CN101663144B - 包括含能量吸收添加剂的内层和外层的一体吹塑内装袋容器、用于制造该内装袋容器的预制坯、以及用于生产出该内装袋容器的方法 - Google Patents

包括含能量吸收添加剂的内层和外层的一体吹塑内装袋容器、用于制造该内装袋容器的预制坯、以及用于生产出该内装袋容器的方法 Download PDF

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Publication number
CN101663144B
CN101663144B CN200880012731.0A CN200880012731A CN101663144B CN 101663144 B CN101663144 B CN 101663144B CN 200880012731 A CN200880012731 A CN 200880012731A CN 101663144 B CN101663144 B CN 101663144B
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container
internal layer
prefabricated blank
skin
bag
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CN101663144A (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

本发明涉及一种一体吹塑内装袋容器(2)和用于吹塑形成该内装袋容器的预制坯(1，1′)。使用内层(11)和外层(12)，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之间的界面(14)处引入气体就将所述容器的获得的内层与因此获得的外层分离。所述内层和外层中的至少一层包括至少一种添加剂，从而能使内层和外层基本上同时达到其相应吹塑温度。

Description

包括含能量吸收添加剂的内层和外层的一体吹塑内装袋容器、用于制造该内装袋容器的预制坯、以及用于生产出该内装袋容器的方法
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，尤其涉及不同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。
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。在吹塑形成共层合塑料容器的领域中不存在这个问题，其中，减小诸层之间的粘合以避免层离，因为对于通常具有相似热性质的相似材料来说，会获得最好的粘合。因此，寻找在加工和粘合方面都相容的材料以用于制造共层合容器比起寻找在加工方面相容而在粘合方面不相容的的材料以用于制造内装袋容器通常较不成问题。
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，从而允许通过首先注射成形外层、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具有完全不同的吹塑温度。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、再将所述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。
替换地且令人惊讶地，已发现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。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。
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。
尽管在相同材料用于内层和外层的情况下，两层之间在吹塑温度中没有差异，但由于内层和外层之间厚度上的巨大差异，两层的加热速率可能基本上不同。而且，内层被厚的外层掩蔽起来而不被红外炉红外照射，该红外炉通常用来使预制坯达到吹塑温度。因此，即使对于在吹塑温度中有很小差异或没有差异的材料来说，同时将两层加热至其加工温度也可能是一个问题。
为了克服形成吹塑多层容器的内层和外层的材料的不同吹塑温度或加热速率的问题，可在不同的炉子中单独加热不同的预制坯部件，从而将它们加热到其对应的吹塑温度(例如参见JPA57174221)。然而，这个解决方案在设备和空间方面都很昂贵，且不能应用到内层和外层无法分离的一体预制坯。
例如在USA5925710、USA6503586、USA6034167、USA4250078、USA6197851、USA4476272、USA5529744等中提出了在用于吹塑形成单层容器的预制坯中使用能量吸收添加剂，以缩短加热阶段进而节省能源。还已提出了在吹塑共层合容器(即，不要层离)的内层中使用能量吸收添加剂，以补偿吹塑操作过程中与外层相比内层所经受的较大应变。在共层合容器中，非常重要的是，内层能充分拉伸以在基本上整个界面上接触和粘合至外层。包含能量吸收添加剂的内层因此被加热至比外层更高的温度，且可进一步拉伸以粘合至外层。
