CN101663141A - 一体两层预制坯、用于生产其的方法和设备、用于生产吹塑内装袋容器的方法、以及因此生产出的内装袋容器 - Google Patents

一体两层预制坯、用于生产其的方法和设备、用于生产吹塑内装袋容器的方法、以及因此生产出的内装袋容器 Download PDF

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Publication number
CN101663141A
CN101663141A CN200880012621A CN200880012621A CN101663141A CN 101663141 A CN101663141 A CN 101663141A CN 200880012621 A CN200880012621 A CN 200880012621A CN 200880012621 A CN200880012621 A CN 200880012621A CN 101663141 A CN101663141 A CN 101663141A
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internal layer
prefabricated blank
container
skin
layer
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CN101663141B (zh
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S·范霍夫
D·佩尔斯曼
R·韦尔波特恩
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Anheuser Busch InBev SA
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Anheuser Busch InBev SA
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Abstract

本发明是一种用于生产一体吹塑内装袋容器(2)的一体两层预制坯(1)。该预制坯具有内层(1)和外层(2)，其中，预制坯一旦吹塑之后就形成两层的容器，并且一旦在两层的界面处引入气体就将容器的如此获得的内层与如此获得的外层分离。内层的熔点高于或等于外层的熔点。

Description

一体两层预制坯、用于生产其的方法和设备、用于生产吹塑内装袋容器的方法、以及因此生产出的内装袋容器
技术领域
本发明总的涉及对于分配式内装袋容器的新研发，尤其涉及对于生产一体吹塑内装袋容器特别有利的一体两层预制坯。本发明还涉及用于生产所述预制坯和内装袋容器的方法。
背景技术
内装袋容器根据外部容器的几何形状也被称为内装袋瓶或内装袋盒，这里被认为包含在术语内装袋容器的含义内的所有物品是一类液体分配包装，该液体分配包装包括外部容器和可收缩的内袋，该外部容器包括通向大气的开口——口部，该内袋连接至所述容器且在所述口部通向大气。该系统必须包括至少一个通风孔，该通风孔将大气流体地连接至内袋和外部容器之间的区域，从而控制所述区域的压力以挤压内袋，因此分配其中包含的液体。
传统上，内装袋容器仍然通过单独地生产设有特定颈部封闭组件的内袋和结构容器(通常呈瓶的形式)来形成。袋可借助于颈部封闭组件插入已完全形成的瓶的开口中且固定至其，该颈部封闭组件包括通向袋内的一个开口和将袋和瓶之间的空间流体地连接至大气的通风孔；这种构造的例子尤其可参见USA3484011、USA3450254、USA4,330,066和USA4892230。这些类型的内装袋容器具有可重复使用的优点，但是它们非常昂贵且生产费力。
最近的研发聚焦于“一体吹塑内装袋容器”的生产，通过将聚合物多层预制坯吹塑成包括内层和外层的容器，以使因此生产出的容器的内层和外层之间的粘合足够弱从而一旦在界面处引入气体就容易层离，从而避免将袋组装入容器的费力步骤。“内层”和“外层”可各包括单层或多层，但是无论如何至少一旦层离就可易于识别。所述技术涉及许多挑战，提出了许多替代解决方案。
