CN101663143A - 具有由相同材料制成的内层和外层的一体吹塑内装袋容器、以及用于制造该内装袋容器的预制坯 - Google Patents

具有由相同材料制成的内层和外层的一体吹塑内装袋容器、以及用于制造该内装袋容器的预制坯 Download PDF

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Publication number
CN101663143A
CN101663143A CN200880012709A CN200880012709A CN101663143A CN 101663143 A CN101663143 A CN 101663143A CN 200880012709 A CN200880012709 A CN 200880012709A CN 200880012709 A CN200880012709 A CN 200880012709A CN 101663143 A CN101663143 A CN 101663143A
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Prior art keywords
prefabricated blank
container
internal layer
bag
skin
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CN200880012709A
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CN101663143B (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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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Abstract

本发明涉及一种一体吹塑内装袋容器(2)，其中，相同的聚合物在内层(11)和外层(12)之间的界面的任一侧上相接触。本发明还涉及一种用于吹塑形成内装袋容器的预制坯(1，1′)，该预制坯具有内层和外层，其中，预制坯一旦吹塑之后就形成两层的容器，并且一旦在所述两层的界面处引入气体就将所述容器的因此获得的内层与因此获得的外层分离。内层和外层是相同材料。

Description

具有由相同材料制成的内层和外层的一体吹塑内装袋容器、以及用于制造该内装袋容器的预制坯
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，尤其涉及单一材料制成的一体吹塑内装袋容器。本发明还涉及用于生产出所述内装袋容器的方法，尤其涉及用于生产出该内装袋容器的预制坯和用于生产出所述预制坯的方法。
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。
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。
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，在共层合容器中，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)。
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。如同下面所说明的那样，有时难以合起来满足这些标准。
针对加工相容性，EPA1356915和USA6649121提出了外层的熔点应高于内层的熔点，从而允许通过注射成形外层、随后在外层之上再注射成形内层来生产出一体预制坯。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。尽管这种材料选择对于预制坯的注射成形生产来说可能是有利的，但是对于吹塑步骤来说远非最佳的，因为聚乙烯和PET具有不同的吹塑温度。再次，在USA-6238201中，描述了一种方法，该方法包括共挤塑形成两层型坯之后、再将该型坯吹塑形成内装袋容器，其中，外层较佳地包括烯烃，而内层较佳地包括非晶聚酰胺。
考虑到用于为了确保使用时内层与外层适当层离所需的弱界面粘合的材料选择，在JP2005047172中提到了“相互不粘合的合成树脂”。回顾背景技术，在USA5921416中提到了在内层和外层之间使用插入的脱模层，从而形成三层或五层结构。USA5301838描述了这种结构的一个例子，其公开了一种复杂的、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。这里再次提到，除了与生产这种预制坯有关的复杂性之外，吹塑温度的基本差异也是这些不同材料的特点。最后但并非最不重要的是，使用不同材料会使这种内装袋容器的重复利用成问题，因为在使用之后无法从容器中容易地取出袋子。
从前述可知，在一体吹塑内装袋容器的领域，对于内层和外层的材料选择和内装袋容器使用后的重复利用仍有需求。
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吹塑内装袋容器，其中，相同的聚合物在内层和外层之间的界面的任一侧上相接触。
本发明还涉及一种用于吹塑形成内装袋容器的预制坯，该预制坯具有内层和外层，其中，预制坯一旦吹塑之后就形成两层的容器，并且一旦在所述两层的界面处引入气体就将所述容器的因此获得的内层与因此获得的外层分离。内层和外层是相同材料。
根据本发明的预制坯的一较佳实施例是具有用于内层的第一预制坯和用于外层的第二预制坯的组件，从而第一预制坯装配入第二预制坯。
在另一实施例中，预制坯是通过层层相叠地注射成形获得的一体预制坯。
附图说明
图1A是根据本发明的预制坯的第一实施例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1B是根据本发明的预制坯的第二实施例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。
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。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。
预制坯可包括两个单独的预制坯的组件11和12，这两个单独的预制坯彼此独立地生产，此后组装在一起以使内部预制坯11装配入外部预制坯12。这个解决方案允许颈部和通风孔设计中的较大自由度。或者，预制坯可以是通过层层相叠地注射成形获得的一体预制坯。后一实施例相对于组装式预制坯是有利的，因为它不包括组装步骤，只需一个生产工位用于预制坯制造。另一方面，通风孔的设计尤其受该方法限制。
尽管直觉暗示且所有现有技术指示使用“(不同的且)相互不粘合的合成树脂”以用于制造内装袋容器的预制坯的内层和外层(参见JPA2005047172)，然而令人惊奇地发现，对于内层和外层由相同材料构成的预制坯也可在内层和外层之间获得优良的层离结果。对于预制坯组件和一体预制坯也可获得类似的结果。在一体上塑预制坯的情况下，通常认为，对于半晶聚合物可获得较好的结果。
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。
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)。
存在少量添加剂不被认为脱离本发明的范围，只要添加剂基本上不改变界面即可。
在外层的基本上整个内表面上，预制坯的两层11和12可通过界面14连接在一起(参见图1A的(1))。相反，它们也可在预制坯本体的大部分区域上隔开包含空气的间隙14′，该间隙14′与至少一个界面通风孔3流体地连通(参见图1B中的(1′))。后一实施例在使用预制坯组件时较易实现，该预制坯组件设计成内预制坯在颈部6处牢固地固定至外预制坯且因此可在内层11和外层12之间形成基本间隙14′。
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；在颈部高度处用吹塑工具中的固定装置固定因此已加热的预制坯；以及对因此已加热的预制坯进行吹塑以形成内装袋容器。因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，尤其是界而粘合强度，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。
即使在上述类型的预制坯上实施吹塑工艺，也可获得优良的结果，在该上述类型的预制坯中，包含空气的间隙使内层和外层在预制坯本体的大部分区域上隔开，且所述间隙与至少一个界面通风孔流体地连通，并且，
·在第一阶段，将气体吹入由内层限定的空间中以拉伸预制坯，同时通过用位于固定装置中的阀封闭所述至少一个预制坯界面通风孔来防止隔开预制坯内层和外层的间隙中的空气排出；以及
·在第二阶段，当所述间隙中累积的空气压力达到预设值时，打开阀从而允许封闭在间隙中的空气排出。
通过该方法，当两层的相应温度最高时，用隔开两层的间隙内封闭的气垫来防止内层与外层相接触。随着拉伸继续，间隙变得越来越薄，且间隙内的空气压力增大。当压力达到预设值时，使封闭通风孔的阀打开，排出空气，允许内层与外层相接触，且在当两层相应温度下降到两层之间无法建立任何基本程度的粘合时的阶段，与外层形成界面。
脱模剂可在界面处涂敷在内预制坯和外预制坯的任一表面或两个表面上，这些表面将形成内装袋容器的界面。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)。脱模剂可就在将预制坯装入吹塑单元之前进行涂敷，或者预制坯可经受预处理。
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。
此外，脱模剂的涂敷能减小将内层与外层隔开的间隙的宽度。通过减小所述间隙的宽度，预制坯的内层可设计成具有相同的厚度但具有较大的径向截面，从而导致吹塑过程中内层拉伸比的减小，进而减小内层中微裂纹的潜在形成。
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11。将熔融材料注射入冷却的第二型腔中，以形成预制坯的外层12。将两个预制坯构件组装在一起，以形成根据本发明的预制坯。
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。将所述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 (14)

