CN102725137A - 由具有内层的无铝平面复合材料通过冷折叠来生产食品容器的方法 - Google Patents

由具有内层的无铝平面复合材料通过冷折叠来生产食品容器的方法 Download PDF

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Publication number
CN102725137A
CN102725137A CN2011800072767A CN201180007276A CN102725137A CN 102725137 A CN102725137 A CN 102725137A CN 2011800072767 A CN2011800072767 A CN 2011800072767A CN 201180007276 A CN201180007276 A CN 201180007276A CN 102725137 A CN102725137 A CN 102725137A
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layer
container
described method
aforementioned
thermoplastic
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CN102725137B (zh
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迈克尔·沃尔特斯
史蒂芬·佩尔泽
马提亚·库尔
金特·洛伦兹
奥利维尔·皮特乔斯
霍尔格·施密特
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SIG Combibloc Services AG
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SIG Technology AG
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C53/02—Bending or folding
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    • B29C53/06—Forming folding lines by pressing or scoring
    • B29C53/063—Forming folding lines by pressing or scoring combined with folding
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明总体涉及一种用于生产包围一内部的容器的方法和可由该方法获得的容器，所述方法包括以下步骤：a.提供平面复合材料，其包括i.载体层，ii.接合到载体层的塑料阻挡层，iii.设置在塑料阻挡层的背对载体层的侧面上的至少两层热塑性塑料KSa和KSw层，其中所述至少两层塑料中的至少一层是至少两种塑料的塑料混合物，b.折叠平面复合材料，以形成具有至少两个彼此相邻的折叠表面的折叠物，以及c.分别接合至少两个折叠表面的至少部分区域，以形成容器区域。

Description

由具有内层的无铝平面复合材料通过冷折叠来生产食品容器的方法
技术领域
本发明总体涉及用于生产包围一内部的容器的方法和可由该方法获得的容器，所述方法包括以下步骤：a.提供平面复合材料，包括i.载体层，ii.接合到载体层的塑料阻挡层，iii.接合到塑料阻挡层的至少一层热塑性塑料KSa层，所述至少一层塑料层可选地可为至少两种塑料的塑料混合物，优选为KSw，优选作为平面复合材料最靠外的层;b.折叠平面复合材料以形成具有至少两个彼此相邻的折叠表面的折叠物;以及c.分别接合至少两个折叠表面的至少部分区域，通过加热所述部分区域来形成容器区域。
背景技术
很长一段时间，无论是人类消费食品还是动物饲料产品，食品都被储存在封以盖子的罐子或玻璃瓶中保存。例如，通过在各种情况下分别地尽可能对食品和容器（此处为玻璃瓶或罐子）进行消毒、然后用食品灌装容器并封闭容器，能够延长保质期。或者，通过高压灭菌容器中的食品，能够延长保质期。然而，这些本身已得到长时间证实的、用于延长食品保质期的措施具有若干缺点。
因为罐子和玻璃瓶基本为圆柱形，其具有难以以非常密集并节省空间的方式进行存储的缺点。此外，罐子和玻璃瓶具有相当大的固有自重，从而导致增加了运输过程中的能量消耗。而且相当高的能量消耗是用于生产玻璃、马口铁或铝所必需的，即使用于此的原材料来自回收利用。在玻璃瓶的情况下，在运输上增加的支出是应运而生的难题。玻璃瓶通常在玻璃厂中预制，然后必须在占用相当大的运输体积下运到食品灌装厂房。而且玻璃瓶和罐子只有在施以相当大的力或者辅以工具时才能打开，因此很不方便。在罐子的情况下，也存在开启期间因锋利的边缘而受伤的高风险。在玻璃瓶的情况下，玻璃碎片总是在灌装期间或打开灌装的玻璃瓶时进入食品中，这在最坏的情况下可能导致食品消费者的体内伤害。
由现有技术已知用于尽量不受损地长时间储存食品的其它包装系统。其为由平面复合材料—通常也称为层压板所制作的容器。这种平面复合材料通常由热塑性塑料层、一般以纸板或纸制造的载体层、助粘剂层、铝层和另一塑料层组成，如特别是在WO 90/09926A2中所公开的。
