JP7080871B2 - ポリエステルフィルム及びその製造方法 - Google Patents
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Description
前記ポリエステルフィルムの製造方法は、物理的手段で一部分の前記再生プラスチックを再製することにより物理的再生ポリエステル樹脂を取得するステップと、化学的手段で他部分の前記再生プラスチックを再製することにより化学的再生ポリエステル樹脂を取得するステップと、前記物理的再生ポリエステル樹脂及び前記化学的再生ポリエステル樹脂を含んだポリエステルの組成物を調製するステップと、前記ポリエステルの組成物を使用して前記ポリエステルフィルムを成形するステップと、を含む。
前記ポリエステルの組成物の総重量を100wt%(重量パーセント濃度)とした場合、前記化学的再生ポリエステル樹脂の重量比率が5wt%以上であり、前記ポリエステルフィルムの総重量を100wt%とした場合、前記物理的再生ポリエステル樹脂と前記化学的再生ポリエステル樹脂の総重量は10wt%~100wt%である。
物理的手段で再生する方法を以下に説明する。まず、ボトル破片を溶融するのに必要な時間や消費エネルギを減らすために、破片を切断する。次に、切断後のボトル破片を溶融して混合する。そして、単軸スクリュー又は二軸スクリュー押出機を使用して造粒し、物理的再生ポリエステル樹脂を製造する。つまり、成形後のボトル破片は切断、溶融及び押出のステップを経てシェーピングされ、元来のボトル破片におけるポリエステル分子は並び替えられる。しかし、物理的手段で再生する過程で、ポリエステル分子はポリエステル分子は再配列されているだけで、再編成されていない。元来に再生プラスチックに存在している成分(例えば、ポリエステルを合成するときに使用される金属触媒、滑剤、酸化防止剤又は添加剤)は依然として物理的再生ポリエステル樹脂に存在する。
化学的手段で再生する方法を以下に説明する。まず、ボトル破片を解重合するのに必要な時間や消費エネルギを減らすために、ボトル破片を切断する。次に、ボトル破片を化学解重合液に投入してポリエステルの分子鎖を破壊し、ポリエステル分子を解重合させ、分子鎖の短いポリエステル単量体と低重合体を取得する。本実施形態において、化学解重合液は、ギ酸、メタノール、酢酸、エタノール、グリコール、プロピオン酸、マロン酸、アセトン、ブタノン、トルエン又はそれらの組成物を含む溶液であってもよいが、これに制限されない。好ましい実施形態では、化学解重合溶液はエチレングリコールである。アルコール分解工程は一般に加圧高温プロセスによって行われ、アルコール分解が完了すると、予備重合セクションに入ると同時に真空が蒸留され、過剰なEGと不純物が除去される。
本発明による一つの有益な効果は以下の通りである。即ち、本発明に係るポリエステルフィルム及びその製造方法は、"物理的再生ポリエステル樹脂と化学的再生ポリエステル樹脂を含んだポリエステルの組成物を調製する"及び"化学的再生ポリエステル樹脂の重量比率は5wt%以上である"といった技術的特徴により、再生ポリエステル樹脂で製造される従来のポリエステルの製品の色相不良の問題を改善することができる。また、様々な需要や用途に応じて、異なる性質の化学的再生ポリエステル樹脂を選用し、さらに物理的再生ポリエステル樹脂と化学的再生ポリエステル樹脂の使用量を調整すれば、異なる性質のポリエステルフィルムを製造することができる。
Claims (11)
- 再生プラスチックを再生利用するためのポリエステルフィルムの製造方法であって、
前記ポリエステルフィルムの製造方法は、
物理的手段で一部分の前記再生プラスチックを再製することにより物理的再生ポリエステル樹脂を取得するステップと、
化学的手段で他部分の前記再生プラスチックを再製することにより化学的再生ポリエステル樹脂を取得するステップと、
前記物理的再生ポリエステル樹脂及び前記化学的再生ポリエステル樹脂を含んだポリエステルの組成物を調製するステップと、
前記ポリエステルの組成物を使用して前記ポリエステルフィルムを成形するステップと、を含み、
前記ポリエステルの組成物の総重量を100wt%とした場合、前記化学的再生ポリエステル樹脂の重量比率が5wt%以上であり、
