CN105431270B - 具有内表面的表面涂层的注射模具 - Google Patents

具有内表面的表面涂层的注射模具 Download PDF

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CN105431270B
CN105431270B CN201480035799.6A CN201480035799A CN105431270B CN 105431270 B CN105431270 B CN 105431270B CN 201480035799 A CN201480035799 A CN 201480035799A CN 105431270 B CN105431270 B CN 105431270B
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mold
layer
prefabricated component
wall
pet
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CN105431270A (zh
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马泰奥·佐帕斯
劳伦特·西格勒
迪诺·恩里科·赞恩
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S I P A 工业设计自动化合伙股份有限公司
SIPA Industrializzazione Progettazione e Automazione SpA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B29B11/08—Injection moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/37—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3842—Manufacturing moulds, e.g. shaping the mould surface by machining
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
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    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
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    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/40—Oxides
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    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
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    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/40—Oxides
    • C23C16/405—Oxides of refractory metals or yttrium
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    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
    • C23C16/455—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
    • C23C16/45523—Pulsed gas flow or change of composition over time
    • C23C16/45525—Atomic layer deposition [ALD]
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
    • C23C16/455—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
    • C23C16/45523—Pulsed gas flow or change of composition over time
    • C23C16/45525—Atomic layer deposition [ALD]
    • C23C16/45555—Atomic layer deposition [ALD] applied in non-semiconductor technology
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/24—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/07—Preforms or parisons characterised by their configuration
    • B29C2949/0715—Preforms or parisons characterised by their configuration the preform having one end closed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
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    • B29K2105/253—Preform
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2267/00—Use of polyesters or derivatives thereof as reinforcement
    • B29K2267/003—PET, i.e. poylethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2467/00—Use of polyesters or derivatives thereof as filler
    • B29K2467/003—PET, i.e. polyethylene terephthalate
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Abstract

用于PET瓶的吹制模具具有在吹制操作期间接触热的PET的内表面，该内表面被涂覆有具有纳米级厚度的陶瓷材料的层，该层的至少一个厚度层是通过ALD技术沉积的Al2O3和/或TiO2。由于此技术，PET预制件在与模具的内部接触期间经受较少的摩擦。