以上考虑并不应用在内装袋容器领域，因为内层和外层之间的良好粘合正是该领域所要避免的。此外，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，外层基本上比内层厚。这对于红外灯加热内层的加热效率有不利作用，因为内层通过外层的后壁与红外灯隔开。
从前述可知，在本领域仍然存在需求，以解决补偿用于生产出一体吹塑内装袋容器的预制坯的由“相互不粘合合成树脂”(参见JP2005047172)制成的内层和外层之间的吹塑温度和加热速率中的差异。
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，本发明涉及一种用于吹塑形成内装袋容器的预制坯。使用内层和外层，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之间的界面处引入气体就将所述容器的获得的内层与因此获得的外层分离。所述内层和外层中的至少一层包括至少一种添加剂，从而能在将内层和外层一起在单个炉子中加热时，使内层和外层基本上同时达到其相应吹塑温度。
本发明还涉及一种用于从上述预制坯生产出内装袋容器的方法、以及因此获得的内装袋容器。最后，本发明涉及使用能量吸收添加剂或着色剂以将预制坯的内层和外层基本上同时加热至所述内层和外层的相应吹塑温度，从而吹塑形成内装袋容器。
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。
用于生产出分配啤酒的通常8升的内装袋容器的预制坯具有外层12，外层12约210mm厚、较佳地约36mm、最佳地约45mm厚，而内层大致约0.33mm厚、较佳地0.315mm厚、最佳地0.51mm厚。
用于本发明的预制坯和内装袋容器的内层和外层的较佳材料是选自以下的成对不同材料：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。聚烯烃和聚酰胺应加热，而诸如PET或PEN之类的材料最佳地应在吹塑之前加热。为了能使用单个炉子将预制坯的内层和外层的树脂基本上同时加热至相应的加工温度，将能量吸收添加剂添加至具有最高加工温度的树脂。然而，也可使两层都包括不同性质和/或不同量的能量吸收添加剂，只要到达内层和外层材料的相应加工温度的所需时间基本相同即可。
添加剂在本发明中是有用的。可用在本发明中的添加剂可以是选择性地在500-2000nm的波长区域吸收辐射的任何化合物，其较佳地足够精细而无法用肉眼看到。它们包括能量吸收添加剂和着色剂。能量吸收添加剂的例子包括但不限于碳黑、石墨、金刚石粉、重氮盐、锍盐(例如溴化三苯基锍)、氧化锍盐、碘鎓盐等。
层中存在的添加剂量取决于添加剂自身，且取决于用于内层和外层的树脂。大的量会影响层的拉伸性。
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。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，该间隙与至少一个界面通风孔3流体地连通。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可通过如下方式来获得：提供如上所述的预制坯，该预制坯的至少一层包括能量吸收添加剂；使所述预制坯的各层达到其相应吹塑温度；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；以及吹塑因此已加热的预制坯以形成内装袋容器，其中，包含在所述预制坯的内层和外层中的至少一层中的能量吸收添加剂的类型和量可使所述两层基本上同时达到其相应吹塑温度。
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，且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，且大大取决于内层和外层所选用的材料。
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层和外层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。在将外层注射成形到内层之上的情况下，脱模剂可在注射成形外层之前涂敷在内层的外表面上。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。
实例
下面的例子示出了本发明的益处。包括由不同材料制成的内层和外层的预制坯在包括六个红外灯的炉子中加热。对于所有的试验，使加热条件保持恒定。在内层和外层处于炉子中之后，测量内层的温度T内和外层的温度T外，然后在温度设为83℃的模具中以10巴的吹塑压力对预制坯进行吹塑。下面的表1列出了内层和外层的测得温度、关于可吹塑性的评论，且指出了层离压力的值。
层离压力如下进行确定。如上所述获得的空内装袋容器的界面通风孔连接至加压空气源。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；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迹象。较佳的结果如下，0.3-0.9巴过压数量级的低层离压力没有结合迹象。

Claims (17)

