TWI548669B - 生質基聚對苯二甲酸乙二酯聚合物及其製法 - Google Patents

生質基聚對苯二甲酸乙二酯聚合物及其製法 Download PDF

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TWI548669B
TWI548669B TW098107560A TW98107560A TWI548669B TW I548669 B TWI548669 B TW I548669B TW 098107560 A TW098107560 A TW 098107560A TW 98107560 A TW98107560 A TW 98107560A TW I548669 B TWI548669 B TW I548669B
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羅伯特 克里格
黃曉燕
米凱爾 舒希斯
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Description

生質基聚對苯二甲酸乙二酯聚合物及其製法 相關申請案資料
本申請案主張標題為「生質基聚對苯二甲酸乙二酯與由生質基聚對苯二甲酸乙二酯所製之物件(Bio-based Polyethylene Terephthalate and Articles Made from Bio-based Polyethylene Terephthalate)」並於2008年3月28日提出申請之美國臨時申請案第61/040349號在35 U.S.C.§ 119(e)下的優先權。
本發明大體上有關含有部分或完全衍生自生質基材料之對苯二甲酸酯及/或二醇組份的生質基聚對苯二甲酸乙二酯聚合物。
部分因聚對苯二甲酸乙二酯與其共聚酯(下文通稱為「PET」或「聚對苯二甲酸乙二酯」)之澄清度、機械性質與氣體阻障性質的優異組合之故，它們係廣泛用作製造包裝物件之原料。PET產物之實例包括但不局限於供包裝食品、清涼飲料、酒精飲品、清潔劑、化妝品、藥劑與食用油用的瓶與容器。
大部分工業方法係以石化衍生之原料製造PET。因此，製造成本與石油價格息息相關。石化衍生之PET因其高石油衍生之碳含量而造成溫室氣體排放。此外，石油 化學品費時數百萬年才自然形成，使得石化衍生產物為非再生的，此意謂其無法再製、再生長或以與其消耗相當之速率再生。
取代石化衍生之PET的途徑之一係由生質基材料(諸如玉米、稻米或其他產生糖與澱粉之植物)製造聚乳酸(PLA)生質塑膠。請參見美國專利第6,569,989號。如美國專利第5,409,751號與美國專利申請案第20070187876號中所述，已嘗試將PLA樹脂以射出拉伸模製法用於製造容器。然而，往往難以令PLA適應現有PET生產線或在許多應用當中因PLA與PET之間明顯不同的性質而使得PLA難以令人滿意地取代PET。例如，PLA通常具有比PET低之氣體阻障性質，這使得PLA容器較不適用於貯存諸如碳酸飲料或對氧氣敏感之飲料。此外，目前所使用的大部分回收系統係針對PET所設計，若導入PLA會受到污染這些系統。此問題可藉由成本高昂的解決方法克服，諸如採用可區別PLA與PET的不同瓶型，或投資適合的分類技術或新回收流程。
因此，對於具有與石油衍生之PET相似性質的衍生自可再生資源之PET仍有需求。在某些應用中也企求的是衍生自再生資源之PET可經由現有PET製造設備處理及/或可容易地經由針對回收石油衍生之PET所設計的系統所回收。