Description

具有内表面的表面涂层的注射模具
技术领域
本发明涉及产生由热塑性材料制成的容器的领域。特别地，其涉及一种模具，该模具在用于模制预制件的工艺中的注射步骤期间减少熔融的PET材料与模具的模制部件的钢表面之间的物理和化学反应，从而减少摩擦。
背景技术
在注射模制的过程中，发生聚合材料向具有确定的形状的制品的转变，所述聚合材料典型地是热塑性塑料，例如呈颗粒形式的PET。该过程开始于熔融材料向通常具有由钢制成的壁的模制空腔(molding cavity)的高压注射，并且结束于在通过冷却的固化后预制件从模具中的取出。冷却模式和时间在模制过程中是关键因素。通过冷却时间，其意指其中组分在模具内，但不再有熔融材料的流动的时间。实际上，熔融材料的冷却的物理现象一经此被注入空腔中并与如所述的通常由钢制成的冷的模具的壁接触就开始。此快速冷却的现象可以导致熔融物质或其一部分在其能够到达模具表面之前的冷却。为了发生模具的完全填充，注射速度和压力必须是足够高的以抵消熔融物质的快速冷却的现象。为了采用薄壁模制PET预制件，需要更高性能的机器，因为在此情况下，快速冷却的问题被更突出，此外，熔融物质与模具的钢壁的摩擦的结果可能是更显著的。结果是变形或不完全的预制件(注量不足)的潜在风险。已知的是，在PET容器工业中，具有大于或等于100mm的总长度L以及大于50的L/t比率(其中“t”是壁的厚度)的预制件的注射模制由于以上原因而是特别地脆弱的。使用传统的设备、模具和材料来模制具有大于50的L/t比率的预制件导致难以克服的技术困难。实际上，为了抵消材料在注射期间的冷冻的现象，高注射速度和高压将被需要。特别地，后者将对形成模具的元件产生强的力，并且所述元件应该被相对以通过必要的另外的压机压板(press platen)的强闭合力防止其不期望的打开。
所有这种所涉及的力的一般增加都将导致形成模具的元件以及形成注射压机的元件的高磨损，如果还不是损坏的话。
除了上述的技术问题以外，在任何情况下都将不存在获得预制件的正确模制的必然性。事实上，熔融材料的高模制压力和高速度将在第一方面导致在预制件上出现毛边(burr)(毛刺(flash))，并且在第二方面导致在由熔融材料填充的操作期间难以从模制空腔排出空气和气体。此第二现象再次导致预制件的某些部件的不完全形成并且特别是颈部端面(neck end surface)、螺纹和夹圈的齿顶(crest)。
此外，与具有薄壁的预制件的模制相关的参数必要地具有非常窄的工艺窗口(要求非常小的合适的温度和压力范围)，并且因此不完全形成(注量不足)的风险增加且废品数也是这样。相同的问题对于具有低于100mm的长度、具有大于45的L/t比率的预制件可能已经遇到。为了改善和便于填充以及注入具有在60与65之间的L/t比率的预制件的能力，考虑到聚合物的粘度高度依赖于其在工艺期间的温度，一种权宜之计可能是在注射步骤期间增加熔融PET的温度，使得PET保持更多的流动性。此权宜之计可能有帮助，但其主要的缺点是温度增加对模制周期的持续时间的负面影响，因为熔融PET的温度越高，该周期的持续时间越长，原因是较长的冷却时间和因此系统的较低的生产率。在这些条件下，另一个缺点在于乙醛水平的急剧的但不期望的增加，并且这是对于产生用于饮料的容器的另外的问题，特别是味道的质量是关键性因素的那些饮料，例如水。在工业中另一个众所周知的权宜之计是改变钢表面的终饰以减少钢与PET之间的机械相互作用。这可以通过应用表面修饰(surface finish)来获得，例如重现因其抗粘性和自洁性而被已知的荷叶的表面的表面修饰。然而迄今为止，已知的是，没有能够改善具有薄壁的预制件的产生的解决方案，并且对于具有小于100mm的L且具有L/t比率>45的薄壁的预制件以及对于具有L≥100mm且具有L/t>50的薄壁的预制件这两者，都存在技术限制，如先前所公开的。传统的模具的另外的缺点在于从模具打开和移除预制件(脱模)的困难。因此意识到找到该问题的解决方案的需求。
发明内容
本发明的主要目的是找到改善薄壁的预制件的产生的方法，即具有大于50的L/t比率的具有典型地但不是必要地大于或等于100mm的预制件，或具有低于100mm的长度的具有大于45的L/t比率的预制件。该目的通过减少熔融PET材料与模具的模制钢表面之间的摩擦经由它们的化学-物理相互作用的减少来实现。因此提出了一种系统，其减少化学-物理相互作用并且不是直接地机械的相互作用，并且其在于应用能够显著减小这些化学-物理相互作用的、模制钢表面的薄涂层。该目的因此通过具有钢壁的根据权利要求1的用于通过注射模制从热塑性材料产生预制件的模具来实现，该模具包括涂层，该涂层具有涂覆模具的壁或模制表面的、具有在10nm与1000nm之间的厚度的材料或纳米材料的至少一个陶瓷层或纳米层，由此，在热塑性材料与模具壁之间的摩擦系数等于或小于0.14。
有利地，陶瓷材料是Al2O3、TiO2或TiN或TiAlN或CrN和CrC或AlN等。有利地，所述至少一层可以是复合纳米层，例如其中单个纳米层还可以各自由不同的材料制成的夹层或多层结构。例如，在具有两个纳米层的复合纳米层的情况下，材料可以是Al2O3和TiO2，优选地具有在90nm与120nm之间的总涂层厚度，使得在热塑性材料与模具壁之间的摩擦系数是约0.13。夹层涂层的实例包括第一陶瓷材料的第一层、不同于第一层的陶瓷材料的第二层、和等于第一层的陶瓷材料的第三层。更具体地，夹层涂层可以，例如，分别由Al2O3-TiO2-Al2O3的三个叠加的层组成。
优选地，模具被提供用于产生PET预制件。PET或聚对苯二甲酸乙二醇酯是世界上用于产生用于食品包装的容器(特别是各种尺寸的瓶)的最多使用的材料，原因是其优良的化学和物理性质，特别是在对最终用户非常重要的表面质量方面。
有利地，借助于本发明的模具，产生减少加工时间和周期的、获得高质量产品的PET预制件是可能的。
有利地，借助于本发明的模具，相比于传统的模具，预制件的脱模的操作被大大改善。
本发明的另一个目的是提供一种用于获得所述钢模具的根据权利要求8的工艺，所述钢模具具有与热塑性材料减小的化学相互作用，这样的方法包括：
-清洁模具壁的表面的步骤，
-抛光模具壁的步骤，
-通过沉积至少一层在10nm与1000nm之间的范围中的厚度的陶瓷材料来涂覆模具壁的步骤。
有利地，提供清洁和/或抛光步骤用于最小化在钢与熔融热塑性材料之间的摩擦系数，例如，最小化至约0.20的值。
优选地，用于产生PET预制件的模具采用此工艺获得。
有利地，沉积过程使用被称为原子层沉积(ALD)的技术。有利地，沉积过程是使用ALD连同其他技术例如化学气相沉积(CVD)、压力蒸气沉积(Pressure Vapor Deposition)(PVD)或其他的工艺。
本发明的优选实施方案的描述
使用ALD技术以及诸如PVD或CVD的、单独的或组合的其他技术进行特定涂层的应用，这是为了减少在熔融PET的物质与用于注射模制的模具的钢的模制表面或臂之间的化学-物理相互作用。在PET的物质与钢之间的化学-物理相互作用的减少以及因此分子的附着的减少，意指在PET与钢之间的摩擦的减少以及因此更容易的注射，具有减少的“注量不足”的风险。用于涂覆模制表面的最化学惰性的材料是薄的基于陶瓷的纳米复合材料涂层，例如Al2O3、TiN、TiO2或TiAlN或CrN或CrN和AlN等。除了减少化学-物理相互作用、减少在熔融材料与模制表面之间的摩擦系数，这些纳米结构化的涂层还已经示出，对于某些质量，例如均一度、硬度、对断裂、磨损、腐蚀的抗性，优于标准涂层，这还产生处理的表面的更好的终饰。在沉积之前对交叠的模制表面的清洁是工艺的关键要素。进行表面的抛光，以便获得已经较低的摩擦系数，还期望预制件从模具中脱离的后续工艺并且还为了准备用于沉积过程的表面。在已经进行抛光后，可以进行陶瓷纳米材料的一个或更多个纳米层的沉积过程。沉积的粘附力及其耐久性也是关键要素，因为其被提供为，沉积应当保持附着于钢表面持续几百万周期的预制件产生。因此必须找到在一个或更多个层的厚度与机械强度之间的适当的平衡，所述厚度涉及沉积的持续时间，甚至是在随时间过去的耗损的情况下，所述机械强度对于薄的层较大。这些要素还依赖于用于沉积的材料并且使用具有不同材料的双层可以提供在选择上的较大灵活性，改变单层的相对厚度以及它们的组成是可能的。
实施例
本发明的另外的优点从下表中是明显的，在下表中，存在作为非限制性实例提供的模具的实例。

