Apparatus and method of molding preforms having a crystalline neck

1 . An apparatus for molding a preform, the apparatus comprising:

a core section having an elongated molding assembly configured to mold at least a portion of the preform, the elongated molding assembly comprising:

a first portion of the elongated molding assembly for molding a first portion of the preform;

a first temperature control system in thermal communication with the first portion;

a second portion of the elongated molding assembly for molding a second portion of the preform; and

a second temperature control system in thermal communication with the second portion;

a cavity section having a cavity, the cavity section and the core section mate to form a cavity space in the shape of the preform, the cavity space positioned between the elongated molding assembly and the cavity; and

wherein the first temperature control system actively controls the temperature of the first portion and the second temperature control system actively controls the temperature of the second portion such that the first portion is at a first temperature for forming crystallized material of the preform while the second portion is at a second temperature for forming substantially amorphous material of the preform.

2 . The apparatus of claim 1 , wherein the first portion of the elongated molding assembly is positioned to form an interior surface of a neck finish of the preform.

3 . The apparatus of claim 1 , wherein the second portion of the elongated molding assembly is positioned to form an interior surface of a body portion of the preform.

4 . The apparatus of claim 1 , wherein the elongated molding assembly is a core that surrounds the second temperature control system which comprises a cooling tube.

5 . The apparatus of claim 1 , wherein the core section comprises a core holder, and the core holder comprises the first portion which extends along a core of the elongated molding assembly.

6 . The apparatus of claim 5 , wherein the first portion defines a neck molding surface for molding an interior surface of a neck finish of the preform.

7 . A mold assembly for molding a preform, comprising:

a first mold half having an elongated molding assembly for molding an interior portion of a preform, the elongated molding assembly having a first portion and a second portion, the first portion defines a first molding surface and the second portion defines a second molding surface;

a second mold half having a cavity molding surface;

a mold temperature control system; and

a mold cavity defined by the first portion, the second portion, and the cavity molding surface, wherein the mold temperature control system is configured to actively maintain the first portion at a temperature for forming crystalline material while actively maintaining the second portion at another temperature for forming amorphous material.

8 . The mold assembly of claim 7 , wherein the mold temperature control system comprises a first temperature control system and a second temperature control system, and the first temperature control system is independent of the second temperature control system.

9 . The mold assembly of claim 8 , wherein the first temperature control system is configured to maintain the first molding surface at the temperature for forming crystalline material and the second temperature control system is configured to maintain the second molding surface at the temperature for forming amorphous material, the temperature for forming crystalline material is greater than the crystallinity temperature of the material forming the preform, and the temperature for forming amorphous material is less than the crystallinity temperature of the material forming the preform.

10 . The mold assembly of claim 7 , wherein the first portion is positioned to form an interior surface of a neck finish of the preform.

11 . The mold assembly of claim 7 , wherein the second portion is positioned to form an interior surface of a body portion of the preform.

12 . The mold assembly of claim 7 , wherein the first portion and the second portion form a mandrel configured to form an interior portion of the preform.

13 . The mold assembly of claim 7 , wherein the elongated molding assembly comprises a core holder and a core that extends from the core holder, and the core holder comprises the first portion that extends along and surrounds a portion of the core.

14 . A mold assembly for molding a preform with a crystalline neck finish, comprising:

a core section having an elongated molding assembly for molding an interior portion of a preform, the elongated molding assembly having a neck finish molding portion and a body molding portion;

a cavity section having a cavity molding surface;

at least one temperature control system; and

a mold cavity defined by the neck finish molding portion, the body molding portion, and the cavity molding surface, the at least one temperature control system is configured to actively maintain the neck finish molding portion at a temperature for forming crystalline material while actively maintaining the body portion at another temperature for forming amorphous material.

15 . A method of making a preform, comprising:

injecting a material into a cavity formed by a mold section and a core section, the core section comprises a core neck finish portion for molding an inner surface of a preform and a core body portion for molding another inner surface of the preform;

maintaining the core neck finish portion at a first temperature and the core body portion at a second temperature, wherein the first temperature is greater than the crystallinity temperature of the material and the second temperature is less than the crystallinity temperature of the material; and

leaving the material in contact with the core section to form a preform having a body portion that is primarily amorphous or semi-crystalline and a neck finish that is primarily crystalline.

16 . The method of claim 15 , further comprising rapidly cooling the preform after a target amount of crystallization.

17 . The method of claim 16 , wherein a substantial portion of the heat absorbed by the core neck finish portion is transferred to a first temperature control system during the cooling of the preform.

18 . The method of claim 17 , wherein the core body portion absorbs heat from the preform, a substantial portion of the heat absorbed by the core body portion is transferred to a second temperature control system that operates independently of the first temperature control system.

19 . The method of claim 15 , further comprising:

placing the preform in a second mold;

injecting a second layer of material over the body portion of the preform to form a two-layer preform; and

removing the two-layer preform from the mold.