1:3.

[0009] In one embodiment, a polyalkylene terephthalate (PAT) alloy can include a PAT with talc. The PAT can include a first portion of a PAT polymer having a first average molecular weight and a second portion of a PAT polymer having a second average molecular weight, the first average molecular weight being less than the second average molecular weight. The talc is present in the PAT in an amount of at least 1% and less than 50%.

[0010] In one embodiment, the mold system comprises: a mold having a mold cavity; The PAT alloy can include a PAT comprising a first portion of a PAT polymer having a first average molecular weight and a second portion of a PAT polymer having a second average molecular weight, and talc in the PAT, wherein the first average molecular weight is less than the second average molecular weight, and the talc is present in an amount of at least 1% and less than 50%, and the PAT alloy completely fills a mold cavity of the mold. The PAT can have the formula: [ka]

[0011] In PAT, n can be any suitable integer, such as 1 (polymethylene terephthalate (PMT)), 2 (polyethylene terephthalate (PET)), 3 polypropylene terephthalate (PPT), 4 (polybutylene terephthalate (PBT)), or 5 polypentylene terephthalate (PPentT), etc. (e.g., n is 6, 7, 8, 9, 10, etc.).

[0012] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the exemplary aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

[0013] The above and following information, as well as other features of the present disclosure, will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings, in which: The present disclosure is described with additional specificity and detail, with the understanding that these drawings illustrate only some embodiments in accordance with the present disclosure and therefore should not be considered limiting of its scope, and [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a schematic diagram of a system for preparing a PET / talc mixture. [Figure 2] 1 is a schematic diagram of a system for preparing a PET alloy with talc. [Figure 3] 1 is a schematic diagram of a system for manufacturing PET alloys into various products, optionally including additional optional components. [Figure 4] 1 is a schematic diagram of an injection molding system for producing PET alloys into injection molded articles. [Figure 5A] FIG. 1 is a graph showing the relationship between fluidity and strength with respect to PET polymer chain length. [Figure 5B] FIG. 1 is another diagram showing the relationship between flowability and strength with respect to PET polymer chain length. [Figure 5C] FIG. 10 is yet another diagram showing the relationship between flowability and strength versus PET polymer chain length. [Figure 6A] 1 includes a graph showing differential scanning calorimetry DSC data for PET. [Figure 6B] 1 includes a graph showing DSC data for PET with talc. [Figure 6C] 1 includes a graph showing DSC data for PET with talc formed at 110° C. [Figure 6D] 1 includes a graph showing DSC data for PET with talc formed at 120° C. [Figure 6E] 1 includes a graph showing DSC data for PET with talc formed at 125° C. [Figure 6F]1 includes a graph showing DSC data for PET with talc formed at 105° C. [Figure 7] Included is a table showing the properties of PET alloys obtained by DSC. [Figure 8] Contains a table showing the oxygen permeability of PET alloys. [Figure 9] Included is a table showing the properties of PET alloys obtained by DSC. [Figure 10] Contains a table showing the molar mass average molecular weight of PET alloys and PET / talc. [Figure 11] 1 is a graph showing the heat distortion temperature (HDT) of PET and PET alloys with various amounts of talc. [Figure 12] Included is a table showing the mechanical properties of PET alloys further having chopped glass fibers (CGF). [Figure 13A] Contains a table showing the mechanical properties of PET alloys. [Figure 13B] Contains a table showing the mechanical properties of general purpose polystyrene (GPPS). DETAILED DESCRIPTION OF THE INVENTION

[0015] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, like symbols generally identify like elements unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that aspects of the present disclosure, as generally described herein and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are expressly contemplated herein.

[0016] Generally, the present technology includes systems and methods for preparing polyethylene terephthalate (PET) alloys containing talc. The PET alloys are formed by preparing a PET / talc mixture and combining the PET / talc mixture with a PET composition to produce the PET alloy. Thus, the present systems and methods can be used to produce precisely manufactured talc-filled PET (e.g., a PET / talc mixture), which can then be mixed with PET (e.g., virgin PET, virgin PET, or talc-free PET) to form a PET alloy material that has better flowability, faster crystallization, a higher HDT, and better barrier properties than PET, while maintaining other desirable properties of PET, such as tensile strength and flexural yield strength.

[0017] PET can be suitable for products because it has water-repellent and moisture-proof properties, which allows PET alloy products to be made into containers for storing liquids such as beverages (e.g., soft drinks, water, beer, etc.) The high mechanical strength of PET alloys can enable their use in tapes, such as carrier containers for magnetic tapes or backings for pressure-sensitive adhesive tapes.

[0018] Here, the crystallization process of PET alloys can be controlled by adjusting the amount and treatment of talc in the PET / talc mixture, as well as in the PET alloy, thereby enabling the adjustment of the transparency, stiffness, and strength of the PET alloy product. PET alloys can also contain low-molecular-weight PET mixed with talc. High-molecular-weight PET can provide faster or otherwise improved flow, allowing PET alloys to be used in injection molding, such as for the production of thin-walled injection-molded parts, as well as extrusion molding to form various extrusion products, such as tails and fibers, and cylinders for pelletizing in a chopper. PET alloys have significantly shorter crystallization cycle times, thereby enabling improved methods and applications for PET using PET alloys. Furthermore, PET alloys have a higher heat distortion temperature (HDT), allowing them to soften at significantly higher temperatures compared to conventional PET (e.g., non-alloyed). Therefore, PET alloys provide polymers with better flow, faster crystallization, and a higher HDT. The improved systems and methods can be used to produce precisely manufactured talc-filled PET (e.g., a PET / talc mixture), which can then be mixed with virgin PET (e.g., talc-free) to form a PET alloy material with improved barrier properties, such as reduced oxygen permeability (see data in Figure 8). The data show that the PET alloy provides a more effective barrier to gas permeation compared to standard, unmodified PET. The data is also expected to show reduced permeability to carbon dioxide, water vapor, and other gases. The improved barrier properties are due to increased crystallinity and the presence of talc, a plate-like, impermeable solid. These two modifications reduce permeability to all types of penetrants.

[0019] PET alloys may be formed into amorphous (transparent) or semi-crystalline products. Depending on their crystalline structure and particle size, semi-crystalline materials appear transparent (e.g., for particle sizes less than 500 nm) or opaque and white (e.g., for particle sizes up to a few micrometers).

[0020] In one example, PET feedstock can be prepared by any suitable process. As is commonly known, the monomer bis(2-hydroxyethyl) terephthalate can be synthesized by the esterification reaction of terephthalic acid with ethylene glycol, with water as a by-product, or by the transesterification reaction of ethylene glycol with dimethyl terephthalate (DMT), with methanol as a by-product. Polymerization is carried out via a polycondensation reaction of the monomers (e.g., immediately following esterification / transesterification), with water as a by-product. PET feedstock can be prepared as described in U.S. Patent Application Publication No. 2009 / 0212457, the entire contents of which are incorporated herein by specific reference. PET feedstock can be in sheet, pellet, or other form, as well as liquid PET. PET feedstock can be processed to a liquid and flowable state suitable for the methodology described herein.