多层预制坯可挤压或注射成形(参见USA6238201、JPA10128833、JPA11010719、JPA9208688、USA6649121)。挤压成形方法在生产率方面是有利的，而当通常在用于分配饮料的容器中要求壁厚精度时，注射成形方法是较佳的。
用于生产一体吹塑内装袋容器的预制坯与用于生产吹塑共层合容器的预制坯明显不同，其中，容器的各层在层厚方向将不层离。内装袋容器由包含柔性可收缩袋的外部结构封装件来构成。因此，容器的外层基本上比内袋厚。这个相同的关系当然也可在预制坯中找到，其特点是，内层基本上比外层薄。而且，在一些情况下，预制坯已经包括通风孔，而在用于生产共层合容器的预制坯中绝不存在通风孔(参见EPA1356915)。
在一体吹塑内装袋容器中形成将袋和瓶之间空间或界面流体地连接至大气的通风孔，仍然是一个关键的步骤，例如在USA5301838、USA5407629、JPA5213373、JPA8001761、EPA1356915、USA6649121、JPA10180853中提出了若干解决方案。
一体吹塑内装袋容器的另一问题是内层和外层材料的选择，必须根据一方面的加工相容性和另一方面的粘合不相容性的严格标准来选择材料。有时难以合起来满足这些标准。
预制坯通常包括两个分离的预制坯的组件，这两个分离的预制坯彼此单独地生产，此后组装在一起以使内部预制坯装配入外部预制坯，如JPA10180853所示。该解决方案允许颈部和通风孔设计中的、以及内层和外层材料选择中的更大自由度：只有内层和外层材料之间的加工相容性关系到该吹塑操作。然而，由于它需要两条单独的生产线和一条组装线，所以很昂贵。
通过层层相叠地注射成形来获得一体预制坯以替换上述的预制坯组件，当然在生产成本方面提供了多个潜在的优点。然而，产生了其它问题，且需要处理这些问题。具体地说，由于内层和外层材料在注射成形和吹塑操作中都必须加工相容，所以内层和外层材料的选择更加复杂。USA5301838公开了一种复杂的、注射成形的、五层一体预制坯，其包括中间交替插入两个薄层材料的三个PET层，该薄层材料选自EVOH、PP、PE、PA6。然而，该解决方案是相当复杂的，需要薄层材料“对于相邻的[PET]层即使有任何主吸引力(即，趋于化学键合或粘合至相邻的[PET]层)的话也是很小的主吸引力”，这就不当地限制了所用材料的选择。
EPA1356915和USA6649121提出了，预制坯的内层和外层材料应如下进行选择：外层的熔点应高于内层的熔点，Tm，外＞Tm，内，以免当将内层注射成形到已首先在型腔内注射成形的外层之上时，在两层之间形成强结合。作者给出的外层材料的例子包括PET和EVOH，而聚乙烯则作为内层的例子给出。
根据前述可知，用于生产由对注射成形和吹塑操作都加工相容材料制成的一体预制坯且生产出具有良好层离性能的内装袋容器的解决方案，在现有技术中仍有空间。
发明内容
本发明由所附的诸独立权利要求来限定。诸较佳实施例由诸从属权利要求来限定。具体地说，本发明涉及一种一体两层预制坯和通过对该预制坯吹塑生产出的内装袋容器，该预制坯包括内层和外层，其中，预制坯一旦吹塑之后就形成两层的容器，并且一旦在两层的界面处引入气体就将所述容器的如此获得的内层与如此获得的外层分离。内层的熔点高于或等于外层的熔点。
较佳的是，预制坯包括至少一个平行于内层和外层之间的界面延伸的界面通风孔，该通风孔在与预制坯口部相邻且定向成与该口部同轴的位置通向大气。
本发明还涉及一种用于生产上述预制坯的方法，该方法包括下列依次的步骤：
·将内层注射成形到芯部上；
·将外层注射成形到内层上；
·将因此形成的预制坯从芯部脱出；
其中，内层的熔点高于或等于外层的熔点。
前述方法有利地可通过使用一种芯壳式工具来生产包括至少一个界面通风孔的预制坯，其特点在于，该工具包括型芯部，该型芯部在其基部处设有至少一个销，所述销适于在所述预制坯的第一层和第二层之间的界面处形成通风孔。
本发明还涉及一种用于生产上述预制坯的设备，该设备包括：
·支承装置，该支承装置设有至少两个相似的芯部(阳模)；
·至少第一和第二壳模(阴模)，各连接至挤压机，从而第一壳模的尺寸可与芯部结合地生产内层，第二壳模的尺寸可生产内层之上的外层；
·可选的至少一个脱模工位；
·用于使支承装置运动的装置，从而每个芯部可依次定位成与第一壳模、第二壳模和可选的脱模工位相对。
附图说明
图1是预制坯和对该预制坯吹塑之后获得的内装袋容器的示意性剖视图。
