CN1223451C - 延伸吹塑容器及其成形方法 - Google Patents

延伸吹塑容器及其成形方法 Download PDF

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CN1223451C
CN1223451C CNB018166288A CN01816628A CN1223451C CN 1223451 C CN1223451 C CN 1223451C CN B018166288 A CNB018166288 A CN B018166288A CN 01816628 A CN01816628 A CN 01816628A CN 1223451 C CN1223451 C CN 1223451C
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CN1466513A (zh
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中村丰
望月刚一
横山功武
日向尚通
大石仁
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Aoki Technical Laboratory Inc
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Abstract

本发明提供一种延伸吹塑容器及其成形方法，容器壁部剖面在结晶密度上进行多层化，使表面结晶密度成为高密度，实现了延伸吹塑容器强度的提高和耐热处理的容易化。该薄壁塑料容器(2)是将有底形坯在纵方向和横方向进行延伸吹塑成形而成的。壁部剖面由经延伸的高结晶密度的内外侧表层(2a)、比表层(2a)密度低的芯层(2b)、以及在两层(2a、2b)间的结晶密度上形成有梯度的中间层(2c)构成。

Description

延伸吹塑容器及其成形方法
技术领域
本发明涉及一种塑料延伸吹塑容器，及其成形方法，其将注射成形的有底形坯在纵方向和横方向进行延伸吹塑，以使主要部分形成薄壁。
背景技术
作为使用延伸吹塑成形方法来成形瓶等细口容器及广口容器等包装用塑料容器的成形手段，有冷形坯法和热形坯法两种，冷形坯法是将预先成形备料的有底形坯，以高于玻璃***点(transitionpoint)的温度加热软化、再延伸吹塑成容器；热形坯法是将注射成形后柔软的有底形坯在还保有超过玻璃***点的热度时直接延伸吹塑成容器。
由于冷形坯法是对室温的形坯用外部热进行加热软化，可得到形坯温度均一、被延伸吹塑成形的容器的壁部剖面的结晶密度也能达到均一化、且耐热处理容易的容器。
由于热形坯法是利用保持热、所以必须在形坯还软化时完成延伸吹塑，因而存在形坯温度均一困难、结晶密度也比冷形坯法低、虽然强度不是很差但耐热处理难的问题。
发明内容
本发明就是基于对上述事情的思考，发明目的在于提供一种新型延伸吹塑容器及其成形方法，其对延伸吹塑容器的壁部剖面在结晶密度上进行多层化处理，在使表层结晶密度比内部结晶密度显著提高的同时，通过中间层实现容器强度的进一步提高和耐热处理的简易化。
基于上述目的，本发明的延伸吹塑容器是一种将注射成形的有底形坯在纵方向和横方向进行延伸吹塑成形的薄壁塑料容器，该容器的壁部剖面，从结晶密度方面来说，是由形成高密度的内外表层、比其表层密度低的芯层、以及介于两层间具有梯度结晶密度的中间层所组成的多层构造构成；上述的塑料容器由聚对苯二甲酸乙酯构成，上述内外表层的结晶密度为大于1.4前后；上述芯层的结晶密度为1.32～1.36，比表层低；介于两层之间的中间层结晶密度具有从大于1.4前后低到1.32～1.36的梯度，位于容器壁部剖面的上述芯层区域，根据形坯壁部剖面的壁厚大小按比例变动，无论芯层区域的大小，上述中间层都具有梯度结晶密度，并介于其间。