[0021] In one embodiment, a method for forming a polyethylene terephthalate (PET) blend containing talc is provided. Such a method can be implemented in a PET / talc system 100, as shown in FIG. 1. The PET / talc system 100 for forming a PET blend containing talc can include a PET feed 120 (PET feed), a talc feed 122 (talc feed), and a mixer 110 coupled to an outlet for the PET feed 120 and an outlet for the talc feed 122. The mixer 110 can mix the PET with the talc in a PET:talc ratio of about 3:1 to about 1:3 to form the PET / talc blend, or any other desired ratio. The system 100 can also include an output 136 operably coupled to the outlet of the mixer 110. The output 136 can be selected from a container, a pump, a flow line, a heater, a cooler, an extruder, a die, a pelletizer, a mixer, combinations thereof, and other components known in the art for PET systems. As shown, the system 100 can include a PET feed 120 having an inlet coupled to a PET supply 124 .

[0022] It should be appreciated that PET may be replaced with PAT or any other type of PAT in the present method and system 100. That is, the present system may be configured for use with any PAT, and as such, the recitation of PET may also refer to PAT herein, as well as other methods and systems provided herein. For example, PET / talc system 100 could be PAT / talc system 100, etc.

[0023] System 100 may also include a talc feed 122 having an inlet coupled to talc supply 126. System 100 may include one or more of a PET reactor system 128, a PET recycling system 130, a PET conditioning system 132, or a PET reservoir 134. PET reactor system 128 is configured to polymerize PET from PET precursor reagents. PET recycling system 130 is configured to recycle PET from PET products. PET conditioning system 132 is configured to condition PET for mixing with talc, where the conditioning is selected from one or more of heating, shredding PET pellets or sheets or other PET components, agitating, extruding, drying, or degassing. PET reservoir 134 contains liquid PET, where the liquid PET is molten PET.

[0024] System 100 can include a talc supply 126 having talc powder in a flowable format. The flowable format can include talc particles, such as in the form of a talc powder. The talc powder includes talc particles of about 0.25 microns to about 100 microns, or about 0.5 microns to about 75 microns, or about 0.75 microns to about 0.5 microns, or about 1 micron to about 40 microns, or about 5 microns to about 30 microns, or about 10 microns to about 25 microns, or about 15 microns to about 20 microns.

[0025] System 100 includes mixer 110, which can be any mixer capable of mixing liquid PET and talc in a batch or continuous manner, including, for example, a single screw mixer, a twin screw mixer, a continuous compounder (e.g., a B&P Littleford continuous compounder, a Buss compounder), a reciprocating screw mixer (e.g., a B&P Littleford TriVolution), a twin screw extruder (B&P Littleford), a continuous plow mixer (e.g., a B&P Littleford), etc. In one embodiment, mixer 110 also performs one or more of degassing, homogenizing, dispersing, or heating.

[0026] System 100 can include a PET / talc mixture reservoir 138. The PET / talc mixture reservoir can be in any form, and the PET / talc can be contained therein in any form. However, the PET / talc can be pelletized or formed into another storable form (e.g., a melt) prior to entering the reservoir.

[0027] System 100 may include an analysis system 140. Analysis system 140 may include one or more analysis systems capable of various analysis processes. For example, analysis system 140 may be configured to determine the intrinsic viscosity of molten PET / talc mixture output 102. In another example, analysis system 140 may be configured to determine the flow rate of molten PET / talc mixture output 102. In another example, analysis system 140 may be configured to determine the melting point of PET / talc mixture output 102. In another example, analysis system 140 may be configured to determine the crystallization temperature of PET / talc mixture output 102. In another example, analysis system 140 may be configured to determine a differential scanning calorimetry profile of PET / talc mixture output 102. In another example, analysis system 140 may be configured to determine the heat distortion temperature of PET / talc mixture output 102.

[0028] A method for forming a PET / talc mixture can be carried out according to system 100. Such a method can include providing a feed of PET 120 (PET feed), providing a feed of talc 122 (talc feed), mixing the PET feed and the talc feed in a PET:talc ratio of about 3:1 to about 1:3 in a mixer 110 to form a PET / talc mixture, and providing the PET / talc mixture as output 102. In one embodiment, PET feed 120 is from a PET supply 124. In one embodiment, talc feed 122 is from a talc supply 126.

[0029] In one embodiment, PET supply 124 receives PET feed from one or more of PET reactor system 128, PET recycling system 130, PET conditioning system 132, or PET reservoir 134. PET reactor system 128 polymerizes PET from PET precursor reagents. PET recycling system 130 recycles PET from PET products. PET conditioning system 132 conditions PET for mixing with talc, where the conditioning is selected from one or more of heating, shredding PET pellets or sheets or other PET components, agitating, extruding, drying, and degassing. PET reservoir 134 has liquid PET, where the liquid PET is molten PET.

[0030] In one embodiment, talc supply 126 includes talc powder in a flowable form, which may include providing the talc as a powder, which may include talc particles of about 0.25 microns to about 100 microns, or about 0.5 microns to about 75 microns, or about 0.75 microns to about 0.5 microns, or about 1 micron to about 40 microns, or about 5 microns to about 30 microns, or about 10 microns to about 25 microns, or about 15 microns to about 20 microns.

[0031] In one embodiment, the method can include preparing talc to have talc particles, where preparing can include mining, grinding, polishing, or other processing to form talc particles. Optionally, system 100 can include equipment for preparing talc, such as mining equipment, grinders, polishers, etc.

[0032] The mixing can be performed by mixer 110, which can be any mixer capable of mixing liquid PET and talc in a batch or continuous manner, such as a single screw mixer, a twin screw mixer, a continuous compounder (e.g., a B&P Littleford continuous compounder, a Buss compounder), a reciprocating screw mixer (e.g., a B&P Littleford TriVolution), a twin screw extruder (B&P Littleford), a continuous plow mixer (e.g., a B&P Littleford), or other mixer capable of mixing PET and talc. Optionally, mixer 110 also performs one or more of degassing, homogenizing, dispersing, or heating.

[0033] The method may also include providing the PET / talc mixture output 102 to an output system 136. The output system 136 provides the PET / talc mixture to a reservoir 138 (e.g., in pellets), a PET alloy system 200, or an analysis system 140. The method may include pelletizing the PET / talc mixture output 102 using a pelletizer. The analysis system 140 includes one or more analysis systems capable of determining the intrinsic viscosity of the molten PET / talc mixture output 102, determining the flow rate of the molten PET / talc mixture output 102, determining the melting point of the PET / talc mixture output 102, determining the crystallization temperature of the PET / talc mixture output 102, determining a differential scanning calorimetry profile of the PET / talc mixture output 102, or determining the heat distortion temperature of the PET / talc mixture output 102.

[0034] PET alloy system 200 is described in detail below. However, in one embodiment, PET alloy system 200 is configured to combine PET / talc mixture output 102 with a second PET feed 220 (second PET feed) to produce PET alloy 202.

[0035] In one embodiment, PET feed 120 does not include another polymer. In another embodiment, talc feed 122 does not include another polymer. However, PET feed 120 and / or talc feed may include other polymers, such as PAT, as defined herein, or polycarbonate. In one embodiment, PET feed 120 consists essentially of (or consists of) PET. In one embodiment, talc feed 122 consists essentially of (or consists of) talc (optionally with trace amounts of water). In one embodiment, PET feed 120 includes molten PET.

