WO2024220458A1

WO2024220458A1 - Copolyester compositions for recyclable heavy gauge sheet articles

Info

Publication number: WO2024220458A1
Application number: PCT/US2024/024864
Authority: WO
Inventors: Marc Alan Strand; Sandra Case; Kayla Breanne BRICKEY
Original assignee: Eastman Chemical Company
Priority date: 2023-04-19
Filing date: 2024-04-17
Publication date: 2024-10-24

Abstract

The present disclosure relates to recyclable heavy gauge sheet articles with made from blended copolyester compositions which comprise residues of terephthalic acid, 1,4-cyclohexanedimethanol (CHDM), and ethylene glycol (EG) residues, in certain compositional ranges that have low haze and are recyclable in a PET stream.

Description

COPOLYESTER COMPOSITIONS FOR RECYCLABLE HEAVY GAUGE SHEET ARTICLES

FIELD OF THE INVENTION

[0001] The present disclosure relates to recyclable, heavy gauge sheet articles made from blended copolyester compositions which comprise residues of terephthalic acid, 1 ,4-cyclohexanedimethanol (CHDM), and ethylene glycol (EG) residues, in certain compositional ranges having certain advantages and improved properties.

BACKGROUND OF THE INVENTION

[0002] There is a commercial need for recyclable heavy gauge sheet articles in which the polymeric materials have sufficient properties to be used in heavy gauge sheet applications and the articles are recyclable in a PET stream.

[0003] To be considered recyclable, the articles must be transformable at the end of life back into usable polymeric material. Currently, polyethylene terephthalate) (PET) is the largest volume thermoplastic with an existing and well-established mechanical recycling stream.

[0004] Recycling of post-consumer PET is a complex process that involves separating opaque, colored and transparent components from each other as well as from containers made from different polymeric materials (e.g. polyethylene, polypropylene, PVC, etc.). Proper separation is critical as each of these polymeric materials can contaminate the PET stream and reduce the quality of the final sorted product. After separation, the clear PET bottles are ground into flake, cleaned, and dried at temperatures between 140°C and 180°C. The flake may be used directly (for example in strapping and fiber extrusion) or further processed into pellets for film, sheet or bottle applications. For some applications the pellets may be further crystallized and solid-state polymerized at temperatures between 200°C and 220°C prior to use. Because of the well-established nature of PET recycling processes, it is desirable for copolyester-based molded articles and containers to be compatible with the existing PET recycle streams. [0005] Historically, compositions such as polycarbonate and acrylics that are used to produce heavy gauge sheet are not compatible with PET recycle streams.

[0006] The present disclosure addresses a long felt commercial need for heavy gauge sheet articles produced from copolyester thermoplastic materials that are transparent, as well as clear, tough and recyclable in a PET stream.

BRIEF SUMMARY OF THE INVENTION

[0007] In one aspect, the heavy gauge sheet articles of the present disclosure are recyclable in a PET recycle stream.

[0008] In one embodiment, the heavy gauge sheet articles of the of the present disclosure are useful as articles of manufacture chosen from at least one of the following: film, sheet, molded articles, and thermoformed articles.

[0009] In one embodiment, the articles of the present disclosure are useful as films, sheet, trim, paneling, vehicle components and parts, food services components, medical device enclosures, trays, equipment parts, fascia, enclosures, covers, paneling, bedliners, dividers, signs, displays, thermoformed signs, in-store displays, art work, EILT(encapsulated image layer technology), laminates, molded sinks, balustrades, and office dividers,

[0010] The present disclosure pertains to polyester compositions and processes that enable heavy gauge sheet articles to be produced that are clear and exhibit improved performance properties.

[0011] One aspect of the present disclosure relates to reactor grade compositions suitable for use in heavy gauge sheet applications that meet the performance requirements and the definition of RIC-1. In one embodiment, the reactor grade compositions that meet both criteria are compositions based on TPA (or DMT) and EG with 4.5 to 11 mole% of CHDM.

[0012] One aspect of the present disclosure relates to blend compositions suitable for use in heavy gauge sheet applications that meet the performance requirements and the definition RIC-1. In one embodiment, the blend compositions that meet both criteria are compositions that comprise a blend of a PET composition with a CHDM rich copolyester composition, and the blend has a final composition with up to 17mol% CHDM.

DETAILED DESCRIPTION

[0013] The present disclosure may be understood more readily by reference to the following detailed description of certain embodiments of the disclosure and the working examples. In accordance with the purpose(s) of this disclosure, certain embodiments of the disclosure are described in the Summary of the Invention and are further described herein below. Also, other embodiments of the disclosure are described herein.

[0014] The present disclosure pertains to certain copolyester compositions that produce heavy gauge sheet articles having the following attributes, all of which are becoming increasingly critical to market needs: (1 ) recyclability in a PET recycle stream; (2) in some embodiments the articles contain postconsumer recycled (PCR) materials, in the form of rPET or recycled copolyesters or the articles are made from polyesters that contain recycle content such as rEG, rDMT, rDEG or rCHDM; (3) the articles are clear and transparent (low haze); and (4) the compositions have a melting temperature (Tm) of 225-255°C, so they qualify as PET for recycling purposes and can be recycled at end of life with current, well established PET recycle streams [0015] In one aspect the heavy gauge sheet articles of the present disclosure pertain to copolyester-based, environmentally friendly and sustainable articles for durable and consumer-oriented product applications that have two critical attributes. First, the articles of the present disclosure enable the ability to produce clear articles. Second, the articles of the present disclosure are compatible in PET recycle streams, i.e. they can be processed under the conditions used for homopolymer PET recycling.

[0016] In 2017, California Assembly Bill No. 906 - Beverage containers: polyethylene terephthalate was signed into law, and it defines “polyethylene terephthalate” (PET) for purposes of resin code labeling as a plastic that meets certain conditions, including limits with respect to the chemical composition of the polymer and a melting peak temperature within a specified range. AB-906 adds Section 18013 to California’s Public Resources Code, which reads, in part: “Polyethylene terephthalate (PET)” means a plastic derived from a reaction between terephthalic acid or dimethyl terephthalate and monoethylene glycol as to which both of the following conditions are satisfied: a. The terephthalic acid or dimethyl terephthalate and monoethylene glycol reacted constitutes at least 90 percent of the mass of the monomer reacted to form the polymer. b. The plastic exhibits a melting peak temperature that is between 225 degrees Celsius and 255 degrees Celsius, as determined during the second thermal scan using procedure 10.1 as set forth in ASTM International (ASTM) D3418 with a heating rate of a sample at 10 degrees Celsius per minute.”

[0017] As such, copolyesters of the present disclosure meet both of the conditions outlined in AB-906, are acceptable for being called “PET”, and thus such materials are likely to be compatible in current PET recycle streams. Furthermore, the articles of the present disclosure meet the California (AB 906 /ASTM 761 1 guidelines for RIC1 definition and they have achieved Association of Plastic Recyclers (APR) Critical Guidance recognition.

[0018] The melting points of the copolyester compositions in the present disclosure make them acceptable under this definition as PET, and thus, compatible in the current PET recycle streams.

[0019] Thus, in one aspect of the present disclosure, “compatible with PET recycle streams” is defined as exhibiting a melting temperature of 225-255°C on the first heat DSC scan (at 10-20C/min scan rate) of an article, while also containing 15wt% or less of glycols and/or acids other than EG, TPA, or DMT (referred to herein as the total wt% of comonomer content). In some embodiments, the compositions contain 10wt% or less of glycols and/or acids other than EG, TPA, or DMT (referred to herein as the total wt% of comonomer content).

[0020] The heavy gauge sheet articles in the present disclosure are also recyclable, and they can be processed with PET recycle streams and end up as a component in the recyclable PET flake leaving the recycling process. As such, they exhibit good properties as heavy gauge sheet articles, but they have high melting points, so they provide superior performance in recycling processes. The heavy gauge sheet articles of the present disclosure have melting temperatures and weight percent comonomer content loading consistent with the definitions in the Assembly Bill, thus it is expected that the molded articles of the present disclosure can be processed in standard PET recycle processes, and they do not have to be removed during the recycle process because they will not impact the process.

[0021] In one aspect of the present disclosure, the presence of a melting temperature peak is critical for functional adoption as a PET material acceptable for recycling. The heavy gauge sheet articles of the present disclosure exhibit a melting temperature of 225-255°C and having a total comonomer content in the 0-15 wt% range.

[0022] In one embodiment, the articles have a melting temperature (T_m) of 225-255°C. In one embodiment, the articles have a melting temperature (Tm) of 230-250°C. In another embodiment, the articles have a melting temperature (Tm) of 235-245°C. In another embodiment, the articles have a melting temperature (Tm) of 230-240°C.

