Recycled Polyester Film with Electrostatic Pinning
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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 failing to meet environmental standards for eco-labels, thus necessitating the use of additional virgin PET chips.
Innovation Solution
A method that combines physically and chemically recycled polyester chips, where chemically recycled electrostatic pinning chips with metal salts are added to enhance the recycling process, allowing for the production of high-quality polyester films with improved electrostatic properties without requiring excessive virgin PET chips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If physical recycling method is used to process recycled PET plastics, then the processing simplicity is improved, but the functional components cannot be added and the usage rate of recycled PET chips decreases
Solution Approach 1:
The patent combines physical recycling and chemical recycling methods into a hybrid recycling system. Physical recycling processes washed PET bottles through shredding and melting to produce chips, while chemical recycling uses glycolysis to depolymerize PET and repolymerize it with added functional components. This merging allows both simple processing and functional enhancement to coexist.
Solution Approach 2:
The patent creates composite recycled PET chips by blending physically recycled chips with chemically recycled chips that contain functional components. The chemical recycling portion introduces electrostatic pinning agents and other additives during the repolymerization process, creating a composite material that maintains recyclability while gaining new functionalities.
2Adaptability or versatility
If additional virgin PET chips are used to add functional components, then the functional requirements are satisfied, but the usage rate of recycled PET chips decreases and environmental standards cannot be met
Solution Approach 1:
The patent changes the chemical parameters of recycled PET during the chemical recycling process. By controlling the glycolysis conditions, catalyst types, and repolymerization parameters, functional components can be incorporated into the polymer structure itself. This allows functional requirements to be met through parameter optimization rather than adding virgin material.
Solution Approach 2:
The patent uses glycolysis as an intermediary process between physical recycling and final product formation. The glycolysis step depolymerizes PET into monomers that can then be repolymerized with added functional components, serving as a bridge that enables functional enhancement while maintaining high recycled content.
3Ease of manufacture
If physical recycling is used to produce high-quality recycled PET chips, then the manufacturing process is simpler, but functional components like electrostatic pinning agents cannot be incorporated
Solution Approach 1:
The patent segments the recycling process into distinct functional modules: physical cleaning and shredding, chemical depolymerization via glycolysis, repolymerization with functional additives, and quality control. This segmentation allows each stage to be optimized independently, maintaining overall process simplicity while enabling functional component incorporation in the chemical recycling stage.
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 material, reduces the need for virgin PET, and enhances the environmental sustainability of PET products by fully utilizing recycled materials while maintaining high transparency and performance standards.
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
melted under high temperature, and then are extruded by an extruder
Implementation Method 3
The chemically recycled electrostatic pinning polyester chips contain electrostatic pinning additives, and the electrostatic pinning additives are metal salts
Data Source
AI summary
A polyester film and a method for manufacturing the same are provided. The polyester film 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 mixed with the physically recycled polyester resin. The plurality of chemically recycled polyester chips further includes 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. Expressed in percent by weight based on a total weight of the polyester film, a content of the electrostatic pinning additives in the polyester film is between 0.005% and 0.1% by weight.