Abstract:
Disclosed are plastic preforms and containers in which the materials in the neck, neck finish and/or neck cylinder are at least partially in the crystalline state and the body is primarily in the amorphous or semi-crystalline state. This structure in a preform enables the preform to be easily blow molded by virtue of the amorphous material in the body, while maintaining dimensional stability in hot-fill applications. In addition, the amorphous inner surface of the neck finish stabilizes the post mold dimensions allowing closer molding tolerances than other crystallizing processes. The crystallized outer surface of the preform supports the amorphous structure during high temperature filling of the container. Physical properties are also enhanced as a result of this unique crystalline/amorphous structure.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims the priority benefit under 35 U.S.C. § 119(e) of the provisional application 60/621,373, filed Oct. 22, 2004, which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates to preforms and containers such as for containing beverages and the like. More specifically, this invention relates to methods and apparatuses for producing preforms and plastic bottles, preferably comprising polyethylene terephthalate (PET), in which the materials in the neck, neck finish and/or neck cylinder are at least partially in a substantially crystalline state.  
         [0004]     2. Description of the Related Art  
         [0005]     The use of plastic containers as a replacement for glass or metal containers in the packaging of beverages has become increasingly popular. The advantages of plastic packaging include lighter weight, decreased breakage as compared to glass, and potentially lower costs. The most common plastic used in making beverage containers today is PET. Virgin PET has been approved by the FDA for use in contact with foodstuffs. Containers made of PET are transparent, thin-walled, lightweight, and have the ability to maintain their shape by withstanding the force exerted on the walls of the container by pressurized contents, such as carbonated beverages. PET resins are also fairly inexpensive and easy to process.  
         [0006]     Most PET bottles are made by a process which includes the blow-molding of plastic preforms which have been made by processes including injection molding. In some circumstances, it is preferred that the PET material in plastic preforms is in an amorphous or semi-crystalline state because materials in this state can be readily blow-molded, whereas fully crystalline materials generally cannot. However, bottles made entirely of amorphous PET may not have enough dimensional stability during a standard hot-fill process due to the relatively low glass transition temperature, Tg, of the PET material and the tight tolerances required when using standard threaded closures. In these circumstances, a bottle comprising crystalline PET would be preferred, as it would hold its shape during hot-fill processes. Unfortunately, typical preforms may have a microstructure that is not suitable for blow molding or hot fill.  
       SUMMARY OF THE INVENTION  
       [0007]     The present disclosure provides a plastic bottle, which has the advantages of both a crystalline bottle and an amorphous or semi-crystalline bottle. By making at least part of the uppermost portion of the preform substantially crystalline while keeping the body of the preform amorphous or semi-crystalline (sometimes referred to herein as “non-crystalline”), one can make a preform that will blow-mold easily yet retain necessary dimensions in the crucial neck area during a hot-fill process. The preform and bottle may be made solely of PET or another material, preferably a polyester, or it may further comprise other materials, including barrier materials and/or oxygen scavenger materials to prevent carbonated beverages or oxygen-sensitive products contained within the bottle from going “flat” or spoiling.  
         [0008]     In preferred embodiments, a heat treatment system for crystallizing a portion of a preform comprises a heat source configured to change the temperature of a preform. A mandrel is adapted to hold a preform while the heat source heats at least a portion of the preform to a crystallization temperature suitable for crystallizing the at least a portion of the preform. In one variation, a preform is held by the mandrel and has a neck portion and a body portion. After the heat source heats the preform, the body portion comprises a non-crystalline material, and the neck portion comprises crystalline material. In one embodiment, the body portion is primarily non-crystalline, and the neck portion is primarily crystalline.  
         [0009]     In some embodiments, a heat treatment system for crystallizing a portion of a preform is provided. The heat treatment system comprises an energy source configured to output thermal energy. A mandrel is adapted to hold a preform such that the preform is heated to a crystallization temperature to reduce the amount of amorphous material of the preform when the energy source outputs a predetermined amount of thermal energy.  
         [0010]     In some embodiments, a heat treatment system for crystallizing a portion of a preform is provided. The system comprises a thermal processing system and a transport system. The thermal processing system is configured to output thermal energy. The transport system comprises a plurality of carriers. Each carrier is movable along a processing line extending alongside the thermal processing system. Each carrier has at least one mandrel that is adapted to hold a preform while the thermal processing system outputs a sufficient amount of thermal energy to cause crystallization of at least a portion of the preform to reduce the amount of amorphous material of the preform.  
         [0011]     In some embodiments, a method for crystallizing a preform is provided. The method comprises holding a preform comprising amorphous material by a carrier that moves the preform along a processing line. The preform is moved by a thermal processing system. At least a portion of the preform is heated with the thermal processing system until the amorphous material by weight percentage of the preform has been reduced.  
         [0012]     In one arrangement, the heat source comprises one or more lamps. For example, the heat source may be a bank of IR lamps. The heat source is preferably movable relative to a preform held by a carrier.  
         [0013]     In some embodiments, a method of heating a preform is provided. The method comprises holding a preform on a mandrel. The preform has a neck finish portion comprising primarily amorphous material and a body portion comprising primarily amorphous material. Thermal energy is delivered to the preform until the body portion of the preform is primarily amorphous or semi-crystalline and the neck finish portion is primarily crystalline. In some variations, the thermal energy is infrared radiation. If desired, the infrared radiation can be outputted from one or more infrared lamps. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  illustrates a preform that can be thermally processed to produce semi-crystalline or crystalline material.  
         [0015]      FIG. 2  is a cross-sectional view of the preform of  FIG. 1 .  
         [0016]      FIG. 2A  is an enlarged cross-section of a neck finish of the preform of  FIG. 2  taken along  2 A- 2 A in accordance with some embodiments.  
         [0017]      FIG. 3  is a plan view of a thermal processing system for processing preforms, and the processing system having a carousel and a heat treatment system.  
         [0018]      FIG. 4  is a side view of a preform held by a carrier that may be used with the carousel of  FIG. 3 .  
         [0019]      FIG. 4A  is a side view of a carrier without a mandrel and associated preform.  
         [0020]      FIG. 4B  is a back view of the carrier of  FIG. 4A .  
         [0021]      FIG. 5  illustrates a mandrel attached to the carrier of  FIG. 4A , wherein a split ring of the mandrel is shown removed.  
         [0022]      FIG. 6  is a cross-sectional view of the preform of  FIG. 1  on the mandrel of  FIG. 5 .  
         [0023]      FIG. 7  is a cross-sectional view of a heat treatment system of  FIG. 3  taken along the line  7 - 7 , and a preform positioned for processing.  
         [0024]      FIG. 7A  is a side view of the heat treatment system of  FIG. 7 .  
         [0025]      FIG. 8  is a cross-sectional view of a modified heat treatment system that is processing a preform.  
