Laminated Polyester Film Using Chemically Recycled Electrostatic Pinning Chips
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Solution Overview
Problem
Current PET recycling methods primarily rely on physical recycling, limiting the incorporation of functional components like electrostatic pinning agents, resulting in low usage rates of recycled PET chips and environmental concerns due to the need for additional virgin PET chips.
Innovation Solution
A laminated polyester film structure is manufactured using both physically and chemically recycled polyester materials, with chemically recycled electrostatic pinning chips containing metal salts, allowing for the integration of electrostatic pinning additives, thereby reducing the need for virgin PET chips and enhancing recycling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If physical recycling method is used to regenerate PET, then the process is simple and widely applicable, but functional components cannot be incorporated and usage rate of recycled PET chips decreases
Solution Approach 1:
The patent combines physical recycling and chemical recycling methods to produce polyester film layers. By merging these two approaches, the invention enables both the simplicity of physical recycling and the functional capabilities of chemical recycling, allowing electrostatic pinning agents to be incorporated while maintaining ease of manufacture
Solution Approach 2:
The patent uses composite material structure with multiple polyester film layers, where some layers are produced from physically recycled PET chips and others from chemically recycled PET chips containing electrostatic pinning agents. This composite approach allows functional components to be incorporated while maintaining overall manufacturing simplicity
2Reliability
If virgin PET chips are added to incorporate functional components, then electrostatic pinning function is achieved, but usage rate of recycled PET chips decreases and environmental concerns arise
Solution Approach 1:
The patent extracts the electrostatic pinning function from virgin PET chips and transfers it to chemically recycled PET chips. By taking out the functional component requirement from the virgin material context and applying it to recycled material, the invention achieves electrostatic pinning function while maintaining high usage rate of recycled PET chips
Solution Approach 2:
The patent changes the chemical parameters of recycled PET chips through chemical recycling processes, transforming them into chemically recycled PET chips that can incorporate electrostatic pinning agents. This parameter change enables functional components to be added to recycled material rather than requiring virgin material
3Productivity
If low usage rate of recycled PET chips is accepted, then manufacturing flexibility is maintained, but environmental regulations and eco-label standards cannot be satisfied
Solution Approach 1:
The patent segments the polyester film into multiple layers with different compositions - some layers use physically recycled PET chips while others use chemically recycled PET chips with electrostatic pinning agents. This segmentation allows each layer to be optimized for its specific function while collectively achieving high recycled content compliance with environmental standards
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
This approach increases the usage rate of recycled PET materials, decreases the reliance on virgin PET chips, and addresses environmental concerns by producing a high-quality polyester film with improved electrostatic properties, suitable for various applications.
Implementation Method 1
chemically reproducing another part of the recycled polyester material and granulating the same to obtain a plurality of chemically recycled polyester chips
Implementation Method 2
physically reproducing a part of the recycled polyester material and granulating the same to obtain a plurality of physically recycled polyester chips
Implementation Method 3
mixing and melting the plurality of physically recycled polyester chips and the plurality of chemically recycled polyester chips to form the polyester film layer
Data Source
Figure 1
AI summary
A polyester film having a laminated structure and a method for manufacturing the same are provided. The polyester film has at least two polyester film layers. Each of the polyester film layers includes a physically recycled polyester resin and a chemically recycled polyester resin. The physically recycled polyester resin is formed by a plurality of physically recycled polyester chips. The chemically recycled polyester resin is formed by a plurality of chemically recycled polyester chips, and is mixed with the physically recycled polyester resin. The plurality of chemically recycled polyester chips further include chemically recycled electrostatic pinning polyester chips. The chemically recycled electrostatic pinning polyester chips contain electrostatic pinning additives, and the electrostatic pinning additives are metal salts. The at least two polyester film layers are a white polyester film layer and a black polyester film layer, respectively.