FILM MADE OF RECYCLED PLASTIC MATERIAL FOR WEARABLE DATA STORAGE MEDIA, A PROCESS FOR PRODUCING THE RECYCLED FILM AND DATA STORAGE MEDIA CONTAINING THE RECYCLED FILM
20220106449 · 2022-04-07
Inventors
Cpc classification
Y02W30/62
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
C08J2379/08
CHEMISTRY; METALLURGY
C08J2407/00
CHEMISTRY; METALLURGY
C08J2367/02
CHEMISTRY; METALLURGY
Y02W90/00
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
Abstract
A plastic foil suitable for manufacturing a data carrier includes at least one layer having a thermoplastic material recycled from mixed plastic waste. A method of manufacturing the plastic foil, to a data carrier with the plastic foil, and to a data carrier recyclate based on a polyolefin material, on a polyester material or on a polyamide material, are provided from mixed plastic waste.
Claims
1.-15. (canceled)
16. A method of producing a thermoplastic material based on a polyolefin, a polyester or a polyamide from mixed plastic waste, wherein the plastic material is suitable for manufacturing a plastic foil for a data carrier, comprising (a) providing a polyolefin material, a polyester material or a polyamide material, which was separated as pure in type as possible from mixed plastic waste, (b) compounding the polyolefin material, the polyester material or the polyamide material with additives for improving the chemical and/or mechanical and/or optical properties in order to obtain a polyolefin regenerate, a polyester regenerate or a polyamide regenerate which is suitable for manufacturing a plastic foil; and (c) modifying the polyolefin material with a thermoplastic olefin elastomer and/or a thermoplastic rubber vulcanizate, or the polyester material with a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer, or the polyamide material with a thermoplastic polyamide elastomer and/or a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer, in order to obtain a data carrier recyclate based on a polyolefin, on a polyester or on a polyamide, wherein the data carrier recyclate is suitable for manufacturing a plastic foil for a data carrier.
17. A data carrier recyclate based on a thermoplastic polyolefin material, on a thermoplastic polyester material or on a thermoplastic polyamide material, which was separated as pure in type as possible from mixed plastic waste, wherein the data carrier recyclate includes additives for improving the chemical and/or mechanical and/or optical properties and at least one modifying agent which makes it suitable for manufacturing a plastic foil for a data carrier, wherein the modifying agent in the case of a polyolefin material, is a thermoplastic olefin elastomer and/or a thermoplastic rubber vulcanizate, in the case of a polyester material, is a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer, and in the case of a polyamide material, is a thermoplastic polyamide elastomer and/or a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer.
18. The data carrier recyclate according to claim 17, wherein the thermoplastic olefin elastomer and/or the thermoplastic rubber vulcanizate is a block copolymer with a polyolefin-based polymer as hard segment and an ethylene-propylene-diene monomer as soft segment, the thermoplastic copolyester elastomer is a block copolymer with a butylene terephthalate block as hard segment and a butylene glycol ether block as soft segment, the thermoplastic urethane elastomer is a block copolymer with a polyurethane block as hard segment and a polyester block as soft segment, and the thermoplastic polyamide elastomer is a block copolymer with a polyamide block as hard segment and a polyether block as soft segment.
19. The data carrier recyclate according to claim 17, wherein the data carrier recyclate includes in the case of a polyolefin material, 2.5-20 wt %, preferably 5-10 wt %, thermoplastic olefin elastomer and/or thermoplastic rubber vulcanizate, in the case of a polyamide material, 2.5-20 wt %, preferably 5-10 wt %, thermoplastic polyamide elastomer and/or copolyester elastomer and/or urethane elastomer, and in the case of a polyester material, 2.5-15 wt %, preferably 5-7 wt %, of thermoplastic copolyester elastomer and/or thermoplastic urethane elastomer.
20. A plastic foil which is suitable for manufacturing a data carrier and comprises at least one layer which includes a thermoplastic material which was recycled from mixed plastic waste, wherein the at least one layer comprises a data carrier recyclate according to claim 17.
21. The plastic foil according to claim 20, wherein the foil is a multilayer composite foil having an inner layer and at least two further layers, and wherein at least the inner layer includes a data carrier recyclate.
