Bio-based PET Fiber Composition and Spinning Process

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

There is a need to produce polyethylene terephthalate (PET) fibers from plant-based sources rather than traditional petroleum sources to meet consumer demand for bio-based products, as conventional PET production relies on petrochemical-derived precursors.

Innovation Solution

A method involving the use of bio-based monoethylene glycol (MEG) compositions, which include monoethylene glycol and minor concentrations of C3-C12 1,2-diols and 2-[(5-methyltetrahydro-2-furanyl)methoxy]ethanol, reacted with diacid compositions like terephthalic acid to form bio-based polyester fibers suitable for various applications, including textiles and packaging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional PET production uses petrochemical-derived precursors, then the production process is well-established and efficient, but it fails to meet consumer demand for bio-based and sustainable products

Engineering Contradiction:

Improveability to meet consumer demand for bio-based productsVSAvoidproduction process established from petrochemical sources

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent changes the source parameter of the precursors from petrochemical to bio-based sources. Specifically, it uses bio-based MEG (monoethylene glycol) instead of petroleum-derived MEG to produce PET fibers, thereby adapting the production process to meet consumer demand for sustainable products while maintaining the established polyester synthesis methodology

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs bio-based MEG that contains minor impurities (1-5000 ppm of C3-C12 1,2-diols and 2-[(5-methyltetrahydro-2-furanyl)methoxy]ethanol) without requiring extensive purification. This approach treats the bio-based precursor as a functional material where minor impurities do not significantly affect the final fiber performance, simplifying the manufacturing process

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of manufacture

If bio-based MEG compositions with minor impurities are used, then the production process is simplified, but the fiber quality and performance must be maintained

Engineering Contradiction:

Improveproduction process simplificationVSAvoidfiber quality consistency

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent establishes specific parameter ranges for the bio-based MEG composition, allowing 1-5000 ppm of C3-C12 1,2-diols and 2-[(5-methyltetrahydro-2-furanyl)methoxy]ethanol. These controlled parameter ranges ensure that the minor impurities do not adversely affect fiber quality while maintaining production simplicity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent ensures that the bio-based MEG composition maintains sufficient homogeneity in terms of its major component (MEG) while accommodating minor natural variations in the bio-based impurities. This homogeneity allows the polyester synthesis and fiber production to proceed consistently without requiring stringent purification

Inventive Principle:

Principle #33Homogeneity

3Object-affected harmful factors

If bio-based MEG composition is used to produce PET fibers, then environmental sustainability is improved, but the production cost may increase

Engineering Contradiction:

Improveenvironmental sustainabilityVSAvoidproduction cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent uses bio-based MEG that can be produced from renewable resources such as sugarcane or corn, providing a sustainable alternative to petroleum-derived MEG. The approach accepts minor impurities in the bio-based MEG without extensive purification, reducing processing costs while maintaining environmental benefits

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent optimizes the composition parameters of bio-based MEG to balance sustainability and cost. By allowing controlled levels of natural impurities (1-5000 ppm), the patent reduces the need for expensive purification steps while maintaining fiber quality, thereby making bio-based PET production economically viable

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The bio-based PET fibers exhibit improved toughness, clarity, and uniform dyeability compared to petroleum-based PET, with reduced lamellar size and spherulitic crystallization, making them suitable for fiber applications and offering a more sustainable alternative.

Implementation Method 1

Conventional PET polyester is usually produced from the condensation reaction of terephthalic acid with monoethylene glycol (MEG)

Methodology Applied

Scientific EffectCondensation reaction:

Implementation Method 2

spinning and/or drawing the resulting polyester composition into a fiber

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentEP3538693B1Bio-based meg and polyester fiber compositions and methods of making the same

Publication Date: 2024.02.21 THE COCA COLA CO

Figure 1

AI summary

Disclosed are bio-based polyester fibers, particularly a PET fibers, and a method of making the same by: contacting a bio-based MEG composition with a diacid composition to form a polyester composition; and spinning and/or drawing the resulting polyester composition into a fiber; wherein the bio-based MEG composition comprises: a) monoethylene glycol (MEG); and b) from about 1 ppm to about 5000 ppm of at least one C3-C12 1,2-diol, wherein the C3-C12 1, 2-diol is linear, branched, or cyclic.