相对于传统的玻璃瓶和罐子，这些层压容器已具有许多优点。不过，对于这些包装系统，也存在改善的可能性。因此，在容器生产过程中暴露于高机械应力的平面复合材料的区域内，小缺陷时有形成，比如裂纹、气泡或未密封的口袋或泄漏的微通道，细菌可以在其中积存或渗入容器，容器中的食品会更容易腐坏。即使通过更彻底的食品消毒也无法消除位于容器的小缺陷内的这些细菌。即使试图在灌装食品之前更加强化地对容器消毒，也几乎不能获得所需的长期储存时间。对铝阻挡层的任何损伤还导致由于氧气进入容器而造成的故障点，这转而又促进了食品质量上的损失，并且由此缩短了保质期。在容器生产期间具有折痕交叉（creasing cross）并且特别大幅度或在几个方向上被折叠的区域，例如在容器的底部和顶部区域的角落尤其面临风险。在含铝平面复合材料的冷折叠和随后的热密封期间，上述的缺陷尤其经常发生。
一般来说，本发明的目的在于至少部分地消除现有技术中出现的缺点。
此外，根据本发明，其目的在于：提供一种方法，利用该方法也可以高件数地生产容器，其中，所述容器适用于以较长的保质期储存食品，而不必特别强化地对容器进行消毒。
而且，根据本发明，其目的在于：在对食品和容纳食品的容器进行同等消毒的情况下，通过食品的重新消毒来降低保质期短的食品灌装容器的比例。
此外，根据本发明，其目的在于：提供一方法，其允许以提高的生产速度生产与现有技术相比至少具有相同质量的容器。
根据本发明的另一个目的在于：提供一方法，其允许特别在容器的生产过程中暴露于机械应力的区域中获得特别精确的、具有最少可能缺陷的折叠，并允许所设想的、通过密封接合的区域能够相对于彼此、并关于连接工具尽可能得以精确放置。特别地，尽可能避免了折痕交叉中的破裂。
由独立权利要求的主题对实现上述目的中的至少一项作出贡献。依赖于独立权利要求的从属权利要求的主题代表了为实现所述目的而作出该贡献的优选实施方式。
为实现上述目的中的至少一项而作出贡献的是用于生产包围一内部的容器的方法，其包括以下步骤：
a.提供平面复合材料，包括
i.载体层；
ii.接合到载体层的塑料阻挡层；
iii.设置在塑料阻挡层的背对载体层的侧面上的至少一层热塑性塑料Ksa层；
b.折叠平面复合材料，以形成具有至少两个彼此相邻的折叠表面的折叠物；
c.分别接合至少两个折叠表面的至少部分区域，通过加热所述部分区域来形成容器区域；
其中，在步骤b中，所述至少一层热塑性塑料Ksa层具有低于该塑料层的熔化温度的温度。
可以根据本发明的方法生产的容器优选具有至少一个、最好是6至16个边缘，特别优选的是7至12个边缘。根据本发明，边缘被理解为特别是指基于表面折叠、由位于彼此之上的该表面的两部分形成的区域。举例来说，边缘为基本上长方体形状的容器的两个壁表面的各自的细长接触区域。通常，这种长方体形状的容器具有12个边缘。在容器中，容器壁优选代表由边缘框定的容器表面。根据本发明的容器的容器壁优选由作为平面复合材料的一部分的载体层形成到其表面至少50%的程度、优选形成到其表面至少70%的程度、并且更优选形成到其表面至少90%的程度。
此处使用的术语“接合”包括超出范德华力的吸引以外的、两个对象的粘合。这些对象可以紧接着另一个或者通过其它的对象接合到另一个上。对于平面复合材料，这意味着，例如，载体层可以直接地、且从而紧密地（immediately）接合到塑料阻挡层，或者也可以通过一个或多个层（例如通过一个或多个助粘剂层）间接地接合，优选为直接接合。根据平面复合材料的特定实施方式，至少一层热塑性塑料KSa层优选为直接结合到塑料阻挡层。
在根据本发明的方法中，对于平面复合材料，优选地，除了载体层、接合到载体层的塑料阻挡层以及至少一层热塑性塑料KSa层之外，还包括一个或两个以及更多其它层，其设置在塑料阻挡层的背向载体层的侧面。优选地，所述一个或更多其它层为助粘剂层。根据一项实施方式，可将它们设置在载体层与塑料阻挡层之间。但是，优选地，塑料阻挡层和载体层不会借由助粘剂层彼此接合。在另一项实施方式中，助粘剂层可设置在塑料阻挡层和至少一层热塑性塑料KSa层之间，以提高层间粘结力，从而使得难以层离。在根据本发明的一项实施方式中，助粘剂层设置在载体层和塑料阻挡层之间；在背对载体层的侧面上，至少一层热塑性塑料KSa层优选为接着塑料阻挡层，最好是紧接着所述塑料阻挡层。在根据本发明的另一项实施方式中，在载体层和塑料阻挡层之间不设置助粘剂层，但至少一层助粘剂层布置于塑料阻挡层与所述至少一层热塑性塑料KSa层之间。此外，在又一项实施方式中，至少一层助粘剂层布置于载体层和塑料阻挡层之间，并且至少又一层助粘剂层布置在塑料阻挡层与所述至少一层热塑性塑料KSa层之间。
可能的助粘剂都是借助合适的官能团的聚合物，适用于通过针对其它特定层表面的离子键或共价键的形成来生成坚固接合。优选地，这是由与丙烯酸、丙烯酸酯、丙烯酸酯衍生物或带有双键的羧酸酐（例如马来酸酐），或其中至少两种的共聚而官能化的聚烯烃。其中，特别优选的是聚乙烯/马来酸共聚物，这些由例如杜邦公司以商品名
Figure BDA00001937233800051
销售。因而，可存在于平面复合材料中的任何热塑性塑料层最好都不是助粘剂。优选地，稍后将说明的上述至少一层热塑性塑料KSa层以及塑料Ksu层都不是助粘剂。
在根据本发明的方法的优选实施方式中，设置至少一层、或二至五层热塑性塑料KSa层。而且，优选地，所述至少一层热塑性塑料KSa层表现为至少两种塑料的混合物。此外，所述至少一层塑料KSa层包括无机颗粒填料。
