CN109204992B - 用于吹塑成型操作的预制件 - Google Patents

用于吹塑成型操作的预制件 Download PDF

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CN109204992B
CN109204992B CN201810697655.7A CN201810697655A CN109204992B CN 109204992 B CN109204992 B CN 109204992B CN 201810697655 A CN201810697655 A CN 201810697655A CN 109204992 B CN109204992 B CN 109204992B
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preform
coating
container
liquid
material forming
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CN109204992A (zh
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理查德·西德勒茨基
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Diskema Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/02—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents
    • B65D1/0207—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by material, e.g. composition, physical features
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2049/4664—Blowing fluids being incompressible staying in the final article
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
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  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Containers Having Bodies Formed In One Piece (AREA)

Abstract

公开了用于吹塑成型以形成塑料容器的预制件和方法，该预制件具有形成在其内表面上的涂层。该涂层减少了在预制件扩张期间从加热的预制件损失的热能量，以确保预制件维持在形成该预制件的材料的相变温度/凝固温度或以上的温度处。

Description

用于吹塑成型操作的预制件
发明领域
本发明涉及用于形成塑料容器的预制件，更具体地，涉及其内表面上具有例如浸渍、喷雾、放置或流涂形成的涂层的预制件。
背景技术
预制件是通过吹塑成型而制成容器的产品。除非另有说明，否则术语“容器”是广义的术语，并以其常规的意义使用，以及包括但不限于，预制件和由预制件得来的瓶子容器两者。大量的塑料和其它材料已被用于容器，并且许多是相当合适的。诸如碳酸饮料和食品的一些产品需要容器，该容器抵抗诸如二氧化碳和氧气的气体的转移。现在在容器行业中广泛使用的树脂是聚对苯二甲酸乙二醇酯(PET)，在这个术语中，我们不仅包括由[β]-羟乙基对苯二甲酸乙二醇酯缩聚形成的均聚物，而且还包括含有少量从其它的乙二醇或二酸衍生出来的单元的共聚多酯，例如，间苯二酸酯共聚物。
传统的吹塑成型和填充已发展为两个独立的过程，在多数情况下由不同的公司操作。为了使瓶子填充更加成本有效，一些填料在内部已采用吹塑成型，在多数情况下吹塑成型机直接集成到它们的填充线中。设备制造商已认识到这一优势，并销售设计成保证吹塑成型机和填料完全同步的“集成”***。尽管在努力使这两个过程更靠近在一起，但是吹塑成型和填充仍然是两个独立的、不同的过程。因此，在单独执行这两个过程时可能会产生显著的成本。因此，已在努力试图开发适于在单次操作中形成并填充容器的液体或液压吹塑成型***。
第8,573,964号美国专利中描述了同时形成并填充容器的一个过程，该专利通过引用以其整体并入本文中。在‘8,573,964专利中公开的过程期间，将PET预制件在进入吹塑成型***之前进行加热。该预制件在约140℃时退出烤炉。在成型过程期间，预制件的温度期望地保持在约140℃和约63℃(PET的相变温度/凝固温度)之间，以确保产生美学和功能上期望的容器。因此，容器必须在用于形成该容器的材料的相变温度/凝固温度或该温度以上的温度形成。加热的处于其最高温度下的预制件具有已知(或可知)量的热能量，在吹塑成型操作期间，该热能量能够在容器形成期间进行分布。