         [0026]      FIG. 9  illustrates a modified heat treatment system for processing preforms.  
         [0027]      FIG. 10  illustrates a cooling system for cooling a preform.  
         [0028]      FIG. 11  is a plan view of an embodiment of a thermal processing system for processing preforms.  
         [0029]      FIG. 12  is a cross-sectional view of the thermal processing system of  FIG. 11  taken along a line  12 - 12 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0030]     Disclosed herein are various methods and apparatuses for producing articles comprising semi-crystalline and/or crystalline material. In some non-limiting embodiments, at least a portion of an article comprises a semi-crystalline and/or crystalline material to achieve one or more desired properties. To form the article, the at least a portion of the preform can be formed by heating the at least a portion of the preform above a crystallization temperature. In some embodiments, at least a portion of the article is adapted to contact food or liquid and comprises a formable material, such as PET, that may impart substantially no flavor to the food or liquid. For example, the article can be a preform, a container, a closure, packaging, a tube, a sheet, and the like. However, for the sake of simplicity, these embodiments will be described herein primarily as articles or by an individual article name. It is to be understood in many cases that other articles may be substituted for the named article.  
         [0031]     The preferred embodiments described herein generally produce preforms with a semi-crystalline or crystalline neck finish, which are typically then blow-molded into beverage containers. The preforms may be monolayer; that is, the preforms can be comprised of a single layer of a base material, or they may be multilayer, including, but not limited to, those which comprise a combination of a base material and another material. The material in such layers may be a single material or it may be a blend of one or more materials so as to include blends of polymers and/or one or more oxygen scavenging materials. The provision of one or more barrier layers, or the inclusion of one or more oxygen scavengers in one or more layers, is generally desirable when the container is to be filled with a carbonated beverage or oxygen sensitive product. The barrier layer may serve to prevent the ingress of oxygen into the container or the egress of carbon dioxide from the container. Additionally, multiple barrier layers may be provided to refine barrier properties or provide desirable structural properties. The preforms can also have other layers that perform other functions.  
         [0032]     The preforms and containers made therefrom can have one or more of the following advantageous characteristics: an insulating layer, a gas barrier layer, UV protection layers, protective layer (e.g., a vitamin protective layer, scuff resistance layer, etc.), a foodstuff contacting layer, a non-flavor scalping layer, non-color scalping layer, a high strength layer, a compliant layer, a tie layer, a gas scavenging layer (e.g., oxygen, carbon dioxide, etc), a layer or portion suitable for hot fill applications, a layer having a melt strength suitable for extrusion, strength, recyclable (post consumer and/or post-industrial), clarity, etc. In one embodiment, the monolayer or multi-layer material comprises one or more of the following materials: PET (including recycled and/or virgin PET), PETG, foam, polypropylene, phenoxy type thermoplastics, polyolefins, phenoxy-polyolefin thermoplastic blends, and/or combinations thereof.  
         [0033]     By achieving a crystallized state in the neck portion of the preform before processing (e.g., blow molding and hot-filling), the final dimensions of the neck portion of a container can be substantially identical to the initial dimensions of the preform. Therefore, dimensional variations are minimized and dimensional stability is improved, especially if the preform is heated to elevated temperatures. Advantageously, this results in improved tolerances of the threads on the neck finish so that a closure or cap can be fastened to the blow-molded container. Preforms having other configurations can also be processed to form crystalline material. By way of example, preforms can have neck finishes configured to receive snap caps, or closures of other configurations. Accordingly, preforms may or may not have threads depending on the end use of the container made therefrom. Any of these preforms made of amorphous material, including their neck finishes, can be thermally processed to form preforms with semi-crystalline or crystalline neck finishes.  
         [0034]     In some embodiments, preforms may have both substantially crystalline and substantially amorphous or substantially semi-crystalline regions. A preform which has both crystalline and amorphous or semi-crystalline regions is shown in U.S. Pat. No. 6,217,818 to Collete et al. However, the preform of Collete et al. is constructed using a separately formed crystalline neck portion, which is then placed into a second cavity which forms an amorphous body portion of the preform. This preform may have undesirable structural properties.  
         [0035]     While a preform having a non-crystalline body portion is preferred for blow-molding, a bottle having greater crystalline character in the neck portion is preferred for its dimensional stability during various stages of high temperature packaging processes, such as a hot-fill process. Accordingly, a preform constructed according to some embodiments has a generally non-crystalline body portion and a crystalline neck portion. To create generally crystalline and non-crystalline portions in the same preform, different levels of heating and/or cooling can be used to achieve the desired preform microstructure. The different levels of heating and/or cooling may be preferably maintained by thermal isolation of one or more regions of the preform. For example, thermal isolation of the preform&#39;s neck region can be accomplished by utilizing a combination of energy sources (e.g., heat lamps), cooling mandrels, and/or other suitable devices as discussed below. A crystalline neck finish can be formed from an amorphous neck finish by heating the neck finish to an elevated temperature suitable for forming a crystalline microstructure. The neck finish can then be slowly cooled to form crystalline material. The cooling rate can vary based on material properties. The body portion of a preform can be maintained below a target temperature to ensure that the body portion remains amorphous, even when the neck finish is crystallized.  
         [0036]     Referring to  FIG. 1 , a preferred preform  1  is depicted. The preform is preferably made of an FDA approved material such as virgin PET and can be of any of a wide variety of shapes and sizes. The preform shown in  FIG. 1  is a 24 gram preform of the type which will form a 16 oz. carbonated beverage bottle, but as will be understood by those skilled in the art, other preform configurations can be used depending upon the desired configuration, characteristics and use of the final article. The preform  1  may be made by injection molding as is known in the art or by other suitable methods.  
         [0037]     Referring to  FIG. 2 , a cross-section of the preferred preform  1  of  FIG. 1  is depicted. The preform  1  has a neck portion  32  and a body portion  34 . The neck portion  32 , also called the neck finish, begins at the opening  18  to the interior of the preform  1  and extends to and includes the support ring  38 . The neck  32  is further characterized by the presence of the threads  40 , which provide a way to fasten a cap onto a container produced from the preform  1 . The body portion  34  is an elongated and cylindrically shaped structure extending down from the neck  32  and culminating in the rounded end cap  42 . The preform thickness  44  will depend upon the overall length of the preform  1  and the wall thickness and overall size of the resulting container. It should be noted that as the terms “neck” and “body” are used herein, in a container that is colloquially called a “longneck” container, the elongated portion just below the support ring  38 , threads  40 , and/or lip where the cap is fastened would be considered part of the “body” of the container and not a part of the “neck.” 