[0023] The term “polyester”, as used herein, is intended to include “copolyesters” and is understood to mean a synthetic polymer prepared by the reaction of one or more difunctional carboxylic acids and/or multifunctional carboxylic acids with one or more difunctional hydroxyl compounds and/or multifunctional hydroxyl compounds, for example, branching agents. Typically, the difunctional carboxylic acid can be a dicarboxylic acid and the difunctional hydroxyl compound can be a dihydric alcohol, for example, glycols and diols. The term “glycol” as used herein includes, but is not limited to, diols, glycols, and/or multifunctional hydroxyl compounds, for example, branching agents. Alternatively, the difunctional carboxylic acid may be a hydroxy carboxylic acid, for example, p-hydroxybenzoic acid, and the difunctional hydroxyl compound may have an aromatic nucleus bearing 2 hydroxyl substituents, for example, hydroquinone. The term “residue”, as used herein, means any organic structure incorporated into a polymer through a polycondensation and/or an esterification reaction from the corresponding monomer. The term “repeating unit”, as used herein, means an organic structure having a dicarboxylic acid residue and a diol residue bonded through an ester group. Thus, for example, the dicarboxylic acid residues may be derived from a dicarboxylic acid monomer or its associated acid halides, esters, salts, anhydrides, and/or mixtures thereof. Furthermore, as used herein, the term “diacid” includes multifunctional acids, for example, branching agents. As used herein, therefore, the term “dicarboxylic acid” is intended to include dicarboxylic acids and any derivative of a dicarboxylic acid, including its associated acid halides, esters, half-esters, salts, half-salts, anhydrides, mixed anhydrides, and/or mixtures thereof, useful in a reaction process with a diol to make a polyester. As used herein, the term “terephthalic acid” is intended to include terephthalic acid itself and residues thereof as well as any derivative of terephthalic acid, including its associated acid halides, esters, half-esters, salts, half-salts, anhydrides, mixed anhydrides, and/or mixtures thereof or residues thereof useful in a reaction process with a diol to make a polyester.

[0024] The polyesters used in the present disclosure typically can be prepared from dicarboxylic acids and diols which react in substantially equal proportions and are incorporated into the polyester polymer as their corresponding residues. The polyesters of the present disclosure, therefore, can contain substantially equal molar proportions of acid residues (100 mole%) and diol (and/or multifunctional hydroxyl compound) residues (100 mole%) such that the total moles of repeating units is equal to 100 mole%. The mole percentages provided in the present disclosure, therefore, may be based on the total moles of acid residues, the total moles of diol residues, or the total moles of repeating units. For example, a polyester containing 10 mole% isophthalic acid, based on the total acid residues, means the polyester contains 10 mole% isophthalic acid residues out of a total of 100 mole% acid residues. Thus, there are 10 moles of isophthalic acid residues among every 100 moles of acid residues. In another example, a polyester containing 15 mole% 1 ,4- cyclohexanedimethanol, based on the total diol residues, means the polyester contains 15 mole% 1 ,4-cyclohexanedimethanol residues out of a total of 100 mole% diol residues. Thus, there are 15 moles of 1 ,4-cyclohexanedimethanol residues among every 100 moles of diol residues.

[0025] In certain embodiments, terephthalic acid or an ester thereof, for example, dimethyl terephthalate or a mixture of terephthalic acid residues and an ester thereof can make up a portion or all of the dicarboxylic acid component used to form the polyesters useful in the present disclosure. In certain embodiments, terephthalic acid residues can make up a portion or all of the dicarboxylic acid component used to form the polyesters useful in this disclosure. For the purposes of this disclosure, the terms “terephthalic acid” and “dimethyl terephthalate” are used interchangeably herein. In one embodiment, dimethyl terephthalate (DMT) is part or all of the dicarboxylic acid component used to make the polyesters useful in the present disclosure. In embodiments, ranges of from 70 to 100 mole%; or 80 to 100 mole%; or 85 to 100 mole%; or 88 to 100 mole%; or 90 to 100 mole%; or 99 to 100 mole%; or 100 mole% terephthalic acid and/or dimethyl terephthalate and/or mixtures thereof may be used. In one embodiment, the DMT is rDMT.

[0026] In addition to terephthalic acid, the dicarboxylic acid component of the polyesters useful in the present disclosure can comprise up to 15 mole%, up to 12 mole%, up to 10 mole%, up to 5 mole%, or up to 1 mole% of one or more modifying aromatic dicarboxylic acids. Yet another embodiment contains 0 mole% modifying aromatic dicarboxylic acids. Thus, if present, it is contemplated that the amount of one or more modifying aromatic dicarboxylic acids can range from any of these preceding endpoint values including, for example, from 0.01 to 15 mole%, from 0.01 to 12 mole%, from 0.01 to 10 mole%, from 0.01 to 5 mole% and from 0.01 to 1 mole%. In one embodiment, modifying aromatic dicarboxylic acids that may be used in the present disclosure include but are not limited to those having up to 20 carbon atoms, and which can be linear, para-oriented, or symmetrical. Examples of modifying aromatic dicarboxylic acids which may be used in this disclosure include, but are not limited to, isophthalic acid, 4,4'-biphenyldicarboxylic acid, 1 ,4-, 1 ,5-, 2,6-, 2,7-naphthalenedicarboxylic acid, and trans-4,4'-stilbenedicarboxylic acid, and esters thereof. In one embodiment, the modifying aromatic dicarboxylic acid is isophthalic acid.

[0027] The carboxylic acid component of the polyesters useful in the present disclosure can be further modified with up to 15 mole%, up to 12 mole%, up to 10 mole%, up to 5 mole% or up to 1 mole% of one or more aliphatic dicarboxylic acids containing 2-20 carbon atoms, for example, cyclohexanedicarboxylic, malonic, succinic, glutaric, adipic, pimelic, suberic, azelaic and/or dodecanedioic dicarboxylic acids. Certain embodiments can also comprise 0.01 to 15 mole%, 0.01 to 12 mole%, 0.01 to 10 mole%, such as 0.1 to 15 mole%, 1 to 15 mole%, 5 to 15 mole%, or 0.1 to 12 mole%, 1 to 12 mole%, 5 to 12 mole%, or 0.1 to 10 mole%, 1 or 10 mole%, 5 to 10 mole% of one or more modifying aliphatic dicarboxylic acids. Yet another embodiment contains 0 mole% modifying aliphatic dicarboxylic acids. The total mole% of the dicarboxylic acid component is 100 mole%. In one embodiment, adipic acid and/or glutaric acid are provided in the modifying aliphatic dicarboxylic acid component of the polyesters and are useful in the present disclosure.

[0028] Esters of terephthalic acid and the other modifying dicarboxylic acids or their corresponding esters and/or salts may be used instead of the dicarboxylic acids. Suitable examples of dicarboxylic acid esters include, but are not limited to, the dimethyl, diethyl, dipropyl, diisopropyl, dibutyl, and diphenyl esters. In one embodiment, the esters are chosen from at least one of the following: methyl, ethyl, propyl, isopropyl, and phenyl esters.

[0029] In one embodiment, the glycol component of the copolyester compositions useful in the present disclosure can comprise 1 ,4- cyclohexanedimethanol. In another embodiment, the glycol component of the copolyester compositions useful in the present disclosure comprise 1 ,4- cyclohexanedimethanol and 1 ,3-cyclohexanedimethanol. The molar ratio of cis/trans 1 ,4-cyclohexandimethanol can vary within the range of 50/50 to 0/100, for example, between 40/60 to 20/80.

[0030] In one embodiment, the glycol component of the copolyester compositions useful in the present disclosure can comprise 2,2,4,4-tetramethyl- 1 ,3-cyclobutanediol. In another embodiment, the molar ratio of cis/trans 2,2,4,4-tetramethyl-1 ,3-cyclobutanediol can vary from the pure form of each and mixtures thereof. In certain embodiments, the molar percentages for cis and/or trans 2,2,4,4,-tetramethyl-1 ,3-cyclobutanediol are greater than 50 mole % cis and less than 50 mole % trans; or greater than 55 mole % cis and less than 45 mole % trans; or 50 to 70 mole % cis and 50 to 30 mole % trans; or 60 to 70 mole % cis and 30 to 40 mole % trans; or greater than 70 mole % cis and less than 30 mole % trans; wherein the total mole percentages for cis- and trans-2, 2, 4, 4-tetramethyl-1 ,3-cyclobutanediol is equal to 100 mole %. In an additional embodiment, the molar ratio of cis/trans 2, 2, 4, 4-tetramethyl-1 ,3- cyclobutanediol can vary within the range of 50/50 to 0/100, for example, between 40/60 to 20/80.

[0031] One aspect of the present disclosure relates to reactor grade compositions suitable for use in heavy gauge sheet applications that meet the performance requirements and the definition of RIC-1.

[0032] In some embodiments, the reactor grade compositions that meet both criteria are compositions based on TPA (or DMT) and EG with 3.5 to 12 mol% of CHDM.

[0033] In some embodiments, the reactor grade compositions that meet both criteria are compositions based on TPA (or DMT) and EG with 4.5 to 11 mol% of CHDM.

[0034] One aspect of the present disclosure relates to blend compositions suitable for use in heavy gauge sheet applications that meet the performance requirements and the definition RIC-1 .

[0035] In some embodiments, the blend compositions that meet both criteria are compositions that are blends of a PET composition and a CHDM rich copolyester composition has final composition with up to 17mol% CHDM.

