Patent Publication Number: US-6217818-B1

Title: Method of making preform and container with crystallized neck finish

Description:
RELATED APPLICATIONS 
     This is a continuation-in-part of and commonly owned U.S. Ser. No. 08/499,570 filed Jul. 7, 1995, now abandoned, entitled APPARATUS AND METHOD FOR MAKING MULTILAYER PREFORMS,” by Suppayan M. Krishnakumar and Wayne N. Collette, which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to thermoplastic preforms, of the type used for blow molding polyester beverage bottles, and more particularly to preforms having a crystallized first portion (e.g., neck finish) for resistance to deformation at elevated temperatures. 
     BACKGROUND OF THE INVENTION 
     There are a variety of applications in which thermoplastic containers are subjected to elevated temperatures. These include hot-fill containers, which must withstand filling with a hot liquid product (for sterilization purposes) without deformation, followed by sealing and a cooling process which produces a vacuum (negative pressure) in the container. Another application is pasteurization—a pasteurizable container is filled and sealed at room temperature, and then exposed to an elevated temperature bath for about ten minutes or longer. The pasteurization process initially imposes high temperatures and positive internal pressures, followed by a cooling process which creates a vacuum in the container. Throughout these procedures, the sealed container must resist deformation so as to remain acceptable in appearance, within a designated volume tolerance, and without leakage. In particular, the threaded neck finish must resist deformation which would prevent a complete seal. 
     Another high-temperature application is use as a returnable and refillable carbonated beverage container, now commercialized in Europe, South America, and Asia. In this application the container must withstand twenty or more wash and reuse cycles in which it is filled with a carbonated beverage at an elevated pressure, sold to the consumer, returned empty, and washed in a hot caustic solution prior to refilling. These repeated cycles of exposure to hot caustic agents and filling at elevated pressures make it difficult to maintain the threaded neck finish within tolerances required to ensure a good seal. 
     A number of methods have been proposed for strengthening the neck finish portion of a container to resist deformation at elevated temperatures. One method is to add an additional manufacturing step whereby the neck finish of the preform or container is exposed to a heating element in order to thermally crystallize the neck finish. However, there are several problems with this approach. First, during crystallization the polymer density increases, which produces a volume decrease. Therefore, in order to obtain a desired neck finish dimension, the as-molded dimension must be larger than the final crystallized dimension. It is difficult to achieve close dimensional tolerances with this method. In general, the variability of the critical neck finish dimensions after crystallization are approximately twice that prior to crystallization. Secondly, there is the increased cost of the additional processing step which requires both time and the application of energy (heat). The overall cost of producing a container is very important and tightly controlled because of competitive pressures. 
     Alternative methods of strengthening the neck finish involve crystallizing select portions of the neck finish, such as the top sealing surface and flange. Again, this requires an additional heating step. Another alternative is to use a high T g  material in one or more layers of the neck finish. Generally, this involves more complex preform injection molding procedures to achieve the necessary layered structure in the finish. 
     Thus, it would be desirable to provide a thermoplastic preform for a container having a neck finish which resists deformation, particularly at elevated temperatures, and a commercially acceptable method of manufacturing the same. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a method for making a preform with a crystallized first portion (e.g., neck finish) and an amorphous second portion (e.g., body-forming portion). The method is both cost effective and can provide a thermal-resistant neck finish within a given dimensional tolerance. 
     In one embodiment, a method of making the preform is provided wherein a first thermoplastic material is introduced into a first mold section to form a crystallized neck portion of a preform, and a second thermoplastic material having a relatively low crystallization rate compared to the first material is introduced into a second mold section to form a substantially amorphous body-forming portion of the preform. By achieving crystallization in the neck finish during the molding step, the initial and final finish dimensions are the same so that dimensional variations are minimized. Also, a higher average level of crystallization in the finish can be achieved by utilizing the higher melt temperatures and/or elevated pressures of the molding process. Furthermore, by crystallizing during the molding step, the prior art step of post-mold thermal crystallization can be eliminated. 
