# Bio-based unsaturated polyester resin from post-consumer PET

## TL;DR

This paper describes a new method to create eco-friendly polyester resin from recycled plastic waste, avoiding harmful styrene.

## Contribution

A novel, bio-based, styrene-free unsaturated polyester resin is synthesized from post-consumer PET using itaconic acid and glycolysis.

## Key findings

- The resin formulated with dimethyl itaconate achieves high flexural strength (161.4 MPa) and compressive yield point (131.3 MPa).
- The process uses a redox initiation system for room-temperature curing followed by post-curing at elevated temperatures.
- The low volatility of dimethyl itaconate reduces health and environmental risks compared to traditional styrene-based resins.

## Abstract

This study explores the utilization of post-consumer poly(ethylene terephthalate) (PET) as a material in the synthesis of styrene-free unsaturated polyester (UP) resin. The process involves glycolysis of PET waste with diethylene glycol and condensation polymerization with bio-based itaconic acid. The resulting unsaturated polyester possesses reactive methylidene functions that, in contrast to commonly employed fumarates/maleates, facilitate copolymerization with non-styrene reactive diluents. To formulate the resins, methacrylates and itaconates were used for dilution, and the curing process is achieved through a redox initiation system at room temperature, followed by post-curing at elevated temperatures. The cured formulations were characterized by their glass transition temperature, determined by DMA analysis. Mechanical properties were evaluated using standardized tests in tension, flexure, and compression. Particularly promising characteristics are observed in formulations incorporating bio-based dimethyl itaconate (DMI), allowing the formulation of materials with a high ultimate flexural strength (σf,max = 161.4 MPa) and compressive yield point (σc,yield = 131.3 MPa). Furthermore, the low volatility of DMI addresses the health, safety, and ecological concerns associated with the commonly used styrene. This technology not only presents a promising avenue for sustainable UP resin for glass fiber reinforced composites but also allows upcycling PET waste.

Styrene-free unsaturated polyester resin synthesized from post-consumer PET is described.