[0036] In one embodiment, the PET feed 120 contains less than 5%, or less than 1%, or less than 0.1%, or trace amounts of water, or no water. Accordingly, the method can include drying the PET feed 120 before mixing with the talc feed 122. The method can also include drying the talc feed 122 before mixing with the PET feed 120.

[0037] In one embodiment, the method can include preparing PET. Thus, the method can include polymerizing PET from a polymerizable reagent.

[0038] The method can include providing a PET / talc mixture output 102 having a PET:talc ratio of about 2:1 to about 1:2 or about 1:1. Alternatively, the provided PET / talc mixture output 102 has a PET concentration of about 20% to about 80%, about 25% to about 75%, about 40% to about 60%, or about 50%. In another alternative, the provided PET / talc mixture output 102 has a talc concentration of about 20% to about 80%, about 25% to about 75%, about 40% to about 60%, or about 50%.

[0039] In one embodiment, the provided PET / talc mixture output 102 has an intrinsic viscosity of from about 0.25 to about 0.7, or from about 0.3 to about 0.65, or from about 0.35 to about 0.6, or from about 0.4 to about 0.5.

[0040] A method for forming a polyethylene terephthalate (PET) alloy with talc can be performed in system 200 of FIG. 2. System 200 for forming a polyethylene terephthalate (PET) alloy talc can include a PET feed 220 (PET feed), which can include virgin PET, recycled PET, or other PET sources (e.g., with or without other polymers, additives, etc.). System 200 can also include a PET / talc feed 222 (talc feed), which can be the PET / talc mixture output 102 obtained from the method used in system 100 of FIG. 1. System 200 can include a mixer 210 coupled to an outlet for PET feed 220 and an outlet for PET / talc feed 222, and mixer 210 can mix PET with the PET / talc to form a PET alloy with about 1% (w / w) to about 50% (w / w) talc. The system 200 can include an output 136 operably connected to the outlet of the mixer 110, the output being selected from a container, a pump, a flow line, a heater, a cooler, an extruder, a die, a pelletizer, and combinations thereof.

[0041] In one embodiment, system 200 can include a PET feed 220 having an inlet coupled to a PET supply 224. PET supply 224 can be the same type as PET supply 124 of system 100 of FIG. 1 . System 200 can include a PET reactor system 128 configured to polymerize PET from PET precursor reagents. System 200 can include a PET recycling system 130 configured to recycle PET from PET products. System 200 can include a PET conditioning system 132 configured to condition PET for blending with PET / talc, where the conditioning is selected from one or more of heating, shredding PET pellets or sheets or other PET components, agitating, extruding, drying, degassing, or other conditioning. System 200 can include a PET reservoir 134 having solid PET pellets or liquid PET, where the liquid PET is molten PET. A heating system can be included to heat the PET to an appropriate temperature and liquefy the solid PET pellets, and such a heating system can be included in any system component or flow line.

[0042] In one embodiment, system 200 can include a PET / talc feed 122 having an inlet coupled to a PET / talc supply 226. PET / talc supply 226 can include a PET / talc mixture output 202, which can be in solid pellet form or molten liquid form. In one aspect, PET / talc supply 226 includes PET / talc in a flowable form and / or includes a heater for heating the PET / talc into a flowable form (e.g., a molten PET / talc liquid). In one aspect, the PET / talc includes talc particles ranging from about 0.25 microns to about 100 microns, or from about 0.5 microns to about 75 microns, or from about 0.75 microns to about 0.5 microns, or from about 1 micron to about 40 microns, or from about 5 microns to about 30 microns, or from about 10 microns to about 25 microns, or from about 15 microns to about 20 microns.

[0043] In one embodiment, mixer 210 is any mixer capable of mixing liquid PET and PET / talc in a batch or continuous manner, including, for example, a single screw mixer, a twin screw mixer, a continuous compounder (e.g., a B&P Littleford continuous compounder, a Buss compounder), a reciprocating screw mixer (e.g., a B&P Littleford TriVolution), a twin screw extruder (B&P Littleford), a continuous plow mixer (e.g., a B&P Littleford), etc. Mixer 210 is configured to perform one or more of degassing, homogenizing, dispersing, or heating.

[0044] In one embodiment, system 200 can include a reservoir 238. Reservoir 238 can contain the PET alloy in any form, such as a heated liquid or a solid (e.g., a pelletized solid).

[0045] System 200 may include analysis system 240. Analysis system 240 includes one or more analysis systems capable of various analysis processes. For example, analysis system 240 may be configured to determine the intrinsic viscosity of molten PET alloy output 202. In another example, analysis system 240 may be configured to determine the flow rate of molten PET alloy output 202. In another example, analysis system 240 may be configured to determine the melting point of PET alloy output 202. In another example, analysis system 240 may be configured to determine the crystallization temperature of PET alloy output 202. In another example, analysis system 240 may be configured to determine a differential scanning calorimetry profile of PET alloy output 202. In another example, analysis system 240 may be configured to determine the heat distortion temperature of PET alloy output 202.

[0046] In one embodiment, system 200 can include a manufacturing system 300 configured to convert PET alloy output 202 into manufactured product 302. Manufacturing system 300 can include an optional ingredient input feed 320. Optional ingredient input feed 320 can be configured to provide optional ingredients to the PET alloy. The optional ingredients can be selected from fillers, TiO, a second polymer, glass pellets, glass fibers, glass particles, sodium ionomers, sodium stearate, nucleating agents, polycarbonate, polybutylene terephthalate (PBT) or other polyalkylene terephthalates (PAT), or other components of PET manufactured product 302. As shown in FIG. 3 , manufacturing system 300 can include one or more of a PET alloy feed 301, one or more flow paths 308 containing a flowable PET alloy, a mixer 310, a heating system 312, an extruder system 316 producing a PET alloy extrudate 317, a pumping system 318, an injection molding system 322, and / or a cooling system 314.

[0047] In one embodiment, optional ingredients can be provided to mixer 110 and mixed into PET / talc mixture output 102, or provided to mixer 210 and mixed into PET alloy output 202. Alternatively, provided PET 220 can include optional ingredients, or provided PET / talc 222 can be prepared to include optional ingredients. Thus, optional ingredients can be introduced into PET at any stage of the processes described herein.

[0048] System 200 can have various modifications, such as those described herein. In one embodiment, PET feed 220 does not include another polymer. In one embodiment, PET / talc feed 222 does not include another polymer. In one embodiment, PET feed 220 consists essentially of (or consists of) PET. In one embodiment, PET / talc feed 222 consists essentially of (or consists of) PET and talc (optionally containing trace amounts of water). In one embodiment, PET feed 220 includes molten PET. In one embodiment, PET feed 220 contains less than 5%, or less than 1%, or less than 0.1%, or trace amounts of water, or no water.

[0049] In one embodiment, system 200 can include a dryer to dry PET feed 220 before mixing with PET / talc feed 222. In one embodiment, system 200 can include a dryer to dry PET / talc feed 222 before mixing with PET feed 220. Such a dryer can be included anywhere in system 200, or any suitable component can be equipped with a dryer. The dryer can facilitate water removal to enhance processing and preparation of the PET alloy with talc.

