ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT FORMULATION FOR CARD STOCK APPLICATIONS – METHODS FOR DISPLACING PVC BY USING RECYCLED PETG, COPOLYESTERS, AND POLYESTERS (INCLUDING “OCEAN BOUND”) OR OTHER SUSTAINABLE POLYESTER MATERIALS (“BIO-BASED”, “RENEWABLY SOURCED”, OR “COMPOSTABLE”) CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of priority to United States Provisional Patent No.63/601,642, filed on 21-November-2023, the entirety of which is incorporated by reference as if fully reproduced and set forth herein in its entirety. FIELD OF THE INVENTION [0002] The present invention relates to replacement and displacement of first–use polymers in product manufacturing by providing recycling methods for polymers, for example, polyesters and polyethylene terephthalates, to provide recycled materials comparable in quality to first-use materials and can be applied to ocean bound polymers or to ocean bound plastic (OBP)
1 which is “at risk of ending up in the ocean” and is particularly difficult to manufacture into durable compositions after recycling. BACKGROUND OF THE INVENTION [0003] The increasing global awareness of environmental sustainability has led to a significant rise in the demand for recycling and reusing materials, particularly polymers and plastics. Traditional plastics, such as PVC and other first-use polymers, have been widely used in the production of various products due to their durability and versatility. However, the environmental impact of these materials, especially their contribution to pollution and landfill waste, has prompted the need for more sustainable alternatives. Recycled polymers offer a promising solution, as they can reduce the reliance on virgin materials and decrease the carbon footprint associated with plastic production. Polymers and plastics provide unparalleled manufacturing benefits, but byproducts and pollution from polymers and plastics have gained global attention, particularly ocean bound plastic (OBP), which is waste in the environment likely to end up in the oceans. In view of the
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT global plastic problem, many credit cards provided by banking authorities are moving or are planned to move to a Sustainable Card Program (SCP)
2. One aspect of the SCP is to remove the majority of first–use, PVC plastics from payment cards on global networks by 2028. This initiative helps provide sustainability commitments and provides more sustainable card offerings for consumers seeking a way to reduce the environmental impact of their bank cards. In addition to bank cards, other producers of products have gained awareness that avoiding first-use PVC (or other polymers) can be achieved if methods for using recycled polyester can be developed. [0004] Various methods have been developed for recycling polymers or plastics to reduce waste and environmental impact. Conventional recycling processes typically involve collecting used plastics, sorting them by type, cleaning, shredding, and melting them down to form new products. However, these processes often result in a loss of material properties and quality due to degradation during repeated heating and processing cycles. Additionally, the recycled materials may not meet the required specifications for use in manufacturing products, limiting their application in various industries. [0005] Despite advancements in recycling technologies, there remains a need for more efficient and sustainable methods for recycling polymers or plastics into high-quality materials that can effectively replace virgin polymers in product manufacturing. The development of innovative processes that can maintain or enhance the properties of recycled materials while reducing the reliance on first-use polymers is crucial for promoting a circular economy and reducing the environmental impact of plastic waste. However, none of these approaches have provided a comprehensive solution that combines the features described in this disclosure. [0006] Meanwhile, determining the amount of plastic that enters the oceans each year has proven difficult due to waste tracking issues. Estimates of the millions of tons of plastic that enters the ocean each year have ranged from 1.1 million tons to 8.8 million tons
3 and higher. It is known that at least 460 million metric tons of plastic are produced year for use in a wide variety of applications, and an estimated 20 million metric tons of plastic litter end up in the natural environment every year
4, with a proportion of that litter being OBP. That amount is expected to increase significantly by 2040. In the
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT manufacturing sector, there is a growing interest in developing methods to enhance the properties of recycled polymers to make them suitable for high-quality applications, such as in the production of monolayer and multi-layer films and sheets. These products are essential in various industries, including packaging, automotive, and construction. However, recycled polymers often face challenges such as reduced mechanical properties and processability compared to their virgin counterparts. Therefore, there is a pressing need for innovative approaches to modify recycled polymers, improving their performance and expanding their application range, while also addressing environmental concerns. Thus, there is an urgent need for new methods to recycle polymers and plastics that will provide recycled materials comparable in quality to first-use polymers and plastics for producing products from recycled polymers. BRIEF SUMMARY OF THE INVENTION [0007] The following presents a brief summary of the innovation to introduce some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify all key or critical elements of the invention nor limit the scope of the invention. Its purpose is to introduce some concepts of the invention as a prelude to the more Detailed Description presented later. By reading the Brief Summary, Figures, reading the Detailed Description, and the Claims, the inventive concepts can be initially discerned. The inventive concepts disclosed herein are not limited by the examples discussed and the concepts can solve a long-felt but unsolved global problem, namely, how to recycle polymers and plastics instead of polluting the environment. [0008] Previous methods for modifying recycled polymers or plastics for use in manufacturing film/sheet products have typically involved limited options for enhancing the properties of the recycled material. Conventional approaches have focused on basic processing steps such as heating the starting material to facilitate melting and mixing. However, these methods have often resulted in recycled materials with inferior mechanical properties and limited versatility compared to virgin polymers, thereby restricting their application in various end products. [0009] In some instances, attempts have been made to incorporate additives or modifiers into the recycled material to improve its performance characteristics. These
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT modifiers have included various types of copolymers and terpolymers, such as ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and ethylene/glycidyl methacrylate copolymer. While these additives have shown some promise in enhancing certain properties of the recycled material, they have not provided a comprehensive solution for effectively replacing PVC or other first-use polymers in the production of extruded film or sheet products. [0010] Overall, the existing methods for modifying recycled polymers or plastics have been limited in their ability to produce a recycled material that can serve as a direct substitute for PVC or other first-use polymers in manufacturing processes. These approaches have often fallen short in terms of achieving the desired balance of properties required for producing high-quality extruded film or sheet products or molded goods. However, none of these approaches have provided a comprehensive solution that combines the features described in this disclosure.In some exemplary recycling methods, chemical modifiers are added to the polymer or plastic during the recycling process to improve the properties of the recycled material. These modifiers can enhance the mechanical strength, thermal stability, and other characteristics of the recycled material, making it more suitable for use in manufacturing applications. Commonly used modifiers include compatibilizers, impact modifiers, and chain extenders, which help to overcome the limitations associated with recycled materials and enable their incorporation into new products. [0011] In some introductory embodiments, in an Invention Brief Summary or discussion, the technology disclosed herein can be discussed by reviewing/discussing the following list of features, in which any composition can be described as a method or vice versa, and which can be inter-combined with any other embodiment, feature, example, or aspect disclosed herein: [0012] Feature 1: A method for modifying a recycled polymer or plastic into a recycled material for use in manufacturing of mono-layer (extruded) or multi-layer (coextruded) film/sheet products, the method comprising the steps of: (1) obtaining a starting material including a polymer for recycling; (2) heating the starting material (in separate, prior melt compounding process step and/or melt extrusion process); (3) adding 1 or more modifiers, prior to melt extrusion process step, including ethylene/acrylate
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer to the starting material to produce a material based on recycled polymer or plastic; and whereby the modified recycled material can displace use of PVC (first-use or recycled) or other first-use polymers or plastic in producing extruded film or sheet products or molded goods. [0013] Feature 2: The method of feature 1, wherein the starting material is comprised of rPETG (a recycled polyethylene terephthalate glycol), PLA, PHA, PEF, PPT, other recycled copolyesters, recycled APET (amorphous polyethylene terephthalate) or a combination of these. [0014] Feature 3: The method of feature 2, wherein the recycled material is operative to displace use of first-use or recycled PVC (polyvinyl chloride) in producing extruded film and sheet products or molded goods for use in card stock applications. [0015] Feature 4: The method of feature 3, wherein the recycled material is operative to provide a thermal lamination to itself or is operative to thermal lamination to itself in an equipment that is designed for a PVC thermal lamination or heat sealing. [0016] Feature 5: The method of feature 3, wherein the recycled material is operative to be durably printed or embedded with an ink, with a metal, with a polymer, with an electronic, a chip, with a semi-conductor, or with a pattern. [0017] Feature 6: The method of feature 1, wherein the acrylate in step (3) includes an acrylate comonomer comprising EA (ethyl acrylate), MA (methyl acrylate), or BA (butyl acrylate). [0018] Feature 7: The method of feature 6, wherein the acrylate comonomer content in the ethylene acrylate copolymer is 9-40 wt%. [0019] Feature 8: The method of feature 1, wherein the modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer where the glycidyl methacrylate comonomer content is 1-8 wt% acrylate comonomer content is 0-28 wt%. [0020] Feature 9: The method of feature 1, wherein the modifier includes 1-4 wt% ethylene/acrylate/glycidyl methacrylate terpolymer and 2-10 wt% ethylene/acrylate copolymer.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [0021] Feature 10: The method of feature 1, wherein the ratio of ethylene/acrylate copolymer to ethylene/acrylate/glycidyl methacrylate terpolymer being in the range of 2:1 to 4:1. [0022] Feature 11: The method of feature 1, further comprising adding ≤ 10 wt% TiO2, other pigments, mineral fillers, or additives before step (2), before step (3), or after step (3). [0023] Feature 12: The method of feature 1, wherein the recycled material is operative to provide a mono-layer card stock substrate suitable for use and core, print and inlay layers used in making a bank card product or a security/ID card product. [0024] Feature 13: The method of feature 12, wherein the thickness of the card stock substrate is in a range of about 101.6 µm to about 685.8 µm or about 4-27 mil (0.004- 0.027 inches). [0025] Feature 14: The method of feature 1, wherein the recycled material is operative to provide a core "structural" layer in a multi-layer card stock substrate wherein the starting recycle material is comprised of rPET (recycled polyethylene terephthalate - including "ocean bound" rPET), and other materials compatible with polyester recycle stream such as, PBT (polybutylene terephthalate, PC (polycarbonate), and bio-based or renewably sourced polyesters including PPT (polypropylene terephthalate) and PEF (polyethylene furanoate). [0026] Feature 15: The method of feature 1, wherein the recycled material is operative to provide a mono-layer extruded skin onto metal or cellulosic (paper, wood) substrate to make a card stock suitable for use and core, print and inlay layers used in making a bank card product or a security/ID card product. [0027] Feature 16: The method of feature 15, wherein the thickness of the card stock substrate is in a range of about 101.6 µm to about 685.8 µm or about 4-27 mil (0.004- 0.027 inches). [0028] Feature 17: The method of feature 14, wherein the core structural layer includes a thickness in the range of 101.6 µm to about 685.8 µm or about 4-27 mil (0.006- 0.027 inches). [0029] Feature 18: The method of feature 17, further comprising a skin layer on one or both sides of the core structural layer with skin layer (that can be printed and thermally
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT laminate to itself) to provide A/B or A/B/A multi-layer card substrate (with A being the skin layer and B being the structural core layer). [0030] Feature 19: The method of feature 18, wherein one skin layer includes a thickness in the range from about 12.7 µm to about 101.6 µm or 0.5-4 mils (0.0005-0.004 inches). [0031] Feature 20: The method of feature 18, wherein the skin layer includes a thickness in the range from about 25.4 µm to about 50.8 µm or 1-2 mils (0.001-0.002 inches). [0032] Feature 21: The method of feature 1, wherein the recycled material is suitable to displace first-use PET or other polyesters and copolyesters in producing a product for use in the core structural layer with the recycled material comprising ≥ 85 wt% of the total polymer (first-use + recycled material) in the product. [0033] Feature 22: The method of feature 1, wherein the starting material includes rPET and wherein the recycled material is suitable for use in coextruded card structures with one or more recycled materals from rPET in the core surrounded by modified rPETG skin layers which are operative for thermal lamination of multiple layers of card stock. [0034] Feature 23: The method of feature 14, further comprising the rPET core has a sufficient modification to improve physical properties so that the rPETG skin layers do not require a modification. [0035] Feature 24: The method of feature 12, wherein the method provides a toughening and/or a modifying of recycled co-polyesters or rPETGs to produce a recycled, single layer card stock that will (1) thermally laminate to itself, (2) bond to printing inks and/or chips/antennae and/or (3) have sufficient physical properties to meet rigorous durability specifications such that can be used for articles or credit/bank cards or security/ID cards. [0036] Feature 25: The method of feature 24, wherein a level of modification is low enough to still be able to produce card stock coming from ≥ 85 wt% recycled polymer. [0037] Feature 26: A recycled material which is capable to be printed and/or thermally laminated to itself comprising a recycled polymer, and a modifier including ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT ethylene/glycidyl methacrylate copolymer; wherein the recycled material is operative to displace use of a first-use polymer or plastic in producing products. [0038] Feature 27: The recycled material of feature 26, wherein the recycled material is in a form of a monolayer card stock substrate. [0039] Feature 28: The recycled material of feature 26, wherein the recycled polymer or plastic comprises rPETG (a recycled polyethylene terephthalate glycol), PLA, PHA, PEF, PPT, other recycled copolyesters, recycled APET (amorphous polyethylene terephthalate) or a combination of these. [0040] Feature 29: The recycled material of feature 26, wherein the recycled material is operative to displace use of first-use PVC (polyvinyl chloride) in producing products. [0041] Feature 30: The recycled material of feature 27, wherein the recycled material is operative to provide a thermal lamination to itself or is operative to thermal lamination to itself in an equipment that is designed for a PVC. [0042] Feature 31: The recycled material of feature 27, wherein the recycled material is operative to be durably printed with an ink, with a metal, with a polymer, with an electronic, with a semi-conductor, or with a pattern. [0043] Feature 32: The recycled material of feature 26, wherein the acrylate includes an acrylate comonomer comprising EA (ethyl acrylate), MA (methyl acrylate), or BA (butyl acrylate). [0044] Feature 33: The recycled material of feature 32, wherein the acrylate comonomer is 9-40 wt%. [0045] Feature 34: The recycled material of feature 26, wherein the modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer where the glycidyl methacrylate conomomer content is 1-8 wt% acrylate comonomer content is 0-28 wt%. [0046] Feature 35: The recycled material of feature 26, wherein the modifier includes 1-4 wt% ethylene/acrylate/glycidyl methacrylate terpolymer and 2-10 wt% ethylene/acrylate copolymer. [0047] Feature 36: The recycled material of feature 26, wherein the ratio of ethylene/acrylate copolymer to ethylene/acrylate/glycidyl methacrylate terpolymer being in the range of 2:1 to 4:1.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [0048] Feature 37: The recycled material of feature 26, further comprising adding ≤ 10 wt% TiO2, other pigments, mineral fillers, or additives before step (2), before step (3), or after step (3). [0049] Feature 38: The recycled material of feature 26, wherein the recycled material is operative to provide a monolayer card stock substrate suitable for making a bank card product. [0050] Feature 39: The recycled material of feature 38, wherein the thickness of the card stock substrate is in a range from about 101.6 µm to about 685.8 µm or about 4 -27 mil (0.004 -0.027 inches). [0051] Feature 40: The recycled material of feature 38, further comprising forming a skin layer on one or more sides of the core layer, to provide an A/B card stock substrate or an A/B/A card stock substrate. [0052] Feature 41: The recycled material of feature 40, wherein one skin layer includes a thickness in the range from about 12.7 µm to about 101.6 µm or 0.5-4 mils (0.0005-0.004 inches). [0053] Feature 42: The recycled material of feature 41, wherein the skin layer includes a thickness in the range from about 25.4 µm to about 50.8 µm or 1-2 mils (0.001- 0.002 inches). [0054] Feature 43: The recycled material of feature 26, wherein the recycled material is suitable to displace first-use PET in producing a product with the recycled material comprising ≥ 90 wt% of the total core polymer (first-use PET + recycled material) in the product. [0055] Feature 44: The recycled material of feature 26, wherein the starting material includes rPET and wherein the recycled material is suitable for used in coextruded card structures with recycled material and/or rPET in the core surrounded by modified rPETG skin layers which are operative for thermal lamination of multiple layers of card stock. [0056] Feature 45: The recycled material of feature 44, further comprising the rPET core has a sufficient modification to improve physical properties so that the rPETG skin layers do not require a modification. [0057] Feature 46: The recycled material of feature 44, wherein the recycled material provides a toughening and/or a modifying of recycled co-polyesters or rPETGs to produce