本发明的成形方法是，将有底形坯在注射成形时，急冷至低于定向温度的温度，利用冷却温度与时间的关系使该形坯壁部内外表层形成为半硬化层，在将通过该半硬化层维持形态的形坯从模具离型后，形坯壁部中央的温度处于非结晶温度区域或其附近，在形坯外层表面温度上升时、半硬化层还充分存在牵引阻力时进行延伸吹塑成形，这样就成形为由壁部剖面上在结晶密度方面形成高密度的内外表层、比该表层密度低的芯层、以及两层间带有梯度结晶密度的中间层所组成的多层构造的容器；上述的塑料容器由聚对苯二甲酸乙酯构成，上述内外表层的结晶密度为大于1.4前后；上述芯层的结晶密度为1.32～1.36，比表层低；介于两层之间的中间层结晶密度具有从大于1.4前后低到1.32～1.36的梯度。
此外，在上述成形方法中，上述形坯由聚对苯二甲酸乙酯组成，该形坯外侧的表面温度为上升中的95℃～115℃，壁部中央的温度在125℃～140℃的范围内，在具有30℃左右温度差时，进行该形坯的延伸吹塑成形。
附图的简单说明
图1为以纵剖图表示本发明有关的延伸吹塑容器形态以及部分剖面和形坯的说明图。
图2为同一延伸吹塑容器的各测定部位的壁厚和结晶密度的关系图。
图3为将形坯离型后10秒左右延伸吹塑制造而成的容器的壁厚和结晶密度的关系图。
图4为将形坯离型后15秒左右延伸吹塑制造而成的容器的壁厚和结晶密度的关系图。
发明具体实施方式
图中1为热可塑性塑料，例如由聚对苯二甲酸乙酯(PET)构成的有底形坯，由口部11和与之相连的体部12及底部13组成，可以通过向模具中注射填充熔融后的塑料成形而成。
2是对上述形坯1进行延伸吹塑成形而做成的广口容器，由根据形坯1的口部11而成的口部21、从该口部下侧被延伸吹塑成薄壁的体部22以及底部23组成，其壁部剖面是由高结晶密度的内外表层2a、2a和与该表层2a、2a相比低密度的芯层2b，以及介于两层2a、2b之间具有梯度结晶密度的中间层2c所构成的多层构造的壁部剖面。
像这样在结晶密度上将壁部剖面多层化的容器2可以通过基于热形坯法的延伸吹塑成形很容易地制造。但是，要构成内外侧的表层2a、2a的结晶密度高、而芯层2b的结晶密度低，就必须要使在形坯1在注射成形时急冷至低于定向温度的温度进行急冷，利用温度与时间的关系使该形坯1壁部的内外表层形成为半硬化层1a、1b。
该半硬化层1a是在形坯1注射成形时，熔融塑料与模腔面接触时生成的，半硬化层1a的厚度可以通过冷却温度和时间的关系来控制。熔融的塑料在预先生成的皮层上流动，填充模腔，在此过程中，皮层的厚度不断增加，并受到流动的熔融塑料的牵引，在那里生成了流动定向。这种流动定向会持续到皮层作为半硬化层1a形成形坯1的表面为止，据推测这种流动定向会与延伸定向相互作用，而使表层2a的结晶化程度增加。
当成形材料是聚对苯二甲酸乙酯时，在该形坯1注射成形时，模具的冷却温度最好设定在15℃前后。同时，在冷却时，形坯1的内外侧是通过温度高于玻璃***点的半硬化层1a、1a形成的，必须要限制利用该半硬化层1a充分维持形坯1形态的时间。
该冷却时间根据被延伸吹塑的体部11的壁部厚度而有所不同，倾向于按照与壁厚成比例地设定冷却时间(例如5～10秒)。如果与壁厚相比冷却时间短，则生成的表面半硬化皮层1a较薄，在直至延伸吹塑的时间内，由于存在保持热而会显著软化，无法从半硬化层1a上得到充分的形坯表层的牵引阻力，但相反的，如果时间过长，半硬化层1a生成了不必要的厚度，也会给延伸吹塑带来问题。但是，根据被成形容器的形态，即使形坯1的壁部厚度相同，为了在内部保存适合于该容器延伸吹塑成形的保持热量，也要设定不同的冷却时间。
