Patent Application
20230212364
The present disclosure relates to a method for manufacturing a polyester film for embossing, and more particularly to a method for manufacturing a polyester film for embossing that is made from a recycled polyester material.
In recent years, usage of plastics has increased significantly, and as a result, a large amount of plastic waste is produced. Since the plastics are not easily degraded, recycling of the plastics and how to process the plastics after recycling have become particularly important issues.
Polyethylene terephthalate (PET) makes up a major portion of recycled plastics, and recycled PET plastics takes up about 52.4% of a total amount of the recycled plastics. In order to deal with such a large amount of recycled PET plastics, researchers in relevant field have to dedicate themselves to developing a method for processing the recycled PET plastics.
Out of the current techniques, the most common method to regenerate PET is through a physical (mechanical) manner. The recycled PET plastics that have been washed clean are firstly shredded to pieces and melted under high temperature, and then are extruded by an extruder to produce regenerated PET chips (also called as r-PET).
To address environmental concerns and to ensure that PET products contain more eco-friendly regenerated PET chips, a large amount of high-quality recycled PET chips is required. In the current industry, the PET recycling is mostly carried out by way of physical recycling. However, functional components (such as a slipping agent and an electrostatic pinning additive) are not allowed to be added, during a manufacturing process, to recycle chips that are produced through physical recycling. Therefore, it is necessary to use additional virgin (not regenerated) PET chips for additionally adding the above-mentioned functional components.
However, after adding the virgin polyester chips, a usage rate of the regenerated PET chips contained in the PET products will decrease. That is to say, in the current techniques, it is not possible to fully utilize the regenerated PET chips to manufacture new PET products. If the usage rate of the regenerated PET chips is too low, it may not be possible to satisfy a standard set up by environmental regulations such that an eco-label can be obtained. Moreover, as virgin PET chips that are newly used in the process of manufacturing the PET products would subsequently become the regenerated PET plastics that require processing, a problem of recycling and reusing would still arise.
In response to the above-referenced technical inadequacies, the present disclosure provides a method for manufacturing a polyester film for embossing.
In one aspect, the present disclosure provides a polyester film for embossing. The polyester film for embossing is formed from a recycled polyester material. The polyester film for embossing includes a base layer and a surface coating layer. The base layer is formed from a polyester composition having a main component of regenerated polyethylene terephthalate. The surface coating layer is disposed on at least one surface of the base layer. A material of the surface coating layer includes a main resin, fillers, and melamine. Based on a total weight of the surface coating layer being 100 wt %, an existing amount of the main resin ranges from 45 wt % to 95 wt %, an existing amount of the fillers ranges from 0.1 wt % to 30 wt %, and an existing amount of the melamine ranges from 0.01 wt % to 25 wt %.
In certain embodiments, the main resin includes an acrylic resin, a polyurethane resin, or a polyester resin. The fillers include at least one of silicon dioxide, calcium carbonate, and aluminum oxide.
In certain embodiments, a total thickness of the polyester film for embossing ranges from 8 μm to 350 μm. The surface coating layer is coated on the base layer. A thickness of the surface coating layer ranges from 0.05 μm to 24 μm.
In certain embodiments, the polyester composition includes a physically regenerated polyester resin and a chemically regenerated polyester resin. A main component of each of the physically regenerated polyester resin and the chemically regenerated polyester resin is regenerated polyethylene terephthalate as a main component. Based on a total weight of the polyester composition being 100 wt %, a content of the physically regenerated polyester resin ranges from 50 wt % to 95 wt %, a content of the chemically regenerated polyester resin ranges from 1 wt % to 40 wt %, and a total content of the physically regenerated polyester resin and the chemically regenerated polyester resin ranges from 50 wt % to 100 wt %.
In certain embodiments, the chemically regenerated polyester resin is formed from chemically regenerated polyester chips. The chemically regenerated polyester chips include chemically regenerated regular polyester chips and chemically regenerated electrostatic pinning polyester chips.