在根据本发明的方法的另一项优选实施方式中，所述至少一层热塑性塑料KSa层中的至少一层、优选为至少两层或者所有层具有低于塑料阻挡层熔化温度的熔化温度。至少一层、优选为至少两层或所有热塑性塑料KSa层的熔化温度与塑料阻挡层的熔化温度优选相差至少1K，特别优选相差至少10K，更优选相差至少20K，进一步优选相差至少100K。温度差优选应当选择得刚好足够高，以使得在接合期间塑料阻挡层的任何塑料都达不到熔化温度，因此不会发生塑料阻挡层的熔化。
在根据本发明的方法中，折叠被理解为这样一种操作：优选借助于折叠工具的折叠边缘，在被折叠的平面复合材料中生成形成有一角度的细长扭折（kink）。为此，平面复合材料的两个相邻表面通常始终朝向彼此弯曲。
在根据本发明的方法中，可通过看起来适于本领域技术人员、并且能够实现尽可能气密或水密的接合的任意措施来实现所述接合。可通过密封或粘合或这两种措施的组合来实现所述接合。在密封的情况下，借助液体及其凝固来产生接合。在粘合的情况下，用于产生接合的化学键形成在待接合的两个对象的交界面之间或表面之间。在密封或粘合的情况下，通常有利的是将待密封或粘合的表面彼此压到一起。
按惯例，根据本发明的容器的载体层可以由对本领域技术人员来说适合于该意图并且具有足够强度和硬度的任意材料制造，该材料赋予容器在灌装状态下基本保持容器形状的稳固性。除了若干塑料之外，优选的是基于植物的纤维物质，特别是纤维素，优选为尺寸定制的、漂白和/或未漂白的纤维素，特别优选为纸和纸板。
通常，在基于此的各种情况下，塑料阻挡层包括至少70%重量百分比、优选为至少80%重量百分比、特别优选为至少95%重量百分比的至少一种对于本领域技术人员来说已知的且适于该意图的塑料，特别是因其阻挡香味或气体的性质，这种性质适用于包装容器。优选地，在此采用热塑性塑料。根据本发明的方法，塑料阻挡层最好具有在大于155°C至300°C的范围内的熔化温度，优选的范围为从160°C至280°C，特别优选的范围为从170°C至270°C。在此，可能的塑料、特别是热塑性塑料为由其自身携带N或O以及在两种或多种的混合物中携带N或O的塑料。塑料阻挡层优选为尽可能均匀，并因此优选为可由熔化物获得，例如通过挤出、优选为层压挤出（laminatingextrusion）而形成。相对地，次优选的是可由塑料溶液或分散液（plastics dispersion）沉积获得的塑料阻挡层，因为其一般具有至少部分颗粒结构，相对于可由熔化物获得的塑料阻挡层显示出较差的阻挡气体和湿度的性质，特别是在上述沉积或成形发生于塑料分散液时。
在根据本发明的方法的一项实施方式中，塑料阻挡层由聚酰胺（PA）或聚乙烯/乙烯醇（EVOH）或其混合物制成。
对于PA来说，所有看起来适合于本领域技术人员通过根据本发明的方法生产容器并用于容器中的PA都是允许的。特别要提及PA 6，PA 6.6，PA 6.10，PA  6.12，PA 11或PA 12或这些中至少两种的混合物，尤其优选PA 6和PA 6.6，进一步优选PA 6。PA 6作为非晶聚酰胺能够以商品名
Figure BDA00001937233800071
和
Figure BDA00001937233800072
或者MXD6，
Figure BDA00001937233800073
和
Figure BDA00001937233800074
由市售获得。PA的分子量优选地应选择为使得分子量范围的选择一方面令在生产用于容器的平面复合材料时可以进行良好的层压挤出，另一方面平面复合材料本身具有用于容器的足够好的机械性能，如高断裂伸长率、高耐磨性和足够的硬度。这导致通过利用光散射（优选基于国际标准ISO/DIS 16014-5:2003）的凝胶渗透色谱（GPC）（优选基于国际标准ISO/DIS 16014-3:2003）而被确定为平均重量的优选分子量位于从3*103至1*107g/mol的范围内，优选位于从5*103至1*106g/mol的范围内，特别优选地位于从6*103至1*105g/mol的范围内。此外，在加工和机械性能方面，对于PA来说，最好具有从1.01至1.40g/cm3的范围内的密度，优选具有从1.05至1.3g/cm3的范围内的密度，特别优选地具有从1.08至1.25g/cm3的范围内的密度。此外，对于PA来说，最好具有从130至185ml/g的范围内的黏度值，优选地具有从140至180ml/g的范围内的黏度值，这是在95％的硫酸中按照ISO 307确定的
对于聚乙烯/乙烯醇（EVOH），可以使用所有看起来适合于本领域技术人员通过根据本发明的方法生产容器并用于容器中的聚合物。合适的EVOH共聚物的例子包括那些由比利时EVAL欧洲公司以商标EVALTM销售的树脂，如EVALTMF101B，EVALTMF171B，EVALTMT101B，EVALTMH171B，EVALTME105B，EVALTMF101A，EVALTMF104B，EVALTME171B，EVALTMFP101B，EVALTMFP104B，EVALTMEP105B，EVALTMM100B，EVALTML171B，EVALTMLR171B，EVALTMJ102B，EVALTMC109B或EVALTMG156B。优选地，EVOH共聚物的特点在于下列属性中的至少一个，更优选为下列全部属性：
-乙烯含量在从20至60mol%的范围内，优选为在从25至45mol%的范围内；
-（根据ISO 1183确定的）密度在从1.00至1.4g/cm3的范围内，优选为在从1.10至1.30g/cm3的范围内；