前記ポリエステルフィルムの総重量を100wt%とした場合、前記物理的再生ポリエステル樹脂と前記化学的再生ポリエステル樹脂の総重量は10wt%~100wt%であり、
化学的手段で他部分の前記再生プラスチックを再製する前記ステップはさらに、
前記再生プラスチックを解重合することで原料混合物を取得するステップと、
前記原料混合物を再重合することで前記化学的再生ポリエステル樹脂を製造するステップと、を含み、
前記原料混合物を再重合する前記ステップはさらに、前記原料混合物に静電密着剤を添加するステップを含み、前記静電密着剤はアルカリ金属化合物又はアルカリ土類金属化合物を含んだ複合物であり、
物理的手段で一部分の前記再生プラスチックを再製する前記ステップにおいて、顆粒寸法が2ミクロンより大きい滑剤を前記再生プラスチックに添加する、ことを特徴とする、ポリエステルフィルムの製造方法。 - 前記ポリエステルの組成物の総重量を100wt%とした場合、前記物理的再生ポリエステル樹脂の含有量は10wt%~90wt%であり、前記化学的再生ポリエステル樹脂の含有量は10wt%~90wt%である、請求項1に記載のポリエステルフィルムの製造方法。
- 前記原料混合物を再重合する前記ステップはさらに、滑剤を前記原料混合物に添加した後、前記原料混合物を再重合するステップを含み、前記滑剤は、シリカ、ポリスチレン、ポリメチルメタクリレート、シリカゲル、アクリル又はそれらの組成物であり、前記ポリエステルフィルムの透明度が85%以上になるように、前記ポリエステルの組成物には更に前記滑剤が0.01wt%~1wt%含まれ、前記滑剤の顆粒寸法は2ミクロンより小さい、請求項1に記載のポリエステルフィルムの製造方法。
- 前記ポリエステルフィルムのヘイズは5%以下である、請求項3に記載のポリエステルフィルムの製造方法。
- 前記原料混合物を再重合する前記ステップはさらに、前記原料混合物に顔料を添加して、前記原料混合物を再重合するステップを含み、前記ポリエステルの組成物には更に前記顔料が10ppm~10wt%含まれる、請求項1に記載のポリエステルフィルムの製造方法。
- 前記原料混合物を再重合する前記ステップはさらに、前記原料混合物に白色の添加物を添加して、前記原料混合物を再重合するステップを含み、前記ポリエステルの組成物には更に前記白色の添加物が5wt%~40wt%含まれる、請求項1に記載のポリエステルフィルムの製造方法。
- 前記白色の添加物としては、二酸化チタン、硫酸バリウム及び炭酸カルシウムから選択される少なくとも1種である、請求項6に記載のポリエステルフィルムの製造方法。
- 前記白色の添加物は二酸化チタン、硫酸バリウム及び炭酸カルシウムを含み、二酸化チタンは前記白色の添加物の総重量の0.01wt%~80wt%を占め、硫酸バリウムは前記白色の添加物の総重量の0.01wt%~80wt%を占め、炭酸カルシウムは前記白色の添加物の総重量の0.0wt%~80wt%を占める、請求項7に記載のポリエステルフィルムの製造方法。
- 前記原料混合物を再重合する前記ステップはさらに、艶消し添加剤を前記原料混合物に添加して、前記原料混合物を再重合するステップを含み、前記艶消し添加剤は、シリカ、シリカゲル、アクリル又はそれらの組成物であり、前記ポリエステルフィルムのヘイズが0.1%~90%になるように、前記ポリエステルの組成物には前記艶消し添加剤が500ppm~20wt%含まれる、請求項1に記載のポリエステルフィルムの製造方法。
- 前記原料混合物を再重合する前記ステップはさらに、分解性材料を前記原料混合物に添加するステップを含み、前記ポリエステルの組成物には前記分解性材料が5wt%~90wt%含まれる、請求項1に記載のポリエステルフィルムの製造方法。
- 物理的手段で一部分の前記再生プラスチックを再製する前記ステップにおいて、有機添加物を前記再生プラスチックに添加し、前記有機添加物は、ポリエチレン、ポリプロピレン、ポリ4-メチルペンテン又はそれらの組成物である、請求項1に記載のポリエステルフィルムの製造方法。
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