RECYCLED POLYETHYLENE TEREPHTHALATE COMPOSITIONS, FIBERS AND ARTICLES PRODUCED THEREFROM, AND METHODS FOR PRODUCING SAME

• US 20100152309A1
• Filed: 09/30/2009
• Published: 06/17/2010
• Est. Priority Date: 09/30/2008
• Status: Active Grant

• Current Assignee: Columbia Insurance Company (Berkshire Hathaway Incorporated)
• Original Assignee: Columbia Insurance Company (Berkshire Hathaway Incorporated)
• Inventors: Keen, James Henry JR., Johnson, Daniel Ray, Bradley, Christopher Eric, Booth, Hubert J.
• Granted Patent: US 8,741,972 B2
• Time in Patent Office: Days
• US Class Current: 521/40.500
• CPC Class Codes: B29B 7/007 for continuous mixing
• CPC Class Codes: C08J 11/04 of polymers
• CPC Class Codes: C08J 2367/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: C08L 2205/025 containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
• CPC Class Codes: C08L 2207/20 Recycled plastic
• CPC Class Codes: C08L 2666/18 Polyesters or polycarbonates according to C08L67/00 - C08L69/00; Derivatives thereof
• CPC Class Codes: C08L 67/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds C08L67/06 takes precedence
• CPC Class Codes: D01D 1/065 Addition and mixing of substances to the spinning solution or to the melt; Homogenising
• CPC Class Codes: D01F 6/62 from polyesters
• CPC Class Codes: D01F 6/84 from copolyesters
• CPC Class Codes: D01F 6/92 of polyesters
• CPC Class Codes: D06N 7/0065 characterised by the pile
• CPC Class Codes: D10B 2331/04 polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2503/04 Floor or wall coverings; Carpets
• CPC Class Codes: Y02P 20/143 the feedstock being recycled material, e.g. plastics
• CPC Class Codes: Y02W 30/62 Plastics recycling; Rubber recycling
• CPC Class Codes: Y10T 428/1362 Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
• CPC Class Codes: Y10T 428/1366 Textile, fabric, cloth, or pile is sandwiched between two distinct layers of material unlike the textile, fabric, cloth, or pile layer
• CPC Class Codes: Y10T 428/1369 Fiber or fibers wound around each other or into a self-sustaining shape [e.g., yarn, braid, fibers shaped around a core, etc.]
• CPC Class Codes: Y10T 428/23993 Composition of pile or adhesive

Abstract

In one aspect, the invention relates to recycled polyethylene terephthalate compositions, fibers and articles produced therefrom, and methods for producing same. In a further aspect, the invention relates to homogenized post-consumer polyethylene terephthalate. In a further aspect, the invention relates to extruded polymer compositions, polymer mixtures, fibers, and/or Bulked Continuous Filament fibers comprising post-consumer polyethylene terephthalate. In a further aspect, the invention relates to processes for preparing recycled polyethylene terephthalate compositions. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present invention.

Claims

1. An extruded polymer composition comprising polyethylene terephthalate present as from about 25% to about 100% deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate.

2. The composition of claim 1, wherein the polyethylene terephthalate is present as at least about 50% deposit post-consumer polyethylene terephthalate by weight.

3. The composition of claim 1, wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.

4. A polymer mixture comprising polyethylene terephthalate present as from about 25% to about 100% homogeneous deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate.

5. The mixture of claim 4, wherein the polyethylene terephthalate is present as at least about 50% deposit post-consumer polyethylene terephthalate by weight.

6. The mixture of claim 4, wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.

7. A fiber extruded from polyethylene terephthalate present as from about 25% to about 100% deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate.

8. The fiber of claim 7, wherein the polyethylene terephthalate is present as at least about 50% deposit post-consumer polyethylene terephthalate by weight.

9. The fiber of claim 7, wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.

10. A Bulked Continuous Filament extruded fiber comprising a polymer composition of polyethylene terephthalate present as from about 25% to about 100% deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate.

11. The fiber of claim 10, wherein the polyethylene terephthalate is present as at least about 50% deposit post-consumer polyethylene terephthalate by weight.

12. The fiber of claim 10, wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.

13. A carpet comprising a fiber comprising a polymer composition of polyethylene terephthalate present as from about 25% to about 100% deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate.

14. An extruded polymer composition comprising polyethylene terephthalate present as from about 50% to about 100% deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate.

15. The composition of claim 14, wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.

16. The composition of claim 14, wherein the polyethylene terephthalate is present as at least about 90% deposit post-consumer polyethylene terephthalate by weight.

17. A polymer mixture comprising polyethylene terephthalate present as from about 50% to about 100% homogeneous deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate.

18. The mixture of claim 17, wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.

19. The mixture of claim 17, wherein the polyethylene terephthalate is present as at least about 90% deposit post-consumer polyethylene terephthalate by weight.

20. A fiber extruded from polyethylene terephthalate present as from about 50% to about 100% deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate.

21. The fiber of claim 20, wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.

22. The fiber of claim 20, wherein the polyethylene terephthalate is present as at least about 90% deposit post-consumer polyethylene terephthalate by weight.

23. A Bulked Continuous Filament extruded fiber comprising a polymer composition of polyethylene terephthalate present as from about 50% to about 100% deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate.

24. The fiber of claim 23, wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.

25. The fiber of claim 23, wherein the polyethylene terephthalate is present as at least about 90% deposit post-consumer polyethylene terephthalate by weight.

26. A carpet comprising a fiber comprising a polymer composition of polyethylene terephthalate present as from about 50% to about 100% deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate.