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT a recycled, single layer card stock that will (1) thermally laminate to itself, (2) bond to printing inks and/or chips/antennae and/or (3) have sufficient physical properties to meet rigorous durability specifications such that can be used for articles or credit/bank cards. [0058] Feature 47: The recycled material of feature 46, wherein a level of modification is low enough to still be able to produce card stock coming from ≥ 85 % wt% recycled polymer. [0059] In one embodiment, the technology provides a method for processing a material based on recycled (industrial and ocean bound) PETg and/or other recycled co- polyester polymers to replace PVC in card stock and to provide desired performance attributes without requiring a coextrusion, the method comprising the steps of: (1) obtaining the material; and (2) adding one or more modifiers to the material, whereby an improved composition is produced. [0060] According to some aspects, the methods herein can be executed wherein the one or more modifiers comprise ethylene / acrylate copolymer. In some embodiments, the method can be executed wherein the one or more modifiers comprise ethylene / acrylate / glycidyl methacrylate terpolymer. [0061] In some embodiments, a method herein can be wherein a ratio of ethylene / acrylate / glycidyl methacrylate terpolymer to ethylene / acrylate copolymer is in the range from between about 1:2 and about 1:3 (wt/wt). According to some aspects, the method can be executed, wherein a ratio of ethylene / acrylate copolymer to ethylene / acrylate / glycidyl methacrylate terpolymer added is in the range from about (2-3) to 1 (wt/wt). [0062] The method can, according to some aspects, further include a step of extrusion at any stage or thereafter. For example, after the improved composition is produced it can be extruded to produce an article that could not be previously obtained by using a recycled plastic. For example, the improved composition may adhere to itself, whereas the starting material will not. [0063] As such, the technology can be, in some embodiments, directed to an improved composition produced by the method of any of the preceding methods or steps. Articles, consumables or packages comprising the improved composition(s) are contemplated herein.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [0064] For example, the improved composition can be as such wherein the composition can be printed, wherein the composition includes one or more requisite physical properties of PVC, wherein the composition is operative to adhere to embedded electronics, and/or wherein the improved composition of is operative to bond to itself during a subsequent processing. [0065] In some embodiments, the methods disclosed herein can be executed using about 1.0 (wt%) to about 3.0 (wt%) ethylene / acrylate (MA, EA, BA) / glycidyl methacrylate terpolymer. In some embodiments, the methods disclosed herein can be executed using from about 0.5 (wt%) to about 5.0 (wt%) ethylene / acrylate (MA, EA, BA) / glycidyl methacrylate terpolymer. In some embodiments, the methods disclosed herein can be executed using from about 0.1 (wt%) to about 10.0 (wt%) ethylene / acrylate (MA, EA, BA) / glycidyl methacrylate terpolymer. [0066] In some embodiments the methods disclosed herein can be executed using about 2.5 (wt%) to about 7.5 (wt%) ethylene / acrylate (MA, EA, BA) copolymer. In some embodiments, the methods disclosed herein can be executed using about 1.0 (wt%) to about 10.0 (wt%) ethylene / acrylate (MA, EA, BA) copolymer. In some embodiments, the methods disclosed herein can be executed using about 0.5 (wt%) to about 15.0 (wt%) ethylene / acrylate (MA, EA, BA) copolymer. [0067] In some examples, the modifier(s) can be purchased or pre-mixed before use in a process described herein. [0068] According to some aspects, a ratio of ethylene / acrylate / glycidyl methacrylate terpolymer to ethylene / acrylate copolymer can be in the range from about 1:2 to about 1:3. In some embodiments, the ratio can be in the range from about 1:1 to about 1:5. [0069] The technology disclosed herein, in some embodiments, provides a method for modifying a rPETG composition such that the modified rPETG is capable to bond to itself. The method provides, according to some aspects, wherein the modified rPETG can be printed upon (or, for example, used in 3D printing or other printing). In some embodiments, the method is configured such that the modified rPETG has requisite physical properties of PVC. According to some aspects, the modified rPETG is operative
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT to adhere to embedded electronics. In some embodiments, the technology is directed to a composition of a modified rPETG that is capable to bond to itself. [0070] According to some aspects, the modified rPETG can be printed upon using other compositions/chemicals. In some embodiments, the improved compositions disclosed herein include one or more properties of PVC. In some embodiments, the modified rPETG composition is operative to adhere to electronics embedded in the composition. [0071] It is contemplated that the technology disclosed herein can be applied to include other polymers in addition to rPETG. According to some aspects, the modified rPETG (or polymers) disclosed herein can be used in monolayer or in coextruded substrates. [0072] Any of the above embodiments can be, in some embodiments, wherein the method steps are executed in any order, one or more method steps are repeated, and/or additional method steps are added, or some method steps are removed. [0073] Any of the above embodiments can be executed as a continuous method executed for greater than 1 hour, greater than 4 hours, greater than 24 hours, or greater than a week. [0074] According to some aspects, a composition made by the method of any of the preceding paragraphs can be wherein the composition comprises > 10%, > 20%, > 30%, > 40%, > 50%, > 60%, > 70%, > 80%, > 90%, or > 95% recycled polymer, is disclosed herein. [0075] In some embodiments, the composition(s) can be bent, twisted, or deformed under a reasonable use without delaminating. [0076] According to some aspects, the methods disclosed herein can be wherein the order of the execution of the steps is changed, the method is repeated or wherein the method is executed as a continuous method in a scaled-up manufacturing process including rollers, cooling baths, 3D-printing, lithography, or any technique known in the art. [0077] This Brief Summary presents some embodiments as discussed above, while the conceptually large and full inventive concepts are explained and grasped by a study of the entire disclosure (e.g., Detailed Description, Drawings, Brief Summary, Abstract,
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT and the Exemplary Claims) along with current news on ocean bound plastics, plastic recycling attempts, and plastic microparticles/nanoparticles in the environment. These and other features and advantages will be apparent from a reading of the following detailed description and a review of the associated figure. It is to be understood that both the foregoing general description and the following detailed description are explanatory only and are not restrictive of aspects as claimed. BRIEF DESCRIPTION OF THE DRAWINGS [0078] The technology will be more fully understood by reference to the detailed description, in conjunction with the following figures. [0079] FIG.1 shows examples of resin identification codes (RIC) that have been developed since about 1988 by the Plastics Industry Association (PLASTICS), formerly known as the Society of the Plastics Industry, Inc (SPI), which began working with ASTM (formerly American Society for Testing and Materials, now known as ASTM International) indicating examples of product labels for: 01 PET(E), polyethylene terephthalate; e.g., polyester fibers, soft drink bottles, food containers, plastic bottles; 02 PEHD or HDPE, e.g., high-density polyethylene, plastic milk containers, plastic bags, bottle caps, trash cans, oil cans, plastic lumber, toolboxes, supplement containers; 03 PVC, polyvinyl chloride, e.g., bank cards, window frames, bottles for chemicals, flooring, plumbing pipes; 04 PELD or LDPE, low-density polyethylene, e.g., plastic bags, Ziploc® bags, buckets, squeeze bottles, plastic tubes, chopping boards; 05 PP, polypropylene, e.g., flower pots, bumpers, car interior trim, industrial fibers, carry-out beverage cups, microwavable food containers, DVD keep cases; 06 PS, polystyrene, e.g., toys, old video cassettes, ashtrays, trunks, beverage/food coolers, beer cups, wine and champagne cups, carry-out food containers, Styrofoam®; 07 O (other), all other (many) plastics, e.g., mixtures. It is important to note that the codes and symbols shown in FIG.1 are often shown using a closed triangle
5 instead of arrows; within the United States, each state has different requirements and there are no known federal regulations
6. In comparison, The People’s Republic of China has about 140 (not shown) resin codes
7, and the first 1-6 of the 140 are consistent with the RIC up to #6. Additional RIC codes have been proposed that are not shown in FIG.1.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [0080] FIG.2A is an example of a method showing steps of a method for modifying a recycled polymer or plastic into a recycled material for use in manufacturing of mono- layer (extruded) or multi-layer (coextruded) film/sheet products. [0081] FIG.2B is an example of a method for processing a material based on recycled (industrial or ocean bound) PETg or other recycled copolyester polymers, for example, to provide capability to replace PVC in card stock and to provide desired performance attributes without a coextrusion. Exemplary steps of (a) obtaining the starting material; (b) adding one or more modifiers to the material, whereby an improved composition is produced (c), are illustrated with one or more optional steps (a1,b1,c1, or d) at any stage (e.g., an extrusion). [0082] FIG.3A is a diagram showing example card structure, according to some aspects. [0083] FIG.3B is an example of an article or layered composition 200 including a core improved material 240, improved by the methods disclosed herein. The material can be comprising an exemplary rPETG produced by a method disclosed herein, for example, having requisite properties of PVC. The material can be utilized in monolayer or in coextruded substrates. In an example, the modified rPETG composition can have capability to be printed, can adhere to embedded electronics and can bond to itself in a thermal lamination as shown by 210, 220, 230, 250, 260, and 270; thereafter forming a single composite that can be bent and used (represented at 280) It should be understood that the arrows in FIG.3B at 280 are illustrative that the layered composition (e.g.,laminate) 200 can be bent and is durable without breaking or delaminating after being made into an article, for example when used in a pocket or as a bank/credit card. The various layers shown are optional and can be modified in number of layers, and as discussed below, can be applied in different order(s), repeatedly laminated, laminated backwards or in any order, or configured as a method for making the composition. The options are discussed in more detail, and the benefits of the recycling provided by composition 200 will next be discussed in more detail. [0084] FIG.4A illustrates a process for recycling PET polymer into a material that can substitute for PVC.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [0085] FIG.4B depicts the enhancement of PET polymer recycling through precise heating and copolymer integration. [0086] FIG.5 depicts example components of a Polymer Recycling System. [0087] FIG.6A illustrates details of the Heating Unit within the Polymer Recycling System (FIG.5). [0088] FIG.6B outlines the First Addition Unit's role in Polymer Recycling. [0089] FIG.6C shows the Second Addition Unit's function in Polymer Recycling. [0090] FIG.6D illustrates the Recycling Unit's process in reusing polymer materials. [0091] FIG.7A and FIG.7B show examples of experimental data for all mono-films, according to the embodiments of methods disclosed herein [0092] FIG.8A and FIG.8B show examples of experimental data for all rPETG films only, according to the embodiments of methods disclosed herein. DETAILED DESCRIPTION OF THE INVENTION [0093] The subject innovation is now described in more detail. In the following description, for purposes of explanation, specific details are set forth in order to provide an understanding of the present invention. It may be evident, however, that the present invention may be practiced without these specific details. In particular, it may become so evident after the conceptually large inventive concepts are grasped in a mind of a skilled operator/artisan. In other instances, the inventive concepts are described with embodiments to provide insights into the hope inspiring, pollution-saving benefits of the invention. [0094] It is to be appreciated that certain aspects, modes, embodiments, variations and features of the invention are described below in various levels of detail in order to provide a substantial understanding of the present invention. [0095] The following description of particular aspect(s) is merely exemplary in nature and is in no way intended to limit the scope of the invention, its application, or uses, which may, of course, vary. The invention is described with relation to the non-limiting definitions and terminology included herein. These definitions and terminology are not designed to function as a limitation on the scope or practice of the invention but are presented for illustrative and descriptive purposes only. While the compositions or processes are
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT described as using specific materials or an order of individual steps, it is appreciated that materials or steps may be interchangeable such that the description of the invention may include multiple parts or steps arranged in many ways as is readily appreciated by one of skill in the art. DEFINITIONS [0096] The definitions of certain terms as used in this specification and the appended claims are provided below. Unless defined otherwise, all technical and scientific terms used herein generally have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. [0097] As used in this specification and the appended claims, the singular forms "a," "an" and "the" include plural referents unless the content clearly dictates otherwise. For example, reference to "a cell" includes a combination of two or more cells, and the like. [0098] The term "approximately" or "about" in reference to a value or parameter are generally taken to include numbers that fall within a range of 5%, 10%, 15%, or 20% in either direction (greater than or less than) of the number unless otherwise stated or otherwise evident from the context (except where such number would be less than 0% or exceed 100% of a possible value). As used herein, reference to "approximately" or "about" a value or parameter includes (and describes) embodiments that are directed to that value or parameter. For example, description referring to "about X" includes description of "X". [0099] As used herein, the term “or” means “and/or.” The term "and/or" as used in a phrase such as "A and/or B" herein is intended to include both A and B; A or B; A (alone); and B (alone). Likewise, the term "and/or" as used in a phrase such as "A, B, and/or C" is intended to encompass each of the following embodiments: A, B, and C; A, B, or C; A or C; A or B; B or C; A and C; A and B; B and C; A (alone); B (alone); and C (alone). [00100] It is understood that wherever embodiments are described herein with the language "comprising" otherwise analogous embodiments described in terms of "consisting of" and/or "consisting essentially of" are also provided. It is also understood that wherever embodiments are described herein with the language "consisting essentially of" otherwise analogous embodiments described in terms of "consisting of" are also provided.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00101] It is to be appreciated that certain features of the invention which are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges include each and every value within that range. If a range is stated, all values within that range are subsumed as endpoints for new ranges to be cited. [00102] The term polyethylene terephthalate (PET) generally refers to: ,
code (RIC) as shown in FIG.1. [00103] The term polybutylene terephthalate (PBT) generally refers to: ,
[00104] The term "rPET” refers to recycled PET (polyethylene terephthalate) plastic. The term “rPETG” generally refers to a recycled, glycol modified version of polyethylene terephthalate (PETG, polyethylene terephthalate glycol or PET-G). A generalized, non- limiting, example of a structure of PETG is shown below:
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT .
