Patent ID: 11111350

Abstract:
A method for producing low density polyester foam utilizing low I.V. polyester feedstock includes providing a low intrinsic viscosity raw material. The low intrinsic viscosity raw material includes between 25% to 100% of a post consumer polyester and has an intrinsic viscosity of less than 0.8 dl/g. The intrinsic viscosity of the low intrinsic viscosity raw material is increased via a de-condensation reaction configured to support foaming. The intrinsic viscosity of the low intrinsic viscosity raw material is increased to 1.1 dl/g or greater. A starting formulation is created including the low intrinsic viscosity raw material with the increased intrinsic viscosity. The starting formulation is foamed to create the polyester foam. Wherein, the polyester foam produced has a specific gravity of less than 0.65 g/cc.