[0050] In one embodiment, system 200 can include a provided PET / talc feed 222 having a PET:talc ratio of about 3:1 to about 1:3, or about 2:1 to about 1:2, or about 1:1. In one aspect, provided PET alloy output 202 has a PET concentration of about 50% to about 99%, about 25% to about 75%, about 40% to about 60%, or about 50%. In one aspect, provided PET alloy output 202 has a talc concentration of about 2% to about 40%, about 5% to about 30%, about 10% to about 25%, or about 20%.

[0051] In one embodiment, the provided PET feed 220 of the system 200 has an intrinsic viscosity of 0.55 or greater, such as from about 0.6 to about 0.9, or from about 0.625 to about 0.8, or from about 0.65 to about 0.7. In one aspect, the provided PET alloy output 102 has an intrinsic viscosity of from about 0.5 to about 0.9, or from about 0.6 to about 0.8, or from about 0.625 to about 0.7, or from about 0.65 to about 0.675.

[0052] In one embodiment, a method for forming a polyethylene terephthalate (PET) alloy with talc can be performed with the system 200 described herein. The method for forming the PET alloy with talc can include providing a PET feed 220 (PET feed), providing a PET / talc feed 222 (PET / talc feed), mixing the PET feed 220 with the PET / talc feed 222 in a mixer 210 to form a PET alloy with about 1% (w / w) to about 50% (w / w) talc, and providing the PET alloy as output 202. In one aspect, the PET feed 220 is from a PET supply 224 as described herein. In one aspect, the PET / talc feed 122 is from a PET / talc supply 226 as described herein.

[0053] In one embodiment, the method can include a PET supply 224 that receives PET feed from one or more of a PET reactor system 128, a PET recycling system 130, a PET conditioning system 132, or a PET reservoir 134. The PET reactor system 128 can polymerize PET from PET precursor reagents. The PET recycling system 130 can recycle PET from PET products. The PET conditioning system 132 can condition PET for blending with PET / talc, where the conditioning is selected from one or more of heating, shredding PET pellets or sheets or other PET components, agitating, extruding, drying, and degassing. The PET reservoir 134 can hold PET in a solid state (e.g., pellets) or as liquid PET, where the liquid PET is molten PET.

[0054] In one embodiment, the method can include obtaining talc. The talc can be obtained as particles or formed into particles by milling. The talc particles can be about 0.25 microns to about 100 microns, or about 0.5 microns to about 75 microns, or about 0.75 microns to about 0.5 microns, or about 1 micron to about 40 microns, or about 5 microns to about 30 microns, or about 10 microns to about 25 microns, or about 15 microns to about 20 microns.

[0055] In one embodiment, the method includes a mixer 210 that mixes the PET and talc into a PET alloy with the talc. Such mixing can be performed by any mixer capable of mixing liquid PET and talc in a batch or continuous manner, including single-screw mixers, twin-screw mixers, continuous compounders (e.g., B&P Littleford continuous compounders, Buss compounders), reciprocating screw mixers (e.g., B&P Littleford TriVolution), twin-screw extruders (B&P Littleford), continuous plow mixers (e.g., B&P Littleford), etc. In one aspect, the mixer 210 also performs one or more of degassing, homogenizing, dispersing, or heating.

[0056] In one embodiment, PET alloy output 202 is provided to output system 236. Output system 236 provides the PET alloy to reservoir 238, analytical system 240, or manufacturing system 300. Reservoir 238 may be adapted to hold the PET alloy as a liquid or as pellets, such as by including a heater, so that output system 236 may include a pelletizer to pelletize the PET alloy. In one aspect, analytical system 240 includes one or more analytical systems capable of performing one or more of the following analytical methods on the PET alloy: determining the intrinsic viscosity of molten PET alloy output 202, determining the flow rate of molten PET alloy output 202, determining the melting point of PET alloy output 202, determining the crystallization temperature of PET alloy output 202, determining a differential scanning calorimetry profile of PET alloy output 202, or determining the heat distortion temperature of PET alloy output 202. In one aspect, manufacturing system 300 is operated to convert PET alloy output 202 into a manufactured product. In one embodiment, the manufactured product can be PET alloy pellets. In one embodiment, the manufactured product can include other components that can be introduced into the PET alloy in system 300 or other systems described herein. Manufacturing system 300 is described in more detail herein.

[0057] In one embodiment, the method includes providing a PET feed 220 that is free of another polymer. In one aspect, the method can include providing a PET / talc feed 222 that is free of another polymer. In one aspect, the method can include providing a PET feed 220 that consists essentially of (or consists of) PET. In another aspect, the method can include providing a PET / talc feed 222 that consists essentially of (or consists of) PET and talc (optionally containing trace amounts of water). In one aspect, the method includes providing the PET feed 220 as molten PET. In one aspect, the method includes providing a PET feed 220 that contains less than 5%, or less than 1%, or less than 0.1%, or trace amounts of water, or no water.

[0058] In one embodiment, the method can include drying the PET feed 220 before mixing with the PET / talc feed 222. In one aspect, the method can include drying the PET / talc feed 222 before mixing with the PET feed 220.

[0059] In one embodiment, the method can include polymerizing PET from a polymerizable reagent.

[0060] In one embodiment, the method can include providing a PET / talc feed 222 having a PET:talc ratio of about 3:1 to about 1:3, or about 2:1 to about 1:2, or about 1:1. In one aspect, the method can include providing a PET alloy output 202 having a PET concentration of about 60% to about 99%, about 70% to about 95%, about 75% to about 90%, or about 80%. In one aspect, the method can include providing a PET alloy output 202 having a talc concentration of about 1% to about 40%, about 5% to about 30%, about 10% to about 25%, or about 20%.

[0061] In one embodiment, the method can include providing a PET feed 220 having an intrinsic viscosity of 0.55 or greater, such as from about 0.6 to about 0.9, or from about 0.625 to about 0.8, or from about 0.65 to about 0.7. In one aspect, the method can include forming a PET alloy output 102 having an intrinsic viscosity of from about 0.5 to about 0.9, or from about 0.6 to about 0.8, or from about 0.625 to about 0.7, or from about 0.65 to about 0.675.

[0062] In one embodiment, system 200 can include a manufacturing system 300 configured to convert PET alloy output 202 into manufactured product 302. Manufacturing system 300 can include an optional ingredient input feed 320. Optional ingredient input feed 320 can be configured to provide optional ingredients to the PET alloy. The optional ingredients can be selected from fillers, TiO, a second polymer, glass pellets, glass fibers, glass particles, sodium ionomer, sodium stearate, nucleating agents, polycarbonate, polybutylene terephthalate (PBT) or other polyalkylene terephthalates (PAT), or other components of PET manufactured product 302.

[0063] As shown in FIG. 3, manufacturing system 300 may include one or more of a PET alloy feed 301, one or more flow paths 308 containing the flowable PET alloy, a mixer 310, a heating system 312 capable of heating any component of system 300, an extruder system 316 for producing PET alloy extrudate 317 (which may also include, for example, a pelletizer for pelletizing PET alloy extrudate 317), a pumping system 318 capable of pumping the PET alloy to any component in system 300, an injection molding system 322, and / or a cooling system 314 capable of cooling any component in the system.