     Another aspect of the invention provides a method and apparatus for the cost-effective manufacture of such preforms. In one embodiment, the apparatus includes an indexer (e.g., rotary or oscilliatory) with two faces, each face having a set of preform molding cores. The cores on the two faces are simultaneously positionable in two different sets of preform molding cavities. In a first set of cavities (first molding station), a crystallized neck portion is being formed on one set of cores, while in the other set of cavities (second molding station) a plurality of amorphous body-forming portions are being formed on the other set of cores. By simultaneously molding in two sets of cavities, an efficient process is provided. By molding the neck and body 20456 . 1  forming portions separately in different cavities, different temperatures and/or pressures may be used to obtain different molding conditions and different properties in the two preform portions. For example, it is possible to render the neck portion opaque by thermally crystallizing the neck portion in the first set of cavities, while maintaining the body-forming portion substantially amorphous in the second set of cavities. 
     Various thermoplastic polymers can be used to form the neck and body-forming portions, and the processing conditions will vary depending on the specific application. In one embodiment, a hot-fillable polyester container is made having a crystallized neck portion of CPET, a terephthalic polyester with nucleating agents which render the polymer rapidly crystallizable during injection molding. The body-forming portion is a two-material, three-layer (2M, 3L) structure, including inner and outer layers of virgin polyethylene terephthalate (PET), and a core layer of for example post-consumer PET (PC-PET). Numerous alternative high glass transition (T g ) polymers may be used in place of CPET, such as arylate polymers, polyethylene naphthalate (PEN) homopolymers, copolymers or blends, polycarbonates, etc. As for the body-forming portion, numerous alternative polymers and layer structures are possible, incorporating PEN, ethylene/vinyl alcohol (EVOH) or MXD-6 nylon barrier layers, oxygen scavenging polymers, etc. 
     The present invention will be more particularly set forth in the following detailed description and accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES 
     FIGS. 1A-1B are schematic illustrations of an indexed injection molding apparatus and the sequence of operation according to one method embodiment of the present invention, wherein 
     FIG. 1A shows two sets of mold cavities and cores in a first closed position, and 
     FIG. 1B shows the cavities/cores in a second open position. 
     FIG. 2A is a cross-section of a first preform embodiment made according to the present invention; and 
     FIG. 2B is an enlarged fragmentary cross-section of the neck finish of the preform in FIG.  2 A. 
     FIG. 3 is a front elevational view of a hot-fill container, made from the preform of FIG.  2 . 
     FIG. 4 is an enlarged fragmentary cross-section of the container sidewall taken along line  4 — 4  of FIG.  3 . 
     FIGS. 5A-5D show sequential steps of a second method embodiment utilizing a reciprocating shuttle. 
    
    
     DETAILED DESCRIPTION 
     First Method Embodiment (Indexer) 
     FIGS. 1A and 1B illustrate schematically one embodiment of a two-stage injection molding apparatus and method of the present invention. A four-sided indexer  2  is interposed between a fixed  3  and a movable  4  platen on an injection molding machine. The indexer  2  is mounted on a carriage  5  which is slidable in the direction of platen motion (shown by arrows A 1  and A 2 ). The indexer  2  is rotatable (shown by arrow A 3 ) about an axis  6  disposed perpendicular to the direction of platen motion. The indexer is rotatable into two operative positions spaced 180° apart. In each of these positions, the two opposing faces  7 ,  8  of the indexer carrying first and second sets of cores  9 ,  10  respectively, are received in a first set of cavities  11  on the movable platen  4 , and a second set of cavities  12  on the fixed platen  3 . After a core set has been successively positioned in each of the mold cavities, the finished preforms may be ejected from the cores. Each of the core sets  9 ,  10  include water passages  15  for heating or cooling of the cores to achieve a desired temperature during molding. 