         [0038]     Conventional preforms may have a microstructure resulting in the preforms not being suitable for blow molding and then hot-filling. For example, conventional preforms may have a neck portion  34  made entirely of amorphous material (e.g., amorphous PET). A container made from one of these preforms will likewise have an amorphous neck. These containers may have low dimensional stability during, e.g., a standard hot-fill process, or other high temperature processes. If the amorphous neck reaches a sufficiently high temperature, the neck may deform and become unsuitable for receiving a closure. As such, these containers may be unsuitable for many applications where a closure needs to be applied to the container. The systems and methods disclosed herein can be used to form preforms with a semi-crystalline or crystalline neck finish.  
         [0039]     Suitable preforms for use with the disclosed embodiments can be purchased from Ball Corporation (Colorado). However, there are many suitable PET and non-PET preforms that can be processed with the disclosed thermal processing systems to obtain a preform with a desired microstructure. PET preforms can exist in crystalline, semi-crystalline, and amorphous forms. However, in preferred embodiments, the crystallinity of the PET in the body portion  34  may be minimized and the amorphous state maximized in order to create a semi-crystalline or crystalline state which, among other things, facilitates the blow molding process. Methods and apparatuses for making preforms are described in U.S. Pat. No. 6,391,408 entitled COATED POLYESTER PREFORMS AND METHOD OF MAKING SAME and pending U.S. patent application Ser. No. 10/614,731 entitled DIP, SPRAY, AND FLOW COATING PROCESS FOR FORMING COATED ARTICLES, and U.S. patent application Ser. No. 11/179,025 entitled COATING PROCESS AND APPARATUS FOR FORMING COATED ARTICLES; which are hereby incorporated by reference in their entireties and form part of the disclosure of the present application. The disclosed thermal processing system  312  can be used to thermally process monolayer or multilayer preforms disclosed in these incorporated references.  
         [0040]     The illustrated preform  1  has the neck portion  32  that comprises crystalline material. In some embodiments, including the embodiment of  FIG. 2A , the neck portion  32  comprises a first portion  31  and a second portion  33 . The first portion  31  can define an outer surface  35  of the preform  1 . The first portion  31  can extend from an upper end  37  to the support ring  38 . In some embodiments, the preform  1  can have a transition portion  39  (shown in phantom) that transitions between crystalline and non-crystalline material.  
         [0041]     The first portion  31  surrounds the second portion  33  and preferably comprises crystalline material, and more preferably comprises primarily crystalline material. In some non-limiting embodiments, the first portion  31  comprises about 50% by weight, also including more than about 60%, 70%, 80%, 90%, or 95% by weight, of crystalline material. The crystalline material of the first portion  31  can be evenly or unevenly distributed. The first portion  31  can have any suitable amount of crystalline material based on the desired manufacturing process or a particular end use for the container made from the preform  1 . The percentage of crystalline material can be increased to improve the dimensional stability of the neck finish during high temperature applications, such as hot-fill processes.  
         [0042]     Optionally, the first portion  31  can define structures or threads  40  that preferably comprise substantially crystalline material. Thus, after the preform  1  has been blow molded, the structures or threads  40  may retain their original configuration so that they can receive a closure or cap.  
         [0043]     The transition portion  39  can comprise material that is generally similar to the material forming the first portion  31 , and preferably transitions to material that is generally similar to the material forming the body  34 . In the illustration of  FIG. 2A , the transition portion  39  is spaced from the upper end  37  of the preform  1 . In some embodiments, the transition portion  39  is located below most of the structures or threads  40 . For example, the transition portion  39  can be located below the lowest thread  41 . In one embodiment, the transition portion  39  is located proximate to the support ring  38 . In the illustrated embodiment, the transition portion  39  is located near the lower surface of the support ring  38 . Alternatively, the transition portion  39  can be spaced below the support ring  38  at some point along the body  34 .  
         [0044]     A transition portion  42  can be located between the first portion  31  and second portion  33 . The transition portion  42  can comprise material that is similar to the material of the first portion  31  and can transition to material that is similar to material forming the second portion  33 . However, in some embodiments, the neck finish  32  is made entirely of crystalline material, if desired.  
         [0045]     With continued reference to  FIG. 2A , the second portion  33  can be comprised of non-crystalline material and can form a generally uniform layer disposed between the interior of the preform  1  and the first portion  31 . However, in some embodiments, a second portion  33  can have a generally non-uniform cross-section and can extend from the body  34  to the end  37 . In some embodiments, the second portion  33  can be made substantially of semi-crystalline material. Alternatively, the second portion  33  can be made substantially of amorphous material. One of ordinary skill in the art can determine the desired crystallinity of the second portion  33  depending on the application.  
         [0046]     With respect to  FIG. 3 , a thermal processing system  369  can be used to produce an article having one or more portions that are amorphous, semi-crystalline, crystalline, or combinations thereof. The illustrated thermal processing system  369  includes a heat treatment system  312  that can selectively thermally process portions of articles (e.g., preforms) to achieve the desired characteristics of the article. A carousel system  372  can carry the preforms along a processing line past the heat treatment system  312 . The thermal processing system  369  can be utilized to produce preform with a crystalline neck finish, such as the neck finish illustrated in  FIG. 2A .  
         [0047]     The heat treatment system  312  of  FIG. 3  can be positioned alongside the carousel system  372 . The carousel system  372  comprises carriers  374  positioned about its periphery. These carriers are configured to grip and hold one or more preforms, and can move about the periphery of a carousel system  372  while holding the preforms. As the preforms travel past the heat treatment system  312 , the preforms are heated to form preforms with the desired amount of crystalline material. The carriers  374  can move clockwise or counter-clockwise about the carousel system  372 , as desired.  
         [0048]     A transfer mechanism  376  of the carousel system  372  can deliver preforms to and/or receive preforms from the carousel  313 . The transfer mechanism  376  can batch feed or continuously feed preforms to the carousel system  372 , and can be any mechanism or delivery device suitable for receiving and/or delivering preforms. For example, the transfer mechanism  376  can be a starwheel assembly that delivers preforms to the moving carriers  374 . In one embodiment, the transfer mechanism  376  can have one device for delivering unprocessed preforms to the carousel system  372  and another device for receiving the processed preforms. The unprocessed preforms can be amorphous preforms, and the processed preforms can have a crystalline neck finish. In alternative embodiments, preforms can be manually fed to the carousel system  372 .  
         [0049]     When the carousel  313  is rotating, the transfer mechanism  376  can deliver preforms to the carriers  374  as the carriers  374  move about the carousel  313 . The carriers  374  can move at any suitable line speed based on the desired thermal processing and settings of the heat treatment system  312 . For example, the line speed of the carriers  374  can be increased or decreased if the heat output of the heat treatment system  312  is increased or decreased, respectively.  
         [0050]     As shown in  FIG. 4 , the carrier  374  is adapted to hold at least one preform  1 . As illustrated in  FIGS. 4 and 6 , the carrier  374  can have a mandrel  420  that engages an inner portion (e.g., an interior surface  16 ) of a preform. The carrier  374  can hold the preform  1  in the illustrated position as the carrier  374  moves about the carousel  313 .  
