Recycle method of polyester fabric
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Solution Overview
Problem
Conventional mechanical recycle methods for polyester fabrics result in poor intrinsic viscosity uniformity and stability due to large IV differences between fabric and PET bottle flakes, leading to poor spinning processability and strength issues.
Innovation Solution
A recycle method involving decolorization treatment, mixing with a thickening material, and multiple stages of liquid state polymerization with reflux to achieve uniform intrinsic viscosity and improved hue performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional mechanical mixing is used to blend polyester fabric with PET bottle flakes, then macroscopic mixing is achieved, but microscopic uniformity remains poor
Solution Approach 1:
The patent applies liquid state polymerization to transform the physical state of the polyester material from solid to liquid, enabling molecular-level mixing. By changing the state parameter from solid to liquid phase, the process achieves uniform distribution of intrinsic viscosity at microscopic level, resolving the mixing uniformity problem that conventional mechanical methods cannot solve.
2Ease of manufacture
If polyester fabric is processed through conventional thermal recycling, then processing is simplified, but intrinsic viscosity decreases and stability deteriorates
Solution Approach 1:
The patent utilizes phase transition from solid to liquid state through controlled polymerization, allowing the material to be processed in liquid form where mixing and uniformity control are achieved, then transitions back to solid form in the final product. This phase transition approach maintains intrinsic viscosity stability while enabling effective processing.
3Quantity of substance
If polyester fabric with low intrinsic viscosity is used directly, then material cost is reduced, but spinning processability and product strength deteriorate
Solution Approach 1:
The patent changes the intrinsic viscosity parameter of the polyester material through liquid state polymerization processing. By controlling the polymerization conditions in liquid phase, the process increases the intrinsic viscosity of recycled polyester from typical low values (0.3-0.5 dL/g) to higher values (0.6-0.8 dL/g), thereby improving fiber strength and spinning processability while utilizing cost-effective recycled materials.
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 method enhances intrinsic viscosity uniformity and stability, ensuring high-quality polyester products with IV above 0.60 and standard deviation less than 0.0036, suitable for spinning, weaving, dyeing, and finishing processes.
Implementation Method 1
A liquid state polymerization is performed on the initial feed to form a liquid state polymer product
Implementation Method 2
The liquid state polymer product is refluxed to be mixed with the initial feed
Data Source
AI summary
The disclosure provides a recycle method of a polyester fabric, which includes the following steps. A decolorization treatment is performed on the polyester fabric to form a decolorized polyester fabric. The decolorized polyester fabric is mixed with a thickening material to form an initial feed. A liquid state polymerization is performed on the initial feed to form a liquid state polymer product. The liquid state polymer product is refluxed to be mixed with the initial feed to form an intermediate feed. The liquid state polymerization is performed on the intermediate feed to form a final polymer product.