-（对低于210°C的熔化温度，在210°C和2.16kg下根据ISO1133确定；对于210°C和230°C之间的熔化温度，在230°C和2.16kg下根据ISO 1133确定）熔体流动速率在从1至15g/10min的范围内，优选为在从2g/10min至13g/10min的范围内；
-（根据ISO11357确定的）熔化温度在从155°C至235°C的范围内，优选为在从165°C至225°C的范围内；
-（在20°C和65%的相对湿度下，根据ISO 14663-2附件C确定的）透氧率在从0.05至3.2cm3·20μm/m2·天·atm的范围内，优选为在从0.1至0.6cm3·20μm/m2·天·atm的范围内。
此外，对于聚酰胺层、聚乙烯/乙烯醇层或是聚酰胺和聚乙烯/乙烯醇的混合物的层，其最好具有在从2至120g/m2的范围内的单位面积重量，优选为在从3至75g/m2的范围内，特别优选为在从5至55g/m2的范围内。此外，对于聚酰胺层、聚乙烯/乙烯醇层或是聚酰胺和聚乙烯/乙烯醇的混合物的层，最好具有在从2至90μm的范围内的厚度，优选为具有在从3至68μm的范围内的厚度，特别优选为具有在从4至50μm的范围内的厚度。
通常，在基于此的各种情况下，至少一层热塑性塑料KSa层包括至少70%重量百分比、优选为至少80%重量百分比、特别优选为至少95%重量百分比的至少一种对于本领域技术人员而言看起来适于该意图的热塑性塑料，特别是适于挤出、保护载体层和良好密封性的意图。
在根据本发明的方法的另一项实施方式中，以颗粒无机固体填充至少一层热塑性塑料KSa层。可行的颗粒无机固体为所有看起来适合于本领域技术人员、并尤其导致塑料中改进的热分布、从而导致更好的塑料密封性的固体。
优选地，由筛分析确定的无机固体的平均粒径（d50%）在从0.1至10μm的范围内，优选为在从0.5至5μm的范围内，特别优选为在从1至3μm的范围内。可行的无机固体优选为金属盐或二价到四价金属氧化物。在此可能提及的例子是钙、钡或镁的硫酸盐或碳酸盐或者二氧化钛，优选为碳酸钙。
基于KSa层的总重量，KSa层中的颗粒无机固体的量可以在从0.1%至30%重量百分比的范围内，优选为在0.5%至20%重量百分比的范围内，更优选为在1%至5%重量百分比的范围内。
在根据本发明的方法的另一项实施方式中，对于折叠表面，其最好形成小于90°的角度μ，优选为小于45°，特别优选为小于20°。折叠表面通常被折叠到这样的程度：使其在折叠端处位于彼此之上。这是有利的，特别是如果位于彼此之上的折叠表面随后彼此接合以形成容器底部和容器顶部，其通常构造为如三角墙那样或构造为平的。关于三角墙式构造，例如可以参考WO 90/09926A2。
在根据本发明的方法的又一项实施方式中，对于所述至少一层热塑性塑料KSa层，其优选为塑料混合物，且在基于塑料混合物的各种情况下，优选地，塑料混合物包括10%至50%重量百分比、优选为15%至45%重量百分比、特别优选为20%至40%重量百分比或者大于50%至95%重量百分比、优选为60%至90%重量百分比、特别优选为75%至85%重量百分比的、借由茂金属制备的聚烯烃（m-聚烯烃），以作为至少两种混合物成分之一。除了良好的密封性，尤其在较高浓度下，m-聚烯烃显示出关于高脂肪或无脂肪含量的食品的相对低的应力腐蚀开裂。而且，在基于塑料混合物的各种情况下，不同于上述聚合物的一种或多种添加剂可以存在于塑料混合物中，最高达到15%重量百分比的程度，优选为最高达到10%重量百分比的程度，特别优选为达到0.1至5%重量百分比的程度。此外，在基于塑料混合物的各种情况下，优选在塑料混合物中存在总共高达100%重量百分比的至少一种、或者全部两种或多种热塑性塑料，其与m-聚烯烃不同，并且如果存在添加剂，其也与添加剂不同。特别地，借由茂金属制备的m-聚乙烯或m-聚丙烯、或二者的混合物也可作为m-聚烯烃，特别优选为m-聚乙烯。这些措施特别有助于拓宽密封窗。此外，在根据本发明的方法的优选实施方式中，至少两层热塑性塑料层具有在从80°C至155°C的范围内的熔化温度，优选为在从85°C至145°C的范围内，特别优选为在从90°C至125°C的范围内。此温度范围促进了通过密封的接合。在根据本发明的方法的另一项优选实施方式中，在平面复合材料内，关于载体层、朝向成品容器的内部设置有至少两层热塑性塑料层。
此外，在根据本发明的方法的一项实施方式中，关于载体层、背向内部设置有至少又一层热塑性塑料KSu层，并将其接合到载体层。因而关于载体层，至少又一层塑料KSa层面向成品容器的外围。对于所述至少又一层热塑性塑料KSu层，其最好具有在从80°C至155°C的范围内的熔化温度，优选为在从90°C至145°C的范围内，特别优选为在从95°C至125°C的范围内。此外，在基于又一层热塑性塑料KSu层的各种情况下，对于所述另一层热塑性塑料KSu层，最好包括至少70%重量百分比程度的热塑性塑料聚合物，优选为至少80%重量百分比，特别优选为至少95%重量百分比。正如塑料KSa层中的情况，除了至少一种热塑性塑料聚合物之外，塑料KSu层也可以包括无机颗粒。基于KSu层的总重量，KSu层中无机颗粒的量可以在从0.1至30%重量百分比的范围内，优选为在从0.5至20%重量百分比的范围内，更优选为在从1至5%重量百分比的范围内。
