Copolyester Elastomer Brightening Agent PCR PET
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Solution Overview
Problem
Thermoplastics with high PCR content struggle to achieve a bright white color, which is essential for consumer-centric applications like personal electronics, due to inherent color issues associated with post-consumer or post-industrial recycled materials.
Innovation Solution
The development of copolyester elastomers incorporating a polybutylene terephthalate (PBT) moiety derived from post-consumer, pre-consumer, or post-industrial recycled polyethylene terephthalate (PET), combined with an elastomer moiety and a high purity terephthalic moiety, where the thermoplastic composition includes greater than 0.1 wt % to 9 wt % of at least one brightening agent, achieving an L* color value of at least 80 according to the CIELab color space standard.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If post-consumer or post-industrial recycled (PCR) components are used to create sustainable materials, then sustainability is improved, but color brightness deteriorates
Solution Approach 1:
The patent extracts and removes color-deteriorating impurities from PCR materials through advanced purification processes, separating the useful polymer components from the harmful colored contaminants. This allows the recycled material to achieve bright white color while maintaining sustainability.
Solution Approach 2:
The patent changes the purity parameter of the terephthalic acid intermediate to at least 95%, which fundamentally alters the color properties of the final product. This parameter change enables PCR-based materials to achieve L* color values of at least 80, resolving the contradiction between sustainability and color brightness.
2Illumination intensity
If high purity terephthalic acid (≥95%) is used to form PBT moiety, then color brightness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent performs preliminary purification of terephthalic acid to ≥95% purity before polymerization, preventing color deterioration at the source. This preliminary action simplifies downstream processing and eliminates the need for complex post-processing color correction steps.
Solution Approach 2:
The patent creates a composite structure in the copolyester elastomer where high-purity PBT moieties (from purified terephthalic acid) are combined with elastomer moieties. This composite approach maintains color brightness while achieving the desired elastomeric properties, avoiding the need for overly complex manufacturing processes.
3Illumination intensity
If brightening agents are added to improve color, then color brightness is improved, but material purity deteriorates
Solution Approach 1:
The patent performs preliminary purification of the terephthalic acid to ≥95% purity before polymerization, preventing color deterioration at the source. This preliminary action simplifies downstream processing and eliminates the need for complex post-processing color correction steps.
Solution Approach 2:
The patent creates a composite structure in the copolyester elastomer where high-purity PBT moieties (from purified terephthalic acid) are combined with elastomer moieties. This composite approach maintains color brightness while achieving the desired elastomeric properties, avoiding the need for overly complex manufacturing processes.
Data Source
AI summary
Thermoplastic compositions include: a copolyester elastomer including a polybutylene terephthalate (PBT) moiety and an elastomer moiety: and from greater than 0.1 wt % to 9 wt % of at least one brightening agent. The copolyester elastomer is formed according to a process including (1) forming the PBT moiety from a high purity terephthalic moiety: and (2) polymerizing the PBT moiety with the elastomer moiety to form the copolyester elastomer, wherein the high purity terephthalic moiety is derived from post-consumer, pre-consumer or post-industrial recycled (PCR) polyethylene terephthalate (PET). The PBT moiety includes PBT derived from post-consumer, pre-consumer or post-industrial recycled (PCR) polyethylene terephthalate (PET), the high purity terephthalic moiety has a purity of at least about 95%, and the thermoplastic composition has an L* color value of at least 80 as determined according to a CIELab color space standard. Methods for forming the copolymer elastomer and compositions including it are also described.