注射成形的形坯1用已知的手段固定口部11，从型腔模和型芯模离型后，直接以中空的状态移送到吹塑模具内，再关闭模具以将其设置在吹塑模腔内。并且同一般情况一样，用吹塑芯塞住口部11后，纵方向上使用中央的延伸杆、横方向上通过鼓风(ブロ一エア)进行延伸吹塑，这样形坯1的口部11原样不变地成为口部21，体部22成为薄壁的容器2。通过这种延伸吹塑，得到了壁部剖面上具有位于高结晶密度的内外侧的表层2a、2a和低结晶密度的芯层2b之间、在结晶密度方面存在梯度的中间层2c、2c的容器2。为此，必须是形坯1壁部中央的温度处于非结晶温度区域或其附近，在形坯1外层表面温度上升过程中，至少在外侧的半硬化层1a充分保有牵引阻力时进行延伸吹塑成形。
当上述形坯1由聚对苯二甲酸乙酯构成时，最好在形坯外侧的表面温度在上升过程中为95℃～115℃、壁部中央温度在125℃～140℃的范围内、并存在30℃左右的温度差时，延伸吹塑成形该形坯。如果表面温度低于95℃、壁部中央温度在上述高温区域内时，表层2a、2a和芯层2b的结晶密度差会变得显著，因此很难生成连接两者的中间层2c。因此，当大强度按压延伸成形薄壁的体部时，常常出现外侧表皮剥落的现象，压曲强度也会变得低下。
此外，由于伴随着离型后时间的推移而使内部热放出，壁部中央和表面的温度差变得低于25℃，温度梯度变小，则表层2a、2a和芯层2b的结晶密度差也会变小，两者间密度的梯度消减，结晶密度也趋于平均化。
从根据下述事实例的成形条件成形的壁厚4.4mm的形坯1来看，由离型后半硬化层1a温度上升引起的软化出人意料的快，图2显示了在估计具有25℃～30℃温度差的离型后6秒时，在图1中容器2的面板部A、肩部B、体部C、底部D的各部位上，对进行了形坯1的延伸吹塑而成形的容器2的壁厚和结晶温度进行测定(用喇曼分光法)的结果。
此处的离型后6秒，可以说是壁厚4.4mm的形坯1的放置时间，如果对形坯内部热量有显著影响的壁厚不同，则可以相应地设定该放置时间，此外，除壁厚以外，也可以根据冷却时间来控制由形坯成形时的冷却而生成的半硬化层1a的成长程度、以及设定放置时间。
在上述容器2的壁厚方面，横向延伸倍率最小的面板部A是1.25mm；横向延伸倍率最大的底部D是0.4mm；肩部B是0.45mm；体部C是0.5mm；平均壁厚0.65mm。但是，由图2的结晶密度各曲线可以看出，即使在上述壁部中存在着壁厚的差异，对于密度上升的表层2a的部分来说，总是在0.2mm左右的厚度范围内，此外，密度上有梯度的中间层2c也介于0.2mm左右的厚度范围内，判断除去这些的部分的中央部形成了芯层2b。此外，无论是容器2的那个测定部分，表层2a的结晶密度都大于1.4，即使被认为是非结晶状态的芯层2b也显示了大于1.32的结晶密度这样的结晶化程度，从各测定部位的对比来看，对于比表层2a密度低的芯层2b来说，按照壁部剖面的壁厚增减呈比例变动，而上述中间层2c在与芯层2b区域大小无关的某一范围内保持呈梯度的结晶密度地介于其中。
从上述可以判断出，即使是容器体部的所有壁厚，与构成上述容器2的一部分的各部位的任一壁厚相同地延伸吹塑成形的容器，被认为也会成为具有和其各部位相同结晶密度分布的多层构造的容器。
图3作为一个对比例，是在形坯1离型后10秒左右延伸吹塑得到的容器2的结晶密度和分布，根据这些，各测定部位的结晶密度虽然有某种程度的上下差别，但在整体上看都在1.36～1.38的范围内平均分布。
此外，图4也作为比较例，是在离型后15秒左右延伸吹塑得到的容器2的结晶密度和分布，根据这些，即使是多经过5秒后再延伸吹塑，其结晶密度也几乎没有变化，可以看出各测定部位的结晶密度更加平均化了。
我们分析，这是由于随着时间的推移，由内部热引起形坯表层温度上升，产生软化，另一方面，内部温度反而由于放热下降，形坯的温度在全体上趋于均衡，因此，延伸吹塑时的牵引阻力在形坯全体上均匀生成，使两表层2a、2a和芯层2b的密度差消失，其结果使延伸后的结晶化在全体上平均。