合适的热塑性塑料聚合物是通过链锁聚合获得的聚合物，特别是聚烯烃，在这些环烯烃共聚物（COC）、多环烯烃共聚物（POC）之中，特别优选的是聚乙烯、聚丙烯或聚乙烯和聚丙烯的混合物，尤其优选的是聚乙烯。借由DIN 1133（对于聚乙烯，优选在190°C和2.16kg下；对于聚丙烯，优选在230°C和2.16kg下）确定的热塑性塑料聚合物的熔融指数最好在从3至15g/10min的范围内，优选为在从3至9g/10min的范围内，特别优选为在从3.5至8g/10min的范围内。
对于根据本发明的方法，在聚乙烯之中，优选HDPE、LDPE、LLDPE、MDPE和PE及它们中至少两种的混合物。借由DIN 1133（优选在190°C和2.16kg下）确定这些聚合物的熔融指数，最好在从3至15g/10min的范围内，优选为在从3至9g/10min的范围内，特别优选为在从3.5至8g/10min的范围内。关于热塑性塑料KSa层，并且优选地也关于热塑性塑料KSu层，优选采用LDPE。
在步骤b中实施的所谓冷折叠可以在对于本领域技术人员来说适于该目的的任何温度下实施，在此温度下，存在于复合材料中的层可以容易地被折叠并且尤其不会过脆而无法折叠，从而使得细缝裂纹或其它损伤的产生不会损害复合材料的气密性，并由此不会损害容器所获得的气密性。优选地，在从0至70℃的温度范围内、优选地在从10至60℃的温度范围内、并且特别优选地在从20至50℃的温度范围内实施折叠。
另外在此，对于至少又一层塑料KSu层，优选在步骤b中，其同样具有低于该又一层塑料KSu层的熔化温度的温度。优选地，在步骤b之前，特别优选为刚好于步骤b之前，实施加热，使温度保持为低于这些层的熔化温度至少1K、优选为高于至少5K、特别优选为低于至少10K。温度应尽可能低于特定塑料的熔化温度，以使得塑料不会在加热时由于折叠、移动和施压而变化到变成液体的程度。
优选地，在步骤b中的折叠之后，在密封步骤c中加热至密封中涉及的塑料的熔化温度；加热到这些温度是通过照射、通过机械振动、通过接触热固体或热气体（优选热空气）、通过感应、通过中频或高频的应用或者这些措施的组合来实施的。在照射的情况下，适合于本领域技术人员用于软化塑料的任何类型的照射都是可行的。优选的辐射类型为红外射线、紫外射线和微波。优选的振动类型为超声波。在红外射线的情况下，应提及从0.7至5μm的波长范围，该红外射线还用于平面复合材料的红外焊。此外可以采用波长范围从0.6至小于10.6μm的激光束。关于红外射线的使用，其由本领域技术人员已知的各种合适的灯生成。在从1至1.6μm范围内的短波长灯优选为卤素灯。在从大于1.6至3.5μm范围内的中波长灯为例如金属箔灯。石英灯常常被用作大于3.5μm范围内的长波长灯。激光器更是经常被采用。因而，二极管激光器用于从0.8至1μm的波长范围，Nd：YAG激光器用于约1μm的波长，CO2激光器用于约10.6μm的波长。还采用了从10至45MHz频率范围的高频技术，功率范围往往为从0.1至100KW。
除折叠之外，特别是在接合期间，在优选的作为机械振动的超声波的情况下，优选下列密封参数中的至少一项，且最好是其全部：
P1频率在从5至100kHz的范围内，优选为在从10至50kHz的范围内，特别优选为在从15至40kHz的范围内；
P2振幅在从2至100μm的范围内，优选为在从5至70μm的范围内，特别优选为在从10至50μm的范围内；
P3振动时间（如超声波发生器的振动体在平面复合材料上接触振动的时段）在从50至1000msec的范围内，优选为在从100至600msec的范围内，特别优选为在从150至300msec的范围内。
此外，对于保持时间，其优选要遵循振动时间。其通常选为要使得熔化的塑料在振动期间再次固化。保持时间通常在从50至2000msec的范围内，优选为在从100至1200msec的范围内，特别优选在从150至600msec的范围内。此外在保持时间的情况下，对于在振动期间作用于待接合的平面复合材料的部分区域上的压力，其在保持期间最好仅下降最多10%，优选为最多5%。
对于辐射或振动条件的合适选择，考虑到塑料的固有共振并选择与其接近的频率是有利的。
通过例如直接接触平面复合材料并向平面复合材料释放热的加热板或加热模具，能够实现经由接触固体的加热。通过合适的风扇、通风口或喷嘴或它们的组合，可以将热空气定向到平面复合材料上。往往同时采用接触加热和热气体。因此例如，通过接触保持设备的壁且通过热气体，保持设备能够加热平面复合材料，保持设备保持有由平面复合材料形成并供热气体穿过其流动的套管，由此，该保持设备被加热并通过合适的开口释放出热气体。此外，还可以通过使用套管保持器来固定套管，并从设置于套管保持器中的一个或两个或多个热气体喷嘴向待加热的套管的区域导流，由此加热套管。
密封温度优选选择为使得参与密封的塑料呈现为熔化物。此外，密封温度的选择不应过高，以使塑料的热暴露不必过于严重，从而它们不会失去其预想的材料属性。因此，密封温度高于特定塑料的熔化温度至少1K、优选为高于至少5K、特别优选为高于至少10K。
在根据本发明的方法的另一项优选实施方式中，设想在步骤b之前或步骤c之后，容器灌装有食品或灌装有用于制备食品的原料。对于所述食品，本领域技术人员已知的、用于人类消耗以及动物饲料的所有食品和原料都是可行的。优选的食品为高于5°C的液体，例如饮料。优选的食品为乳制品、汤、调味汁、非碳酸饮料，比如果汁饮料和果汁或茶。也可以在容器中纳入块状材料。食品或原料一方面可以事先在消毒后灌装进同样事先消毒的容器中。此外，可以在将食品或原料灌装到并封闭在容纳它们的容器中之后再对其进行消毒。这通常通过高压灭菌来实施。