[0064] As described herein, the system 100 and corresponding methods can prepare polyethylene terephthalate / talc (PET / talc) blends containing PET and talc. PET / talc can include various amounts of talc in PET. Therefore, the PET:talc ratio can be suitable for use in forming PET alloys with talc. PET / talc can include a PET:talc ratio of about 3:1 to about 1:3, although other ratios are possible.

[0065] The PET / talc may contain talc particles. The talc particles may be about 0.25 microns to about 100 microns, or about 0.5 microns to about 75 microns, or about 0.75 microns to about 0.5 microns, or about 1 micron to about 40 microns, or about 5 microns to about 30 microns, or about 10 microns to about 25 microns, or about 15 microns to about 20 microns. In one embodiment, the PET / talc mixture has a PET:talc ratio of about 2:1 to about 1:2, or about 1:1. In one embodiment, the PET / talc mixture has a PET concentration of about 20% to about 80%, about 25% to about 75%, about 40% to about 60%, or about 50%. In another embodiment, the PET / talc mixture has a talc concentration of about 20% to about 80%, about 25% to about 75%, about 40% to about 60%, or about 50%.

[0066] In one embodiment, the PET / talc mixture contains less than 5%, or less than 1%, or less than 0.1%, or trace amounts of water, or no water. Thus, the PET and / or talc feeds that form the PET / talc may contain no water or very small amounts of water.

[0067] In one embodiment, the PET / talc blend has an intrinsic viscosity of about 0.25 to about 0.7, or about 0.3 to about 0.65, or about 0.35 to about 0.6, or about 0.4 to about 0.5.

[0068] As described herein, the system 200 and corresponding method can prepare polyethylene terephthalate alloys with talc. PET alloys can include various amounts of talc in PET. Thus, the PET:talc ratio can be suitable for forming various manufactured products, such as injection molding. Such PET alloys can include PET and talc. The PET in the PET alloy can include a first portion of a PET polymer having a first average molecular weight and a second portion of a PET polymer having a second average molecular weight. The first average molecular weight is less than the second average molecular weight. The talc is present in the PET in an amount of at least 1% and less than 50%.

[0069] Higher molecular weight PET chains provide greater strength but less fluidity. Typically, any treatment to improve fluidity sacrifices strength, creating a trade-off. This PET alloy offers excellent fluidity and strength. As shown in Figure 5C, the PET alloy can be considered bimodal PET. Figure 5A shows the average molecular weight distribution of regular PET, with lower molecular weights providing excellent fluidity but lower strength, and higher molecular weights providing excellent strength but poor fluidity. Figure 5B shows a lower average molecular weight distribution, with more PET polymers providing excellent fluidity but lower strength. In Figure 5B, the PET polymer chains are shortened, resulting in good fluidity, due to hydrolysis from talc or water within the talc, but the shorter chains are not long enough to effectively entangle, resulting in a decrease in PET strength. Figure 5C shows a PET alloy with a portion that is both fluid and weak, and a portion that is regular PET. The lower molecular weight portion contributes to the excellent fluidity without significantly reducing the strength of the alloy. It has been surprisingly discovered that by producing a low molecular weight, highly flowable PET / talc blend and combining a small amount of the PET / talc blend with virgin, high molecular weight PET, a PET alloy material is obtained that exhibits excellent flow while retaining excellent strength. The illustrations in Figures 5A-5C are for illustrative purposes only.

[0070] In one embodiment, a majority of the talc is associated with the PET polymer in the first portion of the PET polymer. It has been found that the talc can reduce the molecular weight of the PET, such that the PET in the PET / talc can have a lower molecular weight than the PET used to form the PET / talc and / or the PET used to form the PET alloy. The PET in the PET / talc can have a first average molecular weight. The PET supplied to system 100 or system 200 can have a second average molecular weight.

[0071] In one embodiment, the PET alloy includes talc that is distributed non-uniformly throughout the PET. In some cases, the PET alloy can be prepared so that some portions have more PET / talc than others, without thoroughly mixing the PET and PET / talc together. This helps facilitate processing of the PET alloy, such as injection molding. Alternatively, the PET alloy includes talc that is distributed uniformly throughout the PET. In some products where consistency and composition are important, there may be value in having talc mixed uniformly throughout the PET.

[0072] In one embodiment, the PET alloy includes talc particles of about 0.25 microns to about 100 microns, or about 0.5 microns to about 75 microns, or about 0.75 microns to about 0.5 microns, or about 1 micron to about 40 microns, or about 5 microns to about 30 microns, or about 10 microns to about 25 microns, or about 15 microns to about 20 microns.

[0073] In one embodiment, the PET alloy contains less than 5%, or less than 1%, or less than 0.1%, or trace amounts of water, or no water.

[0074] In one embodiment, the PET alloy has a PET concentration of about 60% to about 99%, about 70% to about 95%, about 75% to about 90%, or about 80%.

[0075] In one embodiment, the PET alloy has a talc concentration of about 1% to about 40%, about 5% to about 30%, about 10% to about 25%, or about 20%.

[0076] In one embodiment, the PET alloy has an intrinsic viscosity of about 0.5 to about 0.9, or about 0.6 to about 0.8, or about 0.625 to about 0.7, or about 0.65 to about 0.675.

[0077] The PET alloy may include optional components selected from fillers, TiO, a second polymer, glass pellets, glass fibers, glass particles, sodium ionomer, sodium stearate, nucleating agents, polycarbonate, polybutylene terephthalate (PBT) or other polyalkylene terephthalates (PAT), or other components of the PET manufacturing product 302. In one embodiment, the PET alloy includes TiO.

[0078] In one embodiment, the PET alloy has a combination of talc particles and TiO particles in a total concentration of about 1% to about 40%, about 5% to about 30%, about 10% to about 25%, or about 20%. In one embodiment, the PET alloy has TiO particles in a concentration of about 1% to about 40%, about 5% to about 30%, about 10% to about 25%, or about 20%. In one embodiment, the PET alloy has optional ingredients in a concentration of about 1% to about 40%, about 5% to about 30%, about 10% to about 25%, or about 20%.

[0079] In one embodiment, the PET alloy has a melting temperature of about 240°C to about 250°C, or about 245°C.

[0080] In one embodiment, the PET alloy has a viscosity of about 3-6 CC / (m 2 / day), + / - 25%, 20%, 15%, 10%, 5%, 2%, or 1%. In one embodiment, the PET alloy has an oxygen permeability of about 3.6 CC / (m 2 / day), + / - 25%, 20%, 15%, 10%, 5%, 2%, or 1%. In one embodiment, the PET alloy has an oxygen permeability of about 5.6 CC / (m 2 / day), with about 20% (w / w) talc to have an oxygen permeability of + / - 25%, 20%, 15%, 10%, 5%, 2%, or 1%.

[0081] In one embodiment, the PET alloy has a crystallization temperature of about 200°C to about 230°C, or about 210°C to about 220°C, or about 212°C.