refers to polyvinyl chloride:
the digit “3” as its RIC, for example, in FIG.1. [00106] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. POLYMER SOLVATES [00107] The present disclosure encompasses the preparation and use of solvates of polymers. Solvates typically do not significantly alter the properties or toxicity of the polymers, and as such may function as equivalents. The term "solvate" as used herein is a combination, physical association and/or solvation of a compound of the present disclosure with a solvent molecule such as, e.g., a disolvate, monosolvate or hemisolvate, where the ratio of solvent molecule to compound of the present disclosure is about 2:1,
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT about 1:1 or about 1:2, respectively. This physical association involves varying degrees of ionic and covalent bonding, including hydrogen bonding. In certain instances, the solvate can be isolated, such as when one or more solvent molecules are incorporated into the crystal lattice of a crystalline solid. Thus, "solvate" encompasses both solution- phase and isolatable solvates. One type of solvate is a hydrate. A "hydrate" relates to a particular subgroup of solvates where the solvent molecule is water. Solvates typically can function as equivalents. Preparation of solvates is known in the art. For example, a polymer is dissolved in water and methanol (or other solvent), dried, and the resulting O- H stretch (from the formation of the solvate/hydrate) is confirmed by an ATR-IR measurement. The O-H stretch is not found in the non-solvate/hydrate form, quickly confirming the formation of the solvate/hydrate in the solid form by the ATR-IR measurement. In some embodiments, the polymers and methods disclosed herein refer to an amorphous product. In some embodiments, the polymers and methods disclosed herein result in a semi-crystalline or crystalline product. [00108] In particular referral to the Definitions used herein, a “small molecule” refers to a chemical that has a molecular weight of 1000 or less in a free form (i.e., as measured in a non-salt form). A reference to a “large molecule” refers to a molecular weight of greater than 1000. DETAILED EXAMPLES OF MOVING AWAY FROM FIRST-USE PVC AS A SUBSTRATE TO MORE GLOBALLY SUSTAINABLE METHODS [00109] There is a desire to move away from PVC as a substrate for card stock used in making bank/credit cards as well as security/ID cards, as well as its use in other articles. One preferred alternative is to use recycled polyester as the source of the card stock. In some embodiments, these bank cards are a single layer with or without an embedded microchip. In some embodiments, the bank cards are multiple layers (some of which are printed) which are heat laminated together and sometime have antennae or chips embedded into or sealed between the layers. As a nonlimiting example, some basic requirements for replacing PVC are that the various layers need to be able to bond to themselves, printing inks, and chips/antennae under thermal laminating conditions. The final card structure (several layers bonded together) needs to have physical properties (tensile, ductility, impact, 280, FIG.3B) and bond strength between layers to meet
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT rigorous specifications (e.g., FIG.3A) including, for example, an optional laminated structure. First-use PVC currently fulfills these requirements, but more sustainable methods are disclosed herein. In some embodiments, the technology can be directed to recycling of ocean bound PET. [00110] In a description of the details that can be included in parameters of the technology disclosed herein the following discussion points, each with optional details described, can be interchanged with any aspect, embodiment, feature, or example disclosed herein: [00111] Discussion point 1: An example method for modifying a recycled polymer or plastic into a recycled material for use in manufacturing of mono-layer (extruded) or multi- layer (coextruded) film/sheet products, the method comprising the steps of: (1) obtaining a starting material including a polymer for recycling, wherein the starting material is optionally sourced from post-consumer waste, post-industrial waste, or a combination thereof, and wherein the starting material is optionally sorted, cleaned, and processed to remove contaminants and impurities, and wherein the starting material optionally has a particle size between 0.1 and 10 mm, a bulk density between 0.2 and 1.0 g/cm3, and a moisture content below 1 wt%; (2) heating the starting material to a temperature optionally between 150°C and 300°C in a separate, prior melt compounding process step and/or a melt extrusion process step, wherein the heating is optionally performed under an inert atmosphere to prevent oxidative degradation of the starting material, and wherein the heating is optionally performed for a residence time between 30 seconds and 30 minutes, at a pressure between 0.1 and 10 MPa, and a shear rate between 10 and 1000 s-1; (3) adding 1 or more modifiers, prior to the melt extrusion process step, including ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer to the starting material to produce a material based on recycled polymer or plastic, wherein the modifiers are optionally added in an amount ranging from 0.1 to 40 wt% based on the total weight of the modified recycled material, and wherein the modifiers are optionally mixed with the starting material to achieve a homogeneous distribution with a mixing energy between 0.01 and 1 kWh/kg; and whereby the modified recycled material can displace use of PVC (first-use or recycled) or other first-use polymers or plastic in producing extruded film or sheet
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT products or molded goods, and wherein the modified recycled material optionally has improved mechanical properties, processability, and compatibility with other polymers compared to the starting material, and optionally reduced environmental impact compared to first-use polymers or plastic, and wherein the modified recycled material optionally has a melt flow index between 0.1 and 100 g/10 min (190°C/2.16 kg), a density between 0.8 and 1.4 g/cm3, a tensile strength between 10 and 100 MPa, an elongation at break between 1 and 1000%, a flexural modulus between 0.1 and 10 GPa, an Izod impact strength between 10 and 1000 J/m, and a Vicat softening temperature between 50 and 200°C. [00112] Discussion point 2: The method of discussion point 1, wherein the starting material optionally comprises rPETG (a recycled polyethylene terephthalate glycol), PLA (polylactic acid), PHA (polyhydroxyalkanoate), PEF (polyethylene furanoate), PPT (polypropylene terephthalate), other recycled copolyesters, recycled APET (amorphous polyethylene terephthalate), recycled PET (polyethylene terephthalate), recycled PP (polypropylene), recycled PE (polyethylene), recycled PS (polystyrene), recycled PVC (polyvinyl chloride), recycled PU (polyurethane), recycled PA (polyamide), recycled PC (polycarbonate), recycled PBT (polybutylene terephthalate), recycled PTT (polytrimethylene terephthalate), recycled PEN (polyethylene naphthalate), recycled PEI (polyetherimide), recycled PES (polyethersulfone), recycled PEEK (polyether- etherketone), or a combination thereof, and wherein the starting material optionally has a melt flow index between 0.1 and 100 g/10 min (190°C/2.16 kg), a density between 0.8 and 1.4 g/cm3, a tensile strength between 10 and 100 MPa, an elongation at break between 1 and 1000%, a flexural modulus between 0.1 and 10 GPa, an Izod impact strength between 10 and 1000 J/m, and a Vicat softening temperature between 50 and 200°C. [00113] Discussion point 3: The method of discussion point 1, wherein the one or more modifiers optionally comprise ethylene/acrylate copolymer with an acrylate content between 1 and 40 wt%, ethylene/acrylate/glycidyl methacrylate terpolymer with an acrylate content between 1 and 40 wt% and a glycidyl methacrylate content between 0.1 and 12 wt%, ethylene/glycidyl methacrylate copolymer with a glycidyl methacrylate content between 0.1 and 12 wt%, or a combination thereof, and wherein the modifiers
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT optionally have a melt flow index between 0.1 and 100 g/10 min (190°C/2.16 kg), a density between 0.85 and 0.98 g/cm3, a melting temperature between 60 and 120°C, a glass transition temperature between -60 and 60°C, a tensile strength between 5 and 50 MPa, an elongation at break between 50 and 2000%, a flexural modulus between 0.01 and 2 GPa, and a Vicat softening temperature between 40 and 100°C. [00114] Discussion point 4: The method of discussion point 1, further comprising heating the starting material to a temperature optionally between 180°C and 270°C prior to adding the one or more modifiers, wherein the heating time optionally ranges from 30 seconds to 30 minutes, at a pressure between 0.1 and 10 MPa, and a shear rate between 10 and 1000 s-1, and wherein the heating is optionally performed under an inert atmosphere of nitrogen, carbon dioxide, or a combination thereof, with an oxygen content below 1 vol%. [00115] Discussion point 5: The method of discussion point 4, wherein the heating is optionally performed in a separate, prior melt compounding process step using a twin- screw extruder, a kneader, or a Banbury mixer, or in a melt extrusion process using a single-screw or twin-screw extruder, or a combination thereof, and wherein the heating is optionally performed with a specific mechanical energy input between 0.05 and 1 kWh/kg, a residence time between 30 seconds and 30 minutes, and a screw speed between 50 and 500 rpm. [00116] Discussion point 6: The method of discussion point 1, wherein adding the one or more modifiers is optionally performed prior to a melt extrusion process step, and wherein the modifiers are optionally added in solid form, as a masterbatch, or as a liquid or molten feed, and wherein the modifiers are optionally mixed with the starting material using a gravimetric or volumetric feeder, a side-arm extruder, or an injection system, and wherein the modifiers are optionally added continuously or intermittently, at a constant or variable rate, and wherein the modifiers are optionally added at a feed rate between 0.1 and 1000 kg/h. [00117] Discussion point 7: The method of discussion point 1, wherein the modified recycled material is optionally used in manufacturing monolayer extruded film or sheet products with a thickness between 10 and 2000 micrometers, and wherein the film or sheet products are optionally produced by cast film extrusion, blown film extrusion, or
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT sheet extrusion, and wherein the film or sheet products optionally have a tensile strength between 10 and 100 MPa, an elongation at break between 50 and 1000%, a tear strength between 1 and 100 N, a puncture resistance between 1 and 100 N, an oxygen permeability between 1 and 10000 cm3/m2/day/atm, a water vapor permeability between 1 and 10000 g/m2/day, and an optical haze between 0.1 and 50%. [00118] Discussion point 8: The method of discussion point 1, wherein the modified recycled material is optionally used in manufacturing multi-layer coextruded film or sheet products comprising 2 to 11 layers, with a total thickness between 10 and 2000 micrometers, and wherein the film or sheet products are optionally produced by cast coextrusion, blown film coextrusion, or sheet coextrusion, and wherein the film or sheet products optionally have a tensile strength between 10 and 100 MPa, an elongation at break between 50 and 1000%, a tear strength between 1 and 100 N, a puncture resistance between 1 and 100 N, an oxygen permeability between 1 and 10000 cm3/m2/day/atm, a water vapor permeability between 1 and 10000 g/m2/day, an optical haze between 0.1 and 50%, and an interlayer adhesion strength between 0.1 and 10 N/mm. [00119] Discussion point 9: The method of discussion point 1, wherein the modified recycled material displaces use of first-use PVC in producing extruded film or sheet products or molded goods, and wherein the displacement ratio optionally ranges from 1:1 to 1:100 by weight of the modified recycled material to the first-use PVC, and wherein the modified recycled material optionally has a lower density, a higher tensile strength, a higher elongation at break, a higher impact strength, a higher glass transition temperature, a higher Vicat softening temperature, a lower oxygen permeability, a lower water vapor permeability, a lower flammability, a lower smoke generation, and a lower toxicity compared to the first-use PVC. [00120] Discussion point 10: The method of discussion point 1, wherein the modified recycled material optionally displaces use of recycled PVC in producing extruded film or sheet products or molded goods, and wherein the displacement ratio optionally ranges from 1:1 to 1:100 by weight of the modified recycled material to the recycled PVC, and wherein the modified recycled material optionally has a lower density, a higher tensile strength, a higher elongation at break, a higher impact strength, a higher glass transition
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT temperature, a higher Vicat softening temperature, a lower oxygen permeability, a lower water vapor permeability, a lower flammability, a lower smoke generation, and a lower toxicity compared to the recycled PVC. [00121] Discussion point 11: The method of discussion point 1, wherein the modified recycled material displaces use of other first-use polymers or plastic, including PET, PP, PE, PS, PU, PA, PC, PBT, PTT, PEN, PEI, PES, or PEEK, in producing extruded film or sheet products or molded goods, and wherein the displacement ratio optionally ranges from 1:1 to 1:100 by weight of the modified recycled material to the other first-use polymers or plastic, and wherein the modified recycled material optionally has a lower density, a higher tensile strength, a higher elongation at break, a higher impact strength, a higher glass transition temperature, a higher Vicat softening temperature, a lower oxygen permeability, a lower water vapor permeability, a lower flammability, a lower smoke generation, and a lower toxicity compared to the other first-use polymers or plastic. [00122] Discussion point 12: The method of discussion point 1, wherein the starting material optionally comprises substantially recycled polyesters or a combination thereof, and wherein the recycled polyesters are optionally sourced from post-consumer or post- industrial waste streams, including bottles, containers, packaging, fibers, or fabrics, and wherein the recycled polyesters optionally have an intrinsic viscosity between 0.4 and 1.2 dL/g, a density between 1.0 and 1.5 g/cm3, a melting temperature between 200 and 300°C, a glass transition temperature between 50 and 100°C, a tensile strength between 30 and 80 MPa, an elongation at break between 1 and 500%, a flexural modulus between 1 and 5 GPa, an Izod impact strength between 10 and 100 J/m, and a Vicat softening temperature between 50 and 200°C. [00123] Discussion point 13: The method of discussion point 1, wherein the modifier optionally includes ethylene/acrylate/glycidyl methacrylate terpolymer where the glycidyl methacrylate comonomer content is optionally 1-8 wt%, the acrylate comonomer content is optionally 0-40 wt%, and the ethylene comonomer content is optionally 52-99 wt%, and wherein the terpolymer optionally has a melt flow index between 0.1 and 100 g/10 min (190°C/2.16 kg), a density between 0.85 and 0.98 g/cm3, a melting temperature between 60 and 120°C, a glass transition temperature between -60 and 60°C, a tensile strength between 5 and 50 MPa, an elongation at break between 50 and 2000%, a flexural
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT modulus between 0.01 and 2 GPa, and a Vicat softening temperature between 40 and 100°C. [00124] Discussion point 14: The method of discussion point 1, wherein the modified recycled material optionally has improved mechanical properties compared to the starting material, including increased tensile strength, flexural strength, impact strength, or elongation at break, and wherein the improvement optionally ranges from 1 to 100% relative to the starting material, and wherein the modified recycled material optionally has a tensile strength between 10 and 100 MPa, an elongation at break between 1 and 1000%, a flexural modulus between 0.1 and 10 GPa, an Izod impact strength between 10 and 1000 J/m, and a Vicat softening temperature between 50 and 200°C. [00125] Discussion point 15: The method of discussion point 1, wherein the modified recycled material optionally has improved processability compared to the starting material, including increased melt flow index, decreased viscosity, improved melt stability, or reduced die pressure during extrusion, and wherein the improvement optionally ranges from 1 to 100% relative to the starting material, and wherein the modified recycled material optionally has a melt flow index between 0.1 and 100 g/10 min (190°C/2.16 kg), a melt viscosity between 100 and 10000 Pa·s (190°C, 100 s-1), a melt stability characterized by a change in melt viscosity of less than 20% after 30 minutes at 190°C, and a die pressure between 1 and 50 MPa during extrusion. [00126] Discussion point 16: The method of discussion point 1, wherein the modified recycled material optionally has improved compatibility with other polymers compared to the starting material, including improved adhesion, miscibility, or interfacial strength when blended or coextruded with other polymers, and wherein the improvement optionally ranges from 1 to 100% relative to the starting material, and wherein the modified recycled material optionally has an interfacial adhesion strength between 0.1 and 10 N/mm, a phase domain size between 10 and 1000 nm, and a storage modulus between 0.1 and 10 GPa when blended or coextruded with other polymers. [00127] Discussion point 17: The method of discussion point 1, wherein the modified recycled material has reduced environmental impact compared to first-use polymers or plastic, including reduced carbon footprint, energy consumption, water usage, or greenhouse gas emissions during production, and wherein the reduction optionally