该结晶密度可以说是和冷形坯法中延伸吹塑成形的容器的结晶密度大致同等的结晶密度，但该时间的延伸吹塑中，由于是在渐冷条件下进行结晶，易生成壁变形和扭曲现象。因此，对于离型10秒以后的延伸吹塑来说，由于基于半硬化皮层1a的温度上升而在形坯成形时引起的流动定向消减、并且由于牵引阻力低下，致使延伸的结晶化程度也变小，容器2的表层2a、2a和芯层2b的结晶密度在整体上成为平均化，两层间生成结晶密度呈梯度分布的中间层2c的余地也不存在了。
在图2中，表层2a的结晶密度是1.4以上，作为聚对苯二甲酸乙酯的容器，可以说是超高密度，其自身具有某种意义上的耐热性。但是，对这样的表层2a进行强制性的延伸，会有很多成形扭曲残存下来。
对应该问题，低密度的芯层2b，是将延伸吹塑时处于非结晶状态、牵引阻力极小的形坯中央部，在伴随形成容器2表层2a的半硬化层1a的延伸而同时延伸形成的，由于该延伸的过程中温度下降，产生结晶，这样就等于容器2的中间层2c中几乎没有因延伸形成的成形扭曲的状态。
像这样具有在结晶密度不同的表层2a和芯层2b之间，介有存在着密度梯度的中间层的多层构造的壁部剖面的容器2中，由成形扭曲产生的对应于表层2a冲击力的脆弱度，通过没有或很少有成形扭曲的芯层2b以内部缓冲的形式加以强化，此外，由于中间层2c的介入，使两者的连接更加紧密，还可产生优良的落下强度。
此外，通过加热处理对表层2a的成形扭曲进行减缓的方法，可以实现耐热性的提高。这种减缓处理是在温度设定在116℃前后的吹塑模具内，像通常的做法一样，可以通过以下方法简单地进行：在延伸吹塑之后不进行开模，直接原样加上大约15秒的吹塑压力，将成形后的容器2压接在模腔面上后进行加热。
此外，在壁部剖面上，对于结晶密度从高密度到低密度急速变化的组织来说，在其结晶密度急变部位上易产生剥离，但是由于在从表层2a的高密度到芯层2b的低密度的过渡中，介入了具有梯度结晶密度的中间层2c，使生成的壁部剖面上，即使结晶密度存在多层状态，也很难产生剥离。通过以上做法，使用本发明的延伸吹塑容器与从前相比在强度有了进一步的提高，并且耐热性也有所提高。
上述实施方式虽然是针对广口容器而言的，当然也可以适用于细口的瓶状物，因此，本发明并不只限定于广口的容器。此外，成形材料也不只限定于聚对苯二甲酸乙酯，也可适用于作为包装用容器的成形材料而被采用的其他具有结晶性的热可塑性塑料。
发明的实施例
(1)形坯
成形材料：聚对苯二甲酸乙酯
尺寸：
口径                          φ59mm
体径(中央部)                  φ56mm
延伸部长度                    63mm
壁厚                          4.4mm
(2)成形条件(注射成形)
注塑模具温度(冷却器)          15℃
树脂温度                      254℃
注射时间                      12.0sec
冷却时间                      7.0sec
(3)成形条件(延伸吹塑)
离型后                        6.0sec
模具温度                      116℃
形坯表面温度                  96.2℃
吹塑压力                      24kgf/cm2
形坯中心温度                  125℃～140℃
吹塑时间                      15.0sec
延伸倍率(纵)                  2.53倍