         [0051]     With respect to  FIGS. 4A and 4B , the carrier  374  can have a lever system  450  for controlling the movement of the mandrel. The carrier  374  of  FIGS. 4A and 4B  is shown with the mandrels removed. The lever system  450  can be articulated to cause the mandrel  420  ( FIG. 6 ) to grip and release a preform, as desired. In the illustrated embodiment, the lever system  450  is attached to the body  452  of the carrier  374 . The lever system  450  preferably comprises a lever  454 , a base  455 , and rods  456 ,  458  ( FIG. 4B ).  
         [0052]     The lever  454  can be rotated in the direction indicated by the arrows  460  and extends from a pivot  462 , as shown in  FIG. 4A . The end of the lever  454  can have a roller  464  for engaging a track positioned along the periphery of the carousel  313 . Contact pads  468 ,  470  can contact the upper ends of the rods  456 ,  458 , respectively, as shown in  FIG. 4B .  
         [0053]     As shown in  FIGS. 4 and 4 A, the base  455  can be rotated in the direction indicated by the arrows  478  and extends from a pivot  482 . The end of the base  455  can have a roller  484  for engaging a track positioned along the periphery of the carousel  313 . In the illustrated embodiment, each of the rods  456 ,  458  extends through a hole in the base  455 . The base  455  can be rotated to position the preform with respect to the heat treatment system  312 .  
         [0054]     With reference to  FIG. 4B , the upper ends  490 ,  492  of the rods  456 ,  458  can contact the contact pads  468 ,  470 , respectively, to cause movement of the rods  456 ,  458  relative to the base  455 . Springs  494 ,  496  disposed about a portion of the rods  456 ,  458 , respectively, bias the ends  490 ,  492  toward the lever  454 . When the carrier  374  travels along the carousel  313 , the rollers  464 ,  484  can be disposed in a pair of tracks along the carousel  313 . As the carrier  374  moves along the tracks, the distance between the tracks can be increased or decreased to move the rollers  464 ,  484  away from or toward each other. When the rollers  464 ,  484  are sufficiently close together, the lever  454  applies a force to the rods  456 ,  458  sufficient to overcome the bias of the springs  494 ,  496  thereby pushing the rods  456 ,  458  out of the ends of the cylindrical housings  500 ,  502 , respectively. Each of the cylindrical housings  500 ,  502  can be disposed through a cylindrical passage  515  in the mandrel  420 .  
         [0055]     The diameter of the rods  456 ,  458  are varied such that at different positions relative to the housings  500 ,  502 , protrusions  444  ( FIG. 5 ), which are disposed through the openings  510 ,  512  of the corresponding housings  500 ,  502 , are extended or retracted.  
         [0056]     With reference again to  FIG. 4 , the carrier  374  can have a drive mechanism to engage a portion of the carousel  313  to cause rotation of the rods  456 ,  458  to rotate the preform  1 . In the illustrated embodiment, a drive mechanism  503  has a drive gear  505  that can mate with teeth, a gear, a chain, and/or other structure of the carousel  313 . As a carousel motor moves all of the carriers  374  along the carousel  313 , the drive gear  505  of the drive mechanism  503  can cause rotation of the rods  456 ,  458  which, in turn, rotate the mandrels  420  and associated preform  1 . Optionally, the rods  456 ,  458  can be interconnected by a belt. Alternatively, the rods can be independently driven by independent drive mechanisms.  
         [0057]     With respect to  FIGS. 5 and 6 , the mandrels  420  can be disposed about the housings  500 ,  502  so that the rods  456 ,  458  can extend out of the lower ends of the mandrels  420 . For example, the housing  500  can be disposed within the passage  515  of the mandrel  420 . Optionally, the housing  500  and the mandrel  420  can be aligned so that one or more of the openings  510  of the housing  500  are aligned with the openings  440  of the mandrel  420 . The protrusions  444  can therefore pass out of both the openings  440 ,  510 . The housing  502  can be similarly aligned with another mandrel  420 .  
         [0058]     The carriers  374  can be connected in order to have carriers  374  that move together about the carousel system  372 . Any suitable means, such as belts, linkages, tie rods, or the like can be used to interconnect the carriers  374 . As such, the carriers  374  move in unison about the carousel system  372 .  
         [0059]     The mandrels  420  of the carriers  374  are configured to fit within and extend into the interior of the preforms. The mandrels  420  can be coupled to the cylindrical housings  500 ,  502  ( FIG. 4B ) of the carrier  374 . The mandrels  420  can be operated to receive, hold, and/or release the preforms.  
         [0060]     The illustrated mandrel  420  comprises a generally cylindrical elongated body that is sized to fit into the opening of a preform. Optionally, the mandrel  420  can extend into and along a substantial portion of the neck  32  of the preform  1 . In another embodiment, the mandrel  420  can extend most of the way into the interior of the preform  1  and terminate along the body  34  of the preform. Preferably, at least a portion of the mandrel  420  is configured to engage the interior surface  16  of the preform  1 .  
         [0061]     At least a portion of the mandrel  420  can be moved to hold and/or release a preform. In some embodiments, at least a portion of the mandrel  420  can be moved radially inward and/or outward. For example, a portion of the mandrel  420  can move radially outward to engage and hold the interior surface  16  of the preform  1 . As shown in  FIG. 6 , the mandrel  420  can have an expandable ring, such as a split ring  424 . The ring  424  is an annular ring with a gap so that the ring can be moved in the radial direction. The mandrel of  FIG. 5  is shown with the split ring removed.  
         [0062]     With reference to  FIGS. 5 and 6 , the mandrel  420  can have an upper lip  430 , a body  432 , and a groove  436 . The upper lip  430  can have a lower surface  431  that can contact the upper edge of a preform and function as a stop. When the preform is delivered to the carrier  374 , the preform can be inserted over the mandrel  420  until the upper edge of the preform is near to or contacts the upper lip  430  of the mandrel  420 .  
         [0063]     The body  432  of the mandrel  420  is preferably sized to fit within the neck finish of the preform. The groove  436  and associated ring  424  are positioned along the body  432 . The groove  436  can receive the inner portion of the ring  424 .  