[0036] In some embodiments, the blend compositions that meet both criteria are compositions that are blends of PET (or lightly modified PET) with a heavily modified copolyester composition and has final composition with up to 17mol% CHDM. [0037] In one embodiment, the total comonomer content from glycols and acids other than ethylene glycol (EG), terephthalic acid (TPA), or dimethyl terephthalate (DMT) of the copolyester compositions useful in the present disclosure is from 0 to 17 wt%, 0 to 15 wt%, 0 to 14 wt%, 0 to 12 wt%, 0 to 1 1 wt%, 0 to 10 wt%, 0 to 8 wt%, 0 to 6 wt%, 0 to 4 wt%, 0 to 3 wt%, 0 to 2 wt%, 1 to 15 wt%, 1 to 14 wt%, 1 to 12 wt%, 1 to 1 1 wt%, 1 to 10 wt%, 1 to 8 wt%, 1 to

6 wt%, 1 to 5 wt%, 1 to 4 wt%, 1 to 4.5 wt%, 1 to 3.5 wt%, 1 to 3 wt%, 1 to 2 wt%, 2 to 12 wt%, or from 5 to 10wt%, or from 10 to 15wt%, or from 2 to 15 wt%, or from 2 to 10 wt%, or from 3 to 15 wt%, or from 3 to 10 wt%, or from 4 to 15 wt%, or from 4 to 12 wt%, 4 to 11 wt%, 4 to 10 wt%, 5 to 12 wt%, 6 to 12 wt%, 2 to 8 wt%, 2 to 12 wt%, or from 3 to 12 wt%, or from 6 to 10 wt%, or from

7 to 15 wt%, or from 7 to 10 wt%, or from 8 to 15 wt%, or from 8 to 10 wt%, or from 9 to 15 wt%, or from 9 to 10 wt%, or from 1 1 to 15 wt%, 12 to 15 wt%, or from 13 to 15 wt%, 14 to 15 wt%, or from 12 to 16 wt%.

[0038] In one embodiment, the total comonomer content from glycols and acids other than ethylene glycol (EG), terephthalic acid (TPA), or dimethyl terephthalate (DMT) of the copolyester compositions useful in the present disclosure is from 11 to 17 wt%.

[0039] In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain from 0 to 17 mole% of 1 ,4- cyclohexanedimethanol (CHDM) based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain from 0 to 15 mole% of 1 ,4-cyclohexanedimethanol (CHDM) based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain from 0 to 12 mole% of 1 ,4-cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain from 0 to 11 mole% of 1 ,4-cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0.01 to less than 20 mole% of 1 ,4-cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0.01 to less than 17 mole% of 1 ,4-cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0.01 to less than 15 mole% of 1 ,4-cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0.01 to 12 mole% of 1 ,4-cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0.01 to less than 11 mole% of 1 ,4-cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0.01 to 5 mole% of 1 ,4-cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0 to less than 5 mole% of 1 ,4-cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 4 mole% of 1 ,4- cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 4.5 mole% of 1 ,4- cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 3.5 mole% of 1 ,4- cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 3 mole% of 1 ,4- cyclohexanedimethanol based on the total mole% of the glycol component being 100 mole%. [0040] In one embodiment, the 1 ,4-cyclohexanedimethanol (CHDM) is rCHDM. In one embodiment, the rCHDM is produced from rDMT.

[0041] In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain from 0 to 17 mole%, or 0 to 15 mole%, or from 0 to 14 mole%, or from 0 to 13 mole%, or from 0 to 12 mole%, or 0 to 11 mole%, or from 0 to 10 mole%, or from 0.01 to 20 mole%, or from 0.01 to 17 mole%, or from 0.01 to 15 mole%, or from 0.01 to 14 mole%, or from 0.01 to 13 mole%, or from 0.01 to 12 mole%, or from 0.01 to 11 mole%, or from 0.01 to 10 mole%, or from 0.01 to 9 mole%, or from 0.01 to 8 mole%, or from 0.01 to 7 mole%, or 0.01 to 6 mole%, or from 0.01 to 5 mole%, or from 0.01 to 4 mole%, or from 0.01 to 3 mole%, or from 0.01 to 2 mole%, or from 0.1 to 20 mole%, or from 0.1 to 17 mole%, or from 0.1 to 15 mole%, or from 0.1 to 14 mole%, or from 0.1 to 13 mole%, or from 0.1 to 12 mole%, or from 0.1 to 11 mole%, or from 0.1 to 10 mole%, or from 5 to 15 mole%, 10 to 12 mole%, or from 9 to 11 mole%, or from 8 to 12 mole%, or from 6 to 12 mole%, or from 3 to 12 mole%, or 4 to 12 mole%, or from 3 to 1 1 mole%, 4 to 11 mole%, or from 3 to 10 mole%, or from 4 to 10 mole%, or from 2 to 14 mole%, or from 2 to 12 mole%, or 2 to 1 1 mole%, or from 2 to 4 mole%, or from 2 to 6 mole%, 3 to 15 mole%, or from 3 to 14 mole%, or from 3 to 13 mole%, or from 3 to 12 mole%, or from 3 to 11 mole%, or 3 to 10 mole%, or from 3 to 9 mole%, or from 3 to 8 mole%, or from 3 to 7 mole%, or from 3 to 6 mole%, or from 3 to 5 mole%, or from 2 to 10 mole%, or from 2 to 9 mole%, or from 2 to 8 mole%, or from 2 to 7 mole%, or from 2 to 5 mole%, or from 2 to 4.5 mole%, or from 1 to 7 mole%, or from 1 to 5 mole%, or from 1 to 4 mole%, 1 ,4-cyclohexanedimethanol residues, based on the total mole% of the glycol component being 100 mole%.

[0042] In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0 to 15 mole% of neopentyl glycol (NPG) based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0 to 14 mole% of neopentyl glycol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0 to 12 mole% of neopentyl glycol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0.1 to 15 mole% of neopentyl glycol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0.1 to 12 mole% of neopentyl glycol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 1 to 12 mole% of neopentyl glycol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 2 to 12 mole% of neopentyl glycol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 2 to 10 mole% of neopentyl glycol based on the total mole% of the glycol component being 100 mole%.

[0043] In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain from 0 to 15 mole%, or from 0 to 14 mole%, or from 0 to 13 mole%, or from 0 to 12 mole%, or from 0 to 10 mole%, or from 0.01 to 15 mole%, or from 0.01 to 14 mole%, or from 0.01 to 13 mole%, or from 0.01 to 12 mole%, or from 0.01 to 11 mole%, or from 0.01 to 10 mole%, or from 0.01 to 9 mole%, or from 0.01 to 8 mole%, or from 0.01 to 9 mole%, or 0.01 to 7 mole%, or from 0.01 to 6 mole%, or from 0.01 to 5 mole%, or from 0.01 to 4.5 mole%, or from 0.01 to 4 mole%, or from 0.01 to 3.5 mole%, or from 0.01 to 3 mole%, or from 0.01 to 2 mole%, or from 0.1 to 15 mole%, or from 0.1 to 14 mole%, or from 0.1 to 13 mole%, or from 0.1 to 12 mole%, or from 0.1 to 10 mole%, or from 0.1 to 8 mole%, 0.1 to 6 mole%, or from 0.1 to 5 mole%, or from 0.1 to 4 mole%, or from 0.1 to 3 mole%, or from 0.1 to 2 mole%, or 0.1 to 4.5 mole%, or from 0.1 to 3.5 mole%, 3.5 to 4.5 mole%, or from 10 to 12 mole%, or from 10 to 15 mole%, or from 2 to 15 mole%, or from 2 to 14 mole%, or 2 to 13 mole%, or from 2 to 12 mole%, 3 to 15 mole%, or from 3 to 14 mole%, or from 3 to 13 mole%, or from 3 to 12 mole%, or from 3 to 11 mole%, or 3 to 10 mole%, or from 3 to 9 mole%, or from 3 to 8 mole%, or from 3 to 7 mole%, or from 2 to 15 mole%, or from 2 to 12 mole%, or from 2 to 10 mole%, or from 2 to 9 mole%, or from 2 to 8 mole%, or from 2 to 7 mole%, or from 2 to 5 mole%, or from 2 to 4 mole%, or from 1 to 7 mole%, or from 1 to 6 mole%, or from 1 to 5 mole%, or from 1 to 4 mole%, or from 1 to 3 mole%, of neopentyl glycol residues, based on the total mole% of the glycol component being 100 mole%.

