Bio-based PET Production via Melt Polymerization

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Solution Overview

Problem

Current petroleum-based PET production contributes to greenhouse emissions and is non-renewable, necessitating a bio-based alternative with similar properties to be used in existing manufacturing and recycling facilities, while also being environmentally friendly and not competing with food resources.

Innovation Solution

A method of producing bio-based PET using bio-based materials such as sugarcane, corn starch, citrus fruits, and agricultural waste, involving steps like refining, fermentation, and melt polymerization to create PET components like monoethylene glycol and terephthalic acid, which are then processed into PET resins and packaging, with recycling methods for used PET packaging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If petroleum-based PET is used for production, then manufacturing cost is tied to petroleum price and production is efficient, but greenhouse emissions increase and resource renewability is lost

Engineering Contradiction:

Improvegreenhouse emissionsVSAvoidmanufacturing process compatibility

Core Design Contradiction:

Object-generated harmful factorsVSEase of manufacture

Solution Approach 1:

The patent changes the chemical origin parameter of PET from petroleum-based to bio-based by using renewable feedstocks like corn starch and sugarcane. This substitution maintains the chemical structure and properties of PET while altering the carbon source, thereby reducing greenhouse emissions without compromising manufacturing compatibility

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The bio-based PET is designed to be universally compatible with existing petroleum-based PET manufacturing facilities and recycling systems. The patent ensures that the bio-based PET can be processed through the same equipment and mixed with recycled PET, providing multi-functionality that addresses both environmental concerns and manufacturing efficiency

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Stability of the object's composition

If bio-based materials are used to produce PET, then renewability and environmental friendliness improve, but compatibility with existing manufacturing facilities must be maintained

Engineering Contradiction:

Improvechemical and physical propertiesVSAvoidprocessing facility requirements

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent maintains the chemical structure parameters of PET (polyethylene terephthalate) while changing only the feedstock origin parameter. By preserving the molecular structure and physical properties, the bio-based PET remains compatible with existing manufacturing equipment without requiring facility modifications

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The bio-based PET is created as a copy of petroleum-based PET in terms of chemical structure and physical properties. This copying approach ensures that the material behaves identically in manufacturing processes and recycling systems, eliminating the need for separate processing facilities

Inventive Principle:

Principle #26Copying

3Object-generated harmful factors

If food-grade bio-based materials are used for PET production, then consumer demand for environmentally friendly products is satisfied, but competition with food resources increases costs

Engineering Contradiction:

Improveenvironmental impactVSAvoidcost of raw materials

Core Design Contradiction:

Object-generated harmful factorsVSQuantity of substance

Solution Approach 1:

The patent utilizes agricultural waste streams and non-food bio-based materials as feedstocks for PET production. These materials are typically discarded or have low economic value, providing a cheap alternative to food-grade materials while maintaining environmental benefits and reducing competition with food resources

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent converts agricultural waste streams, which are typically discarded as byproducts, into valuable feedstocks for PET production. This approach transforms a waste problem into an economic opportunity, reducing raw material costs while maintaining environmental sustainability

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

This approach reduces waste, decreases environmental impact, and provides a sustainable, renewable PET alternative that can be processed and recycled similarly to traditional PET, meeting environmental and economic demands.

Implementation Method 1

melt polymerizing the monoethylene glycol with the terephthalic acid to form a polyethylene terephthalate

Methodology Applied

Scientific EffectMelt polymerization:

Implementation Method 2

The polymer is then solid state polymerized

Methodology Applied

Scientific EffectSolid state polymerization:

Data Source

PatentEP3878887A1Method of making a bio-based polyethylene terephthalate

Publication Date: 2021.09.15 THE COCA COLA CO

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AI summary

This invention relates to a method of making a bio-based polyethylene terephthalate (PET) container comprising: (a) forming monoethylene glycol (MEG) from at least one bio-based material; (b) melt polymerizing the MEG with terephthalic acid (TA) to form a bio-based PET; (c) solid state polymerizing the bio-based PET to form a PET resin; and (d) processing the PET resin into a PET container.