     The sequence of operation is as follows. In FIG. 1A, the movable platen  4  carrying the first set of mold cavities  11 , and the carriage  5  carrying the indexer  2 , are each moved on guide bars (tie rods)  13 ,  14  to the left towards the fixed platen  3  to close the mold (i.e., both cavities). The first set of cores  9  on the left face  7  of the indexer are positioned in the first cavity set  11  (first molding station) alternatively configured for heating or cooling; each first core/cavity pair defines an enclosed chamber for molding a neck portion  40  about the first core  9 . A first polymer material having a relatively high rate of crystallization is injected via nozzle  120  into the first mold cavities to form the neck portions. Simultaneously, the second core set  10  on the second face  8  of the indexer is positioned in the second cavity set  12  (second molding station), which is water cooled. Multiple polymer materials having a relatively low rate of crystallization are simultaneously or sequentially injected via nozzle  150  into the second set of cavities to form multilayer transparent body-forming portions  50  (below previously molded neck portions) on the second set of cores. 
     Next, the mold is opened as shown in FIG. 1B by moving both the movable platen  4  and carriage  5  to the left, whereby the first cores  9  are removed from the first cavities  11  and the second cores  10  are removed from the second cavities  12 . Now, the finished preforms  30  on the second core set are ejected. The finished preforms  30  may be ejected into a set of robot-actuated cooling tubes (not shown) as is well known in the art. Next, the indexer  2  is rotated 180°, whereby the first set of cores  9  with the neck portions  40  thereon are moved to the right side (ready for insertion into the second set of cavities  12 ), and the second set of (now empty) cores  10  is moved to the left side (ready for insertion into the first set of mold cavities  11 ). Again, the mold is closed as shown in FIG.  1 A and injection of the polymer materials into the first and second sets of cavities proceeds as previously described. 
     A suitable injection molding apparatus for use at the second molding station  12  of FIG. 1, i.e., a metered, sequential co-injection apparatus for forming the multiple layers of the preform body-forming portion  50 , is described in U.S. Pat. No. 4,710,118 to Krishnakumar et al. granted Dec. 1, 1987, which is hereby incorporated by reference in its entirety. 
     The method and apparatus of FIG. 1 may be advantageously used to produce multilayer preforms with crystallized neck finishes for a variety of applications, including refillable, pasteurizable, and hot-fillable containers. A number of specific embodiments are described below. 
     Hot-Fill Preform/Container Embodiment 
     A first preform/container embodiment is illustrated in FIGS. 2-4. FIG. 2 shows a multilayer preform  30  made from the method and apparatus of FIG.  1 . FIGS. 3-4 show a hot-fill beverage bottle  70  made from the preform of FIG. 2, including a cross-section of the multilayer sidewall. 
     FIG. 2A shows a substantially cylindrical preform  30  (defined by vertical centerline  32 ) which includes an upper neck portion or finish  40  integral with a lower body-forming portion  50 . The crystallized neck portion is a monolayer of CPET and includes an upper sealing surface  41  which defines the open top end  42  of the preform, and an exterior surface having threads  43  and a lowermost flange  44 . CPET, sold by Eastman Chemical, Kingsport, TN, is a polyethylene terephthalate polymer with nucleating agents which cause the polymer to crystallize during the injection molding process. Below the neck finish  40  is a body-forming portion  50  which includes a flared shoulder-forming section  51 , increasing (radially inwardly) in wall thickness from top to bottom, a cylindrical panel-forming section  52  having a substantially uniform wall thickness, and a base-forming section  53 . Body-forming section  50  is substantially amorphous and is made of the following three layers in serial order: outer layer  54  of virgin PET; core layer  56  of post-consumer PET; and inner layer  58  of virgin PET. The virgin PET is a low copolymer having 3% comonomers (e.g., cyclohexane dimethanol (CHDM) or isophthalic acid (IPA)) by total weight of the copolymer. A last shot of virgin PET (to clean the nozzle) forms a core layer  59  in the base. 
