Impact-Resistant Polyester Composition via Continuous Recycled PET Processing
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Solution Overview
Problem
Existing methods for preparing impact-resistant polyester compositions from recycled materials are inefficient and high in energy consumption, leading to increased carbon emissions and waste.
Innovation Solution
A continuous process for preparing an impact-resistant polyester composition involves crushing, compacting, and drying a recycled PET resin, followed by melting, extrusion, and modification with impact modifiers, compatibilizers, antioxidants, and lubricants, resulting in improved impact resistance and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a segmented process is adopted for preparing impact-resistant polyester from recycled materials, then each process step can be controlled independently, but repeated temperature rises and drops generate energy waste and increase carbon emissions
Solution Approach 1:
The patent combines multiple segmented processes (crushing, drying, melting, extrusion, modification) into a single continuous production line. The recycled PET resin undergoes all processing steps in one continuous flow without repeated heating and cooling cycles, thereby reducing energy consumption and carbon emissions while maintaining independent control through integrated process design
2Ease of manufacture
If a segmented process with multiple temperature cycles is used, then material properties can be adjusted at each stage, but production efficiency decreases and energy consumption increases
Solution Approach 1:
The patent implements a continuous production process where recycled PET resin flows continuously through crushing, drying, melting, extrusion, and modification stages without interruption. This continuous action eliminates idle time between processes and maintains steady-state operation, significantly improving production efficiency while material properties are adjusted through continuous parameter control
3Object-generated harmful factors
If recycled materials are used to reduce carbon emissions, then environmental sustainability improves, but the mechanical performance and processability may be affected
Solution Approach 1:
The patent employs parameter changes during the continuous processing of recycled PET resin, including temperature control (240-290°C for melting, 250-275°C for modification), residence time adjustment, and shear rate optimization. These parameter optimizations ensure that the mechanical performance and processability of recycled materials meet application requirements while maintaining environmental sustainability
Solution Approach 2:
The patent creates composite materials by incorporating modifiers (impact modifiers, compatibilizers, antioxidants, lubricants) into the recycled PET resin during continuous extrusion. This composite formulation enhances the mechanical properties and processability of recycled materials, making them suitable for replacing ABS, PC, and PP in high-impact applications
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The continuous process significantly enhances the impact-resistant strength of PET materials from 3.6 kg-cm/cm to 56.2 kg-cm/cm, making them suitable replacements for ABS, PC, and PP in high-impact applications, while also reducing energy waste and carbon emissions.
Implementation Method 1
a temperature of melting, extruding and degassing is 240° C. to 290° C.
Implementation Method 2
After filtration, a liquid viscosifying system is used for thickening
Implementation Method 3
After the rubber strips are cooled with water
Data Source
AI summary
The disclosure provides a preparation method of an impact-resistant polyester composition, which is a continuous process and includes the following steps. A recycled release film is crushed, compacted and dried, and then melted, extruded and degassed. The recycled release film contains a recycled PET resin. After filtration, a liquid viscosifying system is used for thickening. Next, it is melted and kneaded, modified with modifiers and extruded. The modifiers include impact modifiers, compatibilizers, antioxidants and lubricants. After the rubber strips are cooled with water, they are then pelletized and dehydrated to produce the impact-resistant polyester composition.