由下列詳細說明、圖式與申請專利範圍將可明暸本發明之其他目的、特徵與優點。
發明詳細說明
本申請案所使用之「生質基」一辭係表示包含衍生自至少一種生質基材料之某些組份。例如，「生質基PET聚合物」係為包含至少一種部分或完全衍生自至少一種生質基材料之組份的PET聚合物。
生質基PET聚合物
本發明之一具體實例包括一種生質基PET聚合物，其包含約25至約75重量百分比之對苯二甲酸酯組份與約20至約50重量百分比之二醇組份，其中至少約1重量百分比之該對苯二甲酸酯組份及/或該二醇組份其中至少一者係衍生自至少一種生質基材料。在一更特別具體實例中，至少約20重量百分比之該對苯二甲酸酯組份及/或該二醇組份其中至少一者係衍生自至少一種生質基材料。
在一具體實例中，該生質基PET聚合物包含約30至約70重量百分比之該對苯二甲酸酯組份。在一更特別具體實例中，該生質基PET聚合物包含約40至約65重量百分比之該對苯二甲酸酯組份。在另一具體實例中，該生質基PET聚合物包含約25至約45重量百分比之該二醇組份。在一更特別具體實例中，該生質基PET聚合物包含約25至約35重量百分比之該二醇組份。
根據本發明一特定具體實例，該對苯二甲酸酯組份係 選自對苯二甲酸、對苯二甲酸二甲酯、間苯二甲酸，及其組合。在一更特別具體實例中，至少約10重量百分比之該對苯二甲酸酯組份係衍生自至少一種生質基材料。在一具體實例中，該對苯二甲酸酯組份包含至少約70重量百分比之對苯二甲酸。在一更特別具體實例中，至少約1重量百分比，較佳係至少約10重量百分比之該對苯二甲酸係由至少一種生質基材料所製得。
在另一具體實例中，該二醇組份係選自乙二醇、環己烷二甲醇，及其組合。在一更特別具體實例中，該二醇組份包含至少約1重量百分比之環己烷二甲醇。在另一具體實例中，至少約10重量百分比之該二醇組份係衍生自至少一種生質基材料。
可在該生質基PET聚合物中添加其他成份。熟悉本技術之人士很容易能選擇添加至該生質基PET聚合物以改善所需性質的適用成份，該等所需性質係取決於所欲應用的類型。在一特別具體實例中，該生質基PET聚合物可以另外包含補充組份，該補充組份係選自至少一種著色劑、至少一種迅速再熱添加劑、至少一種氣體阻障添加劑(fast reheat additive)、至少一種UV阻斷添加劑，及其組合。
生質基PET聚合物可用以形成生質基樹脂，該等生質基樹脂可使用包括但不局限於射出成形與拉伸吹塑之方法進一步加工成生質基容器。本發明之具體實例包括包含上述具體實例之生質基PET聚合物的生質基容器。為了 適用於某些應用，容器具有特定固有黏度以承受移動、傾斜與其他需求。在本發明的更特別具體實例中，該生質基容器具有之固有黏度為約0.45dL/g至約1.0dL/g。
本技術中已習知在生質基材料中但並非在化石燃料中發現半衰期約5,700年之碳-14(C-14)。因此，「生質基材料」係指其中碳係來自非化石生物來源之有機材料。生質基材料之實例包括但不局限於糖、澱粉、玉米、天然纖維、甘蔗、甜菜、柑橘類水果、木本植物、纖維素、木質纖維素、半纖維素、馬鈴薯、植物油、其他多醣類，諸如果膠、甲殼素、聚果糖、與支鏈澱粉，以及其組合。根據一特定具體實例，該至少一種生質基材料係選自玉米、甘蔗、甜菜、馬鈴薯、澱粉、柑橘類水果、木本植物、纖維木質素、植物油、天然纖維、油質木材原料，及其組合。
如前文所述，C-14之偵測係生質基材料的表示。C-14水準可經由液體閃爍計數測量其衰退過程(每分鐘每克碳之衰變或dpm/gC)而測定。在本發明一具體實例中，該生質基PET聚合物包含至少約0.1dpm/gC(每分鐘每克碳之衰變)之C-14。