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT ranges from 1 to 100% relative to the first-use polymers or plastic, and wherein the modified recycled material optionally has a carbon footprint between 0.1 and 10 kg CO2 equivalent per kg of material, an embodied energy between 1 and 100 MJ per kg of material, a water footprint between 1 and 1000 liters per kg of material, and a greenhouse gas emission between 0.1 and 10 kg CO2 equivalent per kg of material. [00128] Discussion point 18: A recycled material which is optionally capable to be printed and/or thermally laminated to itself comprising a recycled polymer optionally selected from rPETG, PLA, PHA, PEF, PPT, other recycled copolyesters, recycled APET, recycled PET, recycled PP, recycled PE, recycled PS, recycled PVC, recycled PU, recycled PA, recycled PC, recycled PBT, recycled PTT, recycled PEN , recycled PEI, recycled PES, recycled PEEK, or a combination thereof, and a modifier optionally selected from ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer in an amount optionally ranging from 0.1 to 40 wt% based on the total weight of the recycled material; wherein the recycled material is optionally operative to displace use of a first-use polymer or plastic in producing products at a displacement ratio optionally ranging from 1:1 to 1:100 by weight of the recycled material to the first-use polymer or plastic; and wherein the material is optionally made by the method of discussion point 1, and wherein the recycled material optionally has a melt flow index between 0.1 and 100 g/10 min (190°C/2.16 kg), a density between 0.8 and 1.4 g/cm3, a tensile strength between 10 and 100 MPa, an elongation at break between 1 and 1000%, a flexural modulus between 0.1 and 10 GPa, an Izod impact strength between 10 and 1000 J/m, and a Vicat softening temperature between 50 and 200°C. [00129] Discussion point 19: An extruded film or sheet product comprising the recycled material of discussion point 18, wherein the film or sheet product optionally has a thickness between 10 and 2000 micrometers, and wherein the film or sheet product is optionally a monolayer or a multi-layer product comprising 2 to 11 layers, and wherein the film or sheet product is optionally produced by cast film extrusion, blown film extrusion, cast sheet extrusion, or blown sheet extrusion, and wherein the film or sheet product optionally has a tensile strength between 10 and 100 MPa, an elongation at break between 50 and 1000%, a tear strength between 1 and 100 N, a puncture resistance
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT between 1 and 100 N, an oxygen permeability between 1 and 10000 cm3/m2/day/atm, a water vapor permeability between 1 and 10000 g/m2/day, an optical haze between 0.1 and 50%, and an interlayer adhesion strength between 0.1 and 10 N/mm. [00130] Discussion point 20: A molded good comprising the recycled material of discussion point 18, wherein the molded good is optionally produced by injection molding, blow molding, rotational molding, or compression molding, and wherein the molded good optionally has a tensile strength between 10 and 100 MPa, an elongation at break between 1 and 1000%, a flexural modulus between 0.1 and 10 GPa, an Izod impact strength between 10 and 1000 J/m, a Vicat softening temperature between 50 and 200°C, a heat deflection temperature between 30 and 150°C, and a surface roughness between 0.01 and 10 micrometers, and wherein the molded good optionally has a wall thickness between 0.1 and 10 mm, a weight between 1 and 1000 grams, and a volume between 1 and 1000 cm3. [00131] Discussion point 21: The recycled material of discussion point 18, wherein the recycled material is operative to displace use of first-use PVC (polyvinyl chloride) in producing products at a displacement ratio optionally ranging from 1:1 to 1:100 by weight of the recycled material to the first-use PVC, and wherein the products optionally include extruded film or sheet products, molded goods, pipes, tubes, fittings, profiles, siding, wire and cable insulation, flooring, roofing membranes, or geomembranes, and wherein the recycled material optionally has a lower density, a higher tensile strength, a higher elongation at break, a higher impact strength, a higher glass transition temperature, a higher Vicat softening temperature, a lower oxygen permeability, a lower water vapor permeability, a lower flammability, a lower smoke generation, and a lower toxicity compared to the first-use PVC. [00132] Discussion point 22: The recycled material of discussion point 18, wherein the modifier optionally includes ethylene/acrylate/glycidyl methacrylate terpolymer where the glycidyl methacrylate comonomer content is optionally 1-8 wt%, the acrylate comonomer content is optionally 0-40 wt%, and the ethylene comonomer content is optionally 52-99 wt%, and wherein the terpolymer optionally has a melt flow index between 0.1 and 100 g/10 min (190°C/2.16 kg), a density between 0.85 and 0.98 g/cm3, a melting temperature between 60 and 120°C, a glass transition temperature between -
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT 60 and 60°C, a tensile strength between 5 and 50 MPa, an elongation at break between 50 and 2000%, a flexural modulus between 0.01 and 2 GPa, and a Vicat softening temperature between 40 and 100°C. [00133] The detailed description can, for example, begin with the foregoing points for discussion and thought. While the foregoing discussion points can be inter-changed with any example, aspect, embodiment, and/or feature herein; additional considerations of the details of the Invention can be considered in the spirit of the features, embodiments, aspects, and examples of the Invention. [00134] In some embodiments, the techniques described herein relate to a method for modifying a recycled polymer or plastic into a recycled material for use in manufacturing of mono-layer (extruded) or multi-layer (coextruded) film/sheet products, the method including the steps of: (1) obtaining a starting material including a polymer for recycling; (2) heating the starting material (in separate, prior melt compounding process step and/or melt extrusion process); (3) adding 1 or more modifiers, prior to melt extrusion process step, including ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer to the starting material to produce a material based on recycled polymer or plastic; and whereby the modified recycled material can displace use of PVC (first-use or recycled) or other first- use polymers or plastic in producing extruded film or sheet products or molded goods. [00135] According to some aspects, the techniques described herein relate to a recycled material which is capable to be printed and/or thermally laminated to itself including a recycled polymer, and a modifier including ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer; wherein the recycled material is operative to displace use of a first-use polymer or plastic in producing products. [00136] In some embodiments, the techniques described herein relate to a method for recycling a polymer or plastic into a recycled material for use in manufacturing of products, the method including the steps of: (1) obtaining a starting material including a polymer or plastic for recycling; (2) heating the starting material; (3) adding a modifier including ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer to the starting material; and
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT whereby the recycled material can displace use of a first-use polymer or plastic in producing products. [00137] According to some aspects, the techniques described herein relate to a method, wherein the starting material includes PET (polyethylene terephthalate). [00138] According to some embodiments, the techniques described herein relate to a method, wherein the recycled material is operative to displace use of first-use PVC (polyvinyl chloride) in producing products. [00139] In some embodiments, the techniques described herein relate to a method, wherein the recycled material is operative to provide a thermal lamination to itself or is operative to thermal lamination to itself in an equipment that is designed for a PVC molding. [00140] According to some aspects, the techniques described herein relate to a method, wherein the recycled material is operative to be durably printed with an ink, with a metal, with a polymer, with an electronic, with a semi-conductor, or with a pattern. [00141] According to some embodiments, the techniques described herein relate to a method, wherein the recycled material includes an amorphous solid-state operative to provide a transparency, a semi-crystalline solid state, a semi-crystalline particle size less than 500 nm, or a semi-crystalline particle size greater than 500 nm operative to provide an opaque or a translucent appearance. [00142] In some embodiments, the techniques described herein relate to a method, wherein the acrylate in step (3) includes an acrylate comonomer including EA (ethyl acrylate), MA (methyl acrylate), or BA (butyl acrylate). [00143] According to some aspects, the techniques described herein relate to a method, wherein the acrylate comonomer utilized is ≤ 40 wt% with 100 wt% being the weight of the modifier. [00144] According to some embodiments, the techniques described herein relate to a method, wherein the acrylate comonomer is 9-40 wt%. [00145] In some embodiments, the techniques described herein relate to a method, wherein the modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer and/or ≤ 20 wt% ethylene/acrylate copolymer.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00146] According to some aspects, the techniques described herein relate to a method, wherein the modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer and/or 2-20 wt% ethylene/acrylate copolymer. [00147] According to some embodiments, the techniques described herein relate to a method, wherein the modifier includes 1-4 wt% ethylene/acrylate/glycidyl methacrylate terpolymer and 2-10 wt% ethylene/acrylate copolymer. [00148] In some embodiments, the techniques described herein relate to a method, wherein the ratio of ethylene/acrylate copolymer to ethylene/acrylate/glycidyl methacrylate terpolymer being in the range of 2:1 to 4:1. [00149] According to some aspects, the techniques described herein relate to a method, wherein the levels of modifier added are in the range of ≤ 6 wt%. [00150] According to some embodiments, the techniques described herein relate to a method, wherein the starting material includes rPETG (a recycled, glycol modified version of polyethylene terephthalate) or rPET (a recycled PET). [00151] In some embodiments, the techniques described herein relate to a method, further including adding ≤ 10 wt% TiO2, other pigments, mineral fillers, or additives before step (2), before step (3), or after step (3). [00152] According to some aspects, the techniques described herein relate to a method, wherein the recycled material is operative to provide a monolayer card stock substrate suitable for making a bank card product. [00153] According to some embodiments, the techniques described herein relate to a method, wherein the thickness of the card stock substrate is in a range of about 76.2 µm to about 635 µm or about 3-25 mils (0.003-0.025 inches). [00154] In some embodiments, the techniques described herein relate to a method, wherein the thickness is about 152.4 µm to about 304.8 µm or about 6-12 mils (0.006- 0.012 inches). [00155] According to some aspects, the techniques described herein relate to a method, further including forming a core layer from the recycled material, and/or further including forming a core layer from the recycled material wherein the thickness of the core layer is about 127 µm to about 304.8 µm or about 5-12 mils (0.005-0.012 inches).
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00156] According to some embodiments, the techniques described herein relate to a method, wherein the thickness is about 127 µm to about 203.2 µm or about 5-8 mils (0.005-0.008 inches). [00157] In some embodiments, the techniques described herein relate to a method, further including forming a skin layer on one or more sides of the core layer, to provide an A/B card stock substrate or an A/B/A card stock substrate. [00158] According to some aspects, the techniques described herein relate to a method, wherein one skin layer includes a thickness in the range from about 12.7 µm to about 101.6 µm or 0.5-4 mils (0.0005-0.004 inches). [00159] According to some embodiments, the techniques described herein relate to a method, wherein the skin layer includes a thickness in the range from about 25.4 µm to about 50.8 µm or 1-2 mils (0.001-0.002 inches). [00160] In some embodiments, the techniques described herein relate to a method, wherein the recycled material is suitable to displace first-use PET in producing a product with the recycled material including ≥ 90 wt% of the total core polymer (first-use PET + recycled material) in the product. [00161] According to some aspects, the techniques described herein relate to a method, wherein the starting material includes an ocean bound rPET and wherein the recycled material is suitable for used in coextruded card structures with recycled materal from ocean bound rPET in the core surrounded by modified rPETG skin layers which are operative for thermal lamination of multiple layers of card stock. [00162] According to some embodiments, the techniques described herein relate to a method, further including the rPET core has a sufficient modification to improve physical properties so that the rPETG skin layers do not require a modification. [00163] In some embodiments, the techniques described herein relate to a method, wherein the method provides a toughening and/or a modifying of recycled co-polyesters or rPETGs to produce a recycled, single layer card stock that will (1) thermally laminate to itself, (2) bond to printing inks and/or chips/antennae and/or (3) have sufficient physical properties to meet rigorous durability specifications such that can be used for articles or credit/bank cards.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00164] According to some aspects, the techniques described herein relate to a method, wherein a level of modification is low enough to still be able to produce card stock coming from ≥ 90% wt% recycled polymer. [00165] According to some embodiments, the techniques described herein relate to a method, wherein the recycled material is extruded and/or cut into cooled pellets suitable for a distribution or a sale of the recycled material. [00166] In some embodiments, the techniques described herein relate to a recycled material which is capable to be printed and/or thermally laminated to itself including a recycled polymer or plastic, and a modifier including ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer; wherein the recycled material is operative to displace use of a first-use polymer or plastic in producing products. [00167] According to some aspects, the techniques described herein relate to a recycled material, wherein the recycled material is in a form of a monolayer card stock substrate. [00168] According to some embodiments, the techniques described herein relate to a recycled material, wherein the recycled polymer or plastic includes PET (polyethylene terephthalate). [00169] In some embodiments, the techniques described herein relate to a recycled material, wherein the recycled material is operative to displace use of first-use PVC (polyvinyl chloride) in producing products. [00170] According to some aspects, the techniques described herein relate to a recycled material, wherein the recycled material is operative to provide a thermal lamination to itself or is operative to thermal lamination to itself in an equipment that is designed for a PVC molding. [00171] According to some embodiments, the techniques described herein relate to a recycled material, wherein the recycled material is operative to be durably printed with an ink, with a metal, with a polymer, with an electronic, with a semi-conductor, or with a pattern. [00172] In some embodiments, the techniques described herein relate to a recycled material, wherein the recycled material includes an amorphous solid-state operative to
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT provide a transparency, a semi-crystalline solid state, a semi-crystalline particle size less than 500 nm, or a semi-crystalline particle size greater than 500 nm operative to provide an opaque or a translucent appearance. [00173] According to some aspects, the techniques described herein relate to a recycled material, wherein the acrylate includes an acrylate comonomer including EA (ethyl acrylate), MA (methyl acrylate), or BA (butyl acrylate). [00174] According to some embodiments, the techniques described herein relate to a recycled material, wherein the acrylate comonomer utilized is ≤ 40 wt% with 100 wt% being the weight of the modifier. [00175] In some embodiments, the techniques described herein relate to a recycled material, wherein the acrylate comonomer is 9-40 wt%. [00176] According to some aspects, the techniques described herein relate to a recycled material, wherein the modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer and/or ≤ 20 wt% ethylene/acrylate copolymer. [00177] According to some embodiments, the techniques described herein relate to a recycled material, wherein the modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer and/or 2-20 wt% ethylene/acrylate copolymer. [00178] In some embodiments, the techniques described herein relate to a recycled material, wherein the modifier includes 1-4 wt% ethylene/acrylate/glycidyl methacrylate terpolymer and 2-10 wt% ethylene/acrylate copolymer. [00179] According to some aspects, the techniques described herein relate to a recycled material, wherein the ratio of ethylene/acrylate copolymer to ethylene/acrylate/glycidyl methacrylate terpolymer being in the range of 2:1 to 4:1. [00180] According to some embodiments, the techniques described herein relate to a recycled material, wherein the levels of modifier added are in the range of ≤ 6 wt%. [00181] In some embodiments, the techniques described herein relate to a recycled material, wherein the starting material includes rPETG (a recycled, glycol modified version of polyethylene terephthalate) or rPET (a recycled PET). [00182] According to some aspects, the techniques described herein relate to a recycled material, further including adding ≤ 10 wt% TiO2, other pigments, mineral fillers, or additives before step (2), before step (3), or after step (3).