在根据本发明的方法的实施方式中，在步骤b之前用食品或原料灌装容器，尤其是对于具有固定的纵向接缝的管状结构，其优选为首先由平面复合材料通过折叠和密封或粘合重叠边界而形成。该管状结构被横向压缩、固定和分离，并通过折叠和密封或粘合而形成为开口容器。此处，可以在固定之后、以及在分离和步骤b意义上的底部折叠之前就将食品灌装到容器中。
根据本发明的方法的实施方式中，在步骤c之后用食品或原料灌装容器，优选是通过平面复合材料成型而获得的、并且在底部区域中封闭、在顶部区域中敞开的容器。或者，可以采用通过平面复合材料成型而获得的、并且在顶部区域中封闭、在底部区域中具有开口的容器。可以通过步骤b和c、由任何对本领域技术人员而言看起来适合于此的工艺来实现平面复合材料的成型和这种敞开的容器的获得。特别地，可以通过折叠（已经考虑到在裁切状态时的容器形状）的薄片状容器坯料的工艺来实施这种成型，从而在芯轴上形成开口容器。这通常由如下过程来实现，即：在折叠该容器坯料之后，密封或粘合其纵向边缘以形成侧壁，并且通过折叠和进一步固定（特别是密封或粘合）来封闭套管的一侧。
在根据本发明的方法的另一项优选实施方式中，对于平面复合材料，其优选具有至少一条折痕，并且沿该折痕进行折叠。折痕通常为平面复合材料的一般为线性的区域，在该区域中，与临近于线或折痕的区域相比，通过冲压工具沿着该线将平面复合材料压得更紧。折痕往往在平面复合材料的一侧上形成为沿线延伸的凹陷，并具有在平面复合材料的相对于该凹陷的另一侧上延伸的凸起。这便于沿着由折痕准备的线进行折叠和形成扭折，从而以这种方式实现尽可能均匀和精确定位的折叠。优选地，折痕将平面复合材料划分为大面积部分和相对于大面积部分的小面积部分。因此，例如，大面积部分可以是容器的侧壁，而小面积部分可以是平面复合材料的形成底部的面。此外，小面积部分可以是在折叠之后被接合、特别是通过密封被接合的平面层压板的区域。可以在生产平面复合材料的各个阶段中提供这种折痕。根据一项实施方式，在一般通过共挤来实施的热塑性塑料涂覆之后，在平面复合材料中制造折痕。在另一项实施方式中，在共挤之前实现印痕，该印痕优选为直接进入载体层中。
关于灌装操作，依照根据本发明的方法的一项实施方式，对于食品或原料，优选在灌装操作之前对其进行至少部分消毒。这可以通过灭菌、超高温加热或巴氏消毒来实施。此外，在根据本发明的方法的优选实施方式中，容器或容器前体自身在灌装操作之前至少经过部分消毒。这可以通过灭菌（优选由过氧化物、特别是双氧水或过氧乙酸）或辐射来实施。此外，在根据本发明的方法中，优选同时实现上述两种实施方式，并且如果可能的话，这些操作应为无菌操作。为了进行消毒，往往采用高于50°C、优选为高于80°C的温度。
在根据本发明的方法中，在步骤b中，该小面积部分的至少一层热塑性塑料层中的至少一层、优选为至少两层、特别优选为每一层或塑料KSu层具有低于其熔化温度的温度。此外，在根据本发明的方法的一项实施方式中，优选通过将折叠工具的边缘压入折痕中来形成折叠物。特别是当形成底部区域时就是这种情况。此外，在另一项实施方式中，优选通过使用折叠工具的边缘沿着折痕进行挤压来形成折叠物。在该情况下，折叠工具的边缘通常直接沿着折痕放置。这种类型的折叠优选用于形成形状如三角墙的顶部区域。
在步骤a之前，或在步骤a之后、稍早于步骤b，可以在平面复合材料中设置折痕。
通常在步骤a之后、稍早于步骤b，在平面复合材料中设置折痕。因此在这种情况下，优选在步骤a中提供带折痕的平面复合材料。通常，平面复合材料通过所述平面复合材料的各单独层的共挤而生成为辊状物。优选地，在这些辊状物上设置折痕。可选地，可以由该辊状物获得容器坯料，并将其作为步骤a中的平面复合材料而提供。可以随后在这些容器坯料中设置折痕，或可以在制备这些容器坯料之前在辊状物中生成这些折痕。然而，也可能在共挤之前就已经在载体层中生成了折痕。在这种情况下，折痕是在步骤a之前在平面复合材料中设置的。
在根据本发明的方法的另一项实施方式中，优选地，在平面复合材料中，在载体层与至少一层热塑性塑料KSa层之间，不设置金属箔，往往是不设置铝箔。通常，塑料阻挡层具有足够好的屏障属性。因此，在根据本发明的方法中采用的平面复合材料可以整体配置为不包含金属箔、特别是不包含铝箔的形式。可以通过这种方式提供不含金属的复合材料或由其制成的容器。在“不含金属”的情况下，应理解为该复合材料不包含任何金属层，比如铝箔。然而，“不含金属”的表述并不排除存在作为填充物的、包含金属盐的层。
根据本发明的方法，在另一项实施方式中，作为步骤d，接着步骤c进行另一次折叠，在该另一次折叠中，至少一层、优选为每一层热塑性塑料层的温度低于该塑料层的熔化温度。此外，上文关于步骤b中的折叠的描述也适用于此。因而出现了冷折叠、热密封和进一步的冷折叠的工序。在形状为长方体的容器的顶部区域中，该工序是特别有利的。在此，在容器已被封闭之后，被称为耳部的基本三角形的区域（其中局部地至少三块平面复合材料位于彼此之上）固定到容器的两个相对侧，在砖形容器的情况下固定到容器的窄边，由于该工序与此处描述的平面复合材料相结合，其结果是，所形成的折痕交叉中的缺点（诸如在折痕交叉中的裂缝）特别少。
可通过根据本发明的方法获得特别适合于食品的长期储存、且可以在温和条件下进行消毒的容器。此外，所述容器具有高度环保性、简单并有利于生产。此容器不一定仅由上面所述的平面复合材料组成，而是可能还包括另外的元素，如一个或多个喷口（spout）、一个或多个辅助开口和/或一个或多个吸管。
测试方法：
