PEF Preform Water Sorption Plasticization

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Solution Overview

Problem

The challenge lies in developing commercially viable poly(ethylene furanoate) (PEF) bottles with properties comparable to or superior to conventional poly(ethylene terephthalate) (PET) for carbonated beverages, as PEF exhibits lower crystallinity, slower crystallization, and reduced entanglement, posing processing difficulties in stretch blow molding.

Innovation Solution

Expanding the processing window for PEF preforms through ambient or higher temperature water plasticization, which involves using moisture in conjunction with heat to pre-condition the material, optimizing conditions to achieve improved morphology, size, and crystallinity distribution, and providing PEF-specific processing parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If PEF is used as a replacement for PET in beverage packaging, then environmental sustainability is improved through bio-based synthesis, but processing difficulty increases due to lower crystallinity and slower crystallization rates

Engineering Contradiction:

Improveenvironmental sustainabilityVSAvoidprocessing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-conditioning PEF preforms through moisture absorption and plasticization before stretch blow molding. This preliminary treatment modifies the material properties to enable successful processing, addressing the inherent processing difficulties of PEF while maintaining its sustainability advantages

Inventive Principle:

Principle #10Preliminary action

2Loss of time

If PEF preforms are processed without moisture plasticization, then processing time is reduced, but manufacturing precision deteriorates due to inadequate crystallinity development

Engineering Contradiction:

Improveprocessing timeVSAvoidcrystallinity distribution

Core Design Contradiction:

Loss of timeVSManufacturing precision

Solution Approach 1:

The patent performs preliminary moisture absorption and plasticization of PEF preforms before the main stretch blow molding process. This preliminary action prepares the material with optimal moisture content and plasticization level, enabling faster subsequent processing while ensuring proper crystallinity development and manufacturing precision

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If water sorption is increased to plasticize PEF, then ease of operation is improved by broadening processing window, but loss of substance occurs through water absorption

Engineering Contradiction:

Improveprocessing windowVSAvoidwater absorption

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The patent applies partial action by controlling water sorption to achieve optimal but not excessive plasticization. The process uses sufficient moisture to broaden the processing window and improve operability, while avoiding excessive water absorption that would cause harmful plasticization or material degradation

Inventive Principle:

Principle #16Partial or excessive action

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 enhances the stretch blow molding processing range of PEF, leading to improved performance and commercial viability by broadening the processing window and optimizing the crystalline structure, thus overcoming the inherent challenges of using PEF in beverage packaging.

Implementation Method 1

The challenge lies in developing commercially viable poly(ethylene furanoate) (PEF) bottles... through ambient or higher temperature water plasticization, which involves using moisture in conjunction with heat to pre-condition the material

Methodology Applied

Scientific EffectWater sorption: Sorption

Implementation Method 2

Expanding the processing window for PEF preforms through ambient or higher temperature water plasticization, which involves using moisture in conjunction with heat to pre-condition the material

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Implementation Method 3

PEF exhibits lower crystallinity, crystallize at slower rates... optimizing conditions to achieve improved morphology, size, and crystallinity distribution

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentUS10940630B2Methods for processing and plasticizing poly(ethylene furanoate) preforms by water sorption

Publication Date: 2021.03.09 THE COCA COLA CO

AI summary

This disclosure provides effective methods for expanding the processing window for poly(ethylene furanoate) (PEF) and poly(ethylene furanoate) co-polymer (PEF co-polymer) polyester preforms, such that these preforms can be beneficially used in the fabrication of bottles and containers, including bottles for carbonated soft drinks. The processing window is expanded by, for example, pre-conditioning the PEF or PEF co-polymer preform prior to stretch blow-molding by contacting the PEF or PEF co-polymer preform with water or high (>50%) relative humidity air for a desired time period and at a temperature greater than or equal to ambient temperature, to take advantage of the unique and unexpected properties afforded the preform by water sorption at these temperatures.