22. The plastic foil according to claim 21, wherein in each layer which includes a data carrier recyclate the portion of recyclate is the higher the further inward in the layer composite the layer is located.
23. The plastic foil according to claim 21, wherein the inner layer includes 90-98 wt. % recyclate and the outer layers, independently of each other, include 0-70 wt. % recyclate.
24. The plastic foil according claim 20, which consists of one single layer with a portion of recyclate of 50-95 wt %.
25. A method of manufacturing a plastic foil which is suitable for manufacturing a data carrier and comprises at least one layer which includes a thermoplastic material which was recycled from mixed plastic waste, comprising the following steps: feeding at least one extruder with a data carrier recyclate according to claim 17, or a material forming a data carrier recyclate according to claim 17, which comprises a polyolefin regenerate or a polyester regenerate or a polyamide regenerate, which was obtained by carrying out the steps of providing a polyolefin material, a polyester material or a polyamide material, which was separated as pure in type as possible from mixed plastic waste, and compounding the polyolefin material, the polyester material or the polyamide material with additives for improving the chemical and/or mechanical and/or optical properties in order to obtain a polyolefin regenerate, a polyester regenerate or a polyamide regenerate which is suitable for manufacturing a plastic foil; and a modifying agent, wherein the modifying agent in the case of a polyolefin material, is a thermoplastic olefin elastomer and/or a thermoplastic rubber vulcanizate, in the case of a polyester material, is a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer, and in the case of a polyamide material, is a thermoplastic polyamide elastomer and/or a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer, and extruding the data carrier recyclate in order to obtain a data carrier recycling foil.
26. The method according to claim 25, wherein a multilayer composite foil having an inner layer and at least two further layers is produced, in which at least the inner layer includes the data carrier recyclate, comprising the following steps: feeding at least the extruder producing the inner layer with the data carrier recyclate or a material forming the data carrier recyclate, feeding one or several further extruders with the data carrier recyclate or with a material forming a data carrier recyclate or with a plastic material that does not include recycled plastic material, coextruding the inner layer and the at least two further layers and thereby producing a composite foil.
27. The method according to claim 25, wherein a composite foil having several layers which include the data carrier recyclate is produced, and wherein in each layer which includes a data carrier recyclate the portion of recyclate is the higher the further inward in the layer composite of the composite foil the layer is located.
28. A data carrier comprising a card body which comprises at least one data carrier recycling foil according to claim 20.
29. The data carrier according to claim 28, further comprising at least one electronic module and/or an imprint.
30. The data carrier according to claim 28, wherein the data carrier is a SIM card, a credit card or an ID card.
Description
[0051] There are shown:
[0052]
[0053]
[0054]
[0055]
[0056]
[0057]
[0058] The data carrier recycling foil 1 may comprise an inner layer 4 and intermediate layers 5, 6 which include recycled polyethylene terephthalate. In the represented embodiment, the inner layer 4 includes 95 wt % of PET recyclate and 5 wt % of copolyester elastomer, the intermediate layers 5, 6 each include 90 wt % of PET recyclate and 10 wt % of the same copolyester elastomer, and the outer layers 7, 8 each consist of the pure copolyester elastomer. Alternatively, recyclates other than PET can of course also be used.
[0059] Such a composite foil can be manufactured as schematically illustrated in
[0060]
[0061] In the case of the composite foil 1 represented in
TABLE-US-00001 TABLE 1 (PET) Extruder Zone 21 22 23 a 85° C. 85° C. 85° C. b 265° C. 265° C. 265° C. c 270° C. 270° C. 270° C. d 270° C. 270° C. 270° C. e 270° C. 270° C. 270° C. Adapter 280° C. 280° C. 280° C. Nozzle 275° C. 275° C. 275° C.
[0062] The process parameters vary in dependence on the feed material. Suitable temperatures for a polyolefin recyclate (for example a polyethylene recyclate) are stated in Table 2 and suitable temperatures for a polyamide recyclate are stated in Table 3. It is to be understood that the values represent exemplary guide values in each case. Starting out from these guide values, the optimum temperatures for a specific feed material can be ascertained by a person skilled in the art with a few tests.