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00183] According to some embodiments, the techniques described herein relate to a recycled material, wherein the recycled material is operative to provide a monolayer card stock substrate suitable for making a bank card product. [00184] In some embodiments, the techniques described herein relate to a recycled material, wherein the thickness of the card stock substrate is in a range of about 76.2 µm to about 635 µm or about 3-25 mils (0.003-0.025 inches). [00185] According to some aspects, the techniques described herein relate to a recycled material, wherein the thickness is about 152.4 µm to about 304.8 µm or about 6-12 mils (0.006-0.012 inches). [00186] According to some embodiments, the techniques described herein relate to a recycled material, further including a form of a core layer from the recycled material, and/or further including a core layer formed from the recycled material wherein the thickness of the core layer is about 127 µm to about 304.8 µm or about 5-12 mils (0.005- 0.012 inches). [00187] In some embodiments, the techniques described herein relate to a recycled material, wherein the thickness is about 127 µm to about 203.2 µm or about 5-8 mils (0.005-0.008 inches). [00188] According to some aspects, the techniques described herein relate to a recycled material, further including forming a skin layer on one or more sides of the core layer, to provide an A/B card stock substrate or an A/B/A card stock substrate. [00189] According to some embodiments, the techniques described herein relate to a recycled material, wherein one skin layer includes a thickness in the range from about 12.7 µm to about 101.6 µm or 0.5-4 mils (0.0005-0.004 inches). [00190] In some embodiments, the techniques described herein relate to a recycled material, wherein the skin layer includes a thickness in the range from about 25.4 µm to about 50.8 µm or 1-2 mils (0.001-0.002 inches). [00191] According to some aspects, the techniques described herein relate to a recycled material, wherein the recycled material is suitable to displace first-use PET in producing a product with the recycled material including ≥ 90 wt% of the total core polymer (first-use PET + recycled material) in the product.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00192] According to some embodiments, the techniques described herein relate to a recycled material, wherein the starting material includes an ocean bound rPET and wherein the recycled material is suitable for used in coextruded card structures with recycled materal from ocean bound rPET in the core surrounded by modified rPETG skin layers which are operative for thermal lamination of multiple layers of card stock. [00193] In some embodiments, the techniques described herein relate to a recycled material, further including the rPET core has a sufficient modification to improve physical properties so that the rPETG skin layers do not require a modification. [00194] According to some aspects, the techniques described herein relate to a recycled material, wherein the recycled material provides a toughening and/or a modifying of recycled co-polyesters or rPETGs to produce a recycled, single layer card stock that will (1) thermally laminate to itself, (2) bond to printing inks and/or chips/antennae and/or (3) have sufficient physical properties to meet rigorous durability specifications such that can be used for articles or credit/bank cards. [00195] According to some embodiments, the techniques described herein relate to a recycled material, wherein a level of modification is low enough to still be able to produce card stock coming from ≥ 90% wt% recycled polymer. [00196] In some embodiments, the techniques described herein relate to a recycled material, wherein the recycled material is extruded and/or cut into cooled pellets suitable for a distribution or a sale of the recycled material. [00197] According to some aspects, the techniques described herein relate to a method for processing a material with a starting material including a recycled polymer, an ocean bound polymer, a PETg, or a recycled copolyester polymer to replace PVC in card stock and to provide desired performance attributes without a coextrusion, the method including the steps of: (1) obtaining the starting material; and (2) adding a modifier to the starting material, whereby an improved composition is produced; wherein the modifier includes ethylene / acrylate copolymer, ethylene / acrylate / glycidyl methacrylate terpolymer, or a combination thereof. [00198] According to some embodiments, the techniques described herein relate to a method, wherein a ratio of ethylene / acrylate / glycidyl methacrylate terpolymer to
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT ethylene / acrylate copolymer is in the range from between about 1:2 and about 1:3 (wt/wt). [00199] In some embodiments, the techniques described herein relate to a method, wherein a ratio of ethylene / acrylate copolymer to ethylene / acrylate / glycidyl methacrylate terpolymer added is in the range from about (2-3) to 1 (wt/wt). [00200] According to some aspects, the techniques described herein relate to a method further including a step of extrusion. [00201] According to some embodiments, the techniques described herein relate to a method, wherein the improved composition includes one or more physical properties of first-use PVC. [00202] In some embodiments, the techniques described herein relate to a method, wherein the improved composition is operative to adhere to embedded electronics, is operative to bond to itself during a subsequent processing, or is operative to be printed. [00203] In some embodiments, the technology disclosed herein can utilize methods developed for toughening semicrystalline polyesters, such as PET, PBT and rPET, and applying such methods to toughen/modify recycled copolyesters (rPETG). In an embodiment, the technology can provide a material based on recycled (industrial and ocean bound) PETg (and other recycled copolyester polymers) to replace PVC in card stock and provide desired performance attributes without requiring coextrusion. Examples of those attributes being: durability (e.g., impact, flex fatigue, bending at 280, FIG.3); printability (e.g., adhesion to ink); ability to adhere to embedded electronics (e.g., antenna and computer chips); and/or to bond to itself during a thermal lamination (e.g., FIG.3). [00204] The materials disclosed herein can be utilized in monolayer or in coextruded substrates. Currently, recycling of ocean bound plastics is limited in that the recovered plastics do not perform, for example, as a first-use PVC can (or a first-use plastic). A major global problem is to develop a material based on recycled (industrial and ocean bound) PETg (and other recycled copolyester polymers) to replace PVC in card stock and provide desired performance attributes without requiring a coextrusion. The exemplary methods disclosed herein overcome these limitations and open the doors to more extensive use of recycled polymers, solving the problem.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00205] In some examples of previous limitations, modified rPET has the physical properties and durability but requires coextrusion as a core layer skin layer(s) of PETg (or rPETG). Current sources rPETG can be printed, bond to embedded electronics but rPETG does not have strength/durability required for card stock application. The technology disclosed herein can provide a modified rPETG composition which does have the requisite physical properties that PVC has, as well as being able to be printed, adhere to embedded electronics and bond to itself in thermal lamination. [00206] In an embodiment, the technology provides a method for processing a material based on recycled (industrial and ocean bound) PETg and other recycled co- polyester polymers to replace PVC in card stock and to provide desired performance attributes without a coextrusion, the method comprising the steps of: (1) obtaining the material; and (2) adding one or more modifiers to the material, whereby an improved composition is produced. [00207] According to some aspects, the method can be executed wherein the one or more modifiers comprise ethylene / acrylate copolymer. In some embodiments, the method can be executed wherein the one or more modifiers comprise ethylene / acrylate / glycidyl methacrylate terpolymer. In some embodiments, these modifiers are utilized in ratios, in specific ways or using skilled operations. [00208] In the various ranges discussed for executing the following methods, endpoints can be derived from within the exemplary ranges. In some embodiments, the method can be wherein a ratio of ethylene / acrylate / glycidyl methacrylate terpolymer to ethylene / acrylate copolymer is in the range from between about 1:2 and about 1:3 (wt/wt). According to some aspects, the method can be executed, wherein a ratio of ethylene / acrylate copolymer to ethylene / acrylate / glycidyl methacrylate terpolymer added is in the range from about (2-3) to 1 (wt/wt). [00209] The method can, according to some aspects, optionally include a step of extrusion at any stage. For example, after the improved composition is produced it can be extruded to produce an article that could not be previously obtained. One or more laminations can be added. For example, to form a monolithic type of layer from multiple layers because the improved compositions disclosed herein can adhere to each other.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00210] As such, the technology can be, in some embodiments, directed to an improved composition (or consumable) produced by the method of any of the preceding claims. Articles, consumables or packages comprising the improved (or recycled) composition(s) are contemplated herein. These articles, consumable or packages are more appealing because utilization of recycled content is enabled herein. [00211] Various banking industry card producers are increasingly aware of the perception of bank cards that are not made from recycled stock. Methods disclosed herein can enable use of recycled material for such items as bank cards. For example, the improved composition can be as such wherein the composition can be printed, wherein the composition includes one or more requisite physical properties of PVC, wherein the composition is operative to adhere to embedded electronics, and/or wherein the improved composition of is operative to bond to itself during a subsequent processing. [00212] The technology disclosed herein, in some embodiments, provides a method for modifying a rPETG composition such that the modified rPETG is capable to bond to itself. The method provides, according to some aspects, wherein the modified rPETG can be printed upon. In some embodiments, the method is configured such that the modified rPETG has requisite physical properties of PVC. According to some aspects, the modified rPETG is operative to adhere to embedded electronics. [00213] In some embodiments, the technology is directed to a composition of a modified rPETG that is capable to bond to itself. According to some aspects, the modified rPETG can be printed upon. In some embodiments, the composition includes one or more properties of PVC. In some embodiments, the modified rPETG composition is operative to adhere to electronics embedded in the composition. [00214] It is contemplated that the technology can be applied to other polymers in addition to rPETG. According to some aspects, the modified rPETG (or polymers) disclosed herein can be used in monolayer or in coextruded substrates. [00215] Recycled polyester, commonly known as “rPET” - especially ocean bound – comes from multiple sources and can be modified as disclosed herein to deliver consistent physical properties that meet specifications. Previously, rPET could not be thermally laminated to itself – even after modification. The methods disclosed herein
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT provide, for example, rPETG-based card that meets physical property specifications and performs as first-use PVC. [00216] There is a need/desire in this application space to have a single layer card stock that will (1) thermally laminate to itself, (2) bond to printing inks and chips/antennae and (3) have sufficient physical properties to meet durability specifications (e.g., FIG.3B). The technology disclosed herein can modify rPETG, for example, to meet durability specs (e.g., of first-use PVC) while maintaining ability to thermally laminate to itself and bond to printing inks and chips/antennae. The level of modification is low enough to still be able to claim card stock comes from >90% recycled polymer. [00217] In some embodiments, the present innovation is a method of toughening/modifying recycled copolyesters (rPETG) to produce a single layer card stock that will (1) thermally laminate to itself, (2) bond to printing inks and chips/antennae and (3) have sufficient physical properties to meet durability specifications. The level of modification is low enough to still be able to claim card stock comes from > 10%—> 90% recycled polymer, (with all values subsumed as endpoints). The level of modification can be, in some embodiments, low enough to still be able to demonstrate card stock comes from > 90% recycled polymer. In some embodiments, the methods can use technology developed for toughening semicrystalline polyesters, such as PET, PBT and rPET, and applies it to toughen/modify recycled copolyesters (rPETG). [00218] In some embodiments, the technology provides a method for toughening and/or modifying recycled co-polyesters (e.g., rPET/rPETG) to produce a single layer card stock. The single layer card stock includes capability of bonding to printing ink, chips/antennae and/or of bonding to itself. [00219] The above method, in some embodiments, is wherein PVC is not required as a substrate and whereby step (2) includes thermally bonding. [00220] Any of the above aspects can be, in some embodiments, wherein one or more of the substrates comprise recycled polymer and/or ocean bound polymer; and/or wherein the core layer comprises modified rPET and one or more additional layers comprises rPETG to thermally bond the layer(s) together. In some embodiments, the methods disclosed herein can provide a single layer that does not require any coextrusion.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00221] Any of the above embodiments can be, in some embodiments, wherein the method steps are executed in any order, one or more method steps are repeated, and/or additional method steps are added, or some method steps are removed. [00222] Any of the above embodiments can be executed as a continuous method executed for greater than 1 hour, greater than 4 hours, greater than 24 hours, or greater than a week. [00223] FIG.3B is an example of a layered composition 200 including a core 240, representing an improved material disclosed herein. The material can be comprising an exemplary rPETG produced by a method disclosed herein, for example, having requisite properties of PVC. The material can be utilized in monolayer or in coextruded substrates. In an example, the modified rPETG composition can be being to be printed, adhere to embedded electronics and bond to itself via lamination as illustrated by 210, 220, 230, 250, 260, and 270 forming a single composite at 280, wherein the arrows illustrate bending, twisting, and normal use without delaminating. It should be understood that the arrows in FIG.3B at 280 are illustrative that the laminate 200 can be bent and is durable without breaking or delaminating, for example when used in a pocket or as a bank/credit card. A single layer can be utilized. The various layers shown are optional and can be modified in number of layers and can be applied in different order(s), repeatedly laminated, laminated backwards or in any order, or configured as a method for making the composition. [00224] According to some aspects, a composition made by the method of any of the preceding paragraphs can be wherein the composition comprises > 10%, > 20%, > 30%, > 40%, > 50%, > 60%, > 70%, > 80%, > 90%, or > 95% recycled polymer, using the methods disclosed herein. [00225] In some embodiments, the composition(s) can be bent, twisted, or deformed (FIG.3, 280) under a reasonable use without delaminating, when adhered to itself. [00226] There is a desire to move away from PVC as a substrate for card stock used in making bank/credit cards as well as security/ID cards. One preferred alternative is to use recycled polyester (especially ocean bound) as the source of the card stock. Typically, these cards are multiple layers (some of which are printed) which are heat laminated together and sometime have antennae or chips embedded into or sealed
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT between the layers. The technology disclosed herein can provide recycled copolyesters (or rPETG) that meet or exceed the specifications of PVC. [00227] In various descriptions of features, examples, aspects, and embodiments, the following list of details can be inter-combined with any other of the optional parameters disclosed herein: [00228] Detail 1: A method for recycling a polymer or plastic into a recycled material for use in manufacturing of products, the method comprising the steps of: (1) obtaining a starting material including a polymer or plastic for recycling; (2) heating the starting material; (3) adding a modifier including ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer to the starting material; and whereby the recycled material can displace use of a first-use polymer or plastic in producing products. [00229] Detail 2: The method of detail 1, wherein the starting material comprises PET (polyethylene terephthalate). [00230] Detail 3: The method of detail 2, wherein the recycled material is operative to displace use of first-use PVC (polyvinyl chloride) in producing products. [00231] Detail 4: The method of detail 3, wherein the recycled material is operative to provide a thermal lamination to itself or is operative to thermal lamination to itself in an equipment that is designed for a PVC molding. [00232] Detail 5: The method of detail 3, wherein the recycled material is operative to be durably printed with an ink, with a metal, with a polymer, with an electronic, with a semi-conductor, or with a pattern. [00233] Detail 6: The method of detail 1, wherein the recycled material comprises an amorphous solid-state operative to provide a transparency, a semi-crystalline solid state, a semi-crystalline particle size less than 500 nm, or a semi-crystalline particle size greater than 500 nm operative to provide an opaque or a translucent appearance. [00234] Detail 7: The method of detail 1, wherein the acrylate in step (3) includes an acrylate comonomer comprising EA (ethyl acrylate), MA (methyl acrylate), or BA (butyl acrylate). [00235] Detail 8: The method of detail 7, wherein the acrylate comonomer utilized is ≤ 40 wt% with 100 wt% being the weight of the modifier.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00236] Detail 9: The method of detail 8, wherein the acrylate comonomer is 9-40 wt%. [00237] Detail 10: The method of detail 1, wherein the modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer and/or ≤ 20 wt% ethylene/acrylate copolymer. [00238] Detail 11: The method of detail 10, wherein the modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer and/or 2-20 wt% ethylene/acrylate copolymer. [00239] Detail 12: The method of detail 1, wherein the modifier includes 1-4 wt% ethylene/acrylate/glycidyl methacrylate terpolymer and 2-10 wt% ethylene/acrylate copolymer. [00240] Detail 13: The method of detail 1, wherein the ratio of ethylene/acrylate copolymer to ethylene/acrylate/glycidyl methacrylate terpolymer being in the range of 2:1 to 4:1. [00241] Detail 14: The method of detail 1, wherein the levels of modifier added are in the range of ≤ 6 wt%. [00242] Detail 15: The method of detail 1, wherein the starting material comprises rPETG (a recycled, glycol modified version of polyethylene terephthalate) or rPET (a recycled PET). [00243] Detail 16: The method of detail 1, further comprising adding ≤ 10 wt% TiO2, other pigments, mineral fillers, or additives before step (2), before step (3), or after step (3). [00244] Detail 17: The method of detail 1, wherein the recycled material is operative to provide a monolayer card stock substrate suitable for making a bank card product. [00245] Detail 18: The method of detail 17, wherein the thickness of the card stock substrate is in a range of about 76.2 µm to about 635 µm or about 3-25 mils (0.003-0.025 inches). [00246] Detail 19: The method of detail 18, wherein the thickness is about 152.4 µm to about 304.8 µm or about 6-12 mils (0.006-0.012 inches). [00247] Detail 20: The method of detail 1, further comprising forming a core layer from the recycled material, and/or further comprising forming a core layer from the recycled
