PET Tableware Composite Material for Heat Distortion Above 150°C
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Solution Overview
Problem
Melamine tableware has a low heat distortion temperature, posing a food safety risk due to the release of toxic melamine at elevated temperatures, and existing PET-based tableware solutions with inorganic fillers lack sufficient mechanical strength and heat resistance.
Innovation Solution
A manufacturing method for heat-resistant tableware using a polyester composite material with 50-85 wt% PET, 0-5 wt% organic nucleating agent, and 10-30 wt% inorganic nucleating agent, processed at a mold temperature above 110°C to achieve a heat distortion temperature of at least 150°C, eliminating the need for PBT and ensuring non-stick properties during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If inorganic filler is added to PET-based tableware to increase heat distortion temperature, then heat resistance is improved, but mechanical strength becomes insufficient
Solution Approach 1:
The patent changes the parameters of inorganic filler by specifying particle size ranges (0.5-5 μm for first inorganic filler, 1-10 μm for second inorganic filler) and content ranges (5-20 wt% and 3-15 wt% respectively). It also controls mold temperature (100-150°C) and crystallinity (20-40%) to optimize both heat resistance and mechanical strength simultaneously
Solution Approach 2:
The patent uses a composite material system consisting of PET resin combined with two different types of inorganic fillers (first and second inorganic fillers with different particle sizes). This composite approach allows the material to achieve both high heat distortion temperature (≥100°C) and sufficient mechanical strength by leveraging the complementary properties of different filler particles
2Temperature
If mold temperature is increased to achieve high crystallinity and heat resistance, then heat distortion temperature is improved, but molding difficulty increases due to stickiness
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: mold temperature (100-150°C), crystallinity (20-40%), inorganic filler content (5-20 wt% first filler, 3-15 wt% second filler), and particle sizes (0.5-5 μm and 1-10 μm). This multi-parameter optimization enables achieving high heat distortion temperature while maintaining easy molding and preventing stickiness
Solution Approach 2:
The inorganic fillers act as intermediaries that facilitate crystallization at controlled rates. They serve as nucleation sites that enable the PET resin to crystallize properly at moderate mold temperatures (100-150°C) without causing excessive stickiness, while still achieving the desired heat distortion temperature of at least 100°C
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 enhances the heat distortion temperature and mechanical strength of the tableware, preventing melamine release and ensuring safe food contact, while allowing for easy mold removal and reduced PET resin usage, thus addressing the limitations of prior art.
Implementation Method 1
10 wt % to 30 wt % of an inorganic nucleating agent
Implementation Method 2
a crystallinity of the polyester composite material in the mold is controlled to be between 20% and 40%
Implementation Method 3
a mold temperature of the mold is controlled to be not less than 110° C.
Data Source
AI summary
A manufacturing method of a heat-resistant tableware and a molded article of the heat-resistant tableware are provided. The manufacturing method of the heat-resistant tableware includes: providing a polyester composite material that includes 50 wt % to 85 wt % of polyethylene terephthalate, 0 wt % to 5 wt % of an organic nucleating agent, and 10 wt % to 30 wt % of an inorganic nucleating agent; and injecting the polyester composite material into a mold in an injection molding process, in which a mold temperature of the mold is controlled to be not less than 110° C., and a crystallinity of the polyester composite material in the mold is controlled to be between 20% and 30%, so that the polyester composite material is formed into the molded article of the heat-resistant tableware in the mold, and the molded article has a heat distortion temperature of not less than 150° C.