除非在此作出另外说明，此处提及的参数借由DIN规范测得。
附图说明
附图：
现在通过非限制性举例给出的附图更详细地阐释本发明，附图中示出了：
图1   通过根据本发明的方法生产的容器的示意图，
图2   根据本发明的方法的工艺流程图，
图3   待通过根据本发明的方法生产的容器的区域的示意图，
图4a  通过根据本发明的方法进行折叠的示意图，
图4b  通过根据本发明的方法所得到的折叠物的示意图，
图5a  在未折叠状态下沿剖面A-A的示意图，
图5b  在折叠状态下沿剖面A-A的示意图，
图6   可以在根据本发明的方法中采用的平面复合材料的示意图，
图7   可以在根据本发明的方法中采用的平面复合材料的示意图，
图8a  在密封之前的超声波发生器-砧座装置的示意图，
图8b  在密封期间和密封结束时的超声波发生器-砧座的示意图。
具体实施方式
图1示出了包围内部1且由平面复合材料3制成的容器2。为了更好地观察，所显示的容器2具有面朝上的容器底部12，该容器常规地立于该容器底部12上。
图2示出了根据本发明的方法的生产步骤和设备的流程图。在复合材料生成20中，平面复合材料3由载体层4、塑料阻挡层5、热塑性塑料KSa层6、可选的另一热塑性塑料KSu层13、以及（如需要时）由挤出工艺所得的助粘剂层19制成，并且通常作为辊状物提供。在间接或直接地跟在复合材料生成20之后的复合材料加工21中，在可以事先已设置有印记或缀饰的辊状物中产生折痕14。此外，如果设置有折痕14的辊状物不用于通过这样生产容器，则在复合材料加工21中生成容器坯料。复合材料加工21之后是容器生成22，其中尤其是通过根据本发明的方法进行折叠和接合。食品的灌装也可以在此实施。在已经用食品灌装容器之后，通过另一折叠和密封操作来封闭容器，其也可以在容器生成22或在随后的生产单元中进行。
图3示出了在根据本发明的方法期间形成的容器2，为了更好地观察，其显示有在顶部上的、设想为底部12的容器区域23。被设想为底部12的容器区域23具有多个折痕14。
图4a示出了穿过平面复合材料3的横截面，具有由凹部24和凸起25形成的折痕14。为了啮合于凹部24，将折叠工具18的边缘17设置在凹部24上，使得能够沿折痕14绕边缘17实施折叠，从而获得如图4b中的横截面图所示的折叠物8。该折叠物8具有两个折叠表面9和10，它们封闭成角μ，并表现为大面积部分15和小面积部分16。至少一层热塑性塑料层6或13，如另一层塑料KSu层，固化在小面积部分16的部分区域11中。通过将折叠表面9、10压在一起，角μ缩小至0°，两个折叠表面9、10通过密封彼此接合，在这一过程中，开始一个位于另一个之上的各塑料层融化。
图5a示出了在折叠之前、带有折痕14的平面复合材料3沿图3中的线A-A的截面。凭借与安装于正面中心的折痕14啮合的、折叠工具18的边缘17，折痕14沿着两个箭头的方向移动，其结果是形成了图5b中所示的具有角μ的折叠物8。穿过被设想为是容器2底部12的容器区域的待折叠的最靠外部分，此处示出的截面具有朝向内部1的部分区域11，至少一层热塑性塑料层6或13，如另一层塑料KSu层，熔化在内部1中。通过将纵向边26挤压在一起，六个角μ缩小至0°，该纵向边26的面向内部1的两个内表面7通过密封彼此接合，从而制成底部12。
图6示出了平面复合材料3，由其生成位于容器2外侧上的上侧和位于内侧上的下侧。所获得的构造从外侧向内如下：具有在从8至40g/m2的范围内的单位面积重量的至少又一层热塑性塑料KSu层13（通常为PE、可选地具有诸如无机盐的无机颗粒的填充物），接着是具有在从120至400g/m2的范围内的单位面积重量的纸板载体层4，接着是具有在从2至50g/m2的范围内的单位面积重量的塑料（通常为PA或EVOH）阻挡层5，接着是具有在从2至30g/m2的范围内的单位面积重量的至少一层助粘剂层19，接着是具有在从2至60g/m2的范围内的单位面积重量、通常为PE（可选地具有诸如无机盐的无机颗粒的填充物）的第一热塑性塑料KSa层6或具有在从2至60g/m2的范围内的单位面积重量的PE和m-PE的混合物。
在图7中，对图6中的平面复合材料增加了另一助粘剂层19，其单位面积重量在从2至30g/m2的范围内，设置于塑料阻挡层5和热塑性塑料KSa层6之间。
图8a示出了在超声波发生器（sonotrode）27和砧座33之间的平面复合材料3的折叠后复合材料区域29，超声波发生器27和砧座33二者各自具有表面浮凸28。折叠后复合材料区域是通过在图5b中所示折叠物的状况下进一步减小角度μ而形成的，并且在具有数层的区域中通常存在中间空间31。表面浮凸28被配置为使得凹部32在表面浮凸28中与在折叠期间形成的厚度较大的多层区域30相对，以允许超声波发生器27上的压力和机械振动的分布尽可能均匀。此外，以这种方式，待接合的折叠后复合材料区域29的固定得以改善，直到中间空间31消失。超声波发生器27沿箭头方向在砧座33上移动，将作用于待接合的折叠后复合材料区域29上的压力保持在表面浮凸28之间。通过这种方式，折叠后复合材料区域如图8b所示被挤压在一起，并依照表面浮凸得以保持，以使得由超声波发生器27生成的机械超声波振动被传输到折叠后复合材料区域29并且通过密封进行接合；通常，在保持时间内，在超声波发生器27已将由该方式处理的折叠后复合材料区域29松开之前，熔化的塑料层因施加的压力而至少部分流入彼此中，并通过冷却再次凝固。
附图标记列表
1    内部
2    容器
3    平面复合材料