[0044] In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0 to 15 mole% of 2-methyl- 1 ,3-propanediol (MPDiol) based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain from 0 to 15 mole%, or from 0 to 14 mole%, or from 0 to 13 mole%, or from 0 to 12 mole%, or from 0 to 10 mole%, or from 0.01 to 15 mole%, or from 0.01 to 14 mole%, or from 0.01 to 13 mole%, or from 0.01 to 12 mole%, or from 0.01 to 11 mole%, or from 0.01 to 10 mole%, or from 0.01 to 9 mole%, or from 0.01 to 8 mole%, or from 0.01 to 7 mole%, or 0.01 to 6 mole%, or from 0.01 to 5 mole%, or from 0.01 to 4 mole%, or from 0.01 to 3 mole%, or from 0.01 to 2 mole%, or from 0.1 to 15 mole%, or from 0.1 to 14 mole%, or from 0.1 to 13 mole%, or from 0.1 to 12 mole%, or from 0.1 to 1 1 mole%, or from 0.1 to 10 mole%, or from 5 to 15 mole%, 10 to 12 mole%, or from 9 to 1 1 mole%, or from 8 to 12 mole%, or from 6 to 12 mole%, or from 3 to 12 mole%, or 4 to 12 mole%, or from 3 to 1 1 mole%, 4 to 11 mole%, or from 3 to 10 mole%, or from 4 to 10 mole%, or from 2 to 14 mole%, or from 2 to 12 mole%, or 2 to 11 mole%, or from 2 to 4 mole%, or from 2 to 6 mole%, 3 to 15 mole%, or from 3 to 14 mole%, or from 3 to 13 mole%, or from 3 to 12 mole%, or from 3 to 11 mole%, or 3 to 10 mole%, or from 3 to 9 mole%, or from 3 to 8 mole%, or from 3 to 7 mole%, or from 3 to 6 mole%, or from 3 to 5 mole%, or from 2 to 10 mole%, or from 2 to 9 mole%, or from 2 to 8 mole%, or from 2 to 7 mole%, or from 2 to 5 mole%, or from 2 to 4.5 mole%, or from 1 to 7 mole%, or from 1 to 5 mole%, or from 1 to 4 mole%, of 2-methyl- 1 ,3-propanediol residues, based on the total mole% of the glycol component being 100 mole%. [0045] In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain from 0 to 15 mole%, or from 0 to 14 mole%, or from 0 to 13 mole%, or from 0 to 12 mole%, or from 0 to 11 mole%, or from 0 to 10 mole%, or from 0 to 9 mole%, or from 0 to 8 mole%, or from 0 to 7 mole%, or from 0 to 6 mole%, or from 0 to 5 mole%, or from 0 to 4.5 mole%, or from 0 to 4 mole%, or from 0 to 3.5 mole%, or from 0 to 3 mole%, or from 0 to 2 mole%, or from 0.01 to 15 mole%, or from 0.01 to 14 mole%, or 0.01 to 13 mole%, or from 0.01 to 12 mole%, or from 0.01 to 1 1 mole%, or from 0.01 to 10 mole%, or from 0.01 to 9 mole%, or from 0.01 to 8 mole%, or from 0.1 to 7 mole%, or from 0.1 to 6 mole%, or from 0.1 to 5 mole%, or from 0.1 to 4.5 mole%, or from 0.1 to 4 mole%, or from 0.1 to 3.5 mole%, or from 0.1 to 3 mole%, or from 0.1 to 2 mole%, or from 1 to 12 mole%, 2 to 12 mole%, or from 1 to 10 mole%, or from 2 to 10 mole%, 1 to 8 mole%, or from 2 to 8 mole%, 3 to 15 mole%, or from 3 to 14 mole%, or from 3 to 13 mole%, or from 3 to 12 mole%, or from 3 to 11 mole%, or 3 to 10 mole%, or from 3 to 9 mole%, or from 3 to 8 mole%, or from 3 to 7 mole%, or from 2 to 10 mole%, or from 2 to 9 mole%, or from 2 to 8 mole%, or from 2 to 7 mole%, or from 2 to 5 mole%, or from 1 to 7 mole%, or from 1 to 5 mole%, or from 1 to 3 mole%, of 2, 2,4,4- tetramethyl-1 ,3-cyclobutanediol residues, based on the total mole% of the glycol component being 100 mole%.

[0046] In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0 to 12 mole% of 2, 2,4,4- tetramethyl-1 ,3-cyclobutanediol (TMCD) based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 0.01 to less than 12 mole% of 2,2,4,4-tetramethyl- 1 ,3-cyclobutanediol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 1 to 12 mole% of 2, 2, 4, -tetramethyl-1 ,3-cyclobutanediol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 2 to less than 12 mole% of 2, 2, 4, -tetramethyl-1 ,3-cyclobutanediol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 3 to 12 mole% of 2,2, 4, 4- tetramethyl -1 ,3- cyclobulanediol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 4 to less than 12 mole% of

2.2.4.4- tetramethyl - 1 ,3-cyclobutanediol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 4 mole% of

2.2. .4 -tetramethyl -1 ,3-cyclobutanediol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 4.5 mole% of

2.2.4.4-tetramethyl-1 ,3-cyclobutanediol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 3 mole% of

2,2,4,4-tetramethyl-1 ,3-cyclobutanediol based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component of the copolyester compositions useful in this disclosure can contain 4.5 mole% of

2,2,4,4-tetramethyl-1 ,3-cyclobutanediol based on the total mole% of the glycol component being 100 mole%.

[0047] It should be understood that some other glycol residues may be formed in situ during processing. For example, in one embodiment, the total amount of diethylene glycol residues can be present in the copolyesters useful in the present disclosure, whether or not formed in situ during processing or intentionally added, or both, in any amount, for example, 0 to 10 mole%„ 1 to 10 mole%, or from 2 to 10 mole%, , or from 2 to 9 mole%, or 3 to 10 mole%, or from 3 to 9 mole%, , or 4 to 10 mole%, or from 4 to 9 mole%, or, from 5 to 12 mole%, or from 5 to 1 1 mole%, or 5 to 10 mole%, or from 5 to 9 mole%, of diethylene glycol residues, based on the total mole% of the glycol component being 100 mole%.

[0048] In one embodiment, the total amount of diethylene glycol (DEG) residues present in the copolyesters useful in the present disclosure, whether or not formed in situ during processing or intentionally added or both, can be from 12 mole% or less, or 10 mole% or less, or 8 mole% or less, or 6 mole% or less, or 5 mole% or less, or 4 mole% or less, or from 3.5 mole% or less, or from 3.0 mole% or less, or from 2.5 mole% or less, or from 2.0 mole% or less, or from 1 .5 mole% or less, or from 1 .0 mole% or less, or from 0 to 12 mole%, or from 1 to 12 mole%, or from 1 to 10 mole%, or from 1 to 8 mole%, or from 1 to 6 mole%, or from 1 to 5 mole%, or from 1 to 4 mole%, or from 1 to 3 mole%, or from 1 to 2 mole% of diethylene glycol residues, or from 2 to 8 mole%, or from 2 to 7 mole%, or from 2 to 6 mole%, or from 2 to 5 mole%, or from 3 to 8 mole%, or from 3 to 7 mole%, or from 3 to 6 mole%, or from 3 to 5 mole%, or in some embodiments there is no intentionally added diethylene glycol residues, based on the total mole% of the glycol component being 100 mole%. In certain embodiments, the copolyester contains no added modifying glycols. In certain embodiments, the diethylene glycol residues in copolyesters can be from 5 mole% or less. It should be noted that any low levels of DEG formed in situ are not included in the total comonomer content from glycols and acids other than EG, TPA or DMT.

[0049] In one embodiment, the DEG is rDEG. In one embodiment, the rDEG is produced from rEG.

[0050] For all embodiments, the remainder of the glycol component can comprise ethylene glycol residues in any amount based on the total mole% of the glycol component being 100 mole%. In one embodiment, the copolyesters useful in the present disclosure can contain 50 mole% or greater, or 55 mole% or greater, or 60 mole% or greater, or 65 mole% or greater, or 70 mole% or greater, or 75 mole% or greater, or 80 mole% or greater, or 85 mole% or greater, or 90 mole% or greater, or 95 mole% or greater, or 98 mole% or greater, or 99 mole% or greater; or from 88 to 99 mole%, 80 to 99 mole%, 50 to 99 mole%, or from 55 to 90 mole%, or from 50 to 80 mole%, or from 55 to 80 mole%, or from 60 to 80 mole%, or from 50 to 75 mole%, or from 55 to 75 mole%, or from 60 to 75 mole%, or from 65 to 75 mole% of ethylene glycol residues, based on the total mole% of the glycol component being 100 mole%. In one embodiment, the glycol component can comprise 100 mole% of ethylene glycol residues.

[0051] In one embodiment, the ethylene glycol is rEG.

[0052] In one embodiment, the glycol component of the copolyester compositions useful in the present disclosure can contain mole%, up to 17 mole%, or up to 16 mole%, or up to 15 mole%, or up to 14 mole%, or up to 13 mole%, or up to 12 mole %, or up to 1 1 mole %, or up to 10 mole %, or up to 9 mole %, or up to 8 mole %, or up to 7 mole%, or up to 6 mole%, or up to 5 mole%, or up to 4.5 mole%, or up to 4 mole%, or up to 3.5 mole %, or up to 3 mole %, or up to 2.5 mole %, or up to 2 mole %, or up to 1 .5 mole % or up to 1 mole %, or up to 0.5 mole %, or up to 0.1 mole %, or less of one or more other modifying glycols (other modifying glycols are defined as glycols which are not ethylene glycol, diethylene glycol, 1 ,4-cyclohexanedimethanol). In certain embodiments, the copolyesters useful in this disclosure can contain 20 mole% or less of one or more other modifying glycols; 15 mole% or less of one or more other modifying glycols; 12 mole% or less of one or more other modifying glycols; 10 mole% or less of one or more other modifying glycols; 5 mole% or less of one or more other modifying glycols; 4 mole% or less of one or more other modifying glycols, or 3 mole% or less of one or more other modifying glycols. In certain embodiments, the copolyesters useful in this disclosure can contain 4.5 mole% or less of one or more other modifying glycols. In certain embodiments, the copolyesters useful in this disclosure can contain 3.5 mole% or less of one or more other modifying glycols. In another embodiment, the copolyesters useful in this disclosure can contain 0 mole % of other modifying glycols. It is contemplated, however, that some other glycol residuals may form in situ so that residual amounts formed in situ are also an embodiment of this disclosure.

[0053] In embodiments, the other modifying glycols for use in the copolyesters, if used, as defined herein contain 2 to 12 carbon atoms. Examples of other modifying glycols include, but are not limited to, 1 ,2- propanediol, 1 ,3-propanediol, isosorbide, 1 ,4-butanediol, 1 ,5-pentanediol, 1 ,6- hexanediol, p-xylene glycol, polytetramethylene glycol, and mixtures thereof. In one embodiment, isosorbide is another modifying glycol. In another embodiment, the other modifying glycols include, but are not limited to, at least one of 1 ,3-propanediol and 1 ,4-butanediol. In one embodiment, 1 ,3- propanediol and/or 1 ,4-butanediol can be excluded. If 1 ,4- or 1 ,3-butanediol are used, greater than 4 mole% or greater than 5 mole % can be provided in one embodiment. In one embodiment, at least one other modifying glycol is 1 ,4-butanediol which present in the amount of 2 to 12 mole%.