     This particular preform is designed for making a hot-fill beverage container. In this embodiment, the preform has a height of about 96.3 mm, and an outer diameter in the panel-forming section  52  of about 26.7 mm. The total wall thickness at the panel-forming section  52  is about 4 mm, and the thicknesses of the various layers are: outer layer  54  of about 1 mm, core layer  56  of about 2 mm, and inner layer  58  of about 1 mm. The panel-forming section  52  may be stretched at an average planar stretch ratio of about 10:1, as described hereinafter. The planar stretch ratio is the ratio of the average thickness of the preform panel-forming portion  52  to the average thickness of the container panel  83 , wherein the “average” is taken along the length of the respective preform or container portion. For hot-fill beverage bottles of about 0.5 to 2.0 liters in volume and about 0.35 to 0.60 millimeters in panel wall thickness, a preferred planar stretch ratio is about 9 to 12, and more preferably about 10 to 11. The hoop stretch is preferably about 3.3 to 3.8 and the axial stretch about 2.8 to 3.2. This produces a container panel with the desired abuse resistance, and a preform sidewall with the desired visual transparency. The specific panel thickness and stretch ratio selected depend on the dimensions of the bottle, the internal pressure, and the processing characteristics (as determined for example, by the intrinsic viscosity of the particular materials employed). 
     In order to enhance the crystallinity of the neck portion, a high injection mold temperature is used at the first molding station. In this embodiment, CPET resin is injection molded at a temperature of about 105 to 160° C. (mold temperature). The first core set, carrying the still warm neck portions, are then transferred to the second station where multiple second polymers are injected to form the multilayer body-forming portions and melt bonding occurs between the neck and body-forming portions. The core and/or cavity set at the second station are cooled (e.g., 5 to 15° C. core/cavity temperature) in order to solidify the performs and enable removal from the molds with acceptable levels of post-mold shrinkage. The cores and cavities at both the first and second stations include water cooling/heating passages for adjusting the temperature as desired. By bonding (between the neck and body-forming portions) it is meant any type of bonding, such as diffusion, chemical, chain entanglement, hydrogen bonding, etc. 
     FIG. 2B is an enlarged view of the neck finish  40  of preform  30 . The monolayer CPET neck finish is formed with a projection  45  at its lower end, which is later surrounded (interlocked) by the virgin PET melt from the inner and outer layers  54 ,  58  at the second molding station. The CPET neck finish and outermost virgin PET layers of the body are melt bonded together. 
     FIG. 3 shows a unitary expanded plastic preform container  70 , made from the preform of FIG.  2 . The container is about 182.0 mm in height and about 71.4 mm in (widest) diameter. This 16-oz. container is intended for use as a hot-fill non-carbonated juice container. The container has an open top end with the same crystallized neck finish  40  as the preform, with external screw threads  43  for receiving a screw-on cap (not shown). Below the neck finish  40  is a substantially amorphous and transparent expanded body portion  80 . The body includes a substantially vertically-disposed sidewall  81  (defined by vertical centerline  72  of the bottle) and base  86 . The sidewall includes an upper flared shoulder portion  82  increasing in diameter to a substantially cylindrical panel portion  83 . The panel  83  has a plurality of vertically-elongated, symmetrically-disposed vacuum panels  85 . The vacuum panels move inwardly to alleviate the vacuum formed during product cooling in the sealed container, and thus prevent permanent, uncontrolled deformation of the container. The base  86  is a champagne-style base having a recessed central gate portion  87  and moving radially outwardly toward the sidewall, an outwardly concave dome  88 , an inwardly concave chime  89 , and a radially increasing and arcuate outer base portion  90  for a smooth transition to the sidewall  81 . The chime  89  is a substantially toroidal-shaped area around a standing ring on which the bottle rests. 
     The multilayer sidewall of bottle  70  is not specifically illustrated in FIG. 3 due to the small scale of the drawing. However, FIG. 4 shows in cross section the multilayer panel portion  83  including an outer layer  92 , a core layer  94 , and an inner layer  96 , corresponding to the outer  54 , core  56  and inner  58  layers of the preform. The inner and outer container layers (of virgin PET copolymer)  92 ,  96  are each about 0.1 mm thick, and the core layer  94  (of post-consumer PET) is about 0.2 mm thick. The shoulder  82  and base  86  are stretched less and therefore are thicker and less oriented than the panel  83 . 
     Second Method Embodiment (Shuttle) 
     FIGS. 5A-5D illustrate an alternative apparatus utilizing a reciprocating shuttle as opposed to the rotary indexer of the first embodiment. Two core sets are mounted on a shuttle which is movable between three cavity sets as described below. 