         [0064]     As shown in  FIG. 5 , openings  440  along the groove  436  can have one or more protrusions  444  for causing radial movement of the split ring  424 . In one embodiment, each protrusion  444  is a spherical body that can extend from a circular opening  440 . When the protrusions  444  extend from the openings  440 , the protrusions  444  push the ring  424  in the outwardly direction so that the outer surface of the ring  424  can apply sufficient pressure to the interior surface  16  to hold the preform. The protrusions  444  can be retracted into the body  432  of the mandrel  420 , thus allowing the ring  424  to surround tightly the body  432 . When the protrusions  444  are retracted, a preform can be loaded onto the mandrel  420  or released from the mandrel  420 . Thus, each protrusion  444  can be moved between an extended position and retracted position in order to hold and release, respectively, a preform. The protrusions can have any shape suitable for engaging the inner surface of the ring  424 . The mandrel  420  can comprise any number of openings  440  and corresponding protrusions  444 . For example, in the illustrated embodiment, the mandrel  420  has four openings  440  and four corresponding protrusions  444 . Preferably, the openings  440  and the protrusions  444  are positioned along the surface of the groove  436 .  
         [0065]     After preforms are fed onto the carriers  374 , the carriers  374  can hold and transport the preforms to and through the heat treatment system  312 . Preferably, the preforms are rotated about their longitudinal axis as they pass through the heat treatment system  312 . The rotation of the preforms can ensure that the preforms are thoroughly and evenly processed, if desired.  
         [0066]     The illustrated thermal processing system  369  can be used or modified with systems and devices described in U.S. Provisional Patent Application No. 60/586,854 entitled DIP, SPRAY, AND FLOW COATING PROCESS FOR FORMING COATED ARTICLES, and U.S. application Ser. No. 11/179,025, which are hereby incorporated by reference in their entirety and forms part of the disclosure of the present application. U.S. application Ser. No. 11/179,025, entitled DIP, SPRAY, AND FLOW COATING PROCESS FOR FORMING COATED ARTICLES, which also disclose additional transport systems, mandrel, apparatuses that can be used in combination with the devices, systems, methods, and techniques disclosed therein.  
         [0067]     The physical orientation of the heat treatment system  312  is adjustable relative to the preforms. As shown in  FIG. 7 , the heat treatment system  312  comprises a heating unit or bank  330  that includes a plurality of energy sources in the form of lamps  736 - 741  that may be moved relative to the preform being held by the mandrel  420  (the carrier is not shown). Each lamp of the bank  330  can be independently moved towards and/or away from the preform  1 . The distances between each lamp and the preform can be determined by the desired thermal processing of the preform. The preforms can be rotated about their longitudinal axis  722  as they pass by the heat treatment system  312  to achieve generally even heating. Thus, sections of the preform  1  can have a generally uniform temperature distribution.  
         [0068]     The bank  330  is configured so that its lamps can be independently operated. Some of the lamps of the bank  330  can heat preforms for a different length of time than other lamps of the bank  330 . The upper lamp  736  preferably heats the preform  1  for a longer time period than one or more of the lamps  737 - 741 . The lamps  737 - 741  preferably do not heat the preform&#39;s body portion to a temperature above the crystallization temperature thereby preserving the amorphous state of the body of the preform  1 . The lamps of the bank  330  can also output different amounts of energy. For example, the upper lamp  736  can output more energy than the other lamps. In such an embodiment, the upper lamp  736  can elevate the neck finish of the preform  1  to a higher temperature than the other portions of the preform  1 .  
         [0069]     If the preform  1  is coated with a material, the bank  330  can cure the coating while also causing crystallization of a portion of the preform. The preform  1  can be coated using the processes described in the pending U.S. patent application Ser. No. 11/179,025 entitled DIP, SPRAY, AND FLOW COATING PROCESS FOR FORMING COATED ARTICLES. The coating can be a liquid which is cured by the bank  330 . Various types of coatings can be cured, dried, activated, or otherwise thermally processed by the heat treatment system  312 .  
         [0070]     With respect to  FIG. 7A , the heat treatment system  312  can have lamps with different lengths to treat the illustrated preform moving along the processing line in the direction indicated by the arrow  742 . The illustrated bank  330  of  FIG. 7A  is especially well suited to process a preform that is coated with a curable material. The coating can be applied to the body of the preform  1 . The lamp  736  may be longer than the other lamps  737 - 741  so that the upper portion of the preform is processed longer than the lower portion of the preform. The lengths of the lamps can be selected based on the desired processing time. The preform  1  enters the left side of the bank  330  and is heated by the bank  330 . The coating can be cured while the neck finish is crystallized. The preform eventually exits the right side of the bank  330 . The preform  1  is shown after it has been thermally processed by the bank  330 .  
         [0071]     A skilled artisan can select the length and intensity of energy (e.g., IR energy) produced by the lamps  737 - 741  to achieve the desired thermal processing of the preform  1 . Of course, the number and lengths of the lamps can be varied to achieve the desired temperature distributions through the preform.  
         [0072]     The cooling rate of the preform can be increased or decreased to reduce or increase the amount of crystalline material of the preform. To form a crystalline neck finish, the neck finish of the preform can be heated by the bank  330  above a crystallization temperature. The neck is then slowly cooled to form the desired amount of crystalline material. The cooling rate can be increased or decreased to decrease or increase, respectively, the degree of crystallization. Alternatively, the neck finish of the preform can be heated by the bank  330  above a crystallization temperature for a target period of time. After crystallization, the preform can be rapidly cooled.  
         [0073]     If the body of the preform has a curable coating, the bank  330  can heat the coating to an appropriate temperature to cure the coating, preferably without forming crystalline material. Thus, the bank  330  can rapidly cool portions of the preform  1  while other portions of the preform  1  are heated and then gradually cooled in order to produce crystalline material.  
         [0074]     With reference again to  FIG. 7 , the heat treatment system  312  in one embodiment can have one or more reflectors  740  that can reflect output from the bank  330  towards the preforms. The reflector  740  can be used with IR lamps to provide thorough heating of the neck portion  32  of the preform. The lamps are positioned on one side of the processing line while the reflector  740  is located on the opposite side of the processing line. The reflector  740  advantageously reflects the output from the bank  330  back onto the preform allowing for a more rapid crystallization, and efficient use of the output of the bank&#39;s lamps. Although not illustrated, additional reflectors can be located at any suitable position relative to the preform to reflect IR rays from the lamps toward the preform. The reflector  740  may be generally flat and/or curved and may have a surface treatment in order to achieve the desired amount of reflected radiant waves.  
         [0075]     Any number of heat treatment systems  312  can be used to heat preforms and cause crystallization. In one embodiment, the heat treatment system  312  comprises four units or banks each having six lamps. Although not illustrated, one or more banks of lamps can be used to surround various sections of the processing line. For example, a plurality of lamps can be positioned on one side of the processing line while another plurality of lamps is located on the opposite side of the processing line. The heat treatment systems can also be used in combination with any preform processing system, such as the system described in U.S. Provisional Patent Application No. 60/586,854.  