In certain embodiments, the physically regenerated polyester resin is formed from physically regenerated polyester chips. The physically regenerated polyester chips include physically regenerated regular polyester chips.
In certain embodiments, a concentration of cyclic oligomer in the physically regenerated polyester resin is lower than a concentration of cyclic oligomer in the chemically regenerated polyester resin.
In certain embodiments, based on a total weight of the polyester composition being 100 wt %, the polyester composition contains 0.5 wt % to 5 wt % of isophthalic acid.
In certain embodiments, based on a total weight of the polyester composition being 100 wt %, the polyester composition contains 1 wt % to 25 wt % of a biomass-derived material. A content of C14 among total carbon atoms in the polyester composition ranges from 0.2 wt % to 5 wt %.
In certain embodiments, based on a total weight of the polyester composition being 100 wt %, the polyester composition contains 0.0003 wt % to 0.04 wt % of a metal catalyst. The metal catalyst is selected from the group consisting of antimony, germanium, titanium, and any combination thereof.
In certain embodiments, an average diameter of the fillers ranges from 10 nm to 8 μm.
In another aspect, the present disclosure provides a method for manufacturing a polyester film for embossing. The method for manufacturing a polyester film for embossing includes the following steps. A recycled polyester material is provided. A part of the recycled polyester material is physically reproduced to obtain physically regenerated polyester chips. The physically regenerated polyester chips include physically regenerated regular polyester chips. Another part of the recycled polyester material is chemically reproduced to obtain chemically regenerated polyester chips. The chemically regenerated polyester chips include chemically regenerated regular polyester chips and chemically regenerated electrostatic pinning polyester chips. The physically regenerated polyester chips and the chemically regenerated polyester chips are mixed to form a base material. The base material is used to form a base layer having a main component of regenerated polyethylene terephthalate. A surface coating layer is formed onto the base layer. A material of the surface coating layer includes a main resin, fillers, and melamine. Based on a total weight of the surface coating layer being 100 wt %, an existing amount of the main resin ranges from 45 wt % to 95 wt %, an existing amount of the fillers ranges from 0.1 wt % to 30 wt %, and an existing amount of the melamine ranges from 0.01 wt % to 25 wt %. A polyester film for embossing is obtained.
In certain embodiments, the main resin includes an acrylic resin, a polyurethane resin, or a polyester resin. The fillers include at least one of silicon dioxide, calcium carbonate, and aluminum oxide.
In certain embodiments, based on a total weight of the base layer being 100 wt %, a usage amount of the physically regenerated polyester chips ranges from 50 wt % to 95 wt %, a usage amount of the chemically regenerated polyester chips ranges from 1 wt % to 40 wt %, and a total usage amount of the physically regenerated polyester chips and the chemically regenerated polyester chips ranges from 50 wt % to 100 wt %.
In certain embodiments, the chemically regenerated polyester chips are prepared by the following steps. The recycled polyester material is depolymerized to obtain an oligomer mixture. The oligomer mixture is repolymerized to obtain the chemically regenerated polyester chips having a main component of regenerated polyethylene terephthalate.
In certain embodiments, the physically regenerated polyester chips are prepared by the following steps. The recycled polyester material is melted to obtain a melted mixture. The melted mixture is molded to obtain the physically regenerated polyester chips having a main component of regenerated polyethylene terephthalate.
Therefore, by virtue of “a main component forming the base layer being regenerated polyethylene terephthalate” and “the surface coating layer being disposed on the base layer, and a material forming the surface coating layer including a main resin, fillers, and melamine”, an amount of the recycled polyester material in the polyester film for embossing can be increased.
These and other aspects of the present disclosure will become apparent from the following description of the embodiment taken in conjunction with the following drawings and their captions, although variations and modifications therein may be affected without departing from the spirit and scope of the novel concepts of the disclosure.