1.一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，所述预制坯一旦吹塑之后就形成两层的容器，所述容器适于分配包含在由所述内层限定的内袋(21)中的液体，这是通过将所述内层从由所述外层限定的外容器(22)释放，并且通过一旦在所述内袋(21)和所述外容器(22)之间的界面处引入气体就对所述内层进行挤压来实现的；以及
所述内层和外层中的至少一层包括至少一种添加剂，从而能在一旦将内层和外层一起在单个炉子中加热之后，使内层和外层基本上同时达到其相应吹塑温度。
2.如权利要求1所述的预制坯，其特征在于，所述至少一种添加剂选自以下：能量吸收添加剂和着色剂。
3.如权利要求2所述的预制坯，其特征在于，所述能量吸收添加剂选自以下：碳黑、石墨、金刚石粉、重氮盐、锍盐和碘鎓盐。
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各选自以下的不同材料构成：PET、PEN、PTT、PA、PP、PE、EVOH、PLA、及其共聚物或混合物。
5.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。
6.如权利要求1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。
7.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。
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。
9.如权利要求1所述的预制坯，其特征在于，所述预制坯包括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。
10.如权利要求1所述的预制坯，其特征在于，所述预制坯包括通过层层相叠地注射成形获得的一体预制坯。
11.一种用于生产出内装袋容器的方法，所述内装袋容器适于分配包含在内袋(21)中的液体，这是通过将所述内袋从外容器(22)释放，并且通过一旦在所述内袋(21)和所述外容器(22)之间的界面处引入气体就对所述内袋进行挤压来实现的，所述方法包括下列步骤：
提供聚合物预制坯，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之间的界面处引入气体就将所述容器的获得的内层与获得的外层分离；并且
所述内层和外层中的至少一层包括至少一种添加剂，从而能在一旦将内层和外层一起在单个炉子中加热之后，使内层和外层基本上同时达到其相应吹塑温度；
在单个炉子中将所述预制坯加热至吹塑温度；以及
对如此已加热的预制坯进行吹塑以形成内装袋容器，所述内装袋容器包括由吹塑的内层限定的内袋以及由吹塑的外层限定的外容器；
其中，所述预制坯的所述内层和外层中的至少一层的添加剂的类型和量可使所述两层基本上同时达到其相应吹塑温度。
12.如权利要求11所述的方法，其特征在于，所述至少一种添加剂选自以下：能量吸收添加剂和着色剂。
13.如权利要求12所述的方法，其特征在于，所述能量吸收添加剂选自以下：碳黑、石墨、金刚石粉、重氮盐、锍盐和碘鎓盐。
14.如权利要求11所述的方法，其特征在于，所述内层和所述外层包括各选自以下的不同材料：PET、PEN、PTT、PA、PP、PE、EVOH、PLA、及其共聚物或混合物。
15.如权利要求11所述的方法，其特征在于，所述炉子包括红外灯。
16.一种内装袋容器，所述内装袋容器适于分配包含在内袋(21)中的液体，这是通过将所述内袋从外容器(22)释放，并且通过一旦在所述内袋(21)和所述外容器(22)之间的界面点上引入气体就对所述内袋进行挤压来实现的，所述内装袋容器通过如下方法制成，所述方法包括：
提供聚合物预制坯，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之间的界面处引入气体就将所述容器的获得的内层与获得的外层分离；并且
所述内层和外层中的至少一层包括至少一种添加剂，从而能在一旦将内层和外层一起在单个炉子中加热之后，使内层和外层基本上同时达到其相应吹塑温度；
在单个炉子中将所述预制坯加热至吹塑温度；以及
对如此已加热的预制坯进行吹塑以形成内装袋容器，所述内装袋容器包括由吹塑的内层限定的内袋以及由吹塑的外层限定的外容器；
其中，所述预制坯的所述内层和外层中的至少一层的添加剂的类型和量可使所述两层基本上同时达到其相应吹塑温度。
17.一种用于生产出内装袋容器的方法，所述内装袋容器适于分配包含在由吹塑的内层限定的内袋(21)中的液体，这是通过将所述内袋从由吹塑的外层限定的外容器外容器(22)释放，并且通过一旦在所述内袋(21)和所述外容器(22)之间的界面处引入气体就对所述内袋进行挤压来实现的，所述方法包括：使用能量吸收添加剂或着色剂以将预制坯的内层和外层基本上同时加热至所述内层和外层的相应吹塑温度，从而吹塑形成内装袋容器。
CN200880012731.0A 2007-04-19 2008-04-18 包括含能量吸收添加剂的内层和外层的一体吹塑内装袋容器、用于制造该内装袋容器的预制坯、以及用于生产出该内装袋容器的方法 Active CN101663144B (zh)

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