Reused PET Film Pelletizing With IV Control for Molded Parts
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Solution Overview
Problem
Existing methods for reusing PET films with ceramics stuck to their surface are limited, primarily focusing on cleaning and recycling as renewed PET films without expanding their utility beyond this scope.
Innovation Solution
A multi-step process involving mechanical removal of ceramics, flaking, pelletizing with additives to set intrinsic viscosity (IV) values, and molding to produce resin molded articles suitable for various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the used PET film is cleaned and recycled as a renewed PET film, then the PET film can be reused, but the utility is limited and the intrinsic viscosity (IV) value may not be suitable for various applications
Solution Approach 1:
The patent applies parameter changes by controlling the intrinsic viscosity (IV) value of the recycled PET resin through selective removal of low molecular weight components and addition of specific additives. This adjusts the rheological properties of the resin to meet different application requirements, transforming the limited utility of conventional recycling into a versatile material platform with tailored performance characteristics.
2Ease of manufacture
If ceramic is mechanically removed from the used PET film surface, then the PET film can be processed further, but the process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the recycling process into distinct stages: ceramic removal, flaking, pelletizing, and resin production. Each stage is optimized independently, with the ceramic removal step preparing the film for subsequent mechanical processing. This segmented approach manages process complexity by creating clear, manageable stages rather than attempting to solve all problems simultaneously.
Solution Approach 2:
The patent applies the extraction principle by removing ceramics from the PET film surface before further processing. This separation of unwanted components (ceramics) from the valuable material (PET film) enables the film to be processed through standard recycling equipment and transformed into high-quality resin suitable for various applications.
3Adaptability or versatility
If additive is added to adjust IV value, then the resin can be suited for various applications, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by adding specific additives during the pelletizing stage, before the resin is formed into final products. This timing allows the additives to be uniformly distributed and integrated into the resin matrix, achieving the desired IV value adjustment and performance characteristics early in the process, which simplifies subsequent manufacturing steps.
Data Source
AI summary
A reuse method of a used PET film includes a removal process including mechanically removing, from the used PET film, the ceramic stuck to the surface of the used PET film, a flaking process including processing the used PET film, from which the ceramic stuck to the surface has been removed, into a flake, a first pelletizing process including processing the flake into a first pellet, an adding process including adding an additive to the first pellet, a second pelletizing process including processing the first pellet, to which the additive has been added, into a second pellet, and a molding process including forming a resin molded article from the second pellet. The adding process also includes setting an IV value of the second pellet to a value within a predetermined range, by adding the additive to the first pellet.