     Th e apparatus includes first and second parallel guide bars  202 ,  203  on which a platen  205  is movably mounted in the direction of arrow A 4 , The platen  205  carries a platform or shuttle  206  which is movable in a transverse direction across the platen  205  as shown by arrow A 5 . A fixed platen  212  at one end of the guide bars holds three injection mold cavity sets  213 ,  214  and  215 , which are supplied by nozzles  218 ,  219  and  220  respectively. The left and right cavity sets  213  and  215  are used to form neck portions of preforms, while the middle cavity set  214  is used for molding body-forming portions. 
     FIG. 5A shows an arbitrarily-designated first step wherein the first core set  207  is positioned in left cavity set  213  for forming a set of preform neck portions. Simultaneously, second core set  208  is positioned in middle cavity set  214  for molding a set of multilayer body-forming portions (adjacent previously molded neck portions). FIG. 5B shows the core sets following removal from the cavity sets, with a neck portion  250  on each core of core set  207 , and a complete preform  260  on each core of core set  208 . The completed preforms  260  are then ejected from the core set  208 . 
     In a second step (FIG.  5 C), the shuttle  206  is moved to the right such that first core set  207  with neck portions  250  is now positioned adjacent middle cavity  214 , while second core set  208  with now empty cores  216  is positioned adjacent right cavity set  215 . Movable platen  205  is then moved towards fixed platen  212  so as to position first core set  207  in middle cavity set  214  and second core set  208  in right cavity set  215  (FIG.  5 D). Again, body-forming portions are formed adjacent the previously-formed neck portions in middle cavity set  214 , while neck portions are molded over each of the cores in the core set  208  in right cavity  215 . The movable platen  205  is then reversed to remove the core sets from the cavity sets, the finished preforms on the first core set  207  are ejected, and the shuttle  206  returned to the left for molding the next set of layers. 
     Alternative Constructions 
     There are numerous preform and container constructions possible, each of which may be adapted for a particular food product and/or package, filling, and manufacturing process. A few representative examples will be given. 
     The neck portion can be monolayer or multilayer and made of various polymers other than CPET, such as arylate polymers, polyethylene naphthalate (PEN), polycarbonates, polypropylene, polyimides, polysulfones, acrylonitrile styrene, etc. As a further alternative, the neck portion can be made of a regular bottle-grade homopolymer or low copolymer PET (i.e., having a low crystallization rate), but the temperature or other conditions of the first molding station can be adjusted to crystallize the neck portion. 
     The body-forming portion can be monolayer or multilayer and made of various polymers including polyesters, polyamides and polycarbonates. Suitable polyesters include homopolymers, copolymers or blends of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polypropylene terephthalate (PPT), polyethylene napthalate (PEN), and a cyclohexane dimethanol/PET copolymer, known as PETG (available from Eastman Chemical, Kingsport, Tenn). Suitable polyamides (PA) include PA6, PA6,6, PA6,4, PA6,10, PA11, PA12, etc. Other options include acrylic/imide, amorphous nylon, polyacrylonitrile (PAN), polystyrene, crystallizable nylon (MXD-6), polyethylene (PE), polypropylene (PP), and polyvinyl chloride (PVC). 
     Polyesters based on terephthalic or isophthalic acid are commercially available and convenient. The hydroxy compounds are typically ethylene glycol and 1,4-di-(hydroxy methyl)-cyclohexane. The intrinsic viscosity for phthalate polyesters are typically in the range of 0.6 to 1.2, and more particularly 0.7 to 1.0 (for O-chlorolphenol solvent). 0.6 corresponds approximately to a viscosity average molecular weight of 59,000, and 1.2 to a viscosity average molecular weight of 112,000. In general, the phthalate polyester may include polymer linkages, side chains, and end groups not related to the formal precursors of a simple phthalate polyester previously specified. Conveniently, at least 90 mole percent will be terephthalic acid and at least 90 mole percent an aliphatic glycol or glycols, especially ethylene glycol. 