        (横)                  1.95倍
(4)成形品(广口容器)
尺寸     口径(同形坯)
体径                          φ95mm
平均壁厚(除口部、底面部之外)        0.58mm
平均密度                            1.348mm
壁厚及结晶密度分布(参照图2)
测定法及使用的机器
密度·定向度测定                    喇曼分光法
JEOL；显微镜喇曼光谱·JRS-SYSTEM2000
温度测定  红外线温度记录仪
TVS-2000Mk2              日本阿尔贝尔尼克斯(アオビオニクス)株式会社制
中央温度的测定方法
用红外线温度记录仪测定壁部剖面
使用成形机
SB3-100LL-20             株式会社青木固研究所制
产业上的可利用性
像这样具有在结晶密度不同的表层和芯层之间，介有存在着密度梯度的中间层的多层构造壁部剖面的容器中，由成形扭曲产生的对应于表层冲击力的脆弱度，通过没有或很少有成形扭曲的芯层以内部缓冲的形式加以强化，此外，由于中间层的介入，使两者的连接更加紧密，还可产生优良的落下强度。
此外，通过加热处理对表层2a的成形扭曲进行减缓的方法，可以实现耐热性的提高。这种减缓处理是在温度设定在116℃前后的吹塑模具内，像通常的做法一样，可以通过以下方法简单地进行：在延伸吹塑之后不进行开模，直接原样加上大约15秒的吹塑压力，将成形后的容器2压接在模腔面上后进行加热。

Claims (4)

1.一种延伸吹塑容器，是将有底形坯在纵方向和横方向进行延伸吹塑而形成的薄壁的塑料容器，其特征在于：该容器的壁部剖面，从结晶密度方面来说，是由形成高密度的内外侧的表层、比该表层密度低的芯层、以及介于两层间具有梯度结晶密度的中间层所组成的多层构造所构成；上述的塑料容器由聚对苯二甲酸乙酯构成，上述内外表层的结晶密度为大于1.4前后；上述芯层的结晶密度为1.32～1.36，比表层低；介于两层之间的中间层结晶密度具有从大于1.4前后低到1.32～1.36的梯度。
2.如权利要求1所述的延伸吹塑容器，其特征在于：位于容器壁部剖面的上述芯层区域，根据形坯壁部剖面的壁厚的增减按比例变动，无论芯层区域的大小，上述中间层都是具有梯度结晶密度，并介于其间。
3.一种延伸吹塑容器的成形方法，其特征在于：在将有底形坯注射成形时，急冷至低于定向温度的温度，利用温度与时间的关系使该形坯壁部内外的表层形成为半硬化层，在将利用该半硬化层维持形态的形坯从模具中离型后，形坯壁部中央的温度处于非结晶温度区域或其附近，在形坯外侧的表面温度上升、半硬化层还充分存在牵引阻力时，进行延伸吹塑成形，这样就成形为由壁部剖面上在结晶密度方面形成高密度的内外表层、比该表层密度低的芯层、以及两层间介有的具有梯度结晶密度的中间层所组成的多层构造的容器；上述的塑料容器由聚对苯二甲酸乙酯构成，上述内外表层的结晶密度为大于1.4前后；上述芯层的结晶密度为1.32～1.36，比表层低；介于两层之间的中间层结晶密度具有从大于1.4前后低到1.32～1.36的梯度。
4.如权利要求3所述的延伸吹塑容器的成形方法，其特征在于：上述形坯由聚对苯二甲酸乙酯构成，该形坯外侧的表面温度为上升时为95℃～115℃，壁部中央的温度在125℃～140℃的范围内，在具有30℃左右的温度差时，将该形坯进行延伸吹塑成形。
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EP1321280A1 (en) 2003-06-25
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