27. Homogenized deposit post-consumer polyethylene terephthalate.

28. A process for preparing a recycled polyethylene terephthalate composition comprising the step of blending deposit post-consumer polyethylene terephthalate to homogeneity prior to mixing with virgin polyethylene terephthalate.

29. The process of claim 28, comprising the steps of:

a. blending deposit post-consumer polyethylene terephthalate to homogeneity;

b. optionally, crystallizing the homogeneous deposit post-consumer polyethylene terephthalate;

c. drying the homogeneous deposit post-consumer polyethylene terephthalate;

d. mixing the homogeneous deposit post-consumer polyethylene terephthalate with virgin polyethylene terephthalate; and

e. extruding the mixture.

30. The process claim 29, further comprising the step of selecting deposit post-consumer polyethylene terephthalate to have one or more of the following specifications:

Bulk density (lb/ft3) of 20-27;

Moisture content (%) of <

1.0;

Floatable contamination (ppm) of <

15;

PVC contamination (ppm) of <

50;

Metal contamination (ppm) of <

10;

Other non-melting particles (ppm) of <

25;

Green pet contamination (ppm) of <

1000;

Light blue contamination (ppm) of <

75,000;

Low melt material (ppm) of <

25;

Black pet contamination (ppm) of <

25;

Pressure rise (psi per pound) of <

75 psi/lb;

Hunter Color L Value of >

50; and

Hunter Color b Value of 0.0 to 2.0.

31. A process for preparing a recycled polyethylene terephthalate composition comprising the step of mixing homogeneous deposit post-consumer polyethylene terephthalate with virgin polyethylene terephthalate prior to extrusion of the mixture.

32. The process of claim 31, comprising the steps of:

a. blending deposit post-consumer polyethylene terephthalate to homogeneity;

b. optionally, crystallizing the homogeneous deposit post-consumer polyethylene terephthalate;

c. drying the homogeneous deposit post-consumer polyethylene terephthalate;

d. mixing the homogeneous deposit post-consumer polyethylene terephthalate with virgin polyethylene terephthalate; and

e. extruding the mixture.

33. The process claim 32, further comprising the step of selecting deposit post-consumer polyethylene terephthalate to have one or more of the following specifications:

Bulk density (lb/ft3) of 20-27;

Moisture content (%) of <

1.0;

Floatable contamination (ppm) of <

15;

PVC contamination (ppm) of <

50;

Metal contamination (ppm) of <

10;

Other non-melting particles (ppm) of <

25;

Green pet contamination (ppm) of <

1000;

Light blue contamination (ppm) of <

75,000;

Low melt material (ppm) of <

25;

Black pet contamination (ppm) of <

25;

Pressure rise (psi per pound) of <

75 psi/lb;

Hunter Color L Value of >

50; and

Hunter Color b Value of 0.0 to 2.0.

34. A process for preparing a recycled polyethylene terephthalate composition comprising the step of extruding a mixture of homogeneous deposit post-consumer polyethylene terephthalate and virgin polyethylene terephthalate

35. The process of claim 34, comprising the steps of:

a. blending deposit post-consumer polyethylene terephthalate to homogeneity;

b. optionally, crystallizing the homogeneous deposit post-consumer polyethylene terephthalate;

c. drying the homogeneous deposit post-consumer polyethylene terephthalate;

d. mixing the homogeneous deposit post-consumer polyethylene terephthalate with virgin polyethylene terephthalate; and

e. extruding the mixture.

36. The process claim 35, further comprising the step of selecting deposit post-consumer polyethylene terephthalate to have one or more of the following specifications:

Bulk density (lb/ft3) of 20-27;

Moisture content (%) of <

1.0;

Floatable contamination (ppm) of <

15;

PVC contamination (ppm) of <

50;

Metal contamination (ppm) of <

10;

Other non-melting particles (ppm) of <

25;

Green pet contamination (ppm) of <

1000;

Light blue contamination (ppm) of <

75,000;

Low melt material (ppm) of <

25;

Black pet contamination (ppm) of <

25;

Pressure rise (psi per pound) of <

75 psi/lb;

Hunter Color L Value of >

50; and

Hunter Color b Value of 0.0 to 2.0.

37. A process for preparing a recycled polyethylene terephthalate composition comprising the step of blending deposit post-consumer polyethylene terephthalate to homogeneity prior to extrusion.

38. The process of claim 37, comprising the steps of:

a. blending deposit post-consumer polyethylene terephthalate to homogeneity;

b. optionally, crystallizing the homogeneous deposit post-consumer polyethylene terephthalate;

c. drying the homogeneous deposit post-consumer polyethylene terephthalate;

d. mixing the homogeneous deposit post-consumer polyethylene terephthalate with virgin polyethylene terephthalate; and

e. extruding the mixture.

39. The process claim 38, further comprising the step of selecting deposit post-consumer polyethylene terephthalate to have one or more of the following specifications:

Bulk density (lb/ft3) of 20-27;

Moisture content (%) of <

1.0;

Floatable contamination (ppm) of <

15;

PVC contamination (ppm) of <

50;

Metal contamination (ppm) of <

10;

Other non-melting particles (ppm) of <

25;

Green pet contamination (ppm) of <

1000;

Light blue contamination (ppm) of <

75,000;

Low melt material (ppm) of <

25;

Black pet contamination (ppm) of <

25;

Pressure rise (psi per pound) of <

75 psi/lb;

Hunter Color L Value of >

50; and

Hunter Color b Value of 0.0 to 2.0.