18 patents in this list

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Manufacturing polyethylene terephthalate (PET) packaging with recycled content presents specific molecular challenges. Current mechanical recycling methods result in materials with intrinsic viscosity values above 0.62 dl/g, leading to processing difficulties and increased film breakage during biaxial orientation. When combined with thermal degradation during reprocessing, these higher viscosity materials can compromise both production efficiency and final product quality.

The fundamental challenge lies in achieving the optimal balance between molecular weight distribution and processability while maintaining the mechanical and barrier properties required for packaging applications.

This page brings together solutions from recent research—including controlled depolymerization techniques, specific surface crystallinity modifications, molecular weight distribution management, and novel laminate architectures. These and other approaches demonstrate how chemical recycling can be optimized to produce PET with intrinsic viscosity below 0.62 dl/g while maintaining critical performance parameters for packaging applications.

1. Laminate Incorporating Chemically Recycled Resin with High Purity and Reduced Thermal Degradation

TOPPAN HOLDINGS INC, 2024

Laminate for packaging materials, containers, and articles that can improve hygiene and quality even when the recycled resin content is high. The laminate uses chemically recycled resin instead of material recycled resin. Chemically recycled resin is made by converting discarded resin into a low molecular weight form and then polymerizing it, rather than cleaning and melting used packaging materials. This reduces impurities and thermal degradation compared to material recycling. The laminate has at least 10% vol or mass of chemically recycled resin.

WO2024228274A1-patent-drawing

2. Biaxially Oriented Polyester Film Incorporating Chemically Recycled Polyester with Defined Surface Crystallinity, Molar Content, and Intrinsic Viscosity

東洋紡株式会社, TOYOBO CO LTD, 2024

Biaxially oriented polyester film for packaging with improved mechanical properties, reduced environmental impact, and reduced breakage during production. The film contains chemically recycled polyester with specific surface crystallinity, molar content, and intrinsic viscosity ranges. The chemically recycled polyester prevents film breakage during stretching and improves mechanical properties like strength and puncture resistance. The surface crystallinity range allows lower molecular weight polyester that balances crystallinity, toughness, and stress. The molar content range improves sealant adhesion. The intrinsic viscosity range further reduces stress and breakage.

JP7514434B2-patent-drawing

3. Biaxially Oriented Polyester Film with Controlled Low Molecular Weight Chemically Recycled Polyester Composition

TOYOBO CO LTD, 2024

Biaxially oriented polyester film containing chemically recycled polyester to reduce environmental impact and yellow tone. The film has a specific composition of chemically recycled polyester with low levels of low molecular weight components. This prevents film breakage during stretching. The chemically recycled polyester has an inherent viscosity lower than regular polyester, but similar to mechanically recycled polyester. The low molecular weight component content is controlled to avoid excessive breakage. The chemically recycled polyester is derived from decomposing and polymerizing the polyester from used bottles.

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4. Biaxially Oriented Polyester Film Comprising Chemically Recycled Polyester with Specific Molecular Weight Characteristics

TOYOBO CO LTD, 2024

Biaxially oriented polyester film made from chemically recycled polyester with improved properties compared to using mechanically recycled polyester. The chemically recycled polyester used in the film has specific molecular weight characteristics. It has an intrinsic viscosity below 0.62 dl/g and a low percentage (<3.5%) of low molecular weight components with a molecular weight of 1000 or less. This chemically recycled polyester can be blended with fossil fuel-derived polyester to make the film. The film has reduced environmental impact from using recycled polyester, improved tensile strength, puncture strength, and reduced breakage during stretching compared to using mechanically recycled polyester.

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5. Gas Barrier Films with Chemically Recycled Polyester and Specific Composition to Prevent Cracking

TOYOBO CO LTD, 2024

Gas barrier films, laminates, and packaging containers that use chemically recycled polyester to reduce environmental impact and yellow tint while improving gas barrier properties. The films have specific compositions to prevent cracking during stretching. The chemically recycled polyester has a low area ratio of low molecular weight components, <3.5% of the total peak area, and low alkaline earth metal content. This reduces pollution during recycling and improves hygiene. The films can be used in laminates and packaging.