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT material wherein the thickness of the core layer is about 127 µm to about 304.8 µm or about 5-12 mils (0.005-0.012 inches). [00248] Detail 21: The method of detail 20, wherein the thickness is about 127 µm to about 203.2 µm or about 5-8 mils (0.005-0.008 inches). [00249] Detail 22: The method of detail 20, further comprising forming a skin layer on one or more sides of the core layer, to provide an A/B card stock substrate or an A/B/A card stock substrate. [00250] Detail 23: The method of detail 22, wherein one skin layer includes a thickness in the range from about 12.7 µm to about 101.6 µm or 0.5-4 mils (0.0005-0.004 inches). [00251] Detail 24: The method of detail 23, wherein the skin layer includes a thickness in the range from about 25.4 µm to about 50.8 µm or 1-2 mils (0.001-0.002 inches). [00252] Detail 25: The method of detail 1, wherein the recycled material is suitable to displace first-use PET in producing a product with the recycled material comprising ≥ 90 wt% of the total core polymer (first-use PET + recycled material) in the product. [00253] Detail 26: The method of detail 1, wherein the starting material includes an ocean bound rPET and wherein the recycled material is suitable for used in coextruded card structures with recycled materal from ocean bound rPET in the core surrounded by modified rPETG skin layers which are operative for thermal lamination of multiple layers of card stock. [00254] Detail 27: The method of detail 26, further comprising the rPET core has a sufficient modification to improve physical properties so that the rPETG skin layers do not require a modification. [00255] Detail 28: The method of detail 22, wherein the method provides a toughening and/or a modifying of recycled co-polyesters or rPETGs to produce a recycled, single layer card stock that will (1) thermally laminate to itself, (2) bond to printing inks and/or chips/antennae and/or (3) have sufficient physical properties to meet rigorous durability specifications such that can be used for articles or credit/bank cards. [00256] Detail 29: The method of detail 28, wherein a level of modification is low enough to still be able to produce card stock coming from ≥ 90% wt% recycled polymer.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00257] Detail 30: The method of detail 1, wherein the recycled material is extruded and/or cut into cooled pellets suitable for a distribution or a sale of the recycled material. [00258] Detail 31: A recycled material which is capable to be printed and/or thermally laminated to itself comprising a recycled polymer or plastic, and a modifier including ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer; wherein the recycled material is operative to displace use of a first-use polymer or plastic in producing products. [00259] Detail 32: The recycled material of detail 31, wherein the recycled material is in a form of a monolayer card stock substrate. [00260] Detail 33: The recycled material of detail 31, wherein the recycled polymer or plastic comprises PET (polyethylene terephthalate). [00261] Detail 34: The recycled material of detail 33, wherein the recycled material is operative to displace use of first-use PVC (polyvinyl chloride) in producing products. [00262] Detail 35: The recycled material of detail 34, wherein the recycled material is operative to provide a thermal lamination to itself or is operative to thermal lamination to itself in an equipment that is designed for a PVC molding. [00263] Detail 36: The recycled material of detail 34, wherein the recycled material is operative to be durably printed with an ink, with a metal, with a polymer, with an electronic, with a semi-conductor, or with a pattern. [00264] Detail 37: The recycled material of detail 31, wherein the recycled material comprises an amorphous solid-state operative to provide a transparency, a semi- crystalline solid state, a semi-crystalline particle size less than 500 nm, or a semi- crystalline particle size greater than 500 nm operative to provide an opaque or a translucent appearance. [00265] Detail 38: The recycled material of detail 31, wherein the acrylate includes an acrylate comonomer comprising EA (ethyl acrylate), MA (methyl acrylate), or BA (butyl acrylate). [00266] Detail 39: The recycled material of detail 38, wherein the acrylate comonomer utilized is ≤ 40 wt% with 100 wt% being the weight of the modifier. [00267] Detail 40: The recycled material of detail 39, wherein the acrylate comonomer is 9-40 wt%.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00268] Detail 41: The recycled material of detail 31, wherein the modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer and/or ≤ 20 wt% ethylene/acrylate copolymer. [00269] Detail 42: The recycled material of detail 41, wherein the modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer and/or 2-20 wt% ethylene/acrylate copolymer. [00270] Detail 43: The recycled material of detail 31, wherein the modifier includes 1- 4 wt% ethylene/acrylate/glycidyl methacrylate terpolymer and 2-10 wt% ethylene/acrylate copolymer. [00271] Detail 44: The recycled material of detail 31, wherein the ratio of ethylene/acrylate copolymer to ethylene/acrylate/glycidyl methacrylate terpolymer being in the range of 2:1 to 4:1. [00272] Detail 45: The recycled material of detail 31, wherein the levels of modifier added are in the range of ≤ 6 wt%. [00273] Detail 46: The recycled material of detail 31, wherein the starting material comprises rPETG (a recycled, glycol modified version of polyethylene terephthalate) or rPET (a recycled PET). [00274] Detail 47: The recycled material of detail 31, further comprising adding ≤ 10 wt% TiO2, other pigments, mineral fillers, or additives before step (2), before step (3), or after step (3). [00275] Detail 48: The recycled material of detail 31, wherein the recycled material is operative to provide a monolayer card stock substrate suitable for making a bank card product. [00276] Detail 49: The recycled material of detail 48, wherein the thickness of the card stock substrate is in a range of about 76.2 µm to about 635 µm or about 3-25 mils (0.003- 0.025 inches). [00277] Detail 50: The recycled material of detail 49, wherein the thickness is about 152.4 µm to about 304.8 µm or about 6-12 mils (0.006-0.012 inches). [00278] Detail 51: The recycled material of detail 31, further comprising a form of a core layer from the recycled material, and/or further comprising a core layer formed from
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT the recycled material wherein the thickness of the core layer is about 127 µm to about 304.8 µm or about 5-12 mils (0.005-0.012 inches). [00279] Detail 52: The recycled material of detail 51, wherein the thickness is about 127 µm to about 203.2 µm or about 5-8 mils (0.005-0.008 inches). [00280] Detail 53: The recycled material of detail 51, further comprising forming a skin layer on one or more sides of the core layer, to provide an A/B card stock substrate or an A/B/A card stock substrate. [00281] Detail 54: The recycled material of detail 53, wherein one skin layer includes a thickness in the range from about 12.7 µm to about 101.6 µm or 0.5-4 mils (0.0005- 0.004 inches). [00282] Detail 55: The recycled material of detail 54, wherein the skin layer includes a thickness in the range from about 25.4 µm to about 50.8 µm or 1-2 mils (0.001-0.002 inches). [00283] Detail 56: The recycled material of detail 31, wherein the recycled material is suitable to displace first-use PET in producing a product with the recycled material comprising ≥ 90 wt% of the total core polymer (first-use PET + recycled material) in the product. [00284] Detail 57: The recycled material of detail 31, wherein the starting material includes an ocean bound rPET and wherein the recycled material is suitable for used in coextruded card structures with recycled materal from ocean bound rPET in the core surrounded by modified rPETG skin layers which are operative for thermal lamination of multiple layers of card stock. [00285] Detail 58: The recycled material of detail 57, further comprising the rPET core has a sufficient modification to improve physical properties so that the rPETG skin layers do not require a modification. [00286] Detail 59: The recycled material of detail 53, wherein the recycled material provides a toughening and/or a modifying of recycled co-polyesters or rPETGs to produce a recycled, single layer card stock that will (1) thermally laminate to itself, (2) bond to printing inks and/or chips/antennae and/or (3) have sufficient physical properties to meet rigorous durability specifications such that can be used for articles or credit/bank cards.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00287] Detail 60: The recycled material of detail 59, wherein a level of modification is low enough to still be able to produce card stock coming from ≥ 90% wt% recycled polymer. [00288] Detail 61: The recycled material of detail 31, wherein the recycled material is extruded and/or cut into cooled pellets suitable for a distribution or a sale of the recycled material. [00289] Detail 62: A method for processing a material with a starting material comprising a recycled polymer, an ocean bound polymer, a PETg, or a recycled copolyester polymer to replace PVC in card stock and to provide desired performance attributes without a coextrusion, the method comprising the steps of: (1) obtaining the starting material; and (2) adding a modifier to the starting material, whereby an improved composition is produced; wherein the modifier comprises ethylene / acrylate copolymer, ethylene / acrylate / glycidyl methacrylate terpolymer, or a combination thereof. [00290] Detail 63: The method of detail 62, wherein a ratio of ethylene / acrylate / glycidyl methacrylate terpolymer to ethylene / acrylate copolymer is in the range from between about 1:2 and about 1:3 (wt/wt). [00291] Detail 64: The method of detail 63, wherein a ratio of ethylene / acrylate copolymer to ethylene / acrylate / glycidyl methacrylate terpolymer added is in the range from about (2-3) to 1 (wt/wt). [00292] Detail 65: The method of detail 62 further comprising a step of extrusion. [00293] Detail 66: The method of detail 62, wherein the improved composition includes one or more physical properties of first-use PVC. [00294] Detail 67: The method of detail 62, wherein the improved composition is operative to adhere to embedded electronics, is operative to bond to itself during a subsequent processing or is operative to be printed. [00295] According to some aspects, the methods disclosed herein can be wherein the order of the execution of the steps is changed, the method is repeated or wherein the method is executed as a continuous method in a scaled-up manufacturing process including rollers, cooling baths, 3D-printing, lithography, or any technique known in the art. Crystallinity of the polymers disclosed herein can be modified by techniques known in the art. Glass transition temperatures can be modified by any known techniques.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00296] The starting materials discussed herein are not limited by the examples provided. It is important to note that any of the starting materials for any of the methods, prophetic experiments, examples, features, details, aspects, and/or embodiments disclosed herein can include a bio-sourced material (or starting material) that is obtained from at least one of petroleum-based synthetic plastics, bioplastic food packaging, electronic circuit boards, product casings, medical equipment, jet and airplane waste plastics, cosmetic bioplastics, ocean plastics pollution, aliphatic polyesters bioplastics, polylactic acid (PLA) bioplastics, poly 3-hydroxybutyrate (PHB) bioplastics, polyhydroxyalkanoates (PHA) plastics, polyamide 11 bioplastic, bio-derived polyethylene, polyhydroxy urethane plastics, genetically modified bioplastics, post-consumer plastic waste, post-industrial plastic waste, agricultural waste, food waste, municipal solid waste, construction and demolition waste, automotive waste, packaging waste, textile waste, rubber waste, leather waste, paper waste, wood waste, glass waste, metal waste, electronic waste, battery waste, paint and coating waste, adhesive waste, composite waste, or any combination thereof. In some embodiments (but not all), a bio-sourced material or starting material can include at least one of recycled polyethylene terephthalate glycol (rPETG), polylactic acid (PLA), polyhydroxyalkanoate (PHA), polyethylene furanoate (PEF), polytrimethylene terephthalate (PPT), recycled copolyesters, or recycled amorphous polyethylene terephthalate (APET). [00297] While example embodiments have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the embodiments encompassed by the appended claims. For example, other useful implementations could be achieved if steps of the disclosed techniques were performed in a different order and/or if components in the disclosed systems were combined in a different manner and/or replaced or supplemented by other components. Accordingly, other implementations are within the scope of the disclosure. EXAMPLES EXAMPLE 1: PRODUCTION OF NEW MATERIAL PROTOTYPES [00298] The methods disclosed herein, for example, in the claims, have been tried and tested. In further examples, FIG.2A is an example of a method showing steps of a
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT method for modifying a recycled polymer or plastic into a recycled material for use in manufacturing of mono-layer (extruded) or multi-layer (coextruded) film/sheet products such as obtaining, heating, adding one or more modifiers, and extruding the modified recycled material into mono-layer film, multi-layer (or co-extruded) film, or onto a solid substrate. FIG.2B is an example of a method for processing a material based on recycled (industrial or ocean bound) PETg or other recycled copolyester polymers, for example, to provide capability to replace PVC in card stock and to provide desired performance attributes without a coextrusion. Exemplary steps of (a) obtaining the starting material; (b) adding one or more modifiers to the material, whereby an improved composition is produced (c), are illustrated with one or more optional steps (a1,b1,c1, or d) at any stage (e.g., an extrusion). [00299] Prototypes of this concept have been sampled. In this example, we add a combination of ethylene/acrylate copolymer and ethylene/acrylate/glycidyl methacrylate terpolymer to the rPETG prior to an extrusion of the card stock film. The ratio of ethylene/acrylate copolymer to ethylene/acrylate/glycidyl methacrylate terpolymer added is 2.5 (~2-3) to 1 (wt/wt%). The total amount modifiers added is 3-10% (wt%), keeping the recycled content at least 90% (wt%). It is found that the ethylene/acrylate copolymer may also be incorporated via a TiO2 masterbatch in ethylene/acrylate carrier. [00300] A prototype is produced of a single layer card stock that will: (1) thermally laminate to itself, (2) bond to printing inks and chips/antennae and (3) have sufficient physical properties to meet durability specifications. The technology is found to enable methods for processing a material based on recycled (industrial and ocean bound) PETg and other recycled co-polyester polymers to replace PVC in card stock and to provide desired performance attributes without requiring a coextrusion. For example, the methods can comprise the steps of: (1) obtaining the starting material; and (2) adding one or more modifiers to the material, whereby an improved composition is produced for uses that could not be previously achieved. [00301] Using the methods discussed above to produce mono-films, FIG.7A and FIG. 7B show examples of experimental data for all mono-films, according to the embodiments of methods disclosed herein
