Chain extension reaction in solid-state polymerization of recycled PET: The influence of 2,2′-bis-2-oxazoline and pyromellitic anhydride

Extrusion and characterization of recycled polyethylene terephthalate (rPET) filaments compounded with chain extender and impact modifiers for material-extrusion additive manufacturing

The continuous growth of annual production and consumption of polyethylene terephthalate (PET) is coined with increasing waste that leaks into the environment, landfills and oceans as microplastics and nano plastics fragments. Upcycling the recycled PET to make a feedstock for the fast-growing material-extrusion additive manufacturing (MEX-AM) technology can contribute to the solution and supports the concept of sustainable materials. In this work, extrudable filaments comprising recycled polyethylene terephthalate (rPET) with low-cost additives, such as pyromellitic dianhydride (PMDA) as a chain extender, styrene-ethylene-butylene-styrene terpolymer functionalized with maleic anhydride (SEBS-g-MA), a thermal modifier and toughening agent, ethylene-ethyl acrylate-glycidyl methacrylate terpolymer (E-EA-GMA), a functional reactive elastomeric impact modifier and ethylene-ethyl-acrylate (EEA), a non-reactive elastomeric impact modifier, have been fabricated using the twin-screw extruder. The optimum extrusion process parameters for producing uniform filaments of different rPET compounded formulations have been identified, this includes the extrusion die temperature of 280 °C and the screw speed of 150 ± 3 rpm. The compounded filaments are then printed into standard ASTM test specimens for thermal characterization and mechanical characterization, including glass transition and melting temperatures, crystallinity and crystallization temperature, tensile strength, tensile modulus, ductility, flexural strength, and Izod impact energy. Furthermore, the melt flow index for the filaments was measured. More significantly, the experimental data showed that compounding rPET with such additives in the reactive twin-screw extrusion process results in uniform filaments that display advantageous thermal and mechanical properties and can be used as a feedstock in the MEX-AM technology. This study suggests that compounding the recycled PET pellets with low-cost additives while extruding them into filaments for MEX-AM offers excellent potential to make high-value-added customized products from a sustainable polymer feedstock, such as prototyping, tooling, testing components or end-use internal components for small machines and cars.

Mechanical Recycling of Partially Bio-Based and Recycled Polyethylene Terephthalate Blends by Reactive Extrusion with Poly(styrene-co-glycidyl methacrylate)

In the present study, partially bio-based polyethylene terephthalate (bio-PET) was melt-mixed at 15-45 wt% with recycled polyethylene terephthalate (r-PET) obtained from remnants of the injection blowing process of contaminant-free food-use bottles. The resultant compounded materials were thereafter shaped into pieces by injection molding for characterization. Poly(styrene-co-glycidyl methacrylate) (PS-co-GMA) was added at 1-5 parts per hundred resin (phr) of polyester blend during the extrusion process to counteract the ductility and toughness reduction that occurred in the bio-PET pieces after the incorporation of r-PET. This random copolymer effectively acted as a chain extender in the polyester blend, resulting in injection-molded pieces with slightly higher mechanical resistance properties and nearly the same ductility and toughness than those of neat bio-PET. In particular, for the polyester blend containing 45 wt% of r-PET, elongation at break (ε_b) increased from 10.8% to 378.8% after the addition of 5 phr of PS-co-GMA, while impact strength also improved from 1.84 kJ·m^-2 to 2.52 kJ·m^-2. The mechanical enhancement attained was related to the formation of branched and larger macromolecules by a mechanism of chain extension based on the reaction of the multiple glycidyl methacrylate (GMA) groups present in PS-co-GMA with the hydroxyl (-OH) and carboxyl (-COOH) terminal groups of both bio-PET and r-PET. Furthermore, all the polyester blend pieces showed thermal and dimensional stabilities similar to those of neat bio-PET, remaining stable up to more than 400 °C. Therefore, the use low contents of the tested multi-functional copolymer can successfully restore the properties of bio-based but non-biodegradable polyesters during melt reprocessing with their recycled petrochemical counterparts and an effective mechanical recycling is achieved.

Improving the properties of recycled PET/PEN blends by using different chain extenders

The main aim of this study was to improve the mechanical properties of the recycled poly(ethylene terephthalate)/poly(ethylene 2,6-naphthalate) (r-PET/PEN) blends by enhancing the miscibility between PET and PEN with the usage of chain extenders. This idea was novel for the recycled PET-based r-PET/PEN blends, as investigation of the effects of the chain extender usage on the properties of r-PET/PEN blends has not been studied in the literature, according to our knowledge. 1,4-Phenylene-bis-oxazoline (PBO), 1,4-phenylene-di-isocyanate (PDI), and triphenyl phosphite (TPP) were selected as chain extenders. The maximum tensile strength value was observed for the 1.0PDI sample. Moreover, PDI-based blends exhibited better Izod impact strength when compared with all other samples. The miscibility and degree of crystallinity values of all blends were discussed by means of thermal analysis. 1H-nuclear magnetic resonance (1H-NMR) analysis was carried out to determine transesterification reaction levels. According to 1H-NMR results, the increase in the level of transesterification was around 40% with the usage of PDI. The optimum loading level for selected chain extenders was determined as 1 wt.%, and PDI-based blends exhibited better properties when compared with those of the blends based on PBO and TPP at this loading level.

Performance improvement of flame-retarded poly(butylene terephthalate)/aluminum diethylphosphinate composites by epoxy-functional polysiloxane

An epoxy-functional polysiloxane (EPM) was employed for improving the performance of flame-retarded poly(butylene terephthalate)/aluminum diethylphosphinate (PBT/AlPi) composites. The effect was investigated by UL-94 test, limiting oxygen index, mechanical test, torque rheometer measurement, differential scanning calorimetry, dynamic mechanical analysis, and heat distortion temperature. An obvious increase in torque evolution of the PBT/AlPi composite during processing was associated with chain-extending, branching, and cross-linking reaction by the combination of EPM. The addition of 0.6 wt% EPM remarkably enhanced not only the mechanical properties but also the flame retardancy and heat resistance of the PBT/AlPi composite. A high-performance PBT/AlPi composite was developed by virtue of EPM.