图2是根据本发明一较佳实施例的预制坯或内装袋容器的口部和颈部的剖切立体图。
具体实施方式
现在参见附图1A和1B，示出了一体吹塑内装袋容器2和用于制造其的预制坯1和1′。预制坯1包括内层11和外层12，内层11和外层12至少在颈部6的高度处通过界面(示于右手侧)结合在一起。内层11和外层12之间的区域可包括两层基本彼此接触的界面14，或包括与通向大气的至少一个通风孔3流体地连通的间隙14′。
已经公开了许多种通风孔几何形状，而选择哪种几何形状并不是关键的。然而，较佳的是，通风孔与所述预制坯的口部5相邻且定向成与该口部5同轴，如图1所示。更佳的是，通风孔具有楔形的形状，楔形具有位于其开口4的高度上的宽侧，且随着其穿透深入容器而变薄，直到两层相接而至少在颈部高度处形成界面14为止，如图2所示。该几何形状允许一旦使用内装袋容器就使内袋更加高效且可重复地层离。容器可包括围绕内装袋口部的唇边均匀分布的一个或多个通风孔。多个通风孔是有利的，因为它们允许一旦通过所述通风孔吹入加压气体就使内装袋容器2的内层21和外层22更加均匀地分离。较佳的是，预制坯包括在容器口部唇边处直径方向相反位置的两个通风孔。更佳的是，在口部唇边上以规律间隔开有三个通风孔，最佳的是，开有至少四个通风孔。
本发明的预制坯包括通过层层相叠地注射成形获得的一体预制坯。该解决方案提供了相对于预制坯组件的多个优点，例如，它无需组装步骤，且只要一个生产工位就足以用于一体预制坯制造，而预制坯组件需要至少两个生产工位。
用于本发明的预制坯和内装袋容器的诸层的较佳材料是：聚酯，诸如PET、PEN、PTT、PTN；聚酰胺，诸如PA6、PA66、PA11、PA12；聚烯烃，诸如PE、PP；EVOH；生物可降解的聚合物，诸如聚乙二醇(PGAc)、聚乳酸(PLA)；及其共聚物和混合物。根据本发明，对于内层和外层材料的要求是，外层的熔点低于或等于内层的熔点，Tm，外＜Tm，内。这个条件与EPA1356915和USA6649121中所说明的条件是完全相反的。这种与所述现有技术的说明的差异使本发明人发现，一体预制坯可以有利地用下列步骤依次生产：
·首先将内层注射成形到芯部上；
·接着将外层注射成形到内层上；以及
·将因此形成的预制坯从芯部脱出；
由于下面的原因，这个方法比EPA1356915和USA6649121中提出的方法更加有利。如背景技术所述，内装袋容器必须包括至少一个界面通风孔，该界面通风孔将内层和外层之间的界面流体地连接至大气。在饮料分配容器的领域，传统上且由于实际原因，过去使用的组装的(即，非一体吹塑的)内装袋容器设有通风孔，这些通风孔与内装袋容器的口部相邻且定向成与该口部同轴。为了用一体吹塑内装袋容器逐渐替换传统的组装内装袋容器，且为了使消费者能将安装内装袋容器的器具保持相同，较佳地保持相同的通风孔位置。只要使用合适的工具，本方法就能提供一体预制坯，其通风孔将内层和外层之间的界面流体地连接至大气。
工具是芯一壳型的且包括型芯部，该型芯部在其基部设有至少一个销，该销适于在预制坯的第一层和第二层之间的界面处形成通风孔。该芯部可包括单个销，但是较佳地包括一个以上的销，从而围绕容器口部的唇边形成多个通风孔。销较佳地具有楔形的形状，因为一方面，楔形的通风孔具有上述优点，另一方面，楔形使得因此生产的一体预制坯能从型芯部更容易地脱出。销的尺寸取决于内装袋的尺寸，尤其取决于其口部和唇边的尺寸。对于容量约为56升的通常家用饮料分配器，销的高度约为5-75mm，较佳地为5-50mm，更佳地为10-20mm，其形成通风孔的基部较佳地是弓形截面形状，该弓形截面的长度为3-15mm，较佳地为5-10mm，该弓形截面的宽度为0.5-5mm，较佳地为0.5-2mm。
较佳的是，本发明的一体预制坯包括用于将内层固定至外层的机械互锁装置8。该机械互锁装置8允许预制坯更加容易和安全地搬运，且有利于将预制坯从注射成形芯部脱出。
本发明的预制坯可用一设备半连续地生产，该设备包括：
·支承装置，该支承装置设有至少两个相似的芯部(阳模)，较佳地是上述类型的；
·至少第一和第二壳模(阴模)，各连接至挤压机，从而第一壳模的尺寸可与芯部结合地生产内层，第二壳模的尺寸可生产内层之上的外层；
·可选的至少一个脱模工位；
·用于使支承装置运动的装置，从而每个芯部可依次定位成与第一壳模、第二壳模和可选的脱模工位相对。
