CN105555501A - 用于制造多屏障层吹模容器的方法 - Google Patents

用于制造多屏障层吹模容器的方法 Download PDF

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Publication number
CN105555501A
CN105555501A CN201480044890.4A CN201480044890A CN105555501A CN 105555501 A CN105555501 A CN 105555501A CN 201480044890 A CN201480044890 A CN 201480044890A CN 105555501 A CN105555501 A CN 105555501A
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China
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material sheet
pipe
barrier
layers
layer
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CN105555501B (zh
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V·A·乔谷尔
R·H·埃雷西
D·T·福斯特
H·S·博温
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Printpack Illinois Inc
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Printpack Illinois Inc
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    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/22—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor using multilayered preforms or parisons
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04—Extrusion blow-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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/36—Bending and joining, e.g. for making hollow articles
    • B29C53/38—Bending and joining, e.g. for making hollow articles by bending sheets or strips at right angles to the longitudinal axis of the article being formed and joining the edges
    • B29C53/48—Bending and joining, e.g. for making hollow articles by bending sheets or strips at right angles to the longitudinal axis of the article being formed and joining the edges for articles of indefinite length, i.e. bending a strip progressively
    • B29C53/54—Guiding, aligning or shaping edges
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
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    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
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    • B65D1/0207—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by material, e.g. composition, physical features
    • B65D1/0215—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by material, e.g. composition, physical features multilayered
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    • B29C2949/30—Preforms or parisons made of several components
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Laminated Bodies (AREA)
  • Wrappers (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Containers And Plastic Fillers For Packaging (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

本发明提供了制备容器的方法，其包括：提供材料薄片(200)，其具有至少2个屏障层(204)和至少2个聚合物层(202)；将所述的材料薄片形成管(312)；在密封区域密封所述的管；以及在密封区域吹模所述的管，从而形成其中至少2个屏障层在密封区域形成基本连续的屏障的容器。

