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The patent badge is an abbreviated version of the USPTO patent document. The patent badge does contain a link to the full patent document.

The patent badge is an abbreviated version of the USPTO patent document. The patent badge covers the following: Patent number, Date patent was issued, Date patent was filed, Title of the patent, Applicant, Inventor, Assignee, Attorney firm, Primary examiner, Assistant examiner, CPCs, and Abstract. The patent badge does contain a link to the full patent document (in Adobe Acrobat format, aka pdf). To download or print any patent click here.

Patent No.:

US 11872797 B1

PDFFull Text
Date of Patent:
Jan. 16, 2024

Filed:

Jan. 13, 2022

Method of making flat foam sheet comprising recycled pet and the product resulting therefrom

Applicant:

Mucell Extrusion, Llc, Woburn, MA (US);

Inventors:

Mehdi Saniei, Belmont, MA (US);

Mark E. Lindenfelzer, Milton, MA (US);

James K. Sakorafos, Shrewsbury, MA (US);

Assignee:

MuCell Extrusion, LLC, Woburn, MA (US);

Attorney:

Wolf, Greenfield & Sacks, P.C.

Primary Examiner:

Lawrence D Ferguson

Int. Cl.
CPC ...
B32B 27/20 (2006.01); B32B 5/18 (2006.01); B32B 27/36 (2006.01); B32B 27/06 (2006.01); B32B 27/30 (2006.01); B29C 48/21 (2019.01); B29C 48/00 (2019.01); B29K 67/00 (2006.01); B29K 23/00 (2006.01); B29K 105/26 (2006.01); B29K 105/04 (2006.01);
U.S. Cl.
CPC ...
B32B 5/18 (2013.01); B29C 48/0012 (2019.02); B29C 48/21 (2019.02); B32B 27/065 (2013.01); B32B 27/20 (2013.01); B32B 27/306 (2013.01); B32B 27/36 (2013.01); B29K 2023/086 (2013.01); B29K 2067/003 (2013.01); B29K 2105/04 (2013.01); B29K 2105/26 (2013.01); B32B 2250/24 (2013.01); B32B 2266/0264 (2013.01); B32B 2266/08 (2013.01); B32B 2272/00 (2013.01); B32B 2307/4026 (2013.01); B32B 2307/54 (2013.01); B32B 2307/72 (2013.01); B32B 2307/732 (2013.01);
Abstract

A method of making multilayer foam sheet from recycled polyester sources, which may be used for packaging applications. The method comprises a co-extrusion system comprising at least two single screw extruders. A low I.V. polyester feedstock comprising up to 100% of the polyester flakes from recycled sources with an intrinsic viscosity (I.V.) of lower than 0.8 dL/g as measured by ASTM D4603-18 is directly being fed into the extruders. Supercritical physical blowing agent is introduced into the melted polyester feedstock in at least one of the extruders wherein the processing temperature is in the range of 15% lower than the melting temperature and 15% higher than the melting temperature. Then, coextruding the feedstock from the extruders of the co-extrusion system through a flat sheet die to make a multilayer foam sheet, wherein at least one layer is a foam layer comprising low I.V. polyester.

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