[0054] In some embodiments, the copolyester compositions according to the present disclosure can comprise from 0 to 10 mole%, for example, from 0.01 to 5 mole%, from 0.01 to 1 mole%, from 0.05 to 5 mole%, from 0.05 to 1 mole%, or from 0.1 to 0.7 mole%, or from 0.05 to 2.0 mole %, 0,05 to 1 .5 mole %, 0.05 to 1 .0 mole %, 0.05 to 0.8 mole %, 0.05 to 0.6 mole%, 0.1 to 2.0 mole %, 0.1 to 1 .5 mole %, 0.1 to 1 .0 mole %, 0.1 to 0.8 mole %, 0.1 to 0.6 mole %, 0.2 to 2.0 mole%, 0.2 to 1 .5 mole %, 0.2 to 1 .0 mole %, 0.2 to 0.8 mole %, 0.2 to 0.6 mole %, 0.3 to 2.0 mole %, 0.3 to 1 .5 mole %, 0.3 to 1 .0 mole %, 0.3 to 0.8 mole %, 0.3 to 0.6 mole %, 0.5 to 2.0 mole %, 0.5 to 1 .5 mole %, 0.5 to 1 .0 mole %, or 0.5 to 0.8 mole %, based the total mole percentages of either the glycol or diacid residues; respectively, of one or more residues of a branching monomer, also referred to herein as a branching agent, having 3 or more carboxyl substituents, hydroxyl substituents, or a combination thereof. In certain embodiments, the branching monomer or agent may be added prior to and/or during and/or after the polymerization of the copolyester. In some embodiments, the copolyester(s) useful in the present disclosure can thus be linear or branched.

[0055] Examples of branching monomers include, but are not limited to, multifunctional acids or multifunctional alcohols such as trimellitic acid, trimellitic anhydride, pyromellitic dianhydride, trimethylolpropane, glycerol, pentaerythritol, citric acid, tartaric acid, 3-hydroxyglutaric acid and the like. In one embodiment, the branching monomer residues can comprise 0 to 0.7 mole% or 0.1 to 0.3 mole% of one or more residues chosen from at least one of the following: trimellitic anhydride, pyromellitic dianhydride, glycerol, sorbitol, 1 ,2,6-hexanetriol, pentaerythritol, trimethylolethane, and/or trimesic acid. The branching monomer may be added to the copolyester reaction mixture or blended with the copolyester in the form of a concentrate as described, for example, in U.S. Pat. Nos. 5,654,347 and 5,696,176, whose disclosure regarding branching monomers is incorporated herein by reference.

[0056] In one embodiment, branching monomer or branching agents useful in making the copolyesters formed within the context of the present disclosure can be ones that provide branching in the acid unit portion of the copolyester, or in the glycol unit portion, or it can be a hybrid. In some embodiments, some examples of branching agents are polyfunctional acids, polyfunctional anhydrides, polyfunctional glycols and acid/glycol hybrids. Examples include trior tetracarboxylic acids and their corresponding anhydrides, such as trimesic acid, pyromellitic acid, and lower alkyl esters thereof and the like, and tetrols such as pentaerythritol. Also, triols such as trimethylopropane or dihydroxy carboxylic acids and hydroxydicarboxylic acids and derivatives, such as dimethyl hydroxy terephthalate, and the like are useful within the context of this disclosure. In one embodiment, trimellitic anhydride is the branching monomer or branching agent.

[0057] The copolyesters compositions useful in the present disclosure can comprise at least one chain extender. Suitable chain extenders include, but are not limited to, multifunctional (including, but not limited to, bifunctional) isocyanates, multifunctional epoxides, including, for example, epoxylated novolacs, and phenoxy resins. In one embodiment, the chain extending agents have epoxide dependent groups. In one embodiment, the chain extending additive can be one or more styrene-acrylate copolymers with epoxide functionalities. In one embodiment, the chain extending additive can be one or more copolymers of glycidyl methacrylate with styrene.

[0058] In certain embodiments, chain extenders may be added at the end of the polymerization process or after the polymerization process. If added after the polymerization process, chain extenders can be incorporated by compounding or by addition during conversion processes such as injection molding or extrusion. In certain embodiments, the chain extending agents may be added to the rPET, to the copolyester, or to the blend during or after blending. In some embodiments, the chain extending agents can be incorporated by compounding or by addition during the conversion processes such as injection molding or extrusion.

[0059] The amount of chain extender used can vary depending on the specific monomer composition used and the physical properties desired but is generally about 0.05 percent by weight to about 10 percent by weight based on the total weight of the copolyester composition, such as about 0.1 to about 10 % by weight or 0.1 to about 5 % by weight, 0.1 to about 2 % by weight, or 0.1 to about 1 % by weight based on the total weight of the copolyester composition. In one embodiment, the copolyester composition comprises 0.05 to 5 percent by weight, of a chain extending agent based on the total weight of the copolyester composition.

[0060] In some embodiments, the chain extending agent can also be added during melt processing to build molecular weight through ‘reactive extrusion’ or ‘reactive chain coupling’ or any other process known in the art.

[0061] In one embodiment, certain copolyester compositions useful in the present disclosure can exhibit a melt viscosity (MV) at a shear rate of 1 radian/sec of greater than 5,000 poise, or greater than 10,000 poise or greater than 20,000 poise, or greater than 30,000 poise, or greater than 40,000 poise, or greater than 50,000 poise, or greater than 60,000 poise where the melt viscosity is measured at 260°C and 1 radian/sec using a rotary viscometer such as a Rheometrics Dynamic Analyzer (RDA II). In one embodiment, certain copolyester compositions useful in the present disclosure can exhibit a melt viscosity (MV) at a shear rate of 1 radian/sec of 5,000 poise to 50,000 poise where the melt viscosity is measured at 260°C. and 1 radian/sec using a rotary viscometer such as a Rheometrics Dynamic Analyzer (RDA II).

[0062] It is contemplated that copolyester compositions useful in the present disclosure can possess at least one of the inherent viscosity ranges described herein and at least one of the monomer ranges for the copolyester compositions described herein, unless otherwise stated. It is also contemplated that copolyester compositions useful in the present disclosure can possess at least one of the T_g ranges described herein and at least one of the monomer ranges for the copolyester compositions described herein, unless otherwise stated. It is also contemplated that copolyester compositions useful in the present disclosure can possess at least one of the inherent viscosity ranges described herein, at least one of the T_g ranges described herein, and at least one of the monomer ranges for the copolyester compositions described herein, unless otherwise stated.

[0063] For embodiments of this disclosure, the copolyester compositions useful in this disclosure can exhibit at least one of the following inherent viscosities as determined in 60/40 (wt/wt) phenol/ tetrachloroethane at a concentration of 0.25 g/50 ml at 25^eC: 0.50 to 0.90 dL/g; 0.50 to 0.80 dL/g; 0.55 to 1.2 dL/g; 0.55 to 1.0 dL/g; 0.55 to 0.90 dL/g; 0.55 to 0.80 dL/g; 0.58 to 1.2 dL/g; 0.58 to 1.0 dL/g; 0.58 to 0.90 dL/g; 0.58 to 0.80 dL/g; 0.60 to 0.90 dL/g; 0.60 to 0.80 dL/g; 0.65 to 0.90 dL/g; 0.60 to 0.80 dL/g; 0.70 to 0.80 dL/g; 0.50 to 0.75 dL/g; 0.55 to 0.75 dL/g; 0.58 to 0.75 dL/g; 0.60 to 0.75 dL/g; 0.60 to 0.70 dL/g; 0.58 to 0.70 dL/g; or 0.55 to 0.70 dL/g.

[0064] The glass transition temperature (T_g) of the copolyesters compositions is determined using a TA DSC Q2000 from Thermal Analyst Instrument at a scan rate of 10^eC/min. The value of the glass transition temperature is determined during the second heat.

[0065] In certain embodiments, the molded articles of this disclosure comprise copolyester compositions wherein the copolyester has a T_g of 70 to 115°C; 70 to 80°C; 70 to 85°C; or 70 to 90°C; or 70 to 95°C; 70 to 100°C; 70 to 105°C; 70 to 110°C; 80 to 1 15°C; 80 to 85°C; or 80 to 90°C; or 80 to 95°C; 80 to 100°C; 80 to 105°C; 80 to 1 10°C; 90 to 1 15°C; 90 to 100°C; 90 to 105°C; 90 to 110°C.

[0066] In one embodiment, the copolyester compositions useful in this disclosure are clear, essentially clear or visually clear. The term “visually clear” is defined herein as an appreciable absence of cloudiness, haziness, and/or muddiness, when inspected visually. In one embodiment, the copolyester blend compositions useful in this disclosure are transparent. The term “transparent” is defined herein as an appreciable absence of cloudiness, haziness, and/or muddiness, such that you can see through the material when inspected visually. These terms are used interchangeably herein. In one aspect the terms clear and/or transparent are defined as having low haze. In one embodiment, clear and/or transparent are defined as having a haze value of 20% or less. In one embodiment, clear and/or transparent are defined as having a haze value of 15% or less. In one embodiment, clear and/or transparent are defined as having a haze value of 12% or less. In one embodiment, clear and/or transparent are defined as having a haze value of 10% or less. In one embodiment, clear and/or transparent are defined as having a haze value of 5% or less.