The described embodiments may be better understood by reference to the following description and the accompanying drawings, in which:
The present disclosure is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. Like numbers in the drawings indicate like components throughout the views. As used in the description herein and throughout the claims that follow, unless the context clearly dictates otherwise, the meaning of “a”, “an”, and “the” includes plural reference, and the meaning of “in” includes “in” and “on”. Titles or subtitles can be used herein for the convenience of a reader, which shall have no influence on the scope of the present disclosure.
The terms used herein generally have their ordinary meanings in the art. In the case of conflict, the present document, including any definitions given herein, will prevail. The same thing can be expressed in more than one way. Alternative language and synonyms can be used for any term(s) discussed herein, and no special significance is to be placed upon whether a term is elaborated or discussed herein. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms is illustrative only, and in no way limits the scope and meaning of the present disclosure or of any exemplified term. Likewise, the present disclosure is not limited to various embodiments given herein. Numbering terms such as “first”, “second” or “third” can be used to describe various components, signals or the like, which are for distinguishing one component/signal from another one only, and are not intended to, nor should be construed to impose any substantive limitations on the components, signals or the like.
Referring to
The base layer 11 has a first surface 111 and a second surface 112 opposite to each other. The base layer 11 is flexible. The surface coating layer 12 is disposed on the first surface 111 of the base layer 11 by coating. In addition, the second surface 112 of the base layer 11 can undergo a corona treatment optionally. In the present embodiment, the surface coating layer 12 is coated on the base layer 11 by in-line coating, but it is not limited thereto. The surface coating layer 12 is an easy-to-press embossed pattern layer.
In the present embodiment, a thickness of the polyester film for embossing 1 ranges from 8 μm to 350 μm. A thickness of the surface coating layer 12 ranges from 0.05 μm to 24 μm.
Referring to
The base layer 11 is formed from a polyester composition having a main component of regenerated polyethylene terephthalate. The polyester composition includes a physically regenerated polyester resin and a chemically regenerated polyester resin. A main component of each of the physically regenerated polyester resin and the chemically regenerated polyester resin is regenerated polyethylene terephthalate.
As for the polyester composition forming the base layer 11, based on a total weight of the polyester composition being 100 wt %, the polyester composition includes 50 wt % to 95 wt % of physically regenerated polyester resin, and 1 wt % to 40 wt % of chemically regenerated polyester resin. A total amount of the physically regenerated polyester resin and the chemically regenerated polyester resin ranges from 50 wt % to 100 wt %.
A material forming the surface coating layer 12 includes a main resin, fillers, and melamine. The main resin is acrylic resin, a polyurethane resin, or a polyester resin. The fillers include at least one of silicon dioxide, calcium carbonate, and aluminum oxide. A diameter of the fillers ranges from 10 nm to 8 μm.
Specifically, based on a total weight of the surface coating layer 12 being 100 wt %, an existing amount of the main resin ranges from 45 wt % to 95 wt %, an existing amount of the fillers ranges from 0.1 wt % to 30 wt %, and an existing amount of the melamine ranges from 0.01 wt % to 25 wt %.
In the present disclosure, the polyester composition forming the base layer 11 contains both of the physically regenerated polyester resin and the chemically regenerated polyester resin. By using both of the physically regenerated polyester resin and the chemically regenerated polyester resin, a proportion of the recycled polyester material used in the base layer 11 can be increased. In addition, even without being added with the virgin polyester chips, the polyester composition of the present disclosure will not have a problem of high impurity resulting from use of the physically regenerated polyester resin only.
Further, the aforementioned physically regenerated polyester resin is formed from one or many kinds of physically regenerated polyester chips. A main component of the physically regenerated polyester chips is regenerated polyethylene terephthalate. The aforementioned chemically regenerated polyester resin is formed from one or many kinds of chemically regenerated polyester chips. A main component of the chemically regenerated polyester chips is regenerated polyethylene terephthalate. The specific preparations of the physically regenerated polyester chips and the chemically regenerated polyester chips are illustrated later.