本发明的设备可包括单独的脱模工位，例如允许在脱模之前进一步冷却部件，或者一旦在第二层注射成形后打开模具时脱出预制坯，也可没有单独的脱模工位。用于将支承装置从一个壳模运动到另一壳模和可选的脱模工位的运动装置可以是使用“滑动件”的直线式、或使用“回转件”的旋转式的。
在外层的基本上整个内表面上，根据本发明的预制坯的两层11和12通过界面14连接在一起。尽管预制坯的内层和外层可在所述界面14处粘合，但是通过对预制坯1进行吹塑生产出的内装袋容器2的内层21和外层22一旦在界面处注射加压气体就会层离。通常认为，内层和外层中的至少一层包括半结晶聚合物时，可获得较好的结果。
令人惊讶地观察到，对于内层和外层由相同材料构成的一体预制坯，也可在内装袋容器的内层和外层之间获得优良的层离结果。这个发现与现有技术中对于内层和外层材料的选择的说明截然不同，如JPA2005047172所述，现有技术的内层和外层必须由“相互不粘合的合成树脂”来构成。现在看来，用相同材料制成的内层和外层，也可生产优良的一体吹塑内装袋容器。因此，根据本发明，内层的熔点可以等于外层的熔点。
在下列情况下，相同的聚合物被认为与内层和外层之间界面的两侧相接触：
·内层和外层由相同材料构成(例如，PET内PET外，无论各PET的特定等级如何)；或
·内层和外层由具有至少一种相同聚合物的混合物或共聚物来构成，假设所述相同聚合物位于界面处，而不同的聚合物基本上不在所述界面处(例如，(0.85PET+0.15PA6)内(0.8PET+0.2PE)外)。
在层中存在少量添加剂不被认为会使材料不同，只要添加剂基本上不改变界面即可。
本发明的内装袋容器2可通过以下方式获得：提供如上所述的预制坯；使所述预制坯达到吹塑温度；用吹塑工具中的固定装置将因此被加热的预制坯固定在颈部高度处；以及对因此被加热的预制坯进行吹塑以形成内装袋容器。如此获得的内装袋容器的内层21和外层22在外层的基本上整个内表面上通过界面24彼此连接。所述界面24通过通风孔3与大气流体地连通，因为通风孔所位于的预制坯颈部由固定装置保持固定且在吹塑过程中不被拉伸，所以通风孔3在整个吹塑过程中保持其原始几何形状。
必要的是，一旦通过通风孔以一致和可重复的方式吹入加压气体，内层21和外层22之间的界面24就分离。所述操作的成功取决于多个参数，尤其是界面粘合强度，通风孔的数量、几何形状和分布，以及注射气体的压力。界面强度当然是关键问题，可以通过内层和外层材料的选择和通过吹塑过程中的工艺参数来调节；所用的压力-时间-温度窗口当然是首要的，主要取决于内层和外层所选用材料。
在将外层注射成形到内层上之前，可将脱模剂涂敷到内层的外表面上。因此，脱模剂定位在界面处，且有利于内层与外层层离。可使用市场上可购得的任何脱模剂，其最好适于预制坯所用材料且耐抗吹塑温度，例如是基于硅或PTFE的脱模剂(例如，Freekote)。
脱模剂的涂敷对于内层设计是尤其有利的。实际上，界面粘合强度的降低有利于内层与外层层离，因此减少了层离时施加在内层上的应力，因此内层可设计成非常薄和柔性，而在层离时不会有损坏内层的风险。显然，内袋的柔性对于液体分配来说是关键参数，而且当内层可设计成非常薄时，也可在节省材料方面来实现节省成本。
实例：
通过如下方式生产出根据本发明的预制坯：将熔融材料注射入冷却的第一型腔来形成预制坯的内层。将包含内层的芯部移至与第一型腔以相同温度冷却的第二型腔，将熔融材料注射到型腔中已存在的内层之上，然后脱出预制坯。该预制坯包括通风孔3和互锁装置8，如图2所示。
在包含红外灯装置的加热室中对如上所述生产出的预制坯进行加热，然后将预制坯固定入吹塑模具中，该吹塑模具的壁保持在所想要的温度。将加压空气吹入预制坯。然后对因此生产出的内装袋容器充注液体，将该内装袋容器连接至包括压缩空气源的用于分配饮料的器具，从而确定层离压力。
层离压力如下进行确定。将内装袋容器的界面通风孔连接至压缩空气源。通过诸通风孔以恒定的压力注射空气，且观察内层和外层之间的界面；逐步增大压力，直到达到层离压力为止。层离压力定义为内层与外层在其整个界面上分离且内层收缩时的压力。对于因此分离的两层的表面检查结合痕迹。
上述内装袋容器的层离压力约为0.5±0.1巴过压，在内层和外层之间几乎没有出现粘合破裂的痕迹。该实例示出了用根据本发明的一体预制坯可生产出优良质量的内装袋容器。