[0067] In some embodiment, the copolyester compositions in the present disclosure are fast crystallizing, making them compatible with the PET recycle stream. For example, in one embodiment, the copolyester compositions have a crystallization half-time of about 1 minute to about 20 minutes. For example, in another embodiment, the copolyester compositions have a crystallization half-time of about 3 minutes to about 20 minutes. In one embodiment the copolyester compositions have a crystallization half-time of up to about 20 minutes, or up to about 15 minutes or up to about 10 minutes or up to about 5 minutes. In one embodiment, the copolyester compositions are suitable for use provided that their crystallization half-times are about 3 minutes. In another embodiment, the copolyester compositions are suitable for use provided that their crystallization half-times are about 5 minutes. In another embodiment, the copolyester compositions are suitable for use provided that their crystallization half-times are about 10 minutes. In another embodiment, the copolyester compositions are suitable for use provided that their crystallization half-times are about 15 minutes. In another embodiment, the copolyester compositions are suitable for use provided that their crystallization half-times are about 20 minutes. In another embodiment, the copolyester compositions are suitable for use provided that their crystallization half-times are less than about 20 minutes. In another embodiment, the copolyester compositions are suitable for use provided that their crystallization half-times are less than about 15 minutes. In another embodiment, the copolyester compositions are suitable for use provided that their crystallization half-times are less than about 10 minutes. In another embodiment, the copolyester compositions are suitable for use provided that their crystallization half-times are less than about 5 minutes.

[0068] The crystallization half times of the copolyester compositions, as used herein, may be measured using conventional methods. For example, in one embodiment, the crystallization half times were measured using a differential scanning calorimeter (DSC). In these cases, the samples were ramped (20°C/min) to 285 °C and held isothermally for 2 mins. Next, the polymer was quickly dropped to a setpoint temperature (180 °C) and held until crystallization was completed, denoted by a full endothermic heat flow curve. Half times were reported as the time from start of crystallization to the time that half of the peak was formed.

[0069] In one embodiment, the copolyester compositions can be produced by processes in homogenous solution, by transesterification processes in the melt, and by two phase interfacial processes. Suitable methods include, but are not limited to, the steps of reacting one or more dicarboxylic acids with one or more glycols at a temperature of 100°C. to 315°C. at a pressure of 0.1 to 760 mm Hg for a time sufficient to form a copolyester. See U.S. Pat. No. 3,772,405 for methods of producing copolyesters, the disclosure regarding such methods is hereby incorporated herein by reference.

[0070] In one embodiment, the copolyesters can be produced from chemically recycled monomers (produced by any known methods of depolymerization).

[0071] In one aspect of the present disclosure, the copolyester compositions comprise recycle content. In one embodiment, the copolyester compositions are produced from chemically recycled monomers. For example, polyesters are depolymerized to form the monomer units originally used in its manufacture. One commercially utilized method for polyester depolymerization is methanolysis. In methanolysis, the polyester is reacted with methanol to produce a depolymerized polyester mixture comprising polyester oligomers, dimethyl terephthalate (“DMT”), and ethylene glycol (“EG”). Other monomers such as, for example, 1 ,4-cyclohexanedimethanol (“CHDM”) and diethylene glycol may also be present depending on the composition of the polyester in the methanolysis feed stream. Some representative methods for the methanolysis of PET are described in U.S. Pat. Nos. 3,037,050; 3,321 ,510; 3,776,945; 5,051 ,528; 5,298,530; 5,414,022; 5,432,203; 5,576,456 and 6,262,294, the contents and disclosure of which are incorporated herein by reference. A representative methanolysis process is also illustrated in U.S. Pat. No. 5,298,530, the contents and disclosure of which is incorporated herein by reference. The ‘530 patent describes a process for the recovery of ethylene glycol and dimethyl terephthalate from scrap polyester. The process includes the steps of dissolving scrap polyester in oligomers of ethylene glycol and terephthalic acid or dimethyl terephthalate and passing super-heated methanol through this mixture. The oligomers can comprise any low molecular weight polyester polymer of the same composition as that of the scrap material being employed as the starting component such that the scrap polymer will dissolve in the low molecular weight oligomer. The dimethyl terephthalate and the ethylene glycol are recovered from the methanol vapor stream that issues from depolymerization reactor.

[0072] Another approach to depolymerize polyesters is glycolysis, in which the polyester is reacted with a glycol such as ethylene glycol or CHDM to produce a depolymerized polyester mixture. U. S. Pat. No. 4,259,478 thus discloses a process comprising heating a polyester in the presence of 1 ,4- cyclohexanedimethanol to glycolize the polymer, distilling out ethylene glycol from the glycolysis mixture, and polycondensing the glycolysis mixture to form a copolyester of which at least a portion of ethylene glycol units are replaced by 1 ,4-cyclohexanedimethanol units. Similarly, U.S. Pat. No. 5,635,584 discloses postconsumer or scrap polyester reacted with glycol to produce a monomer or low molecular weight oligomer by depolymerization of the polyester. The monomer or oligomer, as the case may be, is then purified using one or more of a number of steps including filtration, crystallization, and optionally adsorbent treatment or evaporation. The monomer or oligomer thus produced is particularly suitable as a raw material for acid or ester based polyester production of packaging grade polyester material. Because the process includes purification steps, specifications for the previously used polyester material need not be strict.

[0073] Another method of reusing scrap polyester is to introduce the scrap into a polymerization process. U.S. Pat. No. 5,559,159 thus discloses previously used polyethylene terephthalate) polyester materials and copolymers thereof, and in particular postconsumer polyester materials, depolymerized and repolymerized to produce bottle grade polymer containing up to 75% of the previously used material. The process involves the solubilization and depolymerization of the previously used polyester material in a transesterification and/or polymerization mixture containing dimethylterephthalate, ethylene glycol and transesterification products thereof. U.S. Pat. No. 5,945,460 discloses a process for producing polyester articles, which generates little or no polyester waste. The process provides esterification or transesterification of one or more dicarboxylic acids or their dialkyl esters, polycondensation to produce a high molecular weight polyester, and molding or shaping of the polyester to produce the desired product. Scrap produced during the molding process is recycled back to the esterification or transesterification or polycondensation portion of the process. Optionally, the scrap may also be recycled to intermediate steps prior to the molding operation. U.S. Pat. No. 7,297,721 discloses a process for the preparation of high molecular weight crystalline PET using up to 50% of postconsumer recycled PET flakes along with Pure Terephthalic Acid, Isophthalic Acid and ethylene glycol as a virgin raw material, in the presence of a combination of catalysts and additives to obtain an intermediate prepolymer heel having a low degree of polymerization, further subjecting to autoclaving to yield an amorphous melt, followed by solid state polymerization.

[0074] The copolyesters in general may be prepared by condensing the dicarboxylic acid or dicarboxylic acid ester with the glycol in the presence of a catalyst at elevated temperatures increased gradually during the course of the condensation up to a temperature of about 225°C to 310°C., in an inert atmosphere, and conducting the condensation at low pressure during the latter part of the condensation, as described in further detail in U.S. Pat. No. 2,720,507 incorporated herein by reference herein.

[0075] In some embodiments, during the process for making the copolyesters useful in the present disclosure, certain agents which colorize the polymer can be added to the melt including toners or dyes. In one embodiment, a bluing toner is added to the melt in order to reduce the b* of the resulting copolyester polymer melt phase product. Such bluing agents include blue inorganic and organic toner(s) and/or dyes. In addition, red toner(s) and/or dyes can also be used to adjust the a* color. Organic toner(s), e.g., blue and red organic toner(s), such as those toner(s) described in U.S. Pat. Nos. 5,372,864 and 5,384,377, which are incorporated by reference in their entirety, can be used. The organic toner(s) can be fed as a premix composition. The premix composition may be a neat blend of the red and blue compounds or the composition may be pre-dissolved or slurried in one of the raw materials, e.g., ethylene glycol.

[0076] The total amount of toner components added can depend on the amount of inherent yellow color in the base copolyester and the efficacy of the toner. In one embodiment, a concentration of up to about 15 ppm of combined organic toner components and a minimum concentration of about 0.5 ppm can be used. In one embodiment, the total amount of bluing additive can range from 0.5 to 10 ppm. In an embodiment, the toner(s) can be added to the esterification zone or to the polycondensation zone. Preferably, the toner(s) are added to the esterification zone or to the early stages of the polycondensation zone, such as to a prepolymerization reactor.

[0077] In one aspect of the present disclosure, the copolyester compositions further comprise recycled polyethylene terephthalate (rPET) or recycled polyesters. It is desirable that recycled PET (rPET) or recycled polyesters be incorporated back into new molded or extruded articles. Use of rPET or recycled polyesters lowers the environmental footprint of a product offering and improves the overall life-cycle analysis. The use of rPET or recycled polyesters offers economic advantages, and it would reduce the overall amount of packaging-related products sent to landfills or that could potentially end up contaminating oceans or other bodies of water.

[0078] There is no limitation on the recycled polyethylene terephthalate (rPET) or recycled polyesters that may be used in the to make blends with the copolyester compositions of the present disclosure. In one embodiment the rPET or recycled polyesters are mechanically recycled. In one embodiment the rPET or recycled polyesters are produced from chemically recycled monomers (produced by any known methods of depolymerization).

[0079] In one embodiment, the rPET may have minor modifications such as with up to 5 mole% of isophthalic acid and/or up to 5 mole % of CHDM or other diols. In one embodiment, the recycled PET (rPET) can be virtually any "waste" industrial or post-consumer PET. In one embodiment, the rPET useful in the blend compositions of the present disclosure may be post-consumer recycled PET. In one embodiment, the rPET is post-industrial recycled PET. In one embodiment, the rPET is post-consumer PET from soft drink bottles. In one embodiment, scrap PET fibers, scrap PET films, and poor-quality PET polymers are also suitable sources of rPET. In one embodiment, the recycled PET comprises substantially PET, although other copolyesters can also be used, particularly where they have a similar structure as PET, such as PET copolymers or the like. In one embodiment, the rPET is clean. In one embodiment, the rPET is substantially free of contaminants. In one embodiment, the rPET may be in the form of flakes.