Claims (4)

1.一种模具，所述模具具有钢壁，所述模具适合用于通过注射模制产生由PET制成的预制件，其中所述预制件用于通过吹制生产容器，所述模具包括具有在90nm与120nm之间的厚度的陶瓷材料的涂层，所述涂层涂覆所述模具的所述壁，其中所述涂层由Al2O3的层制成或包括由Al2O3制成的第一层和由TiO2制成的第二层，适于产生当L>100mm时具有L/t>50的预制件，或当L<100mm时具有L/t>45的预制件，其中“L”和“t”分别是所述预制件的总长度和所述预制件的壁厚度。
2.一种用于获得根据权利要求1的模具的工艺，所述模具具有与所述PET的减小的化学相互作用，这样的工艺包括：
-清洁模具壁的表面的步骤，
-抛光所述模具壁的步骤，
-在所述模具壁上沉积具有在90nm与120nm之间的范围中的厚度的陶瓷涂层的步骤，所述陶瓷涂层由Al2O3的层制成或包括由Al2O3制成的第一层和由TiO2制成的第二层。
3.根据权利要求2所述的工艺，其中ALD技术被提供用于沉积所述陶瓷涂层。
4.根据权利要求1的模具用于产生由PET制成的预制件的用途，所述预制件当L>100mm时具有L/t>50，或当L<100mm时具有L/t>45，其中“L”和“t”分别是所述预制件的总长度和所述预制件的壁厚度。
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