TABLE-US-00002 TABLE 2 (PE) Extruder Zone 21 22 23 a 60° C. 60° C. 60° C. b 225° C. 225° C. 225° C. c 230° C. 230° C. 230° C. d 235° C. 235° C. 235° C. e 235° C. 235° C. 235° C. Adapter 235° C. 235° C. 235° C. Nozzle 235° C. 235° C. 235° C.
TABLE-US-00003 TABLE 3 (PA6.6) Extruder Zone 21 22 23 a 85° C. 85° C. 85° C. b 255° C. 255° C. 255° C. c 260° C. 260° C. 260° C. d 260° C. 265° C. 260° C. e 260° C. 265° C. 260° C. Adapter 265° C. 265° C. 265° C. Nozzle 260° C. 260° C. 260° C.
[0063] The streams of melt of the extruders 21, 22, 23 are brought together in the adapter 32 and extruded together through the wide slot nozzle 33, for example a coat hanger nozzle, thereby the prefilm 34 being formed. The still liquid prefilm is cooled down and solidified by placing it against the casting roll 35, thereby obtaining the data carrier recycling foil 1, which is represented enlarged in a sectional view below the device 20.
[0064] Instead of using polyester recyclate for the inner layer 4 and the intermediate layers 5, 6 respectively, different recyclates could also be used, for example a polyethylene terephthalate recyclate for the inner layer 4 and a polyethylene recyclate for the intermediate layers 5, 6. In an analogous manner, for modifying the recyclates there can also be used different thermoplastic elastomers, in the case of a polyester recyclate for example a copolyester elastomer in the inner layer 4 and a urethane elastomer in the intermediate layers 5, 6.
[0065] Likewise, the different layers of a data carrier recycling foil configured as a composite foil may include different additives in different amounts. For example, the outer layers 7, 8 could include antioxidants, light stabilizers and flame retardants, while the inner layer 4 could include admixtures for improving the impact strength as well as pigments for coloring and/or opacification.
[0066] The innermost layer does not necessarily have to be the layer with the highest recyclate portion. For example, in the embodiment according to
[0067]
[0068] Such a foil can be coextruded by means of a device which is similar to the device 20 of
[0069] A data carrier recycling foil 1 having the layer structure represented in
[0070] If very specific properties are desired for a particular surface of a data carrier recycling foil, for example sealability or particularly good printability, it may be necessary to keep the recyclate portion in the relevant layer low or to configure the relevant layer without recyclate. In such a case, it is preferred to configure the recyclate-free layer as thin as possible, for example with a thickness of 5-10 μm.
[0071] According to further embodiments of the invention (not shown), the data carrier recycling foils may also be composite foils having an even number of layers, for example with 2, 4 or 6 layers. For example, a data carrier recycling foil having two layers could have a layer of 95 wt % recyclate and 5 wt % thermoplastic elastomer, which makes up 80% of the thickness of the data carrier recycling foil, and a layer of thermoplastic elastomer which makes up 20% of the thickness of the data carrier recycling foil. Such a data carrier recycling foil is manufacturable with the help of two extruders whose streams of melt are brought together in a suitable adapter.
[0072]
[0073]
[0074] The recycling foil according to the invention and the data carriers manufactured from the recycling foil according to the invention can be manufactured in an environmentally friendly and cost-effective manner. They have no disadvantages compared to foils or data carriers which are manufactured of plastic materials without recycling portion.
[0075] Advantageous embodiments of the invention are stated below:
1. A method of producing a thermoplastic material based on a polyolefin, a polyester or a polyamide from mixed plastic waste, wherein the plastic material is suitable for manufacturing a plastic foil for a data carrier, comprising
(a) providing a polyolefin material, a polyester material or a polyamide material, which was separated as pure in type as possible from mixed plastic waste,
(b) compounding the polyolefin material, the polyester material or the polyamide material with additives for improving the chemical and/or mechanical and/or optical properties in order to obtain a polyolefin regenerate, a polyester regenerate or a polyamide regenerate which is suitable for manufacturing a plastic foil; and
(c) Modifying
[0076] the polyolefin material with a thermoplastic olefin elastomer and/or a thermoplastic rubber vulcanizate, or
the polyester material with a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer, or
the polyamide material with a thermoplastic polyamide elastomer and/or a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer,
in order to obtain a data carrier recyclate based on a polyolefin, on a polyester or on a polyamide, wherein the data carrier recyclate is suitable for manufacturing a plastic foil for a data carrier.