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00302] Using the methods discussed above to produce rPETG films, FIG.8A and FIG.8B show examples of experimental data for all rPETG films only, according to the embodiments of methods disclosed herein. [00303] FIG.3A is a diagram showing example card structures that have been made and tested, according to some aspects. For example, the card structure can displace first- use PVC in bank cards. EXAMPLE 2: TESTING OF RECYCLING SYSTEMS AND METHODS [00304] Experimental methods and systems for recycling polymers or plastics are tested, involving the use of a PET (polyethylene terephthalate) polymer as a starting material. The processes include heating the starting material and adding a modifier comprising ethylene/acrylate copolymer and/or ethylene/acrylate/glycidyl methacrylate terpolymer. The resulting recycled material is capable of replacing first-use polymers or plastics and first-use PVC (polyvinyl chloride) in product manufacturing. [00305] The recycling of polymers and plastics is a critical aspect of reducing environmental impact and conserving resources. Traditional recycling methods often degrade the quality of the plastic, limiting its use in high-value applications. There is a need for improved recycling processes that can produce recycled materials with properties that are comparable to or better than those of virgin materials, enabling their use in a wider range of products. [00306] In accordance with example embodiments, a method is provided for recycling a polymer or plastic, which involves obtaining a starting material that includes a PET (polyethylene terephthalate) polymer. The starting material is heated, and a modifier comprising ethylene/acrylate copolymer and ethylene/acrylate/glycidyl methacrylate terpolymer is added to produce a recycled material capable of displacing first-use polymers or plastics and PVC in product manufacturing. [00307] In accordance with other embodiments, a system for recycling a polymer or plastic is provided, comprising a heating unit for heating a polymer material, a first addition unit for adding a copolymer modifier, a second addition unit for adding a terpolymer modifier, and a recycling unit for producing a recycled material that can displace first-use polymers or plastics and PVC in products.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00308] In yet other embodiments, a composition for recycling a polymer or plastic is provided, including a PET polymer, a heating component, and a modifier consisting of ethylene/acrylate copolymer and ethylene/acrylate/glycidyl methacrylate terpolymer [00309] Prophetic experiment (PE) 1: A method for recycling a polymer or plastic, comprising: obtaining a starting material including a PET (polyethylene terephthalate) polymer for recycling; heating the starting material; adding a modifier to the heated starting material, wherein the modifier includes ethylene/acrylate copolymer and ethylene/acrylate/glycidyl methacrylate terpolymer; and recycling an initial polymer or plastic to produce a recycled material that can displace use of a first-use polymer or plastic and first-use PVC (polyvinyl chloride) in producing products. [00310] PE 2: The method of PE 1, wherein the heating is applied to the starting material. [00311] PE 3: The method of PE 1, wherein the starting material includes PET (polyethylene terephthalate) polymer. [00312] PE 4: A system for recycling a polymer or plastic, comprising: a heating unit for heating a polymer material; a first addition unit for adding a copolymer modifier to the heated polymer material; a second addition unit for adding a terpolymer modifier to the mixture of the heated polymer material and the copolymer modifier; a recycling unit for recycling an initial polymer or plastic to produce a recycled material. [00313] PE 5: The system of PE 4, wherein the polymer material includes PET (polyethylene terephthalate) polymer. [00314] PE 6: The system of PE 4, wherein the copolymer modifier includes ethylene/acrylate copolymer. [00315] PE 7: The system of PE 4, wherein the terpolymer modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer. [00316] PE 8: The system of PE 4, wherein the recycled material can displace use of a first-use polymer or plastic in producing products. [00317] PE 9: The system of PE 4, wherein the recycled material can displace use of a first-use PVC (polyvinyl chloride) in producing products. [00318] PE 10: The system of PE 4, wherein the heating unit is configured to apply heat to the starting material.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00319] PE 11: The system of PE 4, wherein the starting material includes PET (polyethylene terephthalate) polymer. [00320] PE 12: The system of PE 4, wherein the first addition unit is configured to add the copolymer modifier to the heated polymer material. [00321] PE 13: The system of PE 4, wherein the second addition unit is configured to add the terpolymer modifier to the mixture of the heated polymer material and the copolymer modifier. [00322] PE 14: The system of PE 4, wherein the recycling unit is configured to recycle an initial polymer or plastic to produce a recycled material. [00323] PE15: The system of PE 4, wherein the recycled material produced by the recycling unit can displace use of a first-use polymer or plastic and first-use PVC (polyvinyl chloride) in producing products. [00324] PE 16: A composition for recycling a polymer or plastic, comprising: a PET (polyethylene terephthalate) polymer for recycling; a heating component for heating the starting material; and a modifier to be added to the heated starting material, wherein the modifier includes ethylene/acrylate copolymer and ethylene/acrylate/glycidyl methacrylate terpolymer. [00325] The Polymer Recycling System, identified as system/component number 500 (FIG.5), encompasses all components and sub-components for recycling a polymer or plastic into a recycled material. This system includes a heating unit, a first addition unit, a second addition unit, and a recycling unit. The process begins with obtaining a starting material that includes a PET (polyethylene terephthalate) polymer for recycling. The heating unit, which includes a heating component, is responsible for heating the starting material. Once the starting material is heated, the first addition unit introduces a copolymer modifier to the heated polymer material. The copolymer modifier includes ethylene/acrylate copolymer. Following this, the second addition unit adds a terpolymer modifier to the mixture of the heated polymer material and the copolymer modifier. The terpolymer modifier includes ethylene/acrylate/glycidyl methacrylate terpolymer. The recycling unit then carries out the recycling process to produce the recycled material. The recycled material produced by this process can displace the use of first-use polymer or plastic and first-use PVC (polyvinyl chloride) in producing products. This promotes
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT sustainability by providing an alternative to first-use polymers and PVC. In summary, the Polymer Recycling System (system/component number 500) integrates several components and sub-components to recycle PET polymers. The process involves heating the starting material, adding specific modifiers to alter its properties, and recycling it into a material that can replace new polymers and PVC in product manufacturing. This system facilitates the recycling of plastics and contributes to environmental sustainability by reducing the reliance on virgin materials. [00326] The heating unit, identified as system/component number 502 (FIG.5, FIG.6A), is responsible for heating the starting material, which includes PET (polyethylene terephthalate) polymer, as part of the recycling process. The heating unit is configured to apply heat to the starting material to prepare it for the subsequent addition of modifiers. The heating unit includes a sub-component, the heating component (502-a, FIG.6A), which directly contributes to the heating process. The heating unit's action of heating the starting material is described as heating the starting material to prepare it for the addition of a modifier. The process includes obtaining a starting material that includes PET (polyethylene terephthalate) polymer for recycling and heating the starting material. The heating unit's role is further elaborated in the PEs (above), where it is stated that the heating unit is configured to apply heat to the starting material. This configuration ensures that the heating process is carried out effectively, preparing the polymer material for the addition of modifiers. The heating unit's action is integral to the overall recycling process, as it sets the stage for the subsequent steps of adding modifiers and recycling the polymer into a usable material. In summary, the heating unit (system/component number 502) and its sub-component, the heating component (502-a), are for heating the starting material, specifically PET polymer, to prepare it for modification. This preparation is for the successful recycling of the polymer into a material that can displace first-use polymers and PVC in product manufacturing. The detailed actions and attributes associated with the heating unit highlight its importance in the overall recycling process, ensuring that the starting material is prepared for the subsequent steps. [00327] The heating component, identified as system/component number 502-a, is a sub-component of the Heating Unit within the Polymer Recycling System. This component is responsible for heating the starting material, which is a step in the recycling
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT process. The starting material includes a PET (polyethylene terephthalate) polymer, which is obtained to provide the material for the recycling process. The heating component's primary function is to prepare the starting material for the addition of modifiers. The heating component is configured to apply heat to the starting material. The heating unit, which includes the heating component, is designed to perform the process of heating, ensuring that the starting material reaches the required temperature for modification. The heating component's role is further elaborated in the method for recycling a polymer or plastic. The method involves obtaining a starting material including a PET (polyethylene terephthalate) polymer for recycling, heating the starting material, and then adding a modifier to the heated starting material. The modifier includes ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer. The heating component's function is in ensuring that the starting material is prepared for the addition of these modifiers. The recycled material produced through this process can displace the use of first-use polymer or plastic and first-use PVC (polyvinyl chloride) in producing products. This displacement promotes sustainability by reducing the reliance on virgin materials. In summary, the heating component (502-a) is for the recycling of PET polymers. It ensures that the starting material is heated to the appropriate temperature, facilitating the subsequent addition of chemical modifiers. This process leads to the production of a recycled material that can replace first-use polymers and PVC in various products, thereby contributing to environmental sustainability. [00328] The First Addition Unit, identified as component number 504 (FIG.6B), is responsible for adding the copolymer modifier to the heated polymer material. The copolymer modifier, which is a sub-component of the First Addition Unit, includes ethylene/acrylate copolymer. In the context of the PEs (above), the First Addition Unit is configured to add the copolymer modifier to the heated polymer material. The copolymer modifier includes ethylene/acrylate copolymer, which is introduced to the heated starting material to produce a recycled material. This recycled material can then displace the use of first-use polymers or plastics in producing products, promoting sustainability and reducing reliance on virgin materials. The process begins with obtaining a starting material that includes PET (polyethylene terephthalate) polymer for recycling. This
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT starting material is then heated to prepare it for the addition of modifiers. The First Addition Unit introduces the copolymer modifier, which includes ethylene/acrylate copolymer, to the heated polymer material. The First Addition Unit's role is further emphasized in the method for recycling a polymer or plastic involves adding a modifier, which can include ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer, to the starting material. The recycled material is also operative to displace the use of first-use PVC in producing products. In summary, the First Addition Unit (component 504) is integral to the recycling process, ensuring that the copolymer modifier is added to the heated polymer material. This action transforms the starting material into a recycled material with enhanced properties, suitable for replacing first-use polymers and PVC in various products, thereby contributing to a more sustainable and eco-friendly manufacturing process. [00329] The sub-component 504-a (FIG.6B), identified as the Copolymer Modifier, is integral to the First Addition Unit within the Polymer Recycling System. This sub- component is responsible for introducing the copolymer modifier into the heated polymer material during the recycling process. The copolymer modifier specifically includes ethylene/acrylate copolymer, as detailed in the PEs (above). In the context of the PEs, the action associated with the copolymer modifier is adding a modifier, which serves the purpose of introducing substances to alter the properties of the material. The copolymer modifier, ethylene/acrylate copolymer, is added to the heated polymer material to produce a recycled material. This recycled material can displace the use of first-use polymers or plastics and first-use PVC (polyvinyl chloride) in producing products. The copolymer modifier's action is similarly described as adding a modifier, with the purpose of producing a recycled material. The modifier can include ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer. The addition of these modifiers chemically alters the starting material to produce a recycled material with properties suitable for displacing first-use polymers in product manufacturing. The specific attributes of the copolymer modifier in the PEs include its composition, which is defined as ethylene/acrylate copolymer. The purpose of adding this modifier is to produce a recycled material that can replace first-use polymers or plastics in the production of new products, thereby promoting sustainability and
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT reducing reliance on virgin materials. In summary, the sub-component 504-a, the Copolymer Modifier, plays a role in the recycling process by introducing ethylene/acrylate copolymer into the heated polymer material. This action modifies the properties of the starting material, resulting in a recycled material that can displace first-use polymers and PVC in manufacturing, aligning with the goals of sustainability and resource efficiency. [00330] The Second Addition Unit, identified as system/component number 506 (FIG.6C), is a component in the polymer recycling system. This unit is responsible for adding the terpolymer modifier to the mixture of the heated polymer material and the copolymer modifier. The terpolymer modifier in question includes ethylene/acrylate/glycidyl methacrylate terpolymer, which is for chemically altering the starting material to produce a recycled material with properties suitable for displacing first- use polymers in product manufacturing. In the context of the PEs (above), the Second Addition Unit is configured to add the terpolymer modifier to the mixture of the heated polymer material and the copolymer modifier. The specific attributes of this process include adding a modifier to the heated starting material, wherein the modifier includes ethylene/acrylate copolymer and ethylene/acrylate/glycidyl methacrylate terpolymer. From the entity actions, the Second Addition Unit's role is to add a modifier, which can be one of the listed copolymers or terpolymers, to chemically alter the starting material. The purpose of adding a modifier, which includes ethylene/acrylate/glycidyl methacrylate terpolymer, is to chemically alter the starting material to produce a recycled material with properties suitable for displacing first-use polymers in product manufacturing. The specific attributes of the Second Addition Unit include the addition of a terpolymer modifier to the mixture of the heated polymer material and the copolymer modifier. The recycled material produced can displace the use of a first-use polymer or plastic and first-use PVC (polyvinyl chloride) in producing products. This method for recycling a polymer or plastic into a recycled material for use in manufacturing products involves obtaining a starting material including a PET (polyethylene terephthalate) polymer for recycling, heating the starting material, and adding a modifier including ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer to the starting material to produce a recycled material. The recycled material that is produced can displace the use of a first-use polymer or plastic in producing
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT products and is operative to displace the use of first-use PVC (polyvinyl chloride) in producing products. In summary, the Second Addition Unit (system/component number 506) plays a role in the recycling process by adding the terpolymer modifier to the mixture, thereby enabling the production of a recycled material that can replace first-use polymers and PVC in manufacturing, promoting sustainability and reducing reliance on virgin materials. [00331] The sub-component 506-a (FIG.6C), identified as the Terpolymer Modifier, is an integral part of the Second Addition Unit in the polymer recycling system. This sub- component is responsible for adding the terpolymer modifier to the mixture of the heated polymer material and the copolymer modifier. The terpolymer modifier specifically includes ethylene/acrylate/glycidyl methacrylate terpolymer. In the context of the PEs (above), the process begins with obtaining a starting material that includes a PET (polyethylene terephthalate) polymer for recycling. This starting material is then heated to prepare it for the addition of modifiers. The heating unit, which includes a heating component, is configured to apply heat to the starting material, thereby preparing it for the subsequent steps. Once the starting material is heated, the first addition unit introduces a copolymer modifier, which includes ethylene/acrylate copolymer. Following this, the second addition unit, which includes the sub-component 506-a (Terpolymer Modifier), adds the terpolymer modifier to the mixture. The purpose of adding this terpolymer modifier is to chemically alter the starting material to produce a recycled material with properties suitable for displacing first-use polymers in product manufacturing. The specific attributes of the terpolymer modifier, as mentioned in the PEs, include ethylene/acrylate/glycidyl methacrylate terpolymer. This modifier plays a role in the recycling process by ensuring that the recycled material produced can displace the use of first-use polymers and first-use PVC (polyvinyl chloride) in producing products. The recycled material, therefore, serves as an alternative to new polymers and PVC, promoting recycling and sustainability. In summary, the sub-component 506-a (Terpolymer Modifier) is for the modification of the heated polymer material, enabling the production of a recycled material that can replace first-use polymers and PVC in various products. This process supports environmental sustainability and provides a practical solution for recycling PET polymers.