         [0076]     The lamps of the heat treatment system  312  can be any energy source suitable for heating a preform to a desired temperature. The lamps can be 1000 W quartz IR lamps. A preferred source is a General Electric Q1500 T3/CL Quartzline Tungsten-Halogen lamp. This particular source and equivalent sources may be purchased commercially from any of a number of sources including General Electric and Phillips. The source may be used at full capacity, or it may be used at partial capacity such as at about 50%, about 65%, about 75% and the like. Preferred embodiments may use a single lamp or a combination of multiple lamps. For example, six IR lamps of the bank  330  may be used at 70% capacity. In one non-limiting embodiment, the lamps heat at least a portion of a preform sufficiently to cause amorphous material to crystallize into semi-crystalline or crystalline material, as detailed above. Preferably, the portion of the preform is heated to a temperature above its T g  to cause crystallization. Of course, preforms made of different materials may have a different T g . The output of the lamps can be chosen based, at least in part, on the material forming the preform.  
         [0077]     Optionally, the heat treatment system  312  can use one or more of the following: conduction, convection, and radiation to control the temperature of the preforms. For example, convection can be used to regulate the surface temperature of the preform, thereby providing flexibility for controlling the effectiveness of the radiant heat. In some embodiments, the heat treatment system  312  can have a flow system for providing a fluid flow that helps control the surface temperature of the preform. The fluid can be heated or chilled, as desired. Preferably, a chilled gas is used to form a boundary layer along the surface of the preform to reduce the surface temperature of the preform. When the surface of the preform is cooled, the radiant can penetrate and heat the preform without damaging the surface of preform due to undesirably high temperatures.  
         [0078]     The heat treatment system  312  and carriers  374  can work alone or in combination to control the temperature of the preform. In some embodiments, the surface temperature of the outer portion of the preform  1  may exceed the T g  of the preform material without heating the inner surface  16  of the preform  1  above its T g  during the crystallization process. This may enable amorphous portions of the preform to become non-crystalline without distorting the preform shape due to overheating of the neck  32 . In another embodiment, the semi-crystalline portions of the preforms may become crystalline without distorting the overall preform shape due to overheating. Preferably, the inner portions of the preform can be maintained below the preform&#39;s T g  while outer portions of the preform may be above their T g , thereby causing crystallization of the outer portions only. In this manner, an amorphous preform can be made into the preform illustrated in  FIGS. 2 and 2 A The temperature gradient through the wall of the preform can be selectively controlled by using IR heating of the system  312  and cooling of the mandrel (as discussed below), although other methods may also be used.  
         [0079]     In one embodiment illustrated in  FIG. 6 , the heat treatment system  312  has a mandrel temperature control system  419  for selectively controlling the temperature of the preform for the crystallization process. In one embodiment, the temperature control system  419  of the mandrel  420  comprises one or more channels  744  for controlling the temperature of the preform, preferably the neck finish  32  of the preform. The body  432  of the mandrel  420  can extend through a portion of the interior chamber of the preform  1 . Heated or chilled fluid (e.g., gas and/or liquid) can pass through the mandrel  420  to control the temperature of the preform  1 . In the illustrated embodiment, chilled fluid (e.g., refrigerant, water, or the like) can flow through the channels  744  to transfer heat away from the preform held on the mandrel  420 . The working fluid can absorb and carry the heat away from the mandrel  420 . As such, the mandrel  420  can continuously cool the preform disposed thereon. When the preform  1  is crystallized, the mandrel  420  can cool the inner portion of the preform  1  so that the preform remains coupled to the mandrel  420 . Additionally, the transverse dimensions (e.g., the inner diameters) of the neck finish can be maintained due to the cooling of the mandrel  420 .  
         [0080]     With continued reference to  FIG. 6 , the channels  744  can be operated independently of one another. That is, a fluid at a first temperature (e.g., a high temperature) can be passed through at least one of the channels  744  and fluid at a second temperature (e.g., a low temperature) can be passed through at least one of the other channels  744 . In such an embodiment, different portions of the preform can be maintained at different temperatures. The mandrel  420  can be used to heat and/or cool portions of the preform  1  before, during, and/or after the heat treatment system  312  thermally processes the preform  1 .  
         [0081]     The IR lamps of the heat treatment system  312  and the mandrel  420  can be used in combination to achieve a semi-crystalline or crystalline neck finish. The IR lamps can heat the preform while the mandrel  420  holds the preform and absorbs heat to ensure that the preform retains its shaped during thermal processing, as discussed above. Additionally, while the preform  1  and the mandrel  420  proceed along the processing line through the heat treatment system  312 , the mandrel  420  and the preform  1  can rotate about the axis  722  of the preform  1  to further ensure a generally uniform heat distribution throughout one or more portions of the preform. In some embodiments, the dimensional stability of the preform is maintained due to its cooled inner layer or surface  16  contacting the cooled mandrel  420 . The microstructure of the inner portion of the preform may remain generally unchanged because the mandrel  420  keeps the temperature of the inner portion at a sufficiently low temperature (e.g., below T g  of the preform), even when the outer portion of the preform is heated and undergoes crystallization.  
         [0082]     The heat treatment system  312  can have a structure or device for selectively controlling the amount of radiant heat that is delivered to the preform  1 . In the illustrated embodiment of  FIG. 8 , a shield  750  may block at least a portion of the radiant heat from the bank  330 . The shield  750  can block most or all of the radiation produced by one or more of the IR lamps. In some embodiments, the shield  750  permits transmission of selected wavelengths but does not transmit other wavelengths. An upper portion  751  preferably is positioned so that a limited amount of IR energy is delivered below the neck ring of the preform  1 . In such embodiments, the amount of IR energy delivered to the body portion of the preform  1  is preferably insufficient to produce crystalline material that would noticeably effect the blow-molding process. If the body of the preform  1  is coated with a curable material, the heat treatment system  312  can heat and cure the coating without forming crystalline material. However, the heat treatment system  312  can simultaneously heat the preform to form a crystalline neck finish.  
         [0083]     The shield  750  can be a piece of, e.g., metal or plastic that blocks at least a portion of the radiant heat output of the bank  330 . The shield  750  can be sized and configured such that it extends along the body  34  to prevent radiation from heating portions of the preform above a predetermined temperature. Optionally, the shield  750  can comprise an opaque material or filter that permits some radiant heat produced by the lamps  736  to pass therethrough. Optionally, a plurality of shields  750  can be used to inhibit or prevent radiation from penetrating different portions of the preform. It is contemplated that one or more of the heat treatment systems  312  can have one or more of these types of shields  750 . Additionally, the amount of radiant heat provided to portions of the preforms can be based on the dimensions of the preforms.  
         [0084]     With respect to  FIG. 9 , the heat treatment system  312  can be adapted to direct thermal energy to a particular portion of a preform. The illustrated heat treatment system  312  has a lamp  736  that heats the upper portion of the preform  1 . The heat treatment system  312  preferably has a reflector  740  or other structure designed to direct energy outputted from the heat treatment system  312  towards selected portion(s) of the preform  1 . In some embodiments, direct radiation from the lamp  736  and reflected radiation from the reflector  740  work in combination to ensure that a substantial portion of the neck  32  reaches a threshold temperature for crystallization. Hence, the heat treatment system  312  can direct energy to specific areas of a preform for precise processing.  