2. A data carrier recyclate based on a thermoplastic polyolefin material, on a thermoplastic polyester material or on a thermoplastic polyamide material, which was separated as pure in type as possible from mixed plastic waste, wherein the data carrier recyclate includes additives for improving the chemical and/or mechanical and/or optical properties and at least one modifying agent which makes it suitable for manufacturing a plastic foil for a data carrier, wherein the modifying agent
in the case of a polyolefin material, is a thermoplastic olefin elastomer and/or a thermoplastic rubber vulcanizate,
in the case of a polyester material, is a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer, and
in the case of a polyamide material, is a thermoplastic polyamide elastomer and/or a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer.
3. The data carrier recyclate according to embodiment 2 or the method according to embodiment 1, wherein
the thermoplastic olefin elastomer and/or the thermoplastic rubber vulcanizate is a block copolymer with a polyolefin-based polymer as hard segment and an ethylene-propylene-diene monomer as soft segment,
the thermoplastic copolyester elastomer is a block copolymer with a butylene terephthalate block as hard segment and a butylene glycol ether block as soft segment,
the thermoplastic urethane elastomer is a block copolymer with a polyurethane block as hard segment and a polyester block as soft segment, and
the thermoplastic polyamide elastomer is a block copolymer with a polyamide block as hard segment and a polyether block as soft segment.
4. The data carrier recyclate according to embodiment 2 or 3 or the method according to embodiment 1 or 3, wherein the data carrier recyclate includes
in the case of a polyolefin material, 2.5-20 wt %, preferably 5-10 wt %, thermoplastic olefin elastomer and/or thermoplastic rubber vulcanizate,
in the case of a polyamide material, 2.5-20 wt %, preferably 5-10 wt %, thermoplastic polyamide elastomer and/or copolyester elastomer and/or urethane elastomer, and
in the case of a polyester material, 2.5-15 wt %, preferably 5-7 wt %, of thermoplastic copolyester elastomer and/or thermoplastic urethane elastomer.
5. The data carrier recyclate according to any of embodiments 2 to 4 or the method according to embodiment 1, 3 or 4, wherein the data carrier recyclate includes at least one additive which is selected from the group consisting of chain extenders, impact modifiers, antioxidants, light stabilizers, colorants and fillers.
6. The data carrier recyclate according to any of embodiments 2 to 5 or the method according to any of embodiments 1 and 3-5, wherein the polyolefin material is polyethylene or the polyester material is polyethylene terephthalate.
7. A plastic foil which is suitable for manufacturing a data carrier and comprises at least one layer which includes a thermoplastic material which was recycled from mixed plastic waste, wherein the at least one layer comprises a data carrier recyclate according to any of embodiments 2 to 6.
8. The plastic foil according to embodiment 7, wherein the foil is a multilayer composite foil having an inner layer and at least two further layers, and wherein at least the inner layer includes a data carrier recyclate according to any of embodiments 2 to 6.
9. The plastic foil according to embodiment 7 or 8, wherein the foil is a multilayer composite foil having an inner layer, two outer layers and at least one intermediate layer respectively between the inner layer and one of the outer layers, and wherein at least the inner layer and the intermediate layers include a data carrier recyclate according to any of embodiments 2 to 6.
10. The plastic foil according to embodiment 8 or 9, wherein in each layer which includes a data carrier recyclate, the portion of recyclate is the higher the further inward in the layer composite the layer is located.
11. The plastic foil according to any of embodiments 8 to 10, wherein at least one outer layer does not include recyclate.
12. The plastic foil according to embodiment 11, wherein at least one outer layer consists of a thermoplastic elastomer or of a sealable thermoplastic material such as a glycol-modified polyethylene terephthalate.
13. The plastic foil according to any of embodiments 8 to 12, wherein the inner layer includes 90-98 wt. % recyclate and the outer layers, independently of each other, include 0-70 wt. % recyclate.