Referring to
In step S1, the recycled polyester material is recycled bottle chips. A main material of the recycled bottle chips is polyester. Generally, polyester is formed by a polycondensation of diol units and diacid units. For recycled bottle chips, the diol units can be ethylene glycol derived from petrochemical sources or ethylene glycol derived from biomass. As for the polyester composition forming the base layer 11, based on the total weight of the polyester composition being 100 wt %, the polyester composition includes 1 wt % to 25 wt % of a biomass-derived material. In other words, a content of C14 among total carbon atoms in the polyester composition ranges from 0.2 wt % to 5 wt %.
The recycled polyester material can include isophthalic acid. Therefore, the polyester composition forming the base layer 11 may also contain isophthalic acid. Based on the total weight of the polyester composition being 100 wt %, the polyester composition contains 0.5 wt % to 5 wt % of isophthalic acid.
The recycled polyester material can include a metal catalyst. Therefore, the polyester composition forming the base layer 11 may also contain the metal catalyst. Based on the total weight of the polyester composition being 100 wt %, the polyester composition contains 0.0003 wt % to 0.04 wt % of the metal catalyst. The metal catalyst is selected from the group consisting of antimony, germanium, titanium, and any combination thereof.
In step S2, a physical reproduction process includes the following steps. The recycled polyester material (such as bottle chips) is cut into pieces, and then melted to form a melted mixture. The melted mixture is extruded by a single-screw extruder or a twin-screw extruder, and then granulated to obtain the physically regenerated polyester chips.
In the present embodiment, the physically regenerated polyester chips include physically regenerated regular polyester chips. The physically regenerated regular polyester chips are polyester chips prepared through the physical reproduction process, and no functional additive is added during the physical reproduction process. In the present embodiment, a main component forming the physically regenerated regular polyester chips is regenerated polyethylene terephthalate.
In addition, in the physical reproduction process, functional additives (such as a slipping agent, a coloring agent, or a matting agent) can be added in the melted mixture, so that physically regenerated slipping polyester chips, physically regenerated color polyester chips, and physically regenerated matting polyester chips can be obtained. It should be noted that, a main component of each of the physically regenerated slipping polyester chips, the physically regenerated color polyester chips, and the physically regenerated matting polyester chips is regenerated polyethylene terephathalate.
In step S3, a chemical reproduction process includes the following steps. The recycled polyester material (such as bottle chips) is cut into pieces and then put in a chemical depolymerization solution, so that molecules of polyester will be broken into polyester monomer (such as diol unit and diacid unit) and oligomers (such as cyclic oligomer), and then an oligomer mixture is formed. Subsequently, the oligomer mixture is isolated, purified, repolymerized, and then granulated to obtain the chemically regenerated polyester chips. In the present embodiment, a main component forming the chemically regenerated polyester chips is regenerated polyethylene terephthalate.
In the present embodiment, the chemical depolymerization solution can be water, methanol, ethanol, ethylene glycol, diethylene glycol or any combination thereof. However, the present embodiment is not limited thereto. For example, water is used for hydrolysis, and methanol, ethanol, ethylene glycol, diethylene glycol are used for alcoholysis. In a preferable embodiment, the chemical depolymerization solution includes ethylene glycol.
In the present embodiment, the chemically regenerated polyester chips include the chemically regenerated regular polyester chips and the chemically regenerated electrostatic pinning polyester chips. The term “chemically regenerated regular polyester chips” refers to polyester chips prepared by direct repolymerization, reproduction process and no functional additive is added in the oligomer mixture during the chemical reproduction process. In the present embodiment, a component forming the chemically regenerated regular polyester chips is regenerated polyethylene terephthalate. The term “chemically regenerated electrostatic pinning polyester chips” refers to those prepared by having electrostatic pinning additives added into the oligomer mixture and then repolymerized. In the present embodiment, the chemically regenerated electrostatic pinning polyester chips include regenerated polyethylene terephthalate and the electrostatic pinning additives.