     Post-consumer PET (PC-PET) is prepared from PET plastic containers and other recyclables that are returned by consumers for a recycling operation, and has now been approved by the FDA for use in certain food containers. PC-PET is known to have a certain level of I.V. (intrinsic viscosity), moisture content, and contaminants. For example, typical PC-PET (having a flake size of one-half inch maximum), has an I.V. average of about 0.66 dl/g, a relative humidity of less than 0.25%, and the following levels of contaminants: 
     PVC:&lt;100 ppm 
     aluminum:&lt;50 ppm 
     olefin polymers (HDPE, LDPE, PP):&lt;500 ppm 
     paper and labels:&lt;250 ppm 
     colored PET:&lt;2000 ppm 
     other contaminants:&lt;500 ppm 
     PC-PET may be used alone or in one or more layers for reducing the cost or for other benefits. 
     Also useful as a base polymer or as a high-oxygen barrier layer is a packaging material with physical properties similar to PET, namely polyethylene naphthalate (PEN). PEN provides a 3-5× improvement in barrier property and enhanced thermal resistance, at some additional expense. Polyethylene naphthalate (PEN) is a polyester produced when dimethyl 2,6-naphthalene dicarboxylate (NDC) is reacted with ethylene glycol. The PEN polymer comprises repeating units of ethylene 2,6 naphthalate. PEN resin is available having an inherent viscosity of 0.67 dl/g and a molecular weight of about 20,000 from Amoco Chemical Company, Chicago, Ill. PEN has a glass transition temperature T g  of about 123° C., and a melting temperature T m  of about 267° C. 
     Oxygen barrier layers include ethylene/vinyl alcohol (EVOH), PEN, polyvinyl alcohol (PVOH), polyvinyldene chloride (PVDC), nylon 6, crystallizable nylon (MXD-6), LCP (liquid crystal polymer), amorphous nylon, polyacrylonitrile (PAN) and styrene acrylonitrile (SAN). 
     The intrinsic viscosity (I.V.) effects the processability of the resins. Polyethylene terephthalate having an intrinsic viscosity of about 0.8 is widely used in the carbonated soft drink (CSD) industry. Polyester resins for various applications may range from about 0.55 to about 1.04, and more particularly from about 0.65 to 0.85 dl/g. Intrinsic viscosity measurements of polyester resins are made according to the procedure of ASTM D-2857, by employing 0.0050±0.0002 g/ml of the polymer in a solvent comprising o-chlorophenol (melting point 0° C.), respectively, at 30° C. Intrinsic viscosity (I.V.) is given by the following formula: 
     
       
         I.V.=(ln(V Soln. /V sol. ))/C  
       
     
     where: 
     V Soln.  is the viscosity of the solution in any units; 
     V sol  is the viscosity of the solvent in the same units; and 
     C is the concentration in grams of polymer per 100 mls of solution. 
     The blown container body should be substantially transparent. One measure of transparency is the percent haze for transmitted light through the wall (HT) which is given by the following formula: 
     
       
         HT=[Yd d ÷(Y d +Y s )]×100  
       
     
     where Y d  is the diffuse light transmitted by the specimen, and Y s  is the specular light transmitted by the specimen. The diffuse and specular light transmission values are measured in accordance with ASTM Method D 1003, using any standard color difference meter such as model D25D3P manufactured by Hunterlab, Inc. The container body should have a percent haze (through the panel wall) of less than about 10%, and more preferably less than about 5%. 
     The preform body-forming portion should also be substantially amorphous and transparent, having a percent haze across the wall of no more than about 10%, and more preferably no more than about 5%. 
     The container will have varying levels of crystallinity at various positions along the height of the bottle from the neck finish to the base. The percent crystallinity may be determined according to ASTM 1505 as follows: 
     
       
         % crystallinity=[(ds−da)/(dc−da)]×100  
       
     
     where ds=sample density in g/cm , da=density of an amorphous film of zero percent crystallinity, and dc=density of the crystal calculated from unit cell parameters. The panel portion of the container is stretched the greatest and preferably has an average percent crystallinity in at least the outer layer of at least about 15%, and more preferably at least about 20%. For primarily PET polymers, a 15-25% crystallinity range is useful in refill and hot-fill applications. 