[0082] In one embodiment, the PET alloy can be used in injection molding to form a manufactured product. Accordingly, an injection molding system 400 can include a PET alloy feed 420, as shown in FIG. 4, to form an injection-molded article 402 including the PET alloy. The PET alloy feed 420 can be a liquid PET alloy (e.g., a molten PET alloy). However, the injection molding system 400 can include a PET alloy heater 424 that heats the PET alloy feed 420 to obtain flowability as a liquid PET alloy. The heater 424 can receive the PET alloy as pellets 428, heated liquid PET alloy 430, or as PET 432 along with PET / talc 434, which is mixed in the heater 424 configured as a mixer, such as those described herein. The heater 424 can provide the PET alloy feed 420 to an extruder 410. Optionally, a dried and / or filtered PET alloy pellet feed 422 can be provided to the extruder 410 from a PET alloy drying and / or filtering device 426.

[0083] The PET alloy can be processed in the injection molding system 400 and through an in-line filtration system of the injection molding system. PET alloy pellets can be fed into the system 400 through a drying hopper, which then feeds the inlet end of the plasticizing screw of the extruder 410. The plasticizing extrusion screw is enclosed in a barrel (i.e., the extruder 410) that is heated by a barrel heater. The helical (or other) flights of the screw transport the PET alloy along the operating axis of the screw. Typically, the root diameter of the screw increases gradually along the operating axis of the screw, away from the inlet end. Once the desired amount of PET alloy melt has accumulated in the extruder 410, it is transferred to a melt accumulator 440, which may include an injection plunger that performs the function of injecting the molten PET alloy into a mold cavity 438.

[0084] A melt filter 436 disposed in fluid communication between the extruder 410 and the melt accumulator 440 performs an in-line filtration step. The purpose of the melt filter 436 is to filter impurities and other foreign matter from the PET alloy material being transferred from the extruder 410 to the melt accumulator 440. The particular implementation of the melt filter is not particularly limited, and by way of example, the melt filter 436 can be implemented using an off-the-shelf filter from Gneuss Inc. of Matthews, North Carolina (www.gneuss.com).

[0085] The in-line filtration step may be carried out in a melt filter 436 having an inlet to allow the PET alloy to be filtered to enter and a filter outlet to allow the filtered PET alloy to exit, the melt filter 436 including a filtration element disposed between the filter inlet and the filter outlet.

[0086] Mold 439 receives the PET alloy to fill mold cavity 438. This is an improvement over conventional PET, which does not inject well in such injection molding systems. Here, mold cavity 438 can be completely filled with the PET alloy without air gaps that would impair the injection molded product. This allows the PET alloy to be injection molded into molded PET manufactured product 402.

[0087] In one embodiment, the mold system can include a mold 439 having a mold cavity 438. The PET alloy can include PET including a first portion of a PET polymer having a first average molecular weight and a second portion of a PET polymer having a second average molecular weight, where the first average molecular weight is less than the second average molecular weight. The PET alloy can include talc in the PET, where the talc is present in an amount of at least 1% and less than 50%. The PET alloy completely fills the mold cavity 438 of the mold 439.

[0088] The systems and methods described herein provide novel PET alloys that can be used to prepare many PET products and can be used in a variety of processing techniques, such as injection molding. This allows the PET alloy to be injected into a mold to form thin-walled products. Furthermore, the PET alloys are injection moldable because the cycle time from liquid PET alloy to solid PET alloy is significantly shorter than the PET cycle time.

[0089] PET alloys also have improved heat distortion temperatures compared to PET. The heat distortion temperature (HDT) of PET can exceed 66°C at 0.46 MPa (i.e., 66 psi), and can range from 68°C at 0.46 MPa to about 95°C at 0.46 MPa, or from about 70°C at 0.46 MPa to about 90°C at 0.46 MPa, or from about 72°C at 0.46 MPa to about 88°C at 0.46 MPa. This allows manufactured products containing PET alloys to be products capable of containing or retaining high-temperature materials, such as hot liquid beverages, and thus PET alloys can be used to prepare containers for hot beverages. Furthermore, many manufacturing processes involve filling containers with hot materials, which are then cooled within the container. Therefore, the improved HDT of PET alloys allows them to be used as containers for holding hot liquids during manufacturing processes. PET alloys retain the shape of the container without buckling or other undesirable distortion. In one embodiment, the PET alloy has sufficient HDT to allow the PET alloy to be formed into a dishwasher-safe product. In one embodiment, the PET alloy has sufficient HDT to allow the PET alloy to be formed into a microwave-safe product. The PET alloy exhibits easy break characteristics that make it useful in notched end products such as yogurt multipacks and medical blister packs and related products.

[0090] Although PET has been described herein, the present systems and methods can also be used to prepare polyalkylene terephthalates (PATs). [ka]

[0091] In the polyalkylene terephthalate (PAT) structure, n can be any suitable integer, such as 1 (polymethylene terephthalate (PMT)), 2 (polyethylene terephthalate (PET)), 3 polypropylene terephthalate (PPT), 4 (polybutylene terephthalate (PBT)), or 5 polypentylene terephthalate (PPentT), etc. (e.g., n can be 6, 7, 8, 9, 10, etc.). Thus, the methods and systems described herein can be adapted for use with any suitable polyalkylene. That is, the PET in PET / talc can be replaced with any PAT to form PAT / talc. The PET in a PET alloy can be replaced with any PAT to form a PAT alloy. In some cases, the PAT / talc can include a first PAT (e.g., PET), and the virgin PAT mixed with the PAT / talc can include a second, different PAT (e.g., PBT), such that the PAT alloy has two different PATs, including talc.

[0092] Thus, although the systems and methods described herein relate to PET, such systems and methods may include any suitable PAT, such as PBT. [Example]

[0093] PET alloys were prepared by first preparing a PET / talc mixture and then preparing the PET alloy. Comparisons were made between PET (e.g., no talc), PET / talc with 50 wt% PET and 50 wt% talc, PET / talc with 80% PET and 20 wt% talc, and a PET alloy with 80% PET and 20 wt% talc. Parameters are shown in Table 1. Table 1 [Table 1]

[0094] Table 1 shows the IV (intrinsic viscosity), which represents the size of the molecules within the polymer for PET, PET / Talc, which contains 50% (by weight) talc in undried PET, PET / Talc 2, a polymer in which 20% talc is added directly to PET without an intermediate step of alloy production, and a PET alloy. As can be seen from the values, the PET alloy has a lower degree of crystallinity and a lower IV. In the direct addition example, the IV is too low to be useful for final products manufactured by injection molding. Thus, the PET alloy offers significant benefits.

[0095] A comparative study was conducted to examine the difference in flowability between PET alloys containing talc and PET without talc. The forks tested were 0.023 inches thick, and the fork molds were tested on a 250MT Krauss Maffei injection molding machine. The PET alloy filled the mold, but the PET did not, even at maximum pressure and long cycle times. Therefore, the PET alloy can be used in injection molding because it can fill the mold space without undesirable air gaps.