在吹塑成型操作期间，热能量损失到围绕预制件的模具中，损失到用于使加热的预制件扩张为容器的流体中，并且热能量沿着由拉伸和吹制的预制件形成的容器的较大表面区域分布。预制件的热能量的部分设置在颈部瓶口中。因为颈部瓶口不接触用于吹塑成型操作的流体也不会毁损或以其他方式受吹塑成型操作的影响，因此颈部瓶口中的热能量在吹塑成型过程期间不会损失和/或进行分布。因此，加热的预制件的总热能量中的较少部分能够进行分布，以吹制/填充流体、模具等。因此，不期望的热量损失可能影响容器的形成和填充中的一致性。将期望的是，开发在预制件的扩张和填充期间维持加热的预制件的热特性的形成容器的预制件和方法。
发明内容
与本发明和谐的以及一致的是，令人惊讶地发现了形成容器的预制件和方法，其中，该方法在预制件的扩张和填充期间维持加热的预制件的热特性。
在本发明的实施方式中，用于吹塑成型以形成塑料容器的预制件包括颈部部分、本体部分和涂层，其中，颈部部分形成提供与预制件的内部流体连通的开口；本体部分具有封闭的端盖，颈部部分和本体部分形成内表面；以及涂层形成在预制件的本体部分的内表面上，涂层具有比形成预制件的材料的导热率小的导热率。
在本发明的另一实施方式中，同时形成并填充容器的方法包括：将其内表面上具有涂层的加热的预制件设置在模腔中，该涂层具有比形成预制件的材料的导热率小的导热率；将液体输送至预制件中，从而使预制件和涂层朝向模腔的内表面扩张以形成结果容器，其中，涂层减少了输送步骤期间从加热的预制件的热能量损失；以及其中，该液体保持在容器内作为最终产品。
在本发明的另一实施方式中，同时形成并填充容器的方法包括：将其内表面上具有牺牲式涂层的加热的预制件设置在模腔中，该涂层具有比形成预制件的材料的导热率小的导热率；将液体输送至预制件中，从而使预制件和涂层朝向模腔的内表面扩张以形成结果容器，其中，该涂层溶解在液体中或蒸发，以减少输送步骤期间从加热的预制件的热能量损失，从而确保预制件维持在形成预制件的材料的相变温度/凝固温度或以上的温度；以及其中，该液体保持在容器内作为最终产品。
附图说明
在根据附图进行考虑时，本发明的上述及其它有益效果将根据以下优选实施方式的详细描述而对本领域技术人员变得显而易见，在附图中：
图1是用作本发明的实施方式的原材料的无涂层的预制件；
图2是图1中所示的无涂层的预制件的剖视图；
图3是根据本发明的实施方式的图2的、在其内表面的部分上具有涂层的预制件的剖视图；
图4是根据本发明的另一实施方式的具有涂层的预制件的剖视图；以及
图5是根据本发明的另一实施方式的具有涂层的预制件的剖视图。
具体实施方式
以下详细描述和附图描述并示出了本发明的不同示例性实施方式。该描述和附图用来使本领域技术人员能够制造和使用本发明，而不是旨在以任何方式限制本发明的范围。关于所公开的方法，所示步骤本质上是示例性的，因此，这些步骤的顺序不是必然的或关键的。另外，所公开的方法提供了待放置在物品上的涂层，该物品具体为预制件，该预制件稍后被吹塑为瓶子。在多数情况下，这种方法优于将涂层放置在瓶子本身上。与由预制件吹制得来的容器相比，预制件的尺寸更小，形状更规整，使得更容易获得均匀和规整的涂层。另外，不同形状和尺寸的瓶子和容器可由类似尺寸和形状的预制件制成。因此，相同的设备和过程可用于涂敷预制件，以形成若干不同类型的容器。吹塑成型过程可在成型和涂敷后不久进行，或预制件可以被制成并存储以用于随后的吹塑成型。如果预制件在吹塑成型操作之前进行存储，则它们较小的尺寸允许它们在存储时占用较少的空间。
参照图1，描绘了无涂层的预制件10。预制件10优选地由FDA批准的材料(诸如，纯净的PET)制成，并且可具有多种形状和尺寸中的任一种。预制件可根据需要由其它材料形成，诸如，可循环的PET、HDPE、PE、PP和/或适于吹塑成型的任何其它聚合物。图1中所示的预制件10为将形成16盎司水瓶的24克预制件类型，但是本领域技术人员应理解，根据由预制件形成的容器的期望配置、特征和最终用途，可使用其它的预制件配置、材料重量、长度和尺寸。无涂层的预制件10可通过如现有技术中已知的注射成型形成或通过其它合适的方法形成。
图2中示出了预制件10的剖视图。无涂层的预制件10具有颈部部分12和本体部分14。颈部部分12(也被称作为颈部瓶口或瓶口)形成开口16，该开口16提供与预制件10内部的流体连通。颈部部分从开口16延伸至支承环18并包括支承环18(还称作为肩部)。颈部部分12还以存在螺纹20为特征，该螺纹20提供了将盖子(未示出)紧固至由预制件10生产出的瓶子(未示出)的装置。本体部分14为从颈部部分12延伸并以圆形端盖22终结的长型圆柱状结构。预制件的厚度24将取决于预制件10的总长度和所产生容器的期望的壁厚度及总尺寸。如果结果容器是非对称的或沿其壁需要不同的厚度，则厚度24还可以沿预制件10的长度变化。应注意的是，由于本文中使用了术语“颈部”和“本体”，在俗称为“长颈”容器的容器中，将略低于紧固有盖子的支承环、螺纹和/或肩部的长型部分认为是容器的“主体”的部分，而不是“颈部”的部分。