本發明進一步藉由下列實例說明，其在任何方面均不應視為對本發明範圍之限制。反之，應清楚暸解的是於閱讀本說明之後，多種其他具體實例、修改與其同等物，在不違背本發明精神及/或附錄申請專利範圍之範圍情況下，對熟悉本技術之人士而言是顯而易知的。
實施例I
下列樣本係以盲檢試驗方式測量，以藉由液體閃爍計數測定C-14之存在。將所偵測水準標準化成喬治亞大學(University of Georgia)之將C-14水準與生質基百分比相關的現有資料。結果示於表1。
如表1所示，完全衍生自石油的樣本(樣本2、3與4)含有可忽略量之C-14，表示該樣本之約0%係由生質基材料所製成。反之，含有已知部分或完全衍生自生質基材料(玉米或糖)的材料的樣本顯示遠遠較高之C-14水準。根據該資料，約0.14dpm/gC相當於該樣本中約1%生質基材料。
製造聚對苯二甲酸乙二酯聚合物之方法
參考圖1，本發明之具體實例亦包括用於製造生質基 PET聚合物16之方法，其包含取得包含乙二醇12a之二醇組份12[步驟20]；取得包含對苯二甲酸之對苯二甲酸酯組份14[步驟22]；其中該二醇組份及/或該對苯二甲酸酯組份(12、14)其中一者之至少約1重量百分比係衍生自至少一種生質基材料10；以及令該二醇組份12與該對苯二甲酸酯組份14反應以形成生質基PET聚合物16[步驟24]，其中該生質基PET聚合物16包含約25至約75重量百分比之該對苯二甲酸酯組份14與約20至約50重量百分比之該二醇組份12。在一更特別具體實例中，如反應I所示，步驟24進一步包含經由酯化反應令二醇組份12與對苯二甲酸酯組份14反應形成生質基PET單體16a，其隨後經聚合而形成生質基PET聚合物16。
在一特別具體實例中，至少約1重量百分比之該二醇組份12係衍生自至少一種生質基材料10。在一更特別具體實例中，至少10重量百分比之該二醇組份12係衍生自至少一種生質基材料10。在另一更特別具體實例中，至少30重量百分比之該二醇組份12係衍生自至少一種生質基材料10。
該二醇組份12可使用任何方法而部分或完全地衍生 自至少一種生質基材料。在一具體實例中，步驟20包含由至少一種生質基材料取得糖或其衍生物，並將該糖或其衍生物發酵成乙醇。在另一具體實例中，步驟20包含至少一種生質基材料10的氣化以產生合成氣，再將合成氣轉化成乙醇。在一更特別具體實例中，如反應II所示，步驟20進一步包含將乙醇脫水成乙烯、將乙烯氧化成環氧乙烷，以及將環氧乙烷轉化成乙二醇。
在另一具體實例中，步驟20包含由至少一種生質基材料取得糖或其衍生物，並將該糖或其衍生物轉化成包含乙二醇與至少一種除乙二醇以外之二醇的混合物。步驟20另外包含從該混合物分離乙二醇。該混合物可經重複反應以取得較高之乙二醇產率。在一更特別具體實例中，該至少一種二醇係選自丁二醇、丙二醇與甘油。
根據另一具體實例，至少約1重量百分比之該對苯二甲酸酯組份14係衍生自至少一種生質基材料10。在一更特別具體實例中，至少10重量百分比之該對苯二甲酸酯組份14係衍生自至少一種生質基材料10。在另一更特別具體實例中，至少30重量百分比之該對苯二甲酸酯組份14係衍生自至少一種生質基材料10。
該對苯二甲酸酯組份14可使用任何方法而部分或完全地衍生自至少一種生質基材料。在一具體實例中，如反應III所示，步驟22包含由至少一種油質木材原料萃取蒈烯，藉由脫氫與芳構化將該蒈烯轉化成對異丙基甲苯與間異丙基甲苯，及將對異丙基甲苯與間異丙基甲苯氧化成對苯二甲酸與間苯二甲酸。