         [0085]     The body  34  of the preform  1  preferably remains substantially amorphous for subsequent blow molding. However, one or more portions of the body  34  may be crystallized. An upper portion of the body  34  near the neck ring  38  may undergo minimal crystallization. A skilled artisan can determine the desired amount and location(s) of crystallization to achieve desired characteristics for blow molding of the preform.  
         [0086]     Any number of heat treatment systems  312  of  FIG. 9  can be employed to treat a preform. To maintain a plurality of regions of a preform at different temperatures, a corresponding number of heat treatment systems  312  can be used to heat the target regions of the preform to particular temperatures.  
         [0087]     In operation, the carousel  313  can move the preforms along the processing line and through the heat treatment system  312 . The heat treatment system  312  can then crystallize a portion of the preform. To crystallize a portion of the preform, the temperature of amorphous material of the preform can be increased above its crystallization temperature. For example, at least a portion of the neck finish  32  can be heated to a temperature (i.e., a crystallization temperature) that may be between the preform&#39;s glass transition temperature (T g ) and its melt temperature (T m ). When the material of the preform is within this range, the mobility of the polymers in the preforms is greatly increased, thereby allowing crystallization. The length of time at which the preform is maintained at an elevated temperature can be increased to increase the weight percentage of semi-crystalline or crystalline material in the preform. After crystallization, the temperature of the preform can be lowered until reaching a temperature suitable for handling. During the crystallization process, a portion of the neck finish  32  remains at a temperature below the preform&#39;s T g  for increased dimensional stability, especially if the preform is held by a mandrel.  
         [0088]     The processed preform preferably has a body portion that comprises an amorphous or semi-crystalline material, while the neck portion preferably comprises mostly crystalline material. In some embodiments, the body portion is primarily amorphous or semi-crystalline, and the neck portion is primarily crystalline. Optionally, the mandrel  420  can cool the inner surface  16  of the preform  1  to ensure that at least a portion of the preform  1  remains below its crystallization temperature, even though the outer portion of the preform  1  is at a relatively high temperature causing amorphous material to crystallize. However, any portion of the preform can be heated to cause amorphous material to crystallize. In one embodiment, for example, the neck finish  32  is heated to an elevated temperature causing amorphous material in the neck finish  32  to become generally semi-crystalline or generally crystalline, while at least a substantial portion of the body  34  of the preform remains amorphous. In one non-limiting embodiment, after the preform  1  is thermally processed, it has the neck finish  32  with a crystalline content that is more than about 20% by weight. In one non-limiting embodiment, the neck finish  32  has a crystalline content that is more than about 10% by weight, including 30%, 40%, 50%, 60%, 70%, 80%, 90%, and about 99% by weight. In one non-limiting embodiment, the neck finish  32  has a semi-crystalline content that is more than about 30% by weight, including 40%, 50%, 60%, 70%, 80%, 90%, and about 99% by weight. In some embodiments, the neck finish  32  has crystalline or semi-crystalline content of about 100% by weight. As the preforms move along the processing line, the preforms can be rotated about their longitudinal axes at a speed of about 30-80 RPM. The line speed, length of the lamps of the bank  330 , number and position of the lamps, and the energy outputted by the lamps can be varied by one of ordinary skill in the art to obtain the desired heat distribution in the preform.  
         [0089]     After the preforms undergo the heating process, the preforms can be cooled. The cooling process can comprise using ambient air, with or without forced convection. The rate of cooling of the preform  1  can be selectively controlled to achieve the desired microstructure of the preform. For example, the rate of cooling may be reduced to increase the crystalline material by weight percentage of the preform. In another embodiment, the cooling process is accelerated by the use of forced chilled air to reduce the ratio of crystalline to amorphous material in the preform. In the illustrated embodiment of  FIG. 10 , the cooling system  336  can comprise a channel  770  through which a blower or fan (not shown) can pump, for example, ambient air or chilled air. The air cools the preforms which are held by the carriers  374  and carried down the length of the channel  770 . It is contemplated that any suitable means can be employed to cool the heated portions of the preforms. After the preforms are sufficiently cooled for handling, they are released from the carriers  374  and transported away by the removal system  346 , which can be a conveyor system. The preforms can then be processed, e.g., blow molded and then hot-filled.  
         [0090]     Optionally, the heat treatment system  312  can have one or more temperature sensors  824  ( FIG. 7 ). The temperature sensors can be optical pyrometers that may be carefully positioned along the processing line to measure the temperature of the preforms. Advantageously, the pyrometers can determine the preforms&#39; temperatures directly by measuring the light radiation emitted by the preforms. Thus, the temperature of the preforms can be obtained without contacting and possibly damaging the preforms. However, other temperature devices can also be used to measure the temperature of the preforms. For example, a thermocouple on the mandrel can be used to measure the temperature of a preform. Other types of temperature sensors can also be used, if desired.  
         [0091]     The heat treatment system  312  can be a closed loop or open loop system. For example, the heat treatment system  312  can be a closed loop system, whereby the power to the lamps is controlled based upon feedback signals from one or more temperature sensors (e.g., pyrometers) and can then adjust the amount of radiant heat produced by the lamps based on those readings. Alternatively, the heat treatment system  312  can be an open loop system wherein the amount of radiant heat produced by the lamps is set by user input. For example, the lamps may be set to a fixed power mode. It is contemplated that the heat treatment system  312  can be switched between a closed and open loop system.  
         [0092]      FIG. 11  is a top view of a thermal processing system  800  for producing preforms comprising crystalline material. The thermal processing system  800  comprises a feed system  802 , a carousel  804 , the heat treatment system  312 , and an output system  806 . The feed system  802  is configured to deliver preforms to the carousel  804 . A pair of drive systems  810  drives the carousel  804  in order to move the preforms along a processing line, either clockwise or counterclockwise. The heat treatment system  312  causes crystallization of at least a portion of each preform. The output system  806  can receive preforms from the carousel  804  and can then transfer the preforms away from the thermal processing system  800 . The carousel  804  comprises a plurality of movable carriers  814  configured to hold and transport preforms.  
         [0093]      FIG. 12  is a cross-sectional view of the carousel  804  taken along a line  12 - 12  of  FIG. 11 . The carrier  814  is configured to control the temperature of the preform  1 . The carrier  814  can be generally similar to the carrier  374 , except as described in further detail below.  