图3示出图1和图2的预制件10的内表面28，该内表面28上形成有基本上连续的(或未破损的)、具有基本上统一厚度的涂层26。在图3所示的实施方式中，涂层26围绕本体部分14的整个表面设置，在支承环18处或支承环18下面终止。涂层未延伸至颈部部分12。在某些实施方式中(未示出)，可能期望的是涂层26延伸至颈部部分12，或涂层26可以例如在其沉积到内表面28上期间由于喷射等而无意地存在于颈部部分12上。涂层26可包括单一材料的一个层、若干材料组合的一个层或至少两种材料的若干层。具有多个层的聚合物预制件在本领域是公知的，其中，已知的多层预型件设计有旨在保持完整以改善预制件和结果容器的特征的多个层。多层预制件可包括涂层或层，以形成蒸汽屏障、气体屏障、用于美学或阻挡光或UV能量的彩色层。另一方面，涂层26由任何易碎的和/或可溶解的材料形成，该材料比形成预制件10的材料具有更低的导热率。涂层26可根据需要由固体材料、半固体材料、凝胶、或高粘性液体形成。根据需要，合适的涂层例如包括凡士林、硅树脂、石蜡或聚丙烯或上述的组合。涂层26还可以是将填充结果容器的最终产品的成分。例如，涂层26可以是旨在溶解在存在于结果容器中的流体中、与其相互作用和/或相混合的着色剂、糖、表面活性剂、添味剂等，以提供使得由涂层26和流体组合的材料在其中形成期望的最终产品。
涂层26可通过任何合适的方法形成在预制件10的内表面28上，诸如喷涂、流涂或在内表面上设置凝胶或液体的其它手动或自动化方法。一旦施加之后，可根据需要对涂层26进行进一步的处理。例如，根据需要，涂层26可以固化、干燥或冷却，或可将形成涂层26的过剩材料从预制件10移除。
一旦提供了在其内表面28上形成有涂层26的预制件10，则可对预制件10进行处理以形成结果容器。一开始，将预制件10加热到其相变/凝固温度之上的温度。对于由PET形成的预制件10，预制件在烤炉中上升到约190℉至约250℉(大致88℃至121℃)之间的温度，然后放置到模腔(未示出)中。然后将加热的预制件10设置在模腔(未示出)中。模腔的两半围绕加热的预制件10闭合，其中，颈部部分12设置在模腔上方，以及本体部分14设置在其中。然后，吹塑喷嘴(未示出)邻近或邻接预制件10设置，并且吹塑喷嘴可在预制件10的颈部部分12处形成密封。模腔可加热至例如大致250℉至350℉(大致93℃至177℃)之间的温度，以在结果容器内赋予增加的结晶度水平。在另一示例中，根据需要，可在大致32℉至90℉(大致0℃至32℃)之间的环境温度或低温温度下提供模腔。
拉伸杆(未示出)可延伸至预制件10中，以启动机械拉伸。此时，根据需要，涂层26还可拉伸或可以开始破裂。涂层26适于在拉伸操作期间维持其热特性。拉伸杆继续拉伸预制件10和涂层26，从而使本体部分14的侧壁和涂层26变薄。此时，诸如活塞状装置(气动、机械和/液压)或伺服***的压力源可以开始启动将期望的大量液体快速输送至预制件10的内部。该液体导致预制件10和涂层26朝向模腔的内表面扩张。根据需要，残余空气可通过拉伸杆进行排放。
在由液体所导致的预制件10的扩张期间，涂层26用于减少从预制件10到液体、残余空气和/或通过扩张预制件10所接触的模腔的热能量的损失。因为涂层26比形成预制件10的材料具有更低的导热率，所以减少了热能量的损失。在减少从预制件10的热能量损失时，涂层26有助于在预制件10的扩张和填充期间维护加热的预制件10的热特性，以确保预制件10维持在形成预制件10的材料的相变温度/凝固温度(例如，对于PET约63℃)或以上的温度，直到结果容器形成。通过确保预制件10在吹塑操作期间维持在形成预制件10的材料的相变温度/凝固温度或以上的温度，改善了结果容器的外观和性能。涂层可通过精确的机理来减少从预制件10的热能量损失，但是机理还可以为通过涂层26溶解在液体中、蒸发、或任何其它的化学或机械机理。以这种方式，涂层26至少部分地是牺牲式涂层。如上文所述，涂层一旦与用于形成容器的液体相混合、溶解在该液体中或与该液体发生化学反应，则涂层26可以是存在于结果容器中的最终产品的组成部分。
一旦容器形成，拉伸杆可从模腔退出，同时继续排放残余空气。拉伸杆可设计成当拉伸杆从模腔退出时转移预定体积的液体，从而允许结果容器内期望的液体填充水平和/或期望的顶部空间。通常，期望的填充水平和/或顶部空间将与结果容器的支承环18的水平处或附近的高度相对应。
图4示出了预制件110，除了其内表面28上形成的涂层126具有变化的厚度之外，该预制件110与上文中描述的和图1至图3中示出的预制件10相类似。涂层126的厚度变化可取决于若干因素，包括但不限于，预制件110的尺寸、预制件110的形状和预制件110的结果容器(未示出)的形状(例如，不对称形状的结果容器)。期望的是包括较厚的涂层126，其中，本文中描述的形成和填充过程期间该涂层126中增加的从预制件110的热能量损失是可预期的。应理解的是，涂层126的变化的厚度根据需要可以是对称的或随机的，并且该厚度根据需要可在颈部部分12或端盖22附近更大。
图5示出了预制件210，除了其内表面28上以不连续的(或断开的)图案形成有涂层226之外，该预制件210与上文中描述的和图1至图3中示出的预制件10相类似。应理解的是，根据需要，涂层226可具有变化的厚度。涂层226沉积的位置可取决于若干因素，包括但不限于：预制件210的尺寸、预制件210的形状和预制件210的结果容器(未示出)的形状(例如，不对称形状的结果容器)。期望的是包括较厚的涂层226，其中，在本文中描述的形成和填充过程期间，该涂层226中增加的从预制件210的热能量损失是可预期的。应理解的是，不连续的涂层226可根据需要以对称模式或随机模式形成，以及涂层226可根据需要沿着整个内表面228设置或仅设置在内表面的部分上。
从上述描述中，本领域普通技术人员可以容易地确定本发明的基本特征，以及在不脱离本发明的精神和范围的情况下，可以对本发明进行各种变化和修改以使其适应各种用途和条件。

