Multilayer Container Preform for Hot-Fill Oxygen Barrier Bottles
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Solution Overview
Problem
There is a need for plastic containers that provide heat stability and oxygen barrier properties at an acceptable cost, while reducing the environmental impact of petrochemically derived materials, and without compromising physical performance.
Innovation Solution
A multilayer preform is developed with outer and inner layers comprising 2,5-furandicarboxylate polyester or co-polyester, and an intermediate layer of a less expensive, compatible material, manufactured through co-injection molding, which is then stretch blow molded to create containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If PET is used to make containers, then clarity and mechanical properties are improved, but environmental impact worsens due to petrochemical derivation
Solution Approach 1:
The patent changes the chemical composition parameters of the polymer material from petrochemical PET to bio-based PEF (polyethylene furanoate), maintaining mechanical properties while improving environmental sustainability by using renewable feedstocks
Solution Approach 2:
The patent creates a multilayer composite structure combining PEF and PET layers, where PEF provides barrier properties and renewable content, while PET provides mechanical strength, achieving both environmental and performance goals
2Productivity
If bottles are filled with hot content at temperature ≥70°C, then filling efficiency is improved, but permanent deformations occur in the bottles
Solution Approach 1:
The patent changes the glass transition temperature parameter of the container material from PET (74°C) to PEF (86°C), allowing the bottle to withstand hot filling temperatures without deformation while maintaining filling efficiency
Solution Approach 2:
The multilayer structure with PEF and PET layers provides enhanced thermal stability, allowing the bottle to maintain structural integrity during hot filling operations
3Stability of the object's composition
If heat-set process is applied to prevent deformation, then heat stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent incorporates heat stability into the material composition itself through PEF's inherently higher glass transition temperature, eliminating the need for post-manufacturing heat-set processes and reducing manufacturing complexity
4Reliability
If multilayer structure is used for oxygen barrier, then oxygen barrier properties are improved, but crystallization during heat-set process occurs causing whitening
Solution Approach 1:
The patent changes the material composition to PEF-based layers with higher thermal stability, preventing crystallization during heat treatment while maintaining oxygen barrier properties, thus avoiding whitening
5Stability of the object's composition
If PEF is used to improve heat stability and oxygen barrier, then performance is improved, but material cost increases
Solution Approach 1:
The patent applies PEF material selectively in specific layers where heat stability and oxygen barrier properties are most needed, while using cost-effective PET in other layers, optimizing the balance between performance and cost
Solution Approach 2:
The multilayer composite structure combines expensive PEF and cheaper PET materials, achieving high performance where needed while controlling overall material costs through strategic material placement
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 multilayer structure enhances heat stability and oxygen barrier properties of the containers, reduces the need for expensive heat-set processes, and lowers material costs by using renewable raw materials, without compromising performance.
Implementation Method 1
For oxygen sensitive products an additional oxygen barrier is often needed in order to prevent degradation of the filled liquid
Implementation Method 2
During bottle blowing the bottle is heated in order increase the crystallinity of the material and thereby increase the heat stability of the bottle
Implementation Method 3
The preform is then subjected to a stretch blow molding process to obtain the finished container
Data Source
AI summary
The present invention relates to a multilayer container preform and a multilayer container, said preform or container comprising a base, a body and a neck finish, said base and body comprising an outer layer defining an exterior surface, an inner layer defining an interior surface and interior space, and an intermediate layer disposed between the outer layer and the inner layer, said outer layer and said inner layer comprising a primary material selected from the group consisting of a 2,5-furandicarboxylate polyester or co-polyester or a blend thereof, and said intermediate layer comprising a secondary material different from the primary material, but compatible with the primary material. The invention relates to methods of producing such a multilayer container preform and multilayer container