Recycled polyethylene terephthalate compositions, fibers and articles produced therefrom, and methods for producing same
In one aspect, the invention relates to recycled polyethylene terephthalate compositions, fibers and articles produced therefrom, and methods for producing same. In a further aspect, the invention relates to homogenized post-consumer polyethylene terephthalate. In a further aspect, the invention relates to extruded polymer compositions, polymer mixtures, fibers, and/or Bulked Continuous Filament fibers comprising post-consumer polyethylene terephthalate. In a further aspect, the invention relates to processes for preparing recycled polyethylene terephthalate compositions. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present invention.
1. An extruded polymer composition comprising polyethylene terephthalate present as from about 25% to about 100% homogeneously blended deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate, wherein the homogeneously blended deposit post-consumer polyethylene terephthalate comprises impurities absent from virgin polyethylene terephthalate; wherein the impurities comprise floatable contamination in an amount less than 15 ppm, PVC contamination in an amount less than 50 ppm, green PET contamination in an amount less than 1000 ppm, and black PET contamination in an amount less than 25 ppm, and wherein the homogeneously blended deposit post-consumer polyethylene terephthalate comprises one or more of the following specifications: bulk density (lb/ft 3 ) of 20-27 and pressure rise (psi per pound) of <75 psi/lb.
2. The composition of claim 1 , wherein the polyethylene terephthalate is present as at least about 50% homogeneously blended deposit post-consumer polyethylene terephthalate by weight.
3. The composition of claim 1 , wherein the polyethylene terephthalate is present as at least about 75% homogeneously blended deposit post-consumer polyethylene terephthalate by weight.
4. A polymer mixture comprising polyethylene terephthalate present as from about 25% to about 100% homogeneous deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate, wherein the homogeneously blended deposit post-consumer polyethylene terephthalate comprises impurities absent from virgin polyethylene terephthalate; wherein the impurities comprise floatable contamination in an amount less than 15 ppm, PVC contamination in an amount less than 50 ppm, green PET contamination in an amount less than 1000 ppm, and black PET contamination in an amount less than 25 ppm and wherein the homogeneously blended deposit post-consumer polyethylene terephthalate comprises one or more of the following specifications: bulk density (lb/ft 3 ) of 20-27 and pressure rise (psi per pound) of <75 psi/lb.
5. The mixture of claim 4 , wherein the polyethylene terephthalate is present as at least about 50% homogeneously blended deposit post-consumer polyethylene terephthalate by weight.
6. The mixture of claim 4 , wherein the polyethylene terephthalate is present as at least about 75% homogeneously blended deposit post-consumer polyethylene terephthalate by weight.
7. A fiber comprising the extruded polymer composition of claim 1 .
8. The fiber of claim 7 , wherein the polyethylene terephthalate is present as at least about 50% deposit post-consumer polyethylene terephthalate by weight.
9. The fiber of claim 7 , wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.
10. A Bulked Continuous Filament extruded fiber comprising the extruded polymer composition of claim 1 .
11. The fiber of claim 10 , wherein the polyethylene terephthalate is present as at least about 50% deposit post-consumer polyethylene terephthalate by weight.
12. The fiber of claim 10 , wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.
13. A carpet comprising the fiber of claim 7 .
14. An extruded polymer composition comprising polyethylene terephthalate present as from about 50% to about 100% homogeneously blended deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate, wherein the homogeneously blended deposit post-consumer polyethylene terephthalate comprises impurities absent from virgin polyethylene terephthalate; wherein the impurities comprise floatable contamination in an amount less than 15 ppm, PVC contamination in an amount less than 50 ppm, green PET contamination in an amount less than 1000 ppm, and black PET contamination in an amount less than 25 ppm and wherein the homogeneously blended deposit post-consumer polyethylene terephthalate comprises one or more of the following specifications: bulk density (lb/ft 3 ) of 20-27 and pressure rise (psi per pound) of <75 psi/lb.
15. The composition of claim 14 , wherein the polyethylene terephthalate is present as at least about 75% homogeneously blended deposit post-consumer polyethylene terephthalate by weight.
16. The composition of claim 14 , wherein the polyethylene terephthalate is present as at least about 90% homogeneously blended deposit post-consumer polyethylene terephthalate by weight.
17. A polymer mixture comprising polyethylene terephthalate present as from about 50% to about 100% homogeneous deposit post-consumer polyethylene terephthalate by weight and balance virgin polyethylene terephthalate, wherein the homogeneously blended deposit post-consumer polyethylene terephthalate comprises impurities absent from virgin polyethylene terephthalate; wherein the impurities comprise floatable contamination in an amount less than 15 ppm, PVC contamination in an amount less than 50 ppm, green PET contamination in an amount less than 1000 ppm, and black PET contamination in an amount less than 25 ppm and wherein the homogeneously blended deposit post-consumer polyethylene terephthalate comprises one or more of the following specifications: bulk density (lb/ft 3 ) of 20-27 and pressure rise (psi per pound) of <75 psi/lb.
18. The mixture of claim 17 , wherein the polyethylene terephthalate is present as at least about 75% homogeneously blended deposit post-consumer polyethylene terephthalate by weight.
19. The mixture of claim 17 , wherein the polyethylene terephthalate is present as at least about 90% homogeneously blended deposit post-consumer polyethylene terephthalate by weight.
20. A fiber extruded from the polymer mixture of claim 17 .
21. The fiber of claim 20 , wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.
22. The fiber of claim 20 , wherein the polyethylene terephthalate is present as at least about 90% deposit post-consumer polyethylene terephthalate by weight.
23. A Bulked Continuous Filament extruded fiber comprising the polymer mixture of claim 17 .
24. The fiber of claim 23 , wherein the polyethylene terephthalate is present as at least about 75% deposit post-consumer polyethylene terephthalate by weight.
25. The fiber of claim 23 , wherein the polyethylene terephthalate is present as at least about 90% deposit post-consumer polyethylene terephthalate by weight.
26. A carpet comprising a fiber comprising the polymer mixture of claim 17 .