6. Gas Barrier Film with Chemically Recycled Polyester and Specific Low Molecular Weight Composition

TOYOBO CO LTD, 2024

Gas barrier films, laminates, and packaging containers with improved gas barrier properties, reduced yellowing, and reduced film breakage during manufacturing. The films contain chemically recycled polyester with a specific low molecular weight composition. The chemically recycled polyester has an area ratio of 1.9-5.5% for components with molecular weight 1000 or less in the biaxially oriented film. This balances low molecular weight components for gas barrier properties against reducing yellowing and film strength issues. The films can also have coatings, protective layers, and compositions with oxazoline or urethane groups to further enhance adhesion and barrier performance. The compositions can be used in laminates and containers with improved sealing and barrier properties.

JP2024018189A-patent-drawing

7. Biaxially Oriented Polyester Film with Controlled Low Molecular Weight Component Distribution

TOYOBO CO LTD, 2024

Biaxially oriented polyester film with reduced environmental impact, yellowing, and breakage during stretching. The film contains chemically recycled polyester with specific molecular weight properties. The chemically recycled polyester has a low percentage (1.9-5.5%) of low molecular weight components (MW < 1000) compared to the total peak area in the GPC curve. This limits yellowing and allows for controlled molecular weight to prevent excessive stretching stress during film formation. The film can be used in laminates and packaging containers.

8. Gas Barrier Film with Chemically Recycled Polyester and Controlled Molecular Weight Distribution

TOYOBO CO LTD, 2024

Gas barrier films, laminates, and packaging containers with improved gas barrier properties, reduced yellowness, and reduced breakage during stretching. The films contain chemically recycled polyester with specific molecular weight distribution. The films have a low area (1.9-5.5%) of region with molecular weight <1000. This limits low molecular weight components that can cause yellowing and breakage. The films can be used in gas barrier laminates and containers.

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9. Biaxially Oriented Polyester Films with Specific Molecular Weight Distribution

TOYOBO CO LTD, 2024

Biaxially oriented polyester films, laminates, and packaging containers with reduced environmental impact, yellowing, and film breakage during stretching compared to conventional biaxially oriented polyester films. The films contain chemically recycled polyester with a specific molecular weight distribution. The area ratio of the region with a molecular weight of 1000 or less is 1.9-5.5% of the total peak area in the GPC curve. This limits low molecular weight components while still allowing some for stability. It reduces yellowing and breakage. The films can be laminated or used in packaging containers.

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10. Biaxially Oriented Polyester Films with Chemically Recycled Polyester Exhibiting Specific Surface Crystallinity and Melting Point

TOYOBO CO LTD, 2024

Biaxially oriented polyester films with improved properties like tensile and puncture strength for packaging applications. The films contain chemically recycled polyester with specific surface crystallinity and melt point ranges. This allows reducing environmental impact while preventing film breakage during stretching. The chemically recycled polyester has a surface crystallinity of 1.10-1.31 and a melting point of 251°C or higher. The surface crystallinity limits molecular weight and provides plasticizer-like components to prevent excessive stretching stress. The higher melt point improves heat resistance. The films can have a chemically recycled polyester layer or multiple layers.

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11. Shrink Film for PET Bottles Comprising Recycled PET Resin with Controlled Haze and Chromaticity

タキロンシーアイ株式会社, ボンセット アメリカ コーポレーション, BONSET AMERICA CORP, 2023

PET bottle with a shrink film derived from a recycled PET resin that maintains transparency and colorlessness when molded into a predetermined shape and recycled. The recycled PET content is 20-50% by weight. The shrink film has low haze and chromaticity coordinates. It uses amorphous PET and limits molecular weight to maintain transparency when recycled. The film is thermally shrunk onto the PET bottle.

12. Gas Barrier Film with Chemically Recycled Polyester and Inorganic Thin Film Layer

東洋紡株式会社, TOYOBO CO LTD, 2023

Gas barrier films, laminates, and packaging containers with reduced environmental impact, improved gas barrier properties, and reduced film breakage during manufacturing. The films contain chemically recycled polyester with specific molecular weight distribution. The recycled polyester has a low content of low molecular weight components, below 5.5% of the total peak area in the GPC curve. This reduces yellowing and film defects. The films also have a small region with molecular weight <1000, 1.9-5.5%. This restricts polyester molecular weight. The films have an inorganic thin film layer for gas barrier. The coating layer between the polyester and inorganic layer improves adhesion. The protective layer on the thin film further reduces gas permeation. The films can be used in laminates and packaging containers.