14. The plastic foil according to embodiment 13, with respectively one intermediate layer between the inner layer and each of the outer layers, wherein the intermediate layers, independently of each other, include 80-95 wt. % recyclate.
15. The plastic foil according to embodiment 7, which consists of one single layer with a portion of recyclate of 50-95 wt %.
16. The plastic foil according to embodiment 7, wherein the foil is a composite foil having at least two layers and wherein at least one of the layers includes a data carrier recyclate according to any of embodiments 2 to 6.
17. The plastic foil according to any of embodiments 8 to 14, which comprises five layers, wherein the thickness of the inner layer constitutes 20-80% of the total thickness of the foil, the thicknesses of the intermediate layers respectively constitute 5-20 wt % of the total thickness of the foil, and the thickness of the outer layers respectively constitute 5-20% of the total thickness of the foil.
18. The plastic foil according to any of embodiments 7 to 17, wherein the total thickness of the foil is 50 μm to 800 μm.
19. The plastic foil according to any of embodiments 7 to 18, wherein at least one foil layer is opaque and the remaining foil layers are transparent, and wherein in a multilayer foil at least one outer layer is transparent.
20. A method of manufacturing a plastic foil which is suitable for manufacturing a data carrier and comprises at least one layer which includes a thermoplastic material which was recycled from mixed plastic waste,
comprising the following steps:
feeding at least one extruder with [0077] a data carrier recyclate according to any of embodiments 2 to 6, or [0078] a material forming a data carrier recyclate according to any of embodiments 2 to 6, which comprises a polyolefin regenerate or a polyester regenerate or a polyamide regenerate, which was obtained by carrying out the steps (a) and (b) according to embodiment 1, and a modifying agent, wherein the modifying agent [0079] in the case of a polyolefin material, is a thermoplastic olefin elastomer and/or a thermoplastic rubber vulcanizate, [0080] in the case of a polyester material, is a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer, and [0081] in the case of a polyamide material, is a thermoplastic polyamide elastomer and/or a thermoplastic copolyester elastomer and/or a thermoplastic urethane elastomer, and
extruding the data carrier recyclate in order to obtain a data carrier recycling foil.
21. The method according to embodiment 20, wherein a multilayer composite foil having an inner layer and at least two further layers is produced, in which at least the inner layer includes a data carrier recyclate according to any of embodiments 2 to 6, comprising the following steps:
feeding at least the extruder producing the inner layer with a data carrier recyclate according to any of embodiments 2 to 6 or a material forming a data carrier recyclate according to any of embodiments 2 to 6,
feeding one or several further extruders with a data carrier recyclate according to any of embodiments 2 to 6 or with a material forming a data carrier recyclate according to any of embodiments 2 to 6 or with a plastic material that does not include recycled plastic material,
coextruding the inner layer and the at least two further layers and thereby producing a composite foil.
22. The method according to embodiment 20 or 21, wherein two further extruders are used and wherein one of the extruders is fed with a data carrier recyclate according to any of embodiments 2 to 6 or a material forming a data carrier recyclate according to any of embodiments 2 to 6, and the other extruder is fed with a plastic material that does not include recycled plastic material.
23. The method according to any of embodiments 20 to 22, wherein a composite foil having several layers which include a data carrier recyclate according to any of embodiments 2 to 6 is produced, and wherein in each layer which includes a data carrier recyclate the portion of recyclate is the higher the further inward in the layer composite of the composite foil the layer is located.
24. A data carrier comprising a card body which comprises at least one data carrier recycling foil according to any of embodiments 7 to 19.
25. The data carrier according to embodiment 24, further comprising at least one electronic module and/or one imprint.
26. The data carrier according to embodiment 24 or 25, comprising an opaque data carrier recycling foil, a design print layer on each of the two main areas of the data carrier recycling foil, and a lacquering on the design print layers.
27. The data carrier according to embodiment 24 or 25, comprising an opaque data carrier recycling foil, a design print layer on each of the two main areas of the data carrier recycling foil, and respectively one transparent data carrier recycling foil covering the design print layers.
28. The data carrier according to any of embodiments 24 to 27, wherein the data carrier is a SIM card, a credit card or an ID card.