1.一种一体吹塑内装袋容器，包括在内层和外层之间的界面的任一侧上相接触的相同聚合物。
2.如权利要求1所述的内装袋容器，其特征在于，所述内层和所述外层包括半晶材料。
3.如权利要求2所述的内装袋容器，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。
4.如权利要求1所述的内装袋容器，其特征在于，所述内装袋容器还包括至少一个楔形的通风孔，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。
5.如权利要求1所述的内装袋容器，其特征在于，一个以上通风孔围绕所述内装袋容器的口部的唇边分布。
6.一种用于吹塑形成内装袋容器的预制坯，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，并且一旦在所述两层之间的至少一个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，其中，所述内层和外层是相同材料。
7.如权利要求6所述的预制坯，其特征在于，所述内层和所述外层由半晶材料构成。
8.如权利要求7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。
9.如权利要求6所述的预制坯，其特征在于，所述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。
10.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。
11.如权利要求6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。
12.如权利要求6所述的预制坯，其特征在于，所述预制坯的所述内层和外层在所述预制坯的本体的大部分区域上由包含空气的间隙来隔开，所述间隙与至少一个界面通风孔流体地连通。
13.如权利要求6所述的预制坯，其特征在于，所述预制坯具有由两个单独的内预制坯和外预制坯彼此装配在一起而形成的组件。
14.如权利要求6所述的预制坯，其特征在于，所述预制坯具有通过层层相叠地注射成形获得的一体预制坯。
CN200880012709.6A 2007-04-19 2008-04-18 具有由相同材料制成的内层和外层的一体吹塑内装袋容器、以及用于制造该内装袋容器的预制坯 Active CN101663143B (zh)

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