[0080] In one embodiment, the copolyester compositions comprise 0 to 50wt% of rPET. In one embodiment, the copolyester compositions comprise 1 to 40wt% of rPET. In one embodiment, the copolyester compositions comprise 2 to 30wt% of rPET. In one embodiment, the copolyester compositions comprise 3 to 20wt% of rPET. In one embodiment, the copolyester compositions comprise 4 to 15wt% of rPET. In one embodiment, the copolyester compositions comprise 5 to 10wt% of rPET.

[0081] In one embodiment, up to about 50% by weight of rPET can be incorporated into the copolyester compositions of the present disclosure. In one embodiment, the rPET/copolyester blend is 15-50 wt% of rPET. In one embodiment, the rPET/copolyester blend is 25-40 wt% of rPET. In one embodiment, the rPET/copolyester blend is 20-30 wt% of rPET. In one embodiment rPET/copolyester blend is 15-50 wt% of rPET and 50-85 wt% of at least one copolyester.

[0082] The copolyester/rPET blends can be prepared by conventional processing techniques known in the art, such as melt blending, melt mixing, compounding via single screw extrusion, compounding via twin-screw extrusion, batch melt mixing equipment or combinations of the aforementioned. In one embodiment, the copolyester/rPET blends are compounded at temperatures of 220-320°C. In one embodiment, the copolyester/rPET blends are compounded at temperatures of 220-300°C. In one embodiment, the copolyester/rPET blends can be pre-dried at 60-160°C. In one embodiment, the copolyester/rPET blends are not pre-dried. In one embodiment, the compounding can occur under vacuum. In one embodiment, the compounding does not occur under vacuum.

[0083] In some embodiments, the copolyester compositions can also contain common additives in the amounts required for the intended application. In some embodiments, the copolyester compositions can contain from 0.01 to 25% or from 0.01 to 10% by weight of the overall composition common additives such as colorants, toner(s), dyes, mold release agents, flame retardants, extenders, reinforcing agents er materials, fillers, antistatic agents, antimicrobial agents, antifungal agents, seif-cleaning or low surface energy agents, scents or fragrances, antioxidants, extrusion aids, slip agents, release agents, carbon black, and other pigments, plasticizers, glass bubbles, nucleating agents, stabilizers, including but not limited to, UV stabilizers, thermal stabilizers, and/or reaction products thereof, fillers, and impact modifiers, and the like, and mixtures thereof, which are known in the art for their utility in copolyester blends. Examples of commercially available impact modifiers include, but are not limited to, ethylene/propylene terpolymers, functionalized polyolefins such as those containing methyl acrylate and/or glycidyl methacrylate, styrene-based block copolymeric impact modifiers, and various acrylic core/shell type impact modifiers. Residues of such additives are also contemplated as part of the copolyester composition.

[0084] Reinforcing materials may be added to the compositions useful in this disclosure. The reinforcing materials may include, but are not limited to, carbon filaments, silicates, mica, clay, talc, titanium dioxide, Wollastonite, glass flakes, glass beads and fibers, and polymeric fibers and combinations thereof. In one embodiment, the reinforcing materials include glass, such as, fibrous glass filaments, mixtures of glass and talc, glass and mica, and glass and polymeric fibers.

[0085] In one embodiment, the compositions of the present disclosure are useful as plastics, films, fibers, and sheet. The compositions of this disclosure are useful as molded or shaped articles, molded or shaped parts or as solid plastic objects. In one embodiment, the compositions of this disclosure are useful as molded parts or molded articles. In one embodiment, the compositions are suitable for use in any applications where clear, hard plastics are required. In one embodiment, the compositions are suitable for use in any applications where heavy gauge sheet materials are used. Examples of such applications include, but are not limited to, the following: trim, paneling, vehicle components and parts, food services components, medical device enclosures, trays, equipment parts, fascia, enclosures, covers, paneling, bedliners, dividers, signs, displays, thermoformed signs, in-store displays, art work, EILT(encapsulated image layer technology), laminates, molded sinks, balustrades, barriers, dividers, guards, office dividers.

[0086] This disclosure further relates to articles of manufacture comprising the film(s) and/or sheet(s) containing the copolyester compositions described herein. In some embodiments, the films and/or sheets of the present disclosure can be of any thickness as required for the intended application. For example, in some embodiments, the thicknesses can range from 40 to 60 mils (0.04 to 0.06 inches or 1 mm to 1.5mm). In other embodiments, the thicknesses can range from 3/8 (0.375) of an inch up to 1 inch. In another embodiment, the thicknesses can range from 100 mils to 500 mils (0.1 to 0.5 inches or 2.5 to 12.5 mm). In another embodiment, the thicknesses can range from 1 mm up to 12.5 mm.

[0087] This disclosure further relates to the film(s) and/or sheet(s) described herein. The methods of forming the copolyester compositions into film(s) and/or sheet(s) includes any methods known in the art. Examples of film(s) and/or sheet(s) of the disclosure including but not limited to extruded film(s) and/or sheet(s), compression molded film(s) and/or sheet(s), Methods of making film and/or sheet include but are not limited to extrusion, and compression molding. [0088] This disclosure further relates to the molded or shaped articles described herein. The methods of forming the copolyester compositions into molded or shaped articles includes any known methods in the art. Examples of molded or shaped articles of this disclosure including but not limited to thermoformed or thermoformable articles, injection molded articles, extrusion molded articles, and extrusion blow molded articles. Methods of making molded articles include but are not limited to thermoforming, injection molding, extrusion, and extrusion blow molding. The processes of this disclosure can include any thermoforming processes known in the art.

[0089] In one aspect of the present disclosure, the disclosed polyester compositions are useful as thermoformed and/or thermoformable sheet(s). The present disclosure is also directed to articles of manufacture which incorporate the thermoformed sheet(s) of this disclosure. In one embodiment, the polyester compositions of the present disclosure are useful as sheet(s) which is easily formed into shaped or molded articles or parts. In one embodiment, the film(s) and/or sheet(s) of the present disclosure may be processed into molded articles or parts by thermoforming. The polyester compositions of the present disclosure may be used in a variety of molding and extrusion applications.

[0090] In addition, in one embodiment, the polyester compositions useful in the thermoformed sheet(s) of this disclosure may also contain from 0.1 to 25% by weight of the overall composition common additives such as colorants, antiblock agents, slip agents, mold release agents, flame retardants, plasticizers, nucleating agents, stabilizers, including but not limited to, LIV stabilizers, thermal stabilizers, fillers, and impact modifiers. [0091] In one embodiment, reinforcing materials may be included in the thermoformed sheet(s) comprising the polyester compositions of this disclosure. For examples, suitable the reinforcing materials may include carbon filaments, silicates, mica, clay, talc, titanium dioxide, Wollastonite, glass flakes, glass beads and fibers, and polymeric fibers and combinations thereof.

[0092] The following examples further illustrate how the copolyester compositions of the present disclosure can be made into recyclable articles and evaluated, and they are intended to be purely exemplary and are not intended to limit the scope thereof. Unless indicated otherwise, parts are parts by weight, temperature is in degrees C (Celsius) or is at room temperature, and pressure is at or near atmospheric.

Examples

[0093] This disclosure can be further illustrated by the following examples of preferred embodiments thereof, although it will be understood that these examples are included merely for purposes of illustration and are not intended to limit the scope of the disclosure unless otherwise specifically indicated.

Table 1 : Samples Compositions Evaluated for RIC-1

The % PET calculation was based on the ratio of starting monomers to produce the formula. The total weight of TPA and EG in the expected formula divided by the total monomer weight of the formulation. The resin compositions for Samples 1 -11 are manufactured by and available from Eastman Chemical Company. The PET for Sample 12 is available from Pushi. Fully compounded samples were melt blended to make a compounded pellet and then formed into a heavy gauge sheet. For the salt and pepper blend samples, the heavy gauge sheet was formed directly from the blend of the two pellets mixed together.

Table 2: DSC Data (all number are in °C)

Table 3: Physical testing

[0094] For the physical testing summarized in table 3, all testing was done on injection molded samples. These samples were 6 inches by 8 inches at a thickness of 1/8 inch to represent extruded Heavy Gauge Sheet. For the Band Saw testing: pass = clean cut, fail = sample broke, an 18 inch Laguna wood working band saw was used and was equipped with a normal wood cutting blade. For the Table Saw test: pass = clean cut, fail = sample broke, a Saw- Stop 3HP table saw was used and was equipped with a standard wood cutting blade. For the Drill Press testing: pass = clean cut, fail = sample broke, Fair = clean cut with excess melted material, a Delta bench top drill press model number DP300 was used with several different drill bits to evaluate the efficiency and clean cut characteristics of drilling holes in the materials. For the Cold Bend test: a 90° bend on a sheet metal brake. Pass=clean bend, fail = sample broke. For the Ball Drop test: All samples passed the drop test up to 57 inches, with a ball weight of 1 Kg. For the Heat Polish testing: a heat gun was used to polish out scratches made by Steel wool. Pass = clear surface, fail = excess crystallization. To evaluate Thermoforming properties: to determine if the samples can be thermoformed using normal copolyester processing conditions. The Hydrotrim thermoforming machine that was used was capable of handling a 6x8 inch sample.