Claims (20)

1.用于吹塑成型以形成塑料容器的预制件，包括：
颈部部分，形成开口，所述开口提供与所述预制件的内部的流体连通；
本体部分，具有封闭的端盖，所述颈部部分和所述本体部分形成内表面；以及
涂层，形成在所述预制件的所述本体部分的所述内表面上，所述涂层的导热率小于形成所述预制件的材料的导热率，所述涂层为牺牲式涂层。
2.根据权利要求1所述的预制件，其中，所述涂层具有统一的厚度。
3.根据权利要求1所述的预制件，其中，所述涂层具有变化的厚度。
4.根据权利要求1所述的预制件，其中，所述涂层以不连续的图案形成在所述内表面上。
5.根据权利要求1所述的预制件，其中，所述涂层为易碎的。
6.根据权利要求1所述的预制件，其中，所述涂层能够溶解在液体中。
7.根据权利要求1所述的预制件，其中，所述涂层选择为在所述预制件的扩张期间维持所述预制件的热特性，以确保所述预制件维持在形成所述预制件的所述本体部分的材料的相变温度处或以上的温度。
8.根据权利要求7所述的预制件，其中，所述涂层为凝胶。
9.根据权利要求7所述的预制件，其中，所述涂层为粘性液体。
10.根据权利要求7所述的预制件，其中，所述涂层是胶状物、硅树脂、石蜡、聚丙烯中的至少一种或其组合。
11.根据权利要求1所述的预制件，其中，所述涂层在所述预制件的扩张期间减少从所述预制件到填充所述预制件的液体的热能量损失。
12.同时形成并填充容器的方法，包括：
将内表面上具有涂层的加热的预制件设置在模腔中，所述涂层的导热率小于形成所述预制件的材料的导热率，并且所述涂层为牺牲式涂层；
将液体输送至所述预制件中，从而使所述预制件和所述涂层朝向所述模腔的内表面扩张，以形成结果容器，其中，所述涂层减少了在输送步骤期间从所述加热的预制件损失的热能量；以及
其中，所述液体保持在所述容器内作为最终产品。
13.根据权利要求12所述的方法，其中，所述涂层减少了在所述输送步骤期间从所述加热的预制件损失的热能量，以确保所述预制件维持在形成所述预制件的材料的相变温度处或以上的温度。
14.根据权利要求12所述的方法，其中，所述涂层在所述预制件的扩张期间溶解在所述液体中。
15.根据权利要求12所述的方法，其中，所述涂层是所述最终产品的组成部分。
16.根据权利要求15所述的方法，其中，所述涂层是着色剂、表面活性剂、添味剂中的至少一种。
17.根据权利要求12所述的方法，其中，所述涂层在所述输送步骤期间蒸发。
18.根据权利要求15所述的方法，其中，所述涂层是糖。
19.同时形成并填充容器的方法，包括：
将内表面上具有牺牲式涂层的加热的预制件设置在模腔中，所述涂层的导热率小于形成所述预制件的材料的导热率；
将液体输送至所述预制件中，从而使所述预制件和所述涂层朝向所述模腔的内表面扩张，以形成结果容器，其中，所述涂层溶解在所述液体中或蒸发，以减少在输送步骤期间从所述加热的预制件损失的热能量，从而确保所述预制件维持在形成所述预制件的材料的相变温度处或以上的温度；以及
其中，所述液体保持在所述容器内作为最终产品。
20.根据权利要求19所述的方法，其中，所述涂层是所述最终产品的组成部分。
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