     Further increases in crystallinity can be achieved by heat setting to provide a combination of strain-induced and thermal-induced crystallization. Thermal-induced crystallinity is achieved at low temperatures to preserve transparency, e.g., holding the container in contact with a low temperature blow mold. In some applications, a high level of crystallinity at the surface of the sidewall alone is sufficient. 
     As a further alternative embodiment, the preform may include one or more layers of an oxygen scavenging material. Suitable oxygen scavenging materials are described in U.S. Ser. No. 08/355,703 filed Dec. 14, 1994 by Collette et al., entitled “Oxygen Scavenging Composition For Multilayer Preform And Container,” which is hereby incorporated by reference in its entirety. As disclosed therein, the oxygen scavenger may be a metal-catalyzed oxidizable organic polymer, such as a polyamide, or an anti-oxidant such as phosphite or phenolic. The oxygen scavenger may be mixed with PC-PET to accelerate activation of the scavenger. The oxygen scavenger may be advantageously combined with other thermoplastic polymers to provide the desired injection molding and stretch blow molding characteristics for making substantially amorphous injection molded preforms and substantially transparent biaxially oriented polyester containers. The oxygen scavenger may be provided as an interior layer to retard migration of the oxygen scavenger or its byproducts, and to prevent premature activation of the scavenger. 
     Refillable containers must fulfill several key performance criteria in order to achieve commercial viability, including: 
     1. high clarity (transparency) to permit visual on-line inspection; 
     2. dimensional stability over the life of the container; and 
     3. resistance to caustic wash induced stress cracking and leakage. 
     Generally, a refillable plastic bottle must maintain its functional and aesthetic characteristics over a minimum of 10 and preferably 20 cycles or loops to be economically feasible. A cycle is generally comprised of (1) an empty hot caustic wash, (2) contaminant inspection (before and/or after wash) and product filling/capping, (3) warehouse storage, (4) distribution to wholesale and retail locations and (5) purchase, use and empty storage by the consumer, followed by eventual return to the bottler. 
     A test procedure for simulating such a cycle would be as follows. As used in this specification and claims, the ability to withstand a designated number of refill cycles without crack failure and/or with a maximum volume change is determined according to the following test procedure. 
     Each container is subjected to a typical commercial caustic wash solution prepared with 3.5% sodium hydroxide by weight and tap water. The wash solution is maintained at a designated wash temperature, e.g., 60° C. The bottles are submerged uncapped in the wash for 15 minutes to simulate the time/temperature conditions of a commercial bottle wash system. After removal from the wash solution, the bottles are rinsed in tap water and then filled with a carbonated water solution at 4.0±0.2 atmospheres (to simulate the pressure in a carbonated soft drink container), capped and placed in a 38° C. convection oven at 50% relative humidity for 24 hours. This elevated oven temperature is selected to simulate longer commercial storage periods at lower ambient temperatures. Upon removal from the oven, the containers are emptied and again subjected to the same refill cycle, until failure. 
     A failure is defined as any crack propagating through the bottle wall which results in leakage and pressure loss. Volume change is determined by comparing the volume of liquid the container will hold at room temperature, both before and after each refill cycle. 
     A refillable container can preferably withstand at least 20 refill cycles at a wash temperature of 60° C. without failure, and with no more than 1.5% volume change after 20 cycles. 
     In this invention, a higher level of crystallization can be achieved in the neck finish compared to prior art processes which crystallize outside the mold. Thus, the preform neck finish may have a level of crystallinity of at least about 30%. As a further example, a neck finish made of a PET homopolymer can be molded with an average percent crystallinity of at least about 35%, and more preferably at least about 40% To facilitate bonding between the neck portion and body-forming portion of the preform, one may use a thread split cavity, wherein the thread section of the mold is at a temperature above 60° C., and preferably above 75° C. 
     As an additional benefit, a colored neck finish can be produced, while maintaining a transparent container body. 
     Other benefits include the achievement of higher hot-fill temperatures (i.e., above 85° C.) because of the increased thermal resistance of the finish, and higher refill wash temperatures (i.e., above 60° C.). The increased thermal resistance is also particularly useful in pasteurizable containers. 
     While there have been shown and described several embodiments of the present invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appending claims.