Claims (18)

1.一种用于生产一体吹塑内装袋容器的一体两层预制坯，所述预制坯包括：
内层和外层，其中，所述预制坯一旦吹塑之后就形成两层的容器，并且一旦在所述两层的界面处引入气体就将所述容器的如此获得的内层与如此获得的外层分离；并且
所述内层的熔点高于或等于所述外层的熔点。
2.如权利要求1所述的预制坯，其特征在于，所述内层和所述外层中的至少一层包括半结晶材料。
3.如权利要求1所述的预制坯，其特征在于，所述内层和所述外层由不同材料构成。
4.如权利要求1所述的预制坯，其特征在于，所述内层和所述外层由相同材料构成。
5.如权利要求1所述的预制坯，其特征在于，所述内层和所述外层由选自以下的材料构成：PET、PEN、PTT、PA、PP、PE、HDPE、EVOH、PGAc、PLA、及其共聚物或混合物。
6.如权利要求1所述的预制坯，其特征在于，至少一个界面处是楔形的通风孔，所述楔形在其开口的高度处具有宽侧，且随着其穿透深入容器而变薄，直到所述内层和所述外层相接形成界面为止。
7.如权利要求6所述的预制坯，其特征在于，一个以上的通风孔围绕所述预制坯的口部的唇边分布。
8.如权利要求1所述的预制坯，其特征在于，所述预制坯的所述内层和所述外层在所述外层的基本上整个内表面上通过界面连接。
9.如权利要求1所述的预制坯，其特征在于，所述内层和所述外层通过位于所述预制坯的颈部的机械互锁装置彼此固定。
10.一种用于生产预制坯的方法，所述预制坯具有
内层和外层，其中，所述预制坯一旦吹塑之后就形成两层的容器，并且一旦在所述两层的界面处引入气体就将所述容器的如此获得的内层与如此获得的外层分离；并且
所述内层的熔点高于或等于所述外层的熔点，
所述方法包括下列依次的步骤：
将所述内层注射成形到芯部上；
将所述外层注射成形到所述内层上；以及
将因此形成的预制坯从所述芯部脱出。
11.如权利要求10所述的方法，其特征在于，所述芯部适于形成将所述内层和所述外层之间的所述界面流体地连接至大气的通风孔。
12.一种适于生产预制坯的芯壳式工具，所述预制坯具有
内层和外层，其中，所述预制坯一旦吹塑之后就形成两层的容器，并且一旦在所述两层的界面处引入气体就将所述容器的如此获得的内层与如此获得的外层分离；并且
所述内层的熔点高于或等于所述外层的熔点，
所述工具包括型芯部，所述型芯部在其基部处设有至少一个销，所述销适于在所述预制坯的第一层和第二层之间的界面处形成通风孔。
13.如权利要求12所述的工具，其特征在于，所述工具包括一个以上围绕所述芯部的基部周边设置的销。
14.如权利要求12所述的工具，其特征在于，所述销具有楔形的形状。
15.一种用于生产预制坯的设备，所述预制坯具有
内层和外层，其中，所述预制坯一旦吹塑之后就形成两层的容器，并且一旦在所述两层的界面处引入气体就将所述容器的如此获得的内层与如此获得的外层分离；并且
所述内层的熔点高于或等于所述外层的熔点，
所述设备包括：
支承装置，所述支承装置设有至少两个相似的阳芯部；
至少第一和第二阴壳模，所述第一和第二阴壳模各连接至挤压机，从而所述第一壳模的尺寸可生产所述内层，所述第二壳模的尺寸可生产所述内层之上的所述外层；
至少一个可选的脱模工位；以及
用于使所述支承装置运动的装置，从而每个芯部可依次定位成与所述第一壳模、与所述第二壳模以及可选地与所述脱模工位相对。
16.如权利要求15所述的设备，其特征在于，所述用于使所述支承装置运动的装置对于所述支承装置施加直线运动。
17.如权利要求15所述的设备，其特征在于，所述用于使所述支承装置运动的装置对于所述支承装置施加旋转运动。
18.通过对预制坯吹塑生产出的一体吹塑内装袋容器，所述容器包括：
内层和外层，其中，所述预制坯一旦吹塑之后就形成两层的容器，并且一旦在所述两层的界面处引入气体就将所述容器的如此获得的内层与如此获得的外层分离；并且
所述内层的熔点高于或等于所述外层的熔点。
CN2008800126214A 2007-04-19 2008-04-18 一体两层预制坯、用于生产其的方法和设备、用于生产吹塑内装袋容器的方法、以及因此生产出的内装袋容器 Expired - Fee Related CN101663141B (zh)

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