在另一具體實例中，如反應IV所示，步驟22包含由至少一種生質基材料萃取薴烯，將該薴烯轉化成至少一種萜烯，將該萜烯轉化成對異丙基甲苯，及將該對異丙基甲苯轉化成對苯二甲酸。在一更特別具體實例中，該至少一種萜烯係選自萜品烯、萜二烯、萜品油烯與其組合。在另一更特別具體實例中，該至少一種生質基材料係選自柑橘類水果、木本植物或其組合。
在本發明一具體實例中，如反應V所示，步驟22包含由生質基材料萃取羥甲基糠醛，將羥甲基糠醛轉化成第一中間產物，令該第一中間產物與乙烯反應以形成第二中間產物，於觸媒存在下以酸處理該第二中間產物以形成羥甲基苯甲醛，及將羥甲基苯甲醛氧化成對苯二甲酸。在一更特別具體實例中，該羥甲基糠醛係萃取自選自玉米糖漿、糖、纖維素與其組合之生質基材料。在另一更特別具體實例中，乙烯係衍生自至少一種生質基材料。
在另一具體實例中，步驟22包含至少一種生質基材料10的氣化以產生合成氣，將合成氣轉化成對二甲苯，並在酸中將對二甲苯氧化以形成對苯二甲酸。
在一具體實例中，至少約1重量百分比之該對苯二甲酸酯組份14係衍生自至少一種生質基材料10，且至少約1重量百分比之該二醇組份12係衍生自至少一種生質基材料10。在一更特別具體實例中，至少約25重量百分比之該對苯二甲酸酯組份14係衍生自至少一種生質基材料 10。在另一更特別具體實例中，至少約70重量百分比之該二醇組份12係衍生自至少一種生質基材料10。根據一特定具體實例，該生質基材料係選自玉米、甘蔗、甜菜、馬鈴薯、澱粉、柑橘類水果、木本植物、纖維木質素、植物油、天然纖維、油質木材原料，及其組合。
在另一具體實例中，該方法另外包含由生質基PET聚合物16製造生質基PET產物18。該生質基PET產物18可用於多種應用，包括但不局限於飲料容器。在另一具體實例中，該生質基PET產物18可經由針對石油衍生之PET產物所設計的回收系統回收或再使用[步驟26]。
應暸解的是前文係關於本發明的特定具體實例，其中可以做出許多改變而不會偏離下列申請專利範圍所界定之本發明範圍情況。
10‧‧‧生質基材料
12‧‧‧二醇組份
14‧‧‧對苯二甲酸酯組份
16‧‧‧生質基PET聚合物
16a‧‧‧生質基PET單體
18‧‧‧生質基PET產物
20‧‧‧步驟
22‧‧‧步驟
24‧‧‧步驟
26‧‧‧步驟
圖1係製造部分或完全衍生自生質基材料之生質基聚對苯二甲酸乙二酯產物之方法的流程圖示。
10‧‧‧生質基材料
12‧‧‧二醇組份
14‧‧‧對苯二甲酸酯組份
16‧‧‧生質基PET聚合物
16a‧‧‧生質基PET單體
18‧‧‧生質基PET產物
20‧‧‧步驟
22‧‧‧步驟
24‧‧‧步驟
26‧‧‧步驟

Claims (7)

  1. 一種包含聚對苯二甲酸乙二酯(PET)聚合物的飲料或食物容器，其中該聚合物包含約70重量百分比之對苯二甲酸及約30重量百分比之乙二醇，其中該對苯二甲酸係完全衍生自石油化學品且該乙二醇係部分或完全衍生自甘蔗。
  2. 如申請專利範圍第1項之飲料或食物容器，其中該乙二醇係部分衍生自甘蔗。
  3. 如申請專利範圍第2項之飲料或食物容器，其中至少約1重量百分比之該乙二醇係衍生自甘蔗。
  4. 如申請專利範圍第2項之飲料或食物容器，其中至少約70重量百分比之該乙二醇係衍生自甘蔗。
  5. 如申請專利範圍第1項之飲料或食物容器，其中該乙二醇係完全衍生自甘蔗。
  6. 如申請專利範圍第1項之飲料或食物容器，其中該飲料或食物容器為瓶子。
  7. 如申請專利範圍第6項之飲料或食物容器，其中該瓶子具有約0.45dL/g至約1.0dL/g的固有黏度。
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