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00332] The recycling unit, identified as system/component number 508 (FIG.6D), is a component in the polymer recycling system. This unit is responsible for recycling the initial polymer or plastic to produce a recycled material. The entities associated with this component include the method for recycling, plastic, and polymer. In the context of the PEs (above), the recycling unit is configured to recycle an initial polymer or plastic to produce a recycled material. This process is for converting used polymers into reusable material, which can then be utilized in the manufacturing of new products. The recycling unit's purpose is to produce a recycled material that can displace the use of first-use polymers or plastics, including first-use PVC (polyvinyl chloride), in product manufacturing. From the entity actions, the recycling unit's function is described as recycling a polymer or plastic to produce a recycled material for use in manufacturing. This involves obtaining a starting material, which includes a PET (polyethylene terephthalate) polymer, heating the starting material, and adding a modifier to the heated material. The modifier can include ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer. The addition of these modifiers chemically alters the starting material, resulting in a recycled material with properties suitable for displacing first-use polymers in product manufacturing. The specific attributes of the recycling unit include the ability to recycle an initial polymer or plastic to produce a recycled material that can displace the use of first-use polymer or plastic and first-use PVC (polyvinyl chloride) in producing products. This recycled material is designed to serve as an alternative to first-use polymers and PVC, thereby promoting recycling and sustainability. In summary, the recycling unit (component 508) plays a role in the polymer recycling system by converting used polymers into a recycled material. This process involves obtaining a PET polymer starting material, heating it, and adding specific modifiers to produce a recycled material that can replace first-use polymers and PVC in product manufacturing. The unit's function and attributes are aligned with the broader goal of reducing reliance on virgin materials and promoting sustainability in the manufacturing industry. [00333] The sub-component 508-a (FIG.6D), identified as the Recycled Material, is an integral part of the Recycling Unit (component number 508) within the Polymer Recycling System (system number 500). This sub-component is for the final stage of the
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT recycling process, where the initial polymer or plastic is transformed into a recycled material that can replace first-use polymers and PVC in product manufacturing. The process begins with obtaining a starting material that includes a PET (polyethylene terephthalate) polymer for recycling. The starting material is then heated using a heating unit (component number 502) and its sub-component, the heating component (sub- component number 502-a). Once the starting material is adequately heated, a modifier is added to the heated starting material. The modifier includes ethylene/acrylate copolymer and ethylene/acrylate/glycidyl methacrylate terpolymer. The first addition unit (component number 504) is responsible for adding the copolymer modifier, while the second addition unit (component number 506) adds the terpolymer modifier to the mixture of the heated polymer material and the copolymer modifier. The purpose of adding these modifiers is to chemically alter the starting material to produce a recycled material with properties suitable for displacing first-use polymers in product manufacturing. The recycling unit (component number 508) then processes the modified polymer to produce the recycled material. The purpose of this recycled material is to serve as an alternative to first-use polymers and PVC, thereby promoting recycling and sustainability. Specifically, the recycled material produced can displace the use of a first-use polymer or plastic in producing products and is operative to displace the use of first-use PVC (polyvinyl chloride) in producing products. In summary, the sub-component 508-a, the recycled material, is the end product of a methodical recycling process involving the heating of a PET polymer starting material, the addition of specific copolymer and terpolymer modifiers, and the final recycling step. This recycled material is designed to replace first- use polymers and PVC in manufacturing, contributing to a more sustainable and environmentally friendly production process. [00334] In step 100 (FIG.4A, FIG.4B), the process begins with obtaining a starting material that includes a PET (polyethylene terephthalate) polymer for recycling. The purpose of obtaining this starting material is to provide a specific type of plastic for the recycling process, which will be transformed into a recycled material. The action of obtaining the starting material is for acquiring the input for the recycling process. The starting material, specifically the PET polymer, is chosen for its properties that make it suitable for recycling into a new material. The PET polymer is a common type of plastic
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT used in various products, and recycling it helps in reducing waste and promoting sustainability. The starting material, which includes the PET polymer, is then subjected to further processing steps in the recycling method. This initial step ensures that the recycling process begins with the right type of material, which will undergo subsequent steps such as heating, adding modifiers, and ultimately producing a recycled material that can replace first-use polymers or plastics in manufacturing new products. [00335] In step 102, the process involves heating the starting material (FIG.4A, FIG. 4B). The entities associated with this step are the heating unit and the heating component. The purpose of heating the starting material is to prepare the PET polymer for the subsequent modification step in the recycling process. The heating unit is configured to apply heat to the starting material. The heating component also serves the same purpose, ensuring that the starting material, which includes PET (polyethylene terephthalate) polymer, is prepared for the next steps in the recycling process. In sub-step 102-a (FIG.4B), it is specified that the heating is applied to the starting material. This sub-step emphasizes the direct application of heat to the PET polymer, ensuring it reaches the necessary temperature for effective modification. The heating process is a preparatory step for the success of the subsequent addition of modifiers, which include ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer. The heating unit and heating component are designed to perform the process of heating, ensuring that the starting material is in the state for the recycling process. This preparation is for achieving the desired properties in the recycled material, which can then displace the use of first-use polymers or plastics, including first-use PVC (polyvinyl chloride), in producing new products. [00336] In step 102-a (FIG.4B), the heating unit is applied to the starting material. The heating unit is designed to perform the process of heating, whichis for preparing the starting material for the addition of modifiers. The purpose of heating the starting material is to prepare the PET polymer for the subsequent modification step in the recycling process. This step ensures that the starting material, which includes PET (polyethylene terephthalate) polymer, is prepared for the addition of the modifier. The heating unit is configured to apply heat to the starting material, ensuring that the material reaches the necessary temperature for effective modification. This process facilitates the chemical
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT alteration of the starting material, enabling the production of a recycled material with properties suitable for displacing first-use polymers in product manufacturing. The heating component's role is to ensure that the starting material is in the state for the recycling process, thereby enhancing the efficiency and effectiveness of the recycling method. [00337] In step 104 (FIG.4A, FIG.4B), the process involves adding a modifier to the heated starting material. The modifier includes ethylene/acrylate copolymer and ethylene/acrylate/glycidyl methacrylate terpolymer. The purpose of adding a modifier, which can be one of the listed copolymers or terpolymers, is to chemically alter the starting material to produce a recycled material with properties suitable for displacing first-use polymers in product manufacturing. The specific attributes of the modifier include ethylene/acrylate copolymer and ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer. This step modifies the properties of the starting material during recycling, ensuring that the recycled material produced can replace first-use polymers or plastics in the production of new products. The addition of these modifiers is designed to introduce substances that alter the properties of the material, making it suitable for recycling into a new, usable form. [00338] In step 106 (FIG.4A, FIG.4B), the process involves recycling an initial polymer or plastic to produce a recycled material that can displace the use of a first-use polymer or plastic and first-use PVC (polyvinyl chloride) in producing products. This step is in the method for recycling polymers or plastics, as it aims to create a sustainable alternative to first-use materials, thereby promoting recycling and sustainability. The recycling unit is designed to carry out the recycling process and produce the recycled material. The purpose of the method is to recycle polymers or plastics into a material that can be used in the manufacturing of new products, thereby reducing the need for first- use polymers or plastics. The recycled material that is produced can displace the use of a first-use polymer or plastic in producing products. Additionally, the recycled material is operative to displace the use of first-use PVC (polyvinyl chloride) in producing products. This means that the recycled material serves as a substitute for first-use polymers or plastics in the production of new products, offering an alternative that reduces the reliance on virgin PVC material. The method for recycling a polymer or plastic into a recycled material for use in manufacturing products comprises several steps. Initially, a starting
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT material including a PET (polyethylene terephthalate) polymer is obtained for recycling. This starting material is then heated to prepare the PET polymer for the subsequent modification step in the recycling process. A modifier, which can include ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer, is added to the heated starting material to produce the recycled material. The purpose of adding a modifier is to chemically alter the starting material to produce a recycled material with properties suitable for displacing first-use polymers in product manufacturing. The recycled material produced by this method can displace the use of a first-use polymer or plastic in producing products. Furthermore, it is designed to replace first-use PVC in the production of new products, offering an alternative that reduces the need for new polymers and PVC. This method not only promotes recycling but also contributes to environmental sustainability by reducing the reliance on virgin materials. [00339] The method for recycling a polymer or plastic begins with obtaining a starting material that includes a PET (polyethylene terephthalate) polymer for recycling. The purpose of obtaining this starting material is to provide a specific type of plastic for the recycling process, which will be transformed into a recycled material. This step sets the foundation for the entire recycling process by ensuring that the input material is available. Next, the starting material undergoes a heating process. The heating is applied to the starting material using a heating unit or heating component. The purpose of heating the starting material is to prepare the PET polymer for the subsequent modification step in the recycling process. This preparation ensures that the material is in the state for the addition of modifiers, which will alter its properties to produce the desired recycled material. Following the heating, a modifier is added to the heated starting material. The modifier includes ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer. The purpose of adding this modifier is to chemically alter the starting material to produce a recycled material with properties suitable for displacing first-use polymers in product manufacturing. The addition of the modifier is a step as it directly influences the quality and characteristics of the recycled material, making it a viable alternative to first-use polymers and PVC (polyvinyl chloride). The recycling process is carried out using a recycling unit, which is
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT designed to recycle an initial polymer or plastic to produce a recycled material. The purpose of this recycling unit is to convert used polymers into reusable material, thereby creating an alternative to first-use polymers and PVC. The recycled material produced by this method can displace the use of first-use polymer or plastic and first-use PVC in producing products. This displacement promotes recycling and sustainability by reducing the reliance on virgin materials. In summary, the method for recycling a polymer or plastic involves obtaining a starting material that includes PET polymer, heating the starting material to prepare it for modification, adding a modifier to alter its properties, and using a recycling unit to produce a recycled material. This recycled material can replace first- use polymers and PVC in product manufacturing, thereby contributing to environmental sustainability and resource conservation. [00340] The logical experiments include starting material, heating, heating unit, and heating component. These entities are in the process of recycling a polymer or plastic, specifically in the preparation phase where the starting material is heated to facilitate the addition of modifiers. The starting material, which includes PET (polyethylene terephthalate) polymer, is obtained as the input for the recycling process. The purpose of obtaining a starting material that includes PET polymer is to provide a specific type of plastic for the recycling process, which will be transformed into a recycled material. This step ensures that the recycling process begins with the appropriate material that can be effectively modified and recycled. Heating the starting material is a step in the recycling process. The heating unit or heating component is configured to apply heat to the starting material. The purpose of heating the starting material is to prepare the PET polymer for the subsequent modification step in the recycling process. This preparation ensures that the material is in the state for the addition of modifiers, which will chemically alter its properties to produce a recycled material. The heating unit and heating component are designed to perform the process of heating. The heating unit is specifically configured to apply heat to the starting material, ensuring that the material reaches the required temperature for effective modification. This step directly impacts the efficiency and effectiveness of the recycling process. In the context of the PEs (above), the heating of the starting material is consistently emphasized. For instance, in PE 2, it is stated that the heating is applied to the starting material. Similarly, in PE 10, the heating unit is described
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT as being configured to apply heat to the starting material. These details highlight the importance of the heating step in the overall recycling process. The heating process prepares the starting material for the addition of a modifier, which includes ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer. The purpose of adding a modifier, which can be one of the listed copolymers or terpolymers, is to chemically alter the starting material to produce a recycled material with properties suitable for displacing first-use polymers in product manufacturing. This step ensures that the recycled material has the desired properties to replace first-use polymers or plastics in the production of new products. In summary, the entities in logical group 2, including the starting material, heating, heating unit, and heating component, play a role in the recycling process. The starting material, specifically PET polymer, is obtained and heated to prepare it for modification. The heating unit and heating component are designed to apply the necessary heat to the starting material, ensuring it is in the state for the addition of modifiers. This preparation is for producing a recycled material that can effectively displace first-use polymers or plastics in product manufacturing, promoting sustainability and reducing reliance on virgin materials. [00341] The method and system for recycling polymers or plastics, specifically focusing on polyethylene terephthalate (PET) polymers, begins with obtaining a starting material that includes a PET polymer for recycling. The purpose of obtaining this starting material is to provide a specific type of plastic for the recycling process, which will be transformed into a recycled material. This step sets the foundation for the entire recycling process. Next, the starting material is heated. The purpose of heating the starting material is to prepare the PET polymer for the subsequent modification step in the recycling process. This heating can be performed using a heating unit or a heating component, both of which are configured to apply heat to the starting material. This step ensures that the material is in the state for the addition of modifiers. Following the heating, a modifier is added to the heated starting material. The modifier includes ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer. The purpose of adding these modifiers is to chemically alter the starting material to produce a recycled material with properties suitable for displacing first-
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT use polymers in product manufacturing. This step is facilitated by a first addition unit for adding the copolymer modifier and a second addition unit for adding the terpolymer modifier. These units are designed to introduce the respective modifiers into the recycling process. The final step involves recycling the initial polymer or plastic to produce a recycled material. This step is carried out by a recycling unit, which is configured to recycle the initial polymer or plastic. The purpose of this recycled material is to serve as a substitute for first-use polymers or plastics in the production of new products, thus promoting recycling and sustainability. The recycled material is also operative to displace the use of first-use PVC (polyvinyl chloride) in producing products, offering an alternative that reduces the reliance on virgin PVC material. In summary, the method and system for recycling a polymer or plastic involve obtaining a PET polymer starting material, heating it, adding specific modifiers to alter its properties, and recycling it to produce a material that can replace first-use polymers and PVC in manufacturing. This process promotes sustainability and provides a viable alternative to using new, virgin materials in product manufacturing. [00342] The recycling unit is a component in the method for recycling a polymer or plastic, as it is configured to recycle an initial polymer or plastic to produce a recycled material. This process is for converting used polymers into reusable material, thereby promoting sustainability. The recycling unit's purpose is to produce a recycled material for use in manufacturing, which can displace the use of first-use polymers or plastics in producing products. This recycled material is designed to serve as a substitute for first- use polymers or plastics, including first-use PVC (polyvinyl chloride), thus reducing the reliance on virgin materials. The method for recycling involves several key steps, starting with obtaining a starting material that includes a PET (polyethylene terephthalate) polymer for recycling. The purpose of obtaining this starting material is to provide a specific type of plastic for the recycling process, which will be transformed into a recycled material. The starting material is then heated using a heating unit or heating component. The purpose of heating the starting material is to prepare the PET polymer for the subsequent modification step in the recycling process. Once the starting material is heated, a modifier is added to the heated starting material. The modifier can include ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT ethylene/glycidyl methacrylate copolymer. The purpose of adding this modifier is to chemically alter the starting material to produce a recycled material with properties suitable for displacing first-use polymers in product manufacturing. The first addition unit is configured to add the copolymer modifier, while the second addition unit is configured to add the terpolymer modifier to the mixture of the heated polymer material and the copolymer modifier. The recycled material produced by this method can displace the use of first-use polymers or plastics in producing products. This includes the ability to displace the use of first-use PVC (polyvinyl chloride) in producing products. The purpose of the recycled material is to serve as an alternative to first-use polymers and PVC, thereby promoting recycling and reducing the environmental impact of plastic waste. In summary, the recycling unit, along with the method for recycling, plays a role in transforming used polymers into reusable materials. By obtaining a starting material that includes PET polymer, heating it, and adding specific modifiers, the process produces a recycled material that can replace first-use polymers and PVC in product manufacturing. This promotes sustainability and reduces the reliance on virgin materials, contributing to a more environmentally friendly approach to plastic recycling. [00343] The process of recycling a polymer or plastic, specifically focusing on the production of a recycled material that can replace first-use polymers and PVC in manufacturing, involves several steps and components. The method begins with obtaining a starting material that includes a PET (polyethylene terephthalate) polymer for recycling. This step provides the material for the recycling process, ensuring that the specific type of plastic, PET, is available for transformation into a recycled material. Once the starting material is obtained, it undergoes heating. The heating component or heating unit is configured to apply heat to the starting material, preparing it for the addition of modifiers. The purpose of heating the starting material is to prepare the PET polymer for the subsequent modification step in the recycling process. This step ensures that the material is in the state for effective modification. Following the heating process, a modifier is added to the heated starting material. The modifier includes ethylene/acrylate copolymer, ethylene/acrylate/glycidyl methacrylate terpolymer, and/or ethylene/glycidyl methacrylate copolymer. The addition of these modifiers is carried out by a first addition unit and a second addition unit, which are configured to add the copolymer and terpolymer
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT modifiers, respectively. The purpose of adding these modifiers is to chemically alter the starting material to produce a recycled material with properties suitable for displacing first- use polymers in product manufacturing. This step modifies the properties of the starting material, making it suitable for use as a recycled material. The recycling unit then takes over to recycle the initial polymer or plastic, producing a recycled material. The purpose of this unit is to carry out the recycling process and produce the recycled material. The recycled material that is produced can displace the use of a first-use polymer or plastic in producing products. Additionally, it is operative to displace the use of first-use PVC (polyvinyl chloride) in producing products. This aspect of the process promotes sustainability by reducing the reliance on virgin materials and encouraging the use of recycled materials in manufacturing. In summary, the method for recycling a polymer or plastic involves obtaining a starting material that includes PET polymer, heating the starting material, adding a modifier to the heated material, and recycling the initial polymer or plastic to produce a recycled material. This recycled material can replace first-use polymers and PVC in product manufacturing, thereby promoting sustainability and reducing the need for new, virgin materials. The detailed steps and components involved in this process ensure that the recycled material produced is of high quality and suitable for various manufacturing applications. REFERENCES:
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ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT [00344] All patents and other publications; including literature references, issued patents, published patent applications, and co-pending patent applications; cited throughout this application are expressly incorporated herein by reference for the purpose of describing and disclosing, for example, the methodologies described in such publications that might be used in connection with the technology described herein. These publications are provided solely for their disclosure prior to the filing date of the present application. Nothing in this regard should be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention or for any other reason. All statements as to the date or representation as to the contents of these documents is based on the information available to the applicants and does not constitute any admission as to the correctness of the dates or contents of these documents. [00345] The foregoing written specification is considered to be sufficient to enable one skilled in the art to practice the present aspects and embodiments. The present aspects and embodiments are not to be limited in scope by examples provided, since the examples are intended as a single illustration of one aspect and other functionally equivalent embodiments are within the scope of the disclosure. Various modifications in addition to those shown and described herein will become apparent to those skilled in the art from the foregoing description and fall within the scope of the appended claims. The advantages and objects described herein are not necessarily encompassed by each embodiment. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments described herein. Such equivalents are intended to be encompassed by the following exemplary claims.
[00104] The term "rPET” refers to recycled PET (polyethylene terephthalate) plastic. The term “rPETG” generally refers to a recycled, glycol modified version of polyethylene terephthalate (PETG, polyethylene terephthalate glycol or PET-G). A generalized, non- limiting, example of a structure of PETG is shown below:
ATTORNEY DOCKET NO.: 408169-521001WO PCT PATENT .
refers to polyvinyl chloride: