Cyclobutanediol Polyester Bottles With Controlled Crystallization
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Solution Overview
Problem
Current polyesters and polycarbonates face challenges in achieving a combination of high impact strength, hydrolytic stability, chemical resistance, and thermoformability while maintaining processability on standard industry equipment, with issues such as rapid crystallization and poor melt processability.
Innovation Solution
A polyester composition comprising terephthalic acid, 2,2,4,4-tetramethyl-1,3-cyclobutanediol, and 1,4-cyclohexanedimethanol with specific monomer ratios and inherent viscosities, allowing for high glass transition temperatures and improved crystallization half-times, enabling the production of bottles with enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If PCT crystallizes rapidly upon cooling from the melt, then crystallization rate is improved, but difficulty in forming amorphous articles increases
Solution Approach 1:
The patent modifies the chemical composition parameters of PCT by incorporating copolymer units (ethylene glycol or isophthalic acid) to change the crystallization kinetics. This compositional parameter change slows the crystallization rate while maintaining the ability to form both crystalline and amorphous articles through standard processing methods.
Solution Approach 2:
The patent creates a composite polyester structure by combining PCT units with copolymer units (ethylene glycol or isophthalic acid). This composite material approach allows the polymer to exhibit both controlled crystallization behavior and improved processability for forming amorphous articles.
2Duration of action of stationary object
If sufficient ethylene glycol or isophthalic acid is added to PCT to provide long crystallization half-times, then crystallization control is improved, but glass transition temperature and impact strength decrease
Solution Approach 1:
The patent optimizes the concentration parameters of copolymer units to achieve a balance point. By controlling the amount of ethylene glycol or isophthalic acid within specific ranges, the patent achieves sufficient crystallization control while minimizing the negative impact on glass transition temperature and impact strength.
Solution Approach 2:
The patent maintains a continuous balance between crystallization control and mechanical properties by using moderate amounts of copolymer units. This continuous optimization allows the material to exhibit both long crystallization half-times and acceptable impact strength without extreme compositional modifications.
3Strength
If bisphenol A polycarbonate is used as an alternative, then heat resistance and impact strength are improved, but melt viscosity increases leading to poor processability
Solution Approach 1:
The patent uses a polyester composition that can be processed on standard industry equipment rather than requiring specialized high-performance polymer equipment. This approach prioritizes ease of manufacture and equipment compatibility while achieving sufficient mechanical properties for bottle applications.
Solution Approach 2:
The patent modifies the polyester composition parameters to achieve melt viscosity levels suitable for standard extrusion and injection molding equipment. By adjusting the copolymer content and molecular weight parameters, the patent ensures good processability while maintaining adequate impact strength and heat resistance.
4Strength
If polymers containing 2,2,4,4-tetramethyl-1,3-cyclobutanediol are used, then inherent viscosity and Tg are improved, but equipment insufficiency occurs for manufacturing and post-polymerization
Solution Approach 1:
The patent controls the inherent viscosity parameter of the polyester to fall within a specific range (0.6-1.2 dL/g) that is compatible with standard industry equipment. By adjusting the copolymer content and molecular weight, the patent achieves sufficient mechanical properties while ensuring manufacturability on existing equipment.
Solution Approach 2:
The patent maintains a continuous balance between achieving high inherent viscosity for mechanical strength and keeping the viscosity within equipment capabilities. This continuous optimization allows standard manufacturing equipment to process the material effectively while achieving the desired glass transition temperature and mechanical properties.
Data Source
AI summary
Described are bottles comprising polyester compositions comprising polyesters which comprise (a) a dicarboxylic acid component having terephthalic acid residues; optionally, aromatic dicarboxylic acid residues or aliphatic dicarboxylic acid residues or ester residues thereof; 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues; and 1,4-cyclohexanedimethanol residues.