It should be noted that, the term “electrostatic pinning” refers to a use of materials that increase electrical conductivity or decrease electrical resistivity. The term “electrostatic pinning additives” in the present disclosure refers to materials that increase electrical conductivity or decrease electrical resistivity.
The electrostatic pinning additives are metal salts. The metal salts can be sodium hydroxide, potassium hydroxide, or metal salts containing aliphatic carboxylic acid. In the metal salts containing aliphatic carboxylic acid, a carbon number of the aliphatic carboxylic acid ranges from 2 to 30. For instance, the aliphatic carboxylic acid (in the form of metal salts) contains monocarboxylic acid and dicarboxylic acid, such as acetic acid, palmitic acid, stearic acid, oleic acid or sebacic acid. In the present embodiment, the aliphatic carboxylic acid is preferably acetic acid. Further, a metal component of the metal salts can be, for example, alkali metal or alkaline earth metal. In other words, the metal salts can be, for example, lithium salts, sodium salts, potassium salts, manganese salts, zinc salts, calcium salts, magnesium salts, or aluminum salts. In the present embodiment, the metal salts are preferably manganese salts or lithium salts. The manganese salts can be magnesium acetate (Mg(CH3COOH)2), and the lithium salts can be lithium acetate (CH3COOLi). However, the present disclosure is not limited thereto.
In addition, in the chemical reproduction process, the functional additives mentioned above (such as slipping agent, coloring agent, and matting agent) can be added into the oligomer mixture. Accordingly, after repolymerizing the oligomer mixture, chemically regenerated slipping polyester chips, chemically regenerated color polyester chips, and chemically regenerated matting polyester chips can be prepared sequentially. It should be noted that, a main component of each of the chemically regenerated slipping polyester chips, the chemically regenerated color polyester chips, and the chemically regenerated matting polyester chips is regenerated polyethylene terephthalate.
In step S5, the base layer 11 is extruded and formed via an extruder.
In step S6, the surface coating layer 12 is formed from a surface coating paste. The surface coating paste includes the main resin, the fillers, and the melamine mentioned previously. The surface coating paste is disposed onto the base layer 11 by in-line coating so as to form the surface coating layer 12 onto the base layer 11. However, the way to form the surface coating layer 12 is not limited thereto.
Referring to
A material of the base layer 11 and a material of the surface coating layer 12 in the second embodiment is similar to the material of the base layer 11 and the material of the surface coating layer 12 in the first embodiment. Therefore, the specific content is not repeated herein.
Referring to
In conclusion, in the polyester film for embossing 1 and the method for manufacturing the same provided in the present disclosure, by virtue of “a main component formed the base layer 11 being regenerated polyethylene terephthalate” and “the surface coating layer 12 being disposed on the base layer 11 and a material forming the surface coating layer 12 including a main resin, fillers, and melamine”, an amount of the recycled polyester material in the polyester film for embossing 1 can be increased.
The foregoing description of the exemplary embodiments of the disclosure has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching.
The embodiments were chosen and described in order to explain the principles of the disclosure and their practical application so as to enable others skilled in the art to utilize the disclosure and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present disclosure pertains without departing from its spirit and scope.
| Number | Date | Country | Kind |
|---|---|---|---|
| 109123798 | Jul 2020 | TW | national |
This application is a divisional application of the U.S. application Ser. No. 17/201,199, filed on Ma. 15, 2021, and entitled “POLYESTER FILM FOR EMBOSSING AND METHOD FOR MANUFACTURING THE SAME,” now pending, the entire disclosures of which are incorporated herein by reference. Some references, which may include patents, patent applications and various publications, may be cited and discussed in the description of this disclosure. The citation and/or discussion of such references is provided merely to clarify the description of the present disclosure and is not an admission that any such reference is “prior art” to the disclosure described herein. All references cited and discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference was individually incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17201199 | Mar 2021 | US |
| Child | 18121194 | US |