[0096] PET alloys were prepared and tested using differential scanning calorimetry (DSC) according to standard procedures. Tests were performed on PET, talc-filled PET sheets, PET alloys thermoformed at 110°C (110 PET alloy), 120°C (120 PET alloy), 125°C (125 PET alloy), and 105°C (105 PET alloy). Figure 6A shows an overlay of the DSC thermogram for PET. Figure 6B shows an overlay of the DSC thermogram for the talc-filled PET sheet. Figure 6C shows an overlay of the DSC thermogram for the 110 PET alloy. Figure 6D shows an overlay of the DSC thermogram for the 120 PET alloy. Figure 6E shows an overlay of the DSC thermogram for the 125 PET alloy. Figure 6F shows an overlay of the DSC thermogram for the 125 PET alloy. The data provided the information shown in Figure 7 below. Additionally, the following percent crystallinity was measured: PET 5.3%, talc-filled PET sheet 13.5%, PET alloy thermoformed at 110°C (110 PET alloy) 25.8%, PET alloy thermoformed at 120°C (120 PET alloy) 27.2%, PET alloy thermoformed at 125°C (125 PET alloy) 29.5%, and PET alloy thermoformed at 105°C (105 PET alloy) 23.8%. The PET alloy contained 16% talc. Therefore, the amount of talc can be increased or decreased to adjust the value; less talc will move closer to the PET value, and more talc will move away from the PET value.

[0097] The presence of talc filler was found to generally lower the thermal transition temperatures. During the first heating cycle, the melting temperature of the unfilled PET sheet (PET only) was approximately 252°C, while the other samples melted at 245°C to 247°C. Other transitions were similarly affected during both heating cycles. Crystallinity was observed to depend on the processing temperature. Samples showed increasing crystallinity with increasing temperature. The increase in crystallinity demonstrates that talc nucleates the crystallization of PET. Increased crystallinity is well known to improve yield strength and barrier properties (crystals are impermeable). Most importantly, to achieve a high HDT, a reinforcing filler such as talc is required in addition to crystallinity, which is achieved with PET alloys containing talc.

[0098] Figure 8 shows gas permeability data for PET (control), PET alloy with 10% talc (VF2), and PET alloy with 20% talc (VF4). This data shows that standard PET has an oxygen permeability of 8.67 CC / (m 2 / day), compared with values ​​of 35% and almost 60% for the PET alloy material. The permeability of other gases changes by the same amount. The reduced gas permeability can be useful in food packaging applications, as it helps keep food fresher for longer, indicating that PET can be used in food containers.

[0099] Dilute solution viscosity measurements were performed on PET, PET 20% talc (e.g., PET containing 20% ​​talc by weight), and PET alloys (e.g., PET containing 50% talc, 40% talc, and 60% PET by weight). The sample mass for each specimen was adjusted to ensure the appropriate filler content. A portion of each sample was dissolved with heating in 60 / 40 phenol / 1,1,2,2 tetrachloroethane containing isooctyl mercaptopropionate stabilizer. The solution was heated for a total of 3 hours and 10 minutes. The solution was then filtered through a wire mesh, and the viscosity was measured at 30.00°C using an Ubbelohde 1B viscometer. The intrinsic viscosities, as well as the intrinsic viscosities calculated using the Billmeyer approximation, are reported as follows: The intrinsic viscosities for PET were 0.654 (dL / g) and 0.684 (dL / g). The intrinsic viscosities of the PET 20% talc were 0.467 (dL / g) and 0.482 (dL / g). The intrinsic viscosities of the PET alloy were 0.636 (dL / g) and 0.664 (dL / g). These three PET compositions were also tested by DSC, resulting in the data shown in Figure 9. The crystallinity of these three PET compositions was measured as follows: PET 30.7%, PET 20% talc 13.0%, and PET alloy 34.4%. The PET 20% talc and PET alloy compositions were subjected to size exclusion chromatography, resulting in the data shown in Figure 10. The refractive index (RI) chromatograms, cumulative molar mass distribution plots, and differential molar mass distributions were compared to calibration curves to determine the molar mass averages (Mn (number average), Mw (weight average), and Mz (Z average)), as well as the polydispersity (Mw / Mn)). The data showed that the PET alloy had a higher molar mass than the PET 20% talc sample. The PET alloy also exhibited a larger polydispersity index, consistent with a broader distribution. The neat PET sample, tested for intrinsic viscosity only, had a higher molar mass than the PET alloy and PET 20% talc samples. The PET 20% talc sample exhibited a melting peak at 247°C. Both the neat PET sample and the PET alloy exhibited bimodal melting peaks with maxima of approximately 233°C and 247°C, respectively. The as-received crystallinity of the PET 20% talc sample was significantly lower at 13% compared to the crystallinity of neat PET (40%) and PET alloy (34%).

[0100] The molecular weight can be defined as shown in the examples. Blends of a small amount of low molecular weight PET with a large fraction of high molecular weight PET should be effective regardless of molecular weight. However, for practical purposes, if the molecular weight of the higher molecular weight component is insufficient to form entanglements, the mechanical properties, especially strength, will be too low. For example, the IV of the high molecular weight fraction (e.g., virgin PET or PAT) should be greater than 0.55.

[0101] Additionally, HDT was tested for PET and PET alloys containing talc over a range of talc weight percentages, as shown in Figure 11. Thus, as the amount of talc increases, HDT increases, indicating that PET alloys can be used in products with higher service temperatures than PET. Figure 12 shows that adding glass fiber further increases HDT, flexural modulus (Kpsi), and flexural strength (psi).

[0102] Furthermore, the mechanical properties of the PET alloy (Figure 13A) were compared with those of general-purpose polystyrene (GPPS) (Figure 13B). The PET alloy exhibited superior mechanical properties to GPPS, and the PET alloy can be prepared at a comparable cost.

[0103] Thus, PET alloys prepared from the two-step preparation of PET and PET / talc by the systems and methods described herein can be useful plastics for preparing numerous manufactured products across a wide range of manufacturing techniques, allowing them to be used in injection molding to produce thin-walled molded articles.

[0104] PET / talc was prepared as described herein for experimental use. An example of such a process is shown. A 60% PET feed and a 40% talc feed were provided to an extruder with a barrel temperature of approximately 517°F to 565°F (e.g., above 500°F), and the mixture was mixed as it exited the extruder. The head pressure was approximately 370 psi, the suction pressure was 293 psi, the discharge pressure was 424 psi, and the melt pressure was 266 psi. The extruder was operated at 145.5 RPM and 49.7 torque, and the gear pump was operated at 17 RPM and 7.1 torque. There were various die zones with a temperature of approximately 530°F. The throughput was approximately 1098 lbs / hr. The intrinsic viscosity was approximately 0.656. Various ratios of PET and talc can be prepared using similar operating parameters.

[0105] Additionally, PET / talc was mixed with virgin PET using similar operating parameters, with some variations, to prepare PET alloys. These parameter values ​​for preparing PET / talc or PET alloys may vary by + / - 1, 2, 3, 5, 10, 15, 20, 25, 30, or 50%.

[0106] PET alloy was successfully injected and filled into the mold. A single-cavity hot runner was used as an example, but multiple cavities have also been successfully used. The molding machine was a KM 120 with a sprue radius of 3.4 inches and a 9.32-inch opening. Barrel temperatures were 470°F, 465°F, 460°F, 455°F, and 445°F throughout the entire length. The injection speed was approximately 2 inches per second, with an injection pressure of 7500 psi and a hold pressure of 5000 psi. The plasticization rate was approximately 200 RPM. The cooling time was approximately 2 seconds, resulting in a cycle time of 8.67 seconds. The injection time was approximately 0.44 seconds. The mold cooling temperatures were approximately 65°F in the front and 90°F in the rear. The gate was a 0.031 pin gate. This indicates that PET alloys can be used in injection molding to produce a variety of injection molded products, from cookware, food containers, hot product containers, plates, and other manufacturing products.

