Polymer Manufacturing Process

Abstract

A process utilizing PET as a reactive constituent to manufacture other polymers containing the pre-condensed moieties by the rapid transesterification of the condensation polymer with a pre-made modifying polymer containing the desired mix of other monomers. The process involves as a first step the manufacture of a modifying polymer containing the desired mix of acids and alcohols to a specific molecular weight such molecular weight dependent on the desired final level of utilized condensation polymer and the finished molecular weight. The second step of the process involves the rapid buildup of molecular weight and/or polymer uniformity by the rapid transesterification of the condensation polymer with the modifying polymer. The second step can be performed in any suitable vessel including an extrusion line. The process has the advantage of greatly reduced cycle times over other condensation polymer utilization processes such as the recycling of PET into other materials.

1 . A process for utilizing a commercially available condensation polymer, without degradation, to modify a modifying polymer to a higher molecular weight final polymer, said process comprising the steps of first synthesizing a modifying polymer from a plurality of monomers and second transesterifying the modifying polymer with said commercially available condensation polymer at a quantity predetermined by the end use application to produce said higher molecular weight final polymer.  
     
     
         2 . The process of  claim 1  wherein said commercially available condensation polymer is polyethylene terephthalate.  
     
     
         3 . The process of  claim 1  wherein said commercially available condensation polymer is polyethylene napthalate.  
     
     
         4 . The process of  claim 1  wherein said higher molecular weight final polymer is a polyol.  
     
     
         5 . The process of  claim 1  wherein said higher molecular weight final can be used as a hot melt adhesive.  
     
     
         6 . The process of  claim 1  wherein said higher molecular weight final polymer can be used as a film forming coating.  
     
     
         7 . The process of  claim 1  wherein said higher molecular weight final polymer can be used as a powder coating resin or component of a fusible coating system.  
     
     
         8 . The process of  claim 1  wherein said higher molecular weight final polymer can be used as a flexible film.  
     
     
         9 . The process of  claim 1  wherein said higher molecular weight polymer can used as an unsaturated resin for casting.  
     
     
         10 . The process of  claim 3  further comprising the step of reacting said polyol with an isocyanate to produce a polyurethane.  
     
     
         11 . A process for utilizing a commercially available condensation polymer, without degradation, to modify a modifying polymer to a higher molecular weight final polymer, said final polymer having a molecular weight greater than 192 g/mol, said process comprising the steps of first synthesizing a modifying polymer from a plurality of monomers, said first synthesizing step occurring at a reaction time of about 1 hour to about 5 hours and at a temperature of about 150 degrees Centigrade to about 270 degrees Centigrade, and second transesterifying the modifying polymer with said commercially available condensation polymer at a quantity predetermined by the end use application, said second transesterifying step occurring at a reaction time of less than about 3 hours and at a temperature of about 200 degrees Centigrade to about 290 degrees Centigrade to produce said higher molecular weight final polymer.  
     
     
         12 . The process of  claim 11  wherein said commercially available condensation polymer is polyethylene terephthalate.  
     
     
         13 . The process of  claim 11  wherein said commercially available condensation polymer is polyethylene napthalate.  
     
     
         14 . The process of  claim 11  wherein said higher molecular weight final polymer is a polyol.  
     
     
         15 . The process of  claim 11  wherein said higher molecular weight final can be used as a hot melt adhesive.  
     
     
         16 . The process of  claim 11  wherein said higher molecular weight final polymer can be used as a film forming coating.  
     
     
         17 . The process of  claim 11  wherein said higher molecular weight final polymer can be used as a powder coating resin or component of a fusible coating system.  
     
     
         18 . The process of  claim 11  wherein said higher molecular weight final polymer can be used as a flexible film.  
     
     
         19 . The process of  claim 11  wherein said higher molecular weight polymer can used as an unsaturated resin for casting.  
     
     
         20 . The process of  claim 13  further comprising the step of reacting said polyol with an isocyanate to produce a polyurethane.