Reactor Grade Compositions

[0095] In one aspect of the present disclosure, reactor grade compositions were identified for heavy gauge sheet applications that meet the performance requirements and the RIC-1 definition. Based on the data in Tables 2 and 3, reactor grade copolyester compositions that are suitable as heavy gauge sheet material and meets the RIC-1 requirements are possible. Sample 4 and Sample 5 meet both of these requirements. They performed well in all of the physical testing as shown in Table 3 and they met the requirements for RIC-1 . However, composition with 4.5 mole% CHDM or less had difficulty with the heat polishing process. Nonetheless, they could work in some heavy gauge sheet applications. On the other hand, reactor grade compositions with more than about 1 1 mole% CHDM (and potentially other modifiers) do not meet the crystalline melting point requirements of the 2^nd rule of RIC-1. Thus, the preferred range of heavy gauge sheet reactor grade compositions are compositions based on TPA (or DMT) and EG with a CHDM modification level of 4.5 to 1 1 mole%. Other modifying glycols could include, TMCD, NPG, isosorbide, and the like. Low levels of IPA can be used to modify the diacid portion of the polymer. However as seen from the Pushi control sample, too much IPA will cause the material to be brittle and fail physical testing in heavy gauge sheet applications.

Blend Compositions

[0096] In one aspect of the present disclosure, blend compositions were identified for heavy gauge sheet applications that meet the performance requirements and the RIC-1 definition. Blending opens up the compositional window. In the reactor grade materials described above, the crystalline melting point is the limiting factor for how much of the co-monomer modifiers can be added to the compositions. However, with blend compositions, it is possible to maintain the crystalline melting point at higher modification levels. The limiting factor in compositions for RIC-1 compatibility is based on the first rule that required 90% by weight of the starting monomers must be consistent with the monomers used to make pure PET. Table 4 shows combinations of blend compositions that meet the first rule for RIC-1 compatibility.

Table 4: Ratio of PET (or lightly modified PET) / heavily modified copolyester to remain within RIC-1 upper compositional limits.

[0097] All of the ratios in Table 4, have a calculated composition that is very close to 90% by weight based on PET monomers (TPA and EG) with the remaining 10% being based on CHDM. Sample 8, 9, 10, and 11 were tested as blend compositions. Each of these samples blend compositions that are suitable for use in heavy gauge sheet applications by meeting the physical testing criteria and they meet the requirements for RIC-1 based on compositional calculations and the second cycle DSC T_m value. The compositional ranges for the blend compositions can include any combination of PET or lightly modified PET (PETG) with one or more PETG or PCTG compositions, such that the resulting composition has 10% or less by weight of the modifying glycols and potentially modifying diacids. On a mole basis, the final blend composition of a PET composition blended with a CHDM rich copolyester composition could have a final composition of up to 17mol% CHDM. This calculates to 10 wt% CHDM based on the monomer weights used to make the polymers.

Claims

What is claimed

1. A recyclable heavy gauge sheet article comprising a blend of polyester resin compositions comprising:

Polyester 1 ) (a) a dicarboxylic acid component comprising: i) 90 to 100 mole % of terephthalic acid residues; ii) 0 to 10 mole % of aromatic and/or aliphatic dicarboxylic acid residues having up to 20 carbon atoms; and

(b) a glycol component comprising: i) 0 to 10 mole % of 1 ,4-cyclohexanedimethanol residues (CHDM); ii) 0 to 10 mole % of other modifying glycols residues chosen from one or more of the following NPG, TMCD, MPdiol, butane d ol, and propane diol; iii) 3 mole% or less of diethylene glycol residues; and iv) up to 100 mole% of ethylene glycol residues; wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and wherein the total comonomer content from (a) ii) and (b) i) and (b) ii) is 10 mole% or less; and

Polyester 2) (a) a dicarboxylic acid component comprising: i) 90 to 100 mole % of terephthalic acid residues; ii) 0 to 10 mole % of aromatic and/or aliphatic dicarboxylic acid residues having up to 20 carbon atoms; and

(b) a glycol component comprising: i) from 20 mole % to 70 mole % of 1 ,4- cyclohexanedimethanol residues (CHDM); ii) from 0 mole % up to 70 mole % of other modifying glycols residues chosen from one or more of the following NPG, TMCD, MPdiol, 1 ,4 butanediol, 1 ,6 hexanediol, 1 , 2 propane diol and 1 ,3 propane diol; iii) 10 mole% or less of diethylene glycol residues (DEG); and iv) from 30 mole % to 80 mole% of ethylene glycol residues (EG); wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %;wherein the total comonomer content from glycols other than ethylene glycol (EG) is between 20 to 70 mole% and the diacids from comonomers other than DMT and TPA are not to exceed 10 mole% ;and wherein the blend of polyester 1 ) and polyester 2) is 90% by weight derived from EG, TPA or DMT and the final blend has a melting point between 225 and 255; and wherein the inherent viscosity of the polyester blend is from 0.50 to 0.9 dL/g as determined in 60/40 (wt/wt) phenol/tetrachloroethane at a concentration of 0.5 g/100 ml at 25°C; wherein the polyester blend has a T_g of 70 to 1 15°C; wherein the article has a haze value of 20% or less; and wherein the article has a thickness of from 1 -12.5 mm; wherein the article has a crystallization half time of about 1 minute to about 20 minutes at 180°C; wherein the article is recyclable in a PET recycle stream.

2. The recyclable, heavy gauge sheet article of claim 1 , wherein polyester blend has up to 17 mole % of 1 ,4-cyclohexanedimethanol residues (CHDM).

3. The recyclable, heavy gauge sheet article of claim 1 , wherein the polyester blend has a T_g of 75 to 95°C.

4. The recyclable, heavy gauge sheet article of claim 1 , wherein the article has a haze value of 10% or less or of 5% or less.

5. The recyclable, heavy gauge sheet article of claim 1 , further comprising at least one polyester with recycle content.

6. The recyclable, heavy gauge sheet article of claim 1 , wherein the EG is recycled EG (rEG).

7. The recyclable, heavy gauge sheet article of claim 1 , wherein the CHDM is rCHDM or the CHDM produced from rDMT.

8. The recyclable, heavy gauge sheet article of claim 1 , wherein the DEG is recycled DEG or the DEG is produced from rEG.

9. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 0 mole% CHDM and Polyester 2) has 31 mole% CHDM.

10. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 0 mole% CHDM and polyester 2) has 31 mole% CHDM and Polyester 1 ) and Polyester 2) are in a ratio of at least 46:54 or less (by weight based on the total weight of the polymer composition).

11 . The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 0 mole% CHDM and Polyester 2) has 50 mole% CHDM.

12. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 0 mole% CHDM and Polyester 2) has 50 mole% CHDM and Polyester 1 ) and Polyester 2) are in a ratio of at least 66:34 or less (by weight based on the total weight of the polymer composition).

13. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 0 mole% CHDM and Polyester 2) has 62 mole% CHDM.

14. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 0 mole% CHDM and Polyester 2) has 62 mole% CHDM and Polyester 1 ) and Polyester 2) are in a ratio of at least 73:27 or less (by weight based on the total weight of the polymer composition).

15. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 3.5 mole% CHDM and Polyester 2) has 31 mole% CHDM.

16. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 3.5 mole% CHDM and Polyester 2) has 31 mole% CHDM and Polyester 1 ) and Polyester 2) are in a ratio of at least 52:48 or less (by weight based on the total weight of the polymer composition).

17. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 3.5 mole% CHDM and Polyester 2) has 50 mole% CHDM.

18. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 3.5 mole% CHDM and Polyester 2) has 50 mole% CHDM and Polyester 1 ) and Polyester 2) are in a ratio of at least 71 :29 or less (by weight based on the total weight of the polymer composition).

19. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 3.5 mole% CHDM and Polyester 2) has 62 mole% CHDM.

20. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 3.5 mole% CHDM and Polyester 2) has 62 mole% CHDM and Polyester 1 ) and Polyester 2) are in a ratio of at least 77:23 or less (by weight based on the total weight of the polymer composition).

21 . The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 4.5 mole% CHDM and Polyester 2) has 31 mole% CHDM.

22. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 4.5 mole% CHDM and Polyester 2) has 31 mole% CHDM and Polyester 1 ) and Polyester 2) are in a ratio of at least 54:46 or less (by weight based on the total weight of the polymer composition).

23. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 4.5 mole% CHDM and Polyester 2) has 50 mole% CHDM.

24. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 4.5 mole% CHDM and Polyester 2) has 50 mole% CHDM and Polyester 1 ) and Polyester 2) are in a ratio of at least 73:27 or less (by weight based on the total weight of the polymer composition).

25. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 4.5 mole% CHDM and Polyester 2) has 62 mole% CHDM.

26. The recyclable, heavy gauge sheet article of claim 1 , wherein Polyester 1 ) has 4.5 mole% CHDM and Polyester 2) has 62 mole% CHDM and Polyester 1 ) and Polyester 2) are in a ratio of at least 79:21 or less (by weight based on the total weight of the polymer composition).

27. The recyclable, heavy gauge sheet article of claim 1 , wherein the article is cold formable at room temperature without breaking; or metal break bent at a 90-degree angle at room temp without breaking and without stress whitening; or cut with a saw or holes drilled into article without breaking or is thermoformed without stress whitening.

28. The recyclable, heavy gauge sheet article of claim 1 , wherein 90% by weight of the blend composition is TPA and EG and the Tm of the composition is from 225-255°C.