[0107] For injection-molded forks, the cycle time for PP copolymer was 7.1 seconds, while the PET alloy material described herein could be molded in 6.2 seconds. Furthermore, the PP forks were too thin and insufficiently rigid to be used, whereas the PET alloy material resulted in a stiffer, usable fork. The mold temperature was varied from 100°F to 60°F. The valve gate was approximately 650°F. Further lowering the mold temperature to 50°F resulted in a cycle time of only 5.9 seconds. Black color was added to the PET alloy material via a masterbatch concentrate. The color was uniform, and the cycle time was unaffected. All tests were performed in multiple runs and under steady-state conditions to ensure repeatability. This test was performed on a 120-ton Krauss Maffei injection molding machine. Other successful tests were performed on different machines with various gate / runner configurations. The average weight of the PET alloy forks was 2.8g, while the weight of the PP forks produced in the same mold was 1.7g.

[0108] Another test compared general-purpose polystyrene with PET alloy material. Ineos Styrolution 3600 / 3601 grade general-purpose polystyrene (GPPS), commonly used in cutlery manufacturing, was used. The GPPS molding process improved the overall cycle time to 8.67 seconds. The fork wall thickness was 0.023 mm, which was sufficient for the modified PET, but produced a weak and brittle general-purpose polystyrene fork. A 0.026 mm diameter hot-pin gate was used. The cycle time for the PET alloy material was 9.6 seconds.

[0109] Further testing was conducted using a 1991 350-ton Krauss Maffei injection molding machine equipped with hydraulic clamps and a 24-ounce barrel. A 25-cavity spoon mold of the so-called "hot-to-cold" type was used. Both 15% and 20% talc-containing PET alloy materials produced good quality molded parts and cycle times.

[0110] For this and other processes and methods disclosed herein, the operations performed in the processes and methods may be implemented in differing orders. Furthermore, the operations outlined are provided only as examples, and some operations are optional and may be combined into fewer operations, eliminated, supplemented with further operations, or expanded into additional operations without detracting from the essence of the disclosed embodiments.

Claims

1. 1. A system for forming a polyethylene terephthalate (PET) alloy with talc, comprising: a PET / talc mixture feed (PET / talc feed), the PET / talc mixture feed comprising PET having a first average molecular weight of a first PET distribution, the PET / talc mixture feed being free of another type of polymer and having a PET:talc weight ratio of 3:1 to 1:3; a feed of PET (PET feed), the feed comprising PET having a second average molecular weight of a second PET distribution, the second average molecular weight being greater than the first average molecular weight; a mixer coupled to the PET / talc feed outlet and the PET feed outlet, the mixer capable of mixing the PET / talc feed and the PET feed to form a PET alloy, the PET alloy comprising 10% (w / w) to 50% (w / w) talc free of the other type of polymer; an output for rendering the PET alloy into bimodal PET, the bimodal PET having the first average molecular weight of the first PET distribution and the second average molecular weight of the second PET distribution, wherein the first average molecular weight and the second average molecular weight are selected from a number average molecular weight, a weight average molecular weight, and a Z average molecular weight.

2. Further comprising a PET supply unit, The PET supply unit comprises: a PET reactor system configured to polymerize the PET from PET precursor reagents; a PET recycling system configured to recycle the PET from a PET product; a PET conditioning system configured to condition the PET for mixing with the PET / talc mixture, the conditioning being selected from one or more of heating, shredding PET pellets, sheets or other PET members, agitating, extruding, drying, and degassing; and A PET reservoir having liquid PET, wherein the liquid PET is molten PET.

10. The system of claim 1, configured to receive the PET feed from one or more of:

3. The system of claim 1 , wherein the mixer is configured to perform one or more of degassing, homogenizing, dispersing, or heating.

4. an output system configured to receive the PET alloy; the output system provides the PET alloy to a reservoir or an analytical system or a manufacturing system; The analytical system comprises: determining a flow rate of the molten PET alloy output; Determining the melting point of the PET alloy output; Determining the crystallization temperature of the PET alloy output; Determining a differential scanning calorimetry profile of the PET alloy output; or Determining the heat distortion temperature of PET alloy output The system of claim 1 , comprising one or more analytical systems capable of performing

5. The system of claim 4 , wherein the manufacturing system is configured to convert the PET alloy into a manufactured product.

6. further comprising an optional ingredient input feed; the optional ingredient input feed is configured to provide an optional ingredient; The optional ingredient is non-polymeric, such as TiO ２ , glass pellets, glass fibers, glass particles, sodium stearate, nucleating agents, antistatic agents, antibacterial agents, foaming agents, stabilizers, UV blocking agents, acetaldehyde scavengers, pigments, or lubricants.

7. drying the PET feed before mixing with the PET / talc feed; or 10. The system of claim 1, comprising a dryer configured to dry the PET / talc feed prior to mixing with the PET feed.

8. 10. The system of claim 1, wherein the PET / talc feed comprises the PET / talc mixture in a flowable form.

9. The system of claim 1 , wherein the talc comprises talc particles between 0.25 microns and 100 microns.

10. The system of claim 1 , wherein the PET alloy contains less than 5% water by weight.

11. The system of claim 1 , wherein the PET alloy has a PET concentration of 60% to 90% by weight.

12. The system of claim 1 , wherein the PET alloy has a talc concentration of 10% to 40% by weight.

13. The PET alloy contains talc and TiO ２ The system of claim 1 , wherein the combination of the particles is in a total concentration of 10% to 40% by weight.

14. The system of claim 1 , wherein the PET alloy has a melting temperature of 240°C to 250°C.

15. The PET alloy has a viscosity of 3 to 6 CC / (m ２ 10. The system of claim 1, wherein the system has an oxygen transmission rate of ±25%.

16. The system of claim 1 , wherein the PET alloy has a crystallization temperature of 200° C. to 230° C.

17. 10. The system of claim 1, wherein the PET / talc feed is a mixture of a second feed of PET (second PET feed) and a feed of talc (talc feed) formed in a second mixer in a PET:talc weight ratio of 3:1 to 1:

3.

18. 20. The system of claim 17, wherein the second mixer is capable of mixing the second PET feed and the talc feed in one or more of a batch or continuous format.

19. 10. A method of forming a PET alloy using the system of claim 1, comprising: providing a feed of a PET / talc mixture (PET / talc feed) that is free of other polymers and has a PET:talc ratio of 3:1 to 1:3 by weight, the PET / talc feed comprising PET having a first average molecular weight of a first distribution of PET; providing a feed of the PET (PET feed), the PET feed comprising the PET having a second average molecular weight of a second distribution of PET, the second average molecular weight being greater than the first average molecular weight; mixing the PET / talc feed with the PET feed in a mixer to form the PET alloy having 10% (w / w) to 50% (w / w) talc without the other type of polymer; providing the PET alloy as bimodal PET having the first average molecular weight of the first distribution of PET and the second average molecular weight of the second distribution of PET, wherein the first average molecular weight and the second average molecular weight are selected from a number average molecular weight, a weight average molecular weight, and a Z average molecular weight.

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