         [0094]     The carrier  814  is configured to fit within the opening defined by the neck finish  32  of the preform  1  ( FIG. 2 ). The carrier  814  comprises a mandrel  818  and a mandrel temperature control system  829 . The mandrel temperature control system  829  can heat and/or cool the mandrel  818 . The illustrated system  829  includes a heat tube  820  configured to draw heat upwardly away from the mandrel  818 . The heat tube  820 , in turn, can be cooled by forced convection via air flowing through the rail  816 .  
         [0095]     The heat tube  820  has a lower portion  831  and an upper portion  832 . In such an embodiment, at least a portion of the heat tube  820  is preferably positioned within the inner chamber  830  defined by the rail  816 . Fluid (e.g., chilled air, refrigerant, or other cooling fluids) can be passed through the inner chamber  830  to cool the upper portion  832 .  
         [0096]     During operation, heat from the preform  1  is transferred to the mandrel  818 . The heat can be generated by a process designed to form crystalline material, such as the processes described above. Heat is conducted through the mandrel  818  to the lower portion  831  which, in turn, transfers the heat upwardly to the upper portion  832 . Chilled air is forced through the chamber  830  so that the air absorbs heat from the tube  820 , although other fluids can also be employed. The fluid can be delivered with or without forced convection. In some embodiments, the heat tube  820  is exposed to ambient air which cools the heat tube. In this manner, heat is absorbed and dissipated by the heat tube  820 .  
         [0097]     In some embodiments, the carrier  814  can rotate the preform  1  about the longitudinal axis of the preform. If the heat treatment system  312  comprises heat lamps, the carrier  814  preferably rotates the preform  1  for a more uniform temperature distribution when the carrier  814  carries the preform past the heat treatment system  312 . However, in other embodiments, the carrier  814  may not rotate the preform  1  about its longitudinal axis. By way of example, the carrier  814  can carry the preform  1  along the processing line without rotating the preform.  
         [0098]     The mandrels described herein can be made of any material suitable for transferring heat away from the preform. For example, the mandrel  818  can be formed of steel, aluminum, metal alloys, plastics, rubber, or other suitable materials. In some embodiments, at least a portion of the mandrel  818  comprises a high heat transfer material for efficient heat transfer between the preform  1  and the heat tube  820  via the mandrel  818 . The high heat transfer material can result in rapid cooling of a neck finish  32 , even at reduced flow rates of the fluid passing through the chamber  830 . The high heat transfer material can include, but is not limited to, a beryllium-free copper alloy (sold under the tradename AMPCOLOY), aluminum, copper and its alloys, or other materials with a high thermal conductivity.  
         [0099]     The heat tube  820  can contain a fluid or gas that aids in the transfer of heat from the lower portion  831  to the upper portion  832  of the heat tube  820 . The fluid can circulate within the heat tube  820  as the fluid is heated and cooled in order to cool the lower portion  831 . In some embodiments, the heat tube  820  can have a system for pumping fluid through the heat tube  820 . Alternatively, the heat tube  820  may be a solid rod that is preferably formed of an especially high heat transfer material, such as copper.  
         [0100]     In another embodiment not illustrated, the heat tube  820  can contact one of the vertical side walls of the rail system  816  in order to conduct heat from the heat tube  820  to the rail system  816 . Thus, forced convection and/or conduction can be used to cool the heat tube  820 , thereby cooling the mandrel  818  which, in turn, cools the neck finish  32  of the preform  1 . In some embodiments, the heat tube  820  is perforated so that air can flow through the tube  820  to further enhance heat dissipation.  
         [0101]     In operation, the feed system  802  delivers preforms to the carousel  804 . In some embodiments, including the illustrated embodiment, the carousel  804  moves the preforms in a clockwise direction along a processing line. The preforms are heated as they pass by the system  312 . The carriers  814  cool the inner surface of the preform  1  to ensure that at least a portion of the preform  1  remains below its T g  as the preform  1  heated by the system  312 . Preferably, when the preform  1  is heated by the system  312 , the outer surface of the preform  1  is at a high temperature causing crystallization. The inner portion of the neck portion  32  thus comprises more amorphous material than the outer portion of the preform. However, any portion of the preform can be heated to cause crystallization of amorphous material. As such, the system  800  can be used to produce preforms with a semi-crystalline or crystalline neck finish. Other types of preforms can also be formed utilizing the system  800 . The carousel  804  then delivers the processed preforms to the output system  806  for ejection.  
         [0102]     All patents and publications mentioned herein are hereby incorporated by reference in their entireties. Except as further described herein, certain embodiments, features, systems, devices, materials, methods and techniques described herein may, in some embodiments, be similar to any one or more of the embodiments, features, systems, devices, materials, methods and techniques described in U.S. Pat. Nos. 6,109,006; 6,808,820; 6,528,546; 6,312,641; 6,391,408; 6,352,426; 6,676,883; U.S. patent application Ser. Nos. 09/745,013 (Publication No. 2002-0100566); 10/168,496 (Publication No. 2003-0220036); 09/844,820 (2003-0031814); 10/090,471 (Publication No. 2003-0012904); 10/395,899 (Publication No. 2004-0013833); 10/614,731 (Publication No. 2004-0071885), provisional application 60/563,021, filed Apr. 16, 2004, provisional application 60/575,231, filed May 28, 2004, provisional application 60/586,399, filed Jul. 7, 2004, provisional application 60/620,160, filed Oct. 18, 2004, provisional application 60/621,511, filed Oct. 22, 2004, and provisional application 60/643,008, filed Jan. 11, 2005, U.S. patent application Ser. No. 11/108,342 entitled MONO AND MULTI-LAYER ARTICLES AND COMPRESSION METHODS OF MAKING THE SAME, filed on Apr. 18, 2005, U.S. patent application Ser. No. 11/108,345 entitled MONO AND MULTI-LAYER ARTICLES AND INJECTION METHODS OF MAKING THE SAME, filed on Apr. 18, 2005, U.S. patent application Ser. No. 11/108,607 entitled MONO AND MULTI-LAYER ARTICLES AND EXTRUSION METHODS OF MAKING THE SAME, filed on Apr. 18, 2005, which are hereby incorporated by reference in their entireties. In addition, the embodiments, features, systems, devices, materials, methods and techniques described herein may, in certain embodiments, be applied to or used in connection with any one or more of the embodiments, features, systems, devices, materials, methods and techniques disclosed in the above-mentioned patents and applications.  
         [0103]     The various methods and techniques described above provide a number of ways to carry out the invention. Of course, it is to be understood that not necessarily all objectives or advantages described may be achieved in accordance with any particular embodiment described herein.  
         [0104]     Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. Similarly, the various features and steps discussed above, as well as other known equivalents for each such feature or step, can be mixed and matched by one of ordinary skill in this art to perform methods in accordance with principles described herein.  
         [0105]     Although the invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses and obvious modifications and equivalents thereof. Accordingly, the invention is not intended to be limited by the specific disclosures of preferred embodiments herein.