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13. Printing Resin Film with Recycled Polyester and Controlled Molecular Weight Distribution

DAINIPPON PRINTING CO LTD, 2022

A printing resin film, laminate, and packaging container with reduced environmental impact and improved hygiene. The printing resin film contains a base polyester film with specific properties. The polyester film is made from recycled polyester sources like chemically recycled, mechanically recycled, fossil fuel, or biomass polyesters. The film has a low content of low molecular weight regions (<1000 Da) in the molecular weight distribution. This reduces the migration of low molecular weight components to other layers like seals during storage. The film also has specific melting and crystallization temperatures, and friction properties. This reduces contamination and migration of polyester components into packed goods. The laminate and packaging container can use this printed film to achieve lower environmental impact and improved hygiene.

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14. Resin Film with Chemically Recycled Polyester and Controlled Low Molecular Weight Fraction

DAI NIPPON PRINTING CO LTD, DAINIPPON PRINTING CO LTD, 2021

Printing resin film, laminate, and packaging containers with reduced environmental impact and improved hygiene. The film is made of a chemically recycled polyester base with a low molecular weight fraction of 1000 Da or less accounting for 1.8% or less of the total peak area. This reduces contamination migration into fillings. The chemically recycled polyester can be polyethylene terephthalate. The film may have layers containing chemically recycled, mechanically recycled, fossil fuel, and biomass polyesters. The low molecular weight fraction prevents contaminant migration when rolled. The laminate and containers use this film.

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15. Coextruded Multilayer Film Web with Foamed PET Core and Sealable PET Layer

REIFENHAEUSER GMBH & CO KG MASCHF, REIFENHÄUSER GMBH & CO KG MASCHINENFABRIK, 2019

Coextruded multilayer film web for food packaging that has improved reliability during production and adhesion between layers. The film web has a first layer made of a foamed PET with low molecular weight (Mn < 20,000) and intrinsic viscosity (0.7-0.79) for better recyclability. The second layer is a sealable PET with higher intrinsic viscosity (0.7-0.9) for sealing at temperatures between 120-180°C. The thin second layer on the foamed first layer provides sealing capability while maintaining the benefits of the foamed layer like cushioning and reduced weight.

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16. Food Packaging Film with Low Molecular Weight Polyester Plasticizer and Integrated Cutting Mechanism

HITACHI CHEMICAL CO LTD, HITACHI CHEMICAL COMPANY LTD, 2017

Food packaging film that reduces additive migration into packaged food. The film contains a thermoplastic resin, a blue colorant, and a polyester plasticizer with a molecular weight of 1000 to 1800. The lower molecular weight polyester plasticizer helps suppress additive migration into the food compared to higher molecular weight plasticizers. The film has good stretchability for packaging and is used in small roll form with a color box for easy cutting. The color box contains the film and a core material, and a knife is set inside the box to cut the film. This allows precise film cutting without contaminating the film surface.

17. Thermoplastic Polyester Composition with Ethylene Glycol and Pyromellitic Dianhydride for Enhanced Gas Barrier and Mechanical Properties

ANHEUSER-BUSCH INBEV SA, 2017

Thermoplastic polyester composition for blow molded containers that provides good gas barrier properties and enhanced mechanical properties like impact resistance compared to traditional polyester compositions. The composition contains a high percentage (90-97%) of a polyester like PET or PEN, along with specific additives like ethylene glycol and pyromellitic dianhydride. These additives reduce the molecular weight and increase branching of the polyester, allowing lower melt viscosity without compromising crystallinity. This enables cost-effective production of containers with improved barrier properties and impact resistance compared to using higher molecular weight polyesters. The containers have good gas barrier properties and burst pressure.

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18. Composition of Renewable Diols Derived from Lignocellulosic Biomass via Catalytic Sugar Conversion

バイオケミテックス エス.ピー.エー., 2016

A composition of diols derived from renewable sources that can be used as a replacement for petroleum-derived diols in the production of polyesters like PET. The composition contains a mix of diols, some of which are biological diols derived from lignocellulosic biomass. The diols are obtained by converting soluble sugars from the lignocellulosic feedstock using catalysis. The composition aims to provide diols with similar properties to petroleum diols like ethylene glycol for PET production, but with better optical properties for packaging applications.

JP2016530172A-patent-drawing

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