PEF Bottle Hot Fill Stability via Heated Mold Blow Molding
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Solution Overview
Problem
Bottles made from traditional plastics like PET are prone to deformation when filled with hot contents, rendering them unsuitable for high-temperature applications, whereas biosourced polymers like PEF are needed to replace PET but face similar deformation issues during hot filling.
Innovation Solution
A method of manufacturing bottles using a thermoplastic polymer composed of FDCA and diol monomers, specifically polyethylene furanoate (PEF), involving a heated mold blow molding process to enhance the bottles' resistance to hot content deformations, with controlled blowing pressures and imprinting techniques to achieve precise features and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bottles are made from traditional PET plastic using blow molding process, then manufacturing is simple and cost-effective, but bottles deform when filled with hot content at temperatures greater than or equal to 70°C
Solution Approach 1:
The patent applies parameter changes by modifying the mold temperature during the blow molding process. Specifically, the mold is heated to temperatures between 65°C and 85°C (optimally 70°C-80°C) before blowing the preform. This temperature parameter change allows the PEF polymer to maintain its structural integrity and resist deformation when subsequently filled with hot content, while still using the standard blow molding manufacturing process.
2Reliability
If bottles are made from biosourced PEF polymer, then environmental sustainability is improved, but bottles still suffer from deformation issues during hot filling
Solution Approach 1:
The patent applies preliminary action by pre-heating the mold to controlled temperatures (65°C-85°C) before the hot filling process. This preliminary thermal treatment of the mold creates optimal conditions for the PEF polymer to withstand subsequent exposure to hot content. The mold temperature is carefully controlled during the blowing process to prepare the bottle structure in advance, preventing deformation when hot content is later introduced.
3Reliability
If mold temperature is increased to improve hot content resistance, then bottle stability under hot fill is improved, but manufacturing energy consumption increases
Solution Approach 1:
The patent optimizes the mold temperature parameter within a specific range of 65°C to 85°C (with optimal values of 70°C-80°C). This controlled parameter change achieves the necessary hot content resistance while avoiding excessive energy consumption. The temperature is high enough to provide deformation resistance but controlled to minimize energy usage compared to uncontrolled high-temperature processing.
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 method allows bottles to withstand hot fill temperatures without deformation, offering improved imprinting precision and resistance compared to PET bottles, ensuring the bottles remain stable even after filling with hot liquids.
Implementation Method 1
the mold is heated at a temperature between 65°C and 85°C
Implementation Method 2
blowing the preform through the opened top end to form the bottle comprising an envelop defining a housing
Data Source
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AI summary
A method of making a bottle (1) made of at least one thermoplastic polymer of at least one FuranDiCarboxylic Acid (FDCA) monomer and at least one diol monomer, comprising the steps of: - providing a preform, - placing the preform in a mold, - blowing the preform to form the bottle (1) comprising an envelop (2) defining a housing, wherein, at the step of blowing the preform, the mold is heated at a temperature greater than or equal to 50°C, preferably comprised between 50°C and 100°C, more preferably between 65°C and 85°C.