4    载体层
5    塑料阻挡层
6    热塑性塑料KSa层
7    内表面
8    折叠物
9    折叠表面
10   另一折叠表面
11   部分区域
12   容器区域（底部）
13   另一热塑性塑料KSu层
14   折痕
15   大面积部分
16   小面积部分
17   边缘
18   折叠工具
19   助粘剂
20   复合材料
21   复合材料加工
22   容器生成
23   容器区域
24   凹部
25   凸起
26   纵向边
27   超声波发生器
28   表面浮凸
29   折叠后复合材料区域
30   多层区域
31   中间空间
32   凹部
33： 铁砧

Claims (28)

1.一种用于生产包围一内部（1）的容器（2）的方法，其包括以下步骤：
a.提供平面复合材料（3），其包括
i.载体层（4）；
ii.接合到所述载体层（4）的塑料阻挡层（5）；
iii.设置在所述塑料阻挡层（5）的背对所述载体层（4）的侧面上的至少一层热塑性塑料KSa层（6）；
b.折叠所述平面复合材料（3），以形成具有彼此相邻的至少两个折叠表面（9、10）的折叠物（8）；
c.分别接合所述至少两个折叠表面（9、10）的至少部分区域（11），通过加热所述部分区域（11）来形成容器区域（12）；
其中，在步骤b中，所述至少一层热塑性塑料层（6）具有低于该塑料层的熔化温度的温度。
2.根据权利要求1所述的方法，其中，通过机械振动来实现所述加热。
3.根据权利要求1或2所述的方法，其中，通过超声波来实现所述加热。
4.根据前述权利要求中一项所述的方法，其中，所述至少一层热塑性塑料层（6）填充有颗粒无机固体。
5.根据前述权利要求中一项所述的方法，其中，所述折叠表面（9、10）形成小于90°的角μ。
6.根据前述权利要求中一项所述的方法，其中，所述至少一层热塑性塑料层（6）为塑料混合物，并包括借由茂金属制备的聚烯烃，作为至少两种混合物成分之一。
7.根据权利要求6所述的方法，其中，所述塑料混合物包括基于所述塑料混合物的10%至50%重量百分比的、借由茂金属制备的聚烯烃，作为所述至少两种混合物成分之一。
8.根据权利要求6所述的方法，其中，所述塑料混合物包括基于所述塑料混合物的大于50%至95%重量百分比的、借由茂金属制备的聚烯烃，作为所述至少两种混合物成分之一。
9.根据前述权利要求中一项所述的方法，其中，所述容器区域（12）为所述容器（2）的底部或顶部。
10.根据前述权利要求中一项所述的方法，其中，依照步骤c的接合是通过依靠所述至少一层热塑性塑料层（6）的密封来实施的。
11.根据前述权利要求中一项所述的方法，其中，所述至少一层热塑性塑料层（6）具有在从80°C至155°C的范围内的熔化温度。
12.根据前述权利要求中一项所述的方法，其中，所述至少一层热塑性塑料层（6）关于所述载体层（4）、朝向所述内部（1）设置于所述平面复合材料（3）中。
13.根据前述权利要求中一项所述的方法，其中，关于所述载体层（4）、背对所述内部设置至少又一层热塑性塑料KSu层（13），并将其接合到所述载体层（4）。
14.根据权利要求13所述的方法，其中，所述又一层热塑性塑料Ksu层（13）包括聚乙烯、聚丙烯或它们的混合物。
15.根据权利要求13或14所述的方法，其中，所述至少又一层热塑性塑料KSu层（13）具有在从80°C至155°C的范围内的熔化温度。
16.根据前述权利要求中一项所述的方法，其中，所述至少一层热塑性塑料层（6）由聚乙烯或聚丙烯或这些中至少两种的混合物制得。
17.根据权利要求13至16中一项所述的方法，其中，所述又一层热塑性塑料KSu层（13）包括聚乙烯、聚丙烯或它们的混合物。
18.根据前述权利要求中一项所述的方法，其中，所述塑料阻挡层（5）具有在从大于155°C至300°C的范围内的熔化温度。
19.根据前述权利要求中一项所述的方法，其中，所述塑料阻挡层由聚酰胺或聚乙烯乙烯醇或其混合物制得。
20.根据前述权利要求中一项所述的方法，其中，刚好于步骤b之前，所述至少一层热塑性塑料层（6）具有低于其熔化温度的温度。
21.根据前述权利要求中一项所述的方法，其中，在步骤b之前或步骤c之后，用食品灌装所述容器（2）。
22.根据前述权利要求中一项所述的方法，其中，所述平面复合材料（3）具有至少一条折痕（14），并且沿着所述折痕（14）来实现所述折叠物（8）。
23.根据权利要求22所述的方法，其中，所述折痕（14）将所述平面复合材料（3）划分为大面积部分（15）和相对于所述大面积部分（15）的小面积部分（16）。
24.根据权利要求23所述的方法，其中，在步骤b中，所述小面积部分（16）的所述至少一层热塑性塑料层（6）具有低于其熔化温度的温度。
25.根据权利要求22至24中一项所述的方法，其中，通过将折叠工具（18）的边缘（17）压入所述折痕（14）中来形成所述折叠物（8）。
26.根据前述权利要求中一项所述的方法，其中，在所述载体层（4）和所述至少一层热塑性塑料KSa层（6）之间，不设置金属箔。
27.根据前述权利要求中一项所述的方法，其中，另一折叠过程跟随步骤c，作为步骤d，其中，在进一步的折叠中，所述至少一层热塑性塑料层（6）具有低于该塑料层的熔化温度的温度。
28.根据前述权利要求中一项所述的方法获得的容器（2）。
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