Description

用于制造多屏障层吹模容器的方法
技术领域
本发明公开总体而言涉及容器的制造，更具体而言，本发明公开涉及用于制造多屏障层吹模容器的方法。
背景技术
可以通过多种工艺制造瓶和其他容器，例如热成型、滚塑、吹模或挤出吹模成型。可以由单层或多层材料生产多种容器。在多层材料中可以包含屏障层，从而延长食品或饮料产品的货架期，其中所述的食品或饮料产物待包装于由所述的多层材料制备的容器中。例如可以使用屏障层，其中待包装的产品对某种气体是敏感的，或者会损失挥发物、风味或芳香。
但是，整体屏障性能通常会发生损失，其中在屏障层之间的间隙存在于容器的熔接或密封区域。因此，需要制备在这些密封区域具有改进的屏障性能的容器的方法。
发明概述
在一个方面中，制备容器的方法包括：(i)提供材料薄片，其具有至少2个屏障层和至少2个聚合物层；(ii)将所述的材料薄片形成管；(iii)在密封区域密封所述的管；以及(iv)对所述的管进行吹模，从而形成其中至少2个屏障层在密封区域形成基本连续的屏障的容器。
在另一个方面中，制备容器的方法包括：(i)提供材料薄片，其具有设置于至少2个聚合物层之间的至少2个乙烯乙烯醇屏障层；(ii)将所述的材料薄片形成管；(iii)在密封区域搭接密封(lapsealing)所述的管；(iv)加热所述的管；以及(v)紧靠模具吹制所述的管，从而形成其中至少2个乙烯乙烯醇屏障层在密封区域形成基本连续的屏障的容器。
附图简述
图1为横截面图，其示出了现有技术的薄片材料的一个实施方案。
图2为横截面图，其示出了薄片材料的一个实施方案。
图3为立体图，其示出了用于制备吹模容器的仪器的一个实施方案。
图4为横截面图，其示出了单屏障层吹模容器的搭接密封区域。
图5为照片，其示出了单屏障层吹模容器的搭接密封区域。
图6为横截面图，其示出了多屏障层吹模容器的搭接密封区域。
图7为横截面图，其示出了多屏障层吹模容器的搭接密封区域。
图8为横截面图，其示出了单屏障层吹模容器的翅形密封(finseal)区域。
图9为横截面图，其示出了多屏障层吹模容器的翅形密封区域。
发明详述
本发明通过提供用于制造具有改进的屏障层性能的容器的方法而解决了上述需要。容器以及制备容器的方法的多个实施方案如下文所述。分别描述多个实施方案的不同步骤、部件和特征的参数，但是可以一致地结合在本说明书和权利要求书中，从而还能够用于本领域那些技术人员可以理解的其他的实施方案中。
在某些实施方案中，用于制备容器的方法包括：(i)提供材料薄片，其具有至少2个屏障层和至少2个聚合物层；(ii)将所述的材料薄片形成管；(iii)在密封区域密封所述的管；以及(iv)对所述的管进行吹模，从而形成其中至少2个屏障层在密封区域形成基本连续的屏障的容器。如本文所用，术语“基本连续的”是指由密封区域处的屏障层形成的屏障，其中所述的屏障层在密封区域上很大程度上是未破损的或未间断的。换言之，如果在形成屏障的2个屏障层之间不存在间隙，或者如果2个屏障层之间的间隙为大约1nm或更低，则该屏障是“基本连续的”。例如氧分子的范德华半径为152pm，这样低于300pm的间隙将小于氧分子。1nm或更低的间隙将提供氧气和其他气体的基本屏障。
通过这些方法制造的容器在密封区域可以具有基本连续的屏障，从而提供食品和饮料包装应用的改进的屏障性质。
材料薄片
如图2所示，材料薄片200包括3个聚合物层202，作为内部层设置在2个外部聚合物层之间的2个屏障层204，以及4个粘合剂层206。粘合剂层可以设置在聚合物层和屏障层之间，2个聚合物层之间，或者2个屏障层之间。备选地，聚合物层和/或屏障层彼此可以相邻设置，而在它们之间不具有粘合剂层。
在某些实施方案中，材料薄片是共挤出的或层压的。例如材料薄片的厚度可以为大约0.2mm至大约3.0mm，例如大约0.2至大约1.0mm，大约1.0mm至大约3.0mm，或者大约0.5mm至大约1.5mm。
可以预见材料薄片的多种构造。例如至少2个聚合物层的2个层可以为薄片的外部层，而至少2个屏障层可以为设置在外部层之间的内部层。第一粘合剂层可以设置在第一外部层和第一内部层之间，并且第二粘合剂层可以设置在第二外部层和第二内部层之间。
多于2个聚合物层和/或多于2个屏障层可以以多种构造排布于材料薄片中。例如材料薄片可以包含设置于2个外部聚合物层之间的3、4、5或更多的屏障层，以及可任选的在屏障层之间包含的一个或多个其他的聚合物层。在某些实施方案中，屏障层设置在材料薄片的外部层的附近。例如屏障层可以与外部聚合层相邻设置，并且可任选地在它们之间具有粘合剂层。
在一个实施方案中，如图7所示，材料薄片700包含2个外部聚合物层702，3个屏障层704，以及设置于屏障层/屏障层界面与屏障层/聚合物层界面之间的4个粘合剂层706。
在某些实施方案中，聚合物层包含热塑性聚合物。例如聚合物层可以包含聚烯烃，例如聚丙烯或聚乙烯；聚苯乙烯类，例如聚苯乙烯；聚酯，例如聚对苯二甲酸乙二醇酯；聚乳酸；后消费树脂；回收再生料(recycledregrinds)；或者它们的任意的组合。材料薄片的实施方案可以包含不同的聚合物层或者基本相似的聚合物层的组合。例如聚合物层的总厚度可以为整体材料薄片厚度的大约1％至整体材料薄片厚度的大约95％，例如整体材料薄片厚度的大约10至大约50％，整体材料薄片厚度的大约25至大约75％，或者整体材料薄片厚度的大约55至大约95％。在一个实施方案中，各个聚合物层的厚度范围为整体材料薄片厚度的大约30至大约60％。
如本文所用，术语“屏障层”是指可以用作限制气体在整个材料薄片中流动的屏障的任何材料层。例如屏障层可以有效地限制挥发物、风味或芳香免于由该屏障层制备的容器中损失。在某些实施方案中，屏障层限制氧气由其中流动通过，从而保护食品或饮料物品被包装在容器中。
例如屏障层可以包含乙烯乙烯醇、尼龙、聚偏氯乙烯、液体结晶聚合物或它们的任意的组合。此外，屏障层还可以包含屏障增强添加剂，例如纳米添加剂或氧清除剂。材料薄片的实施方案可以包含不同屏障层或基本相似的屏障层的组合。例如每个屏障层的氧气传输速率可以为大约0.01至大约0.1cm3·mil/100m2/天/atm，例如大约0.025至大约0.05cm3·mil/100m2/天/atm，大约0.01至大约0.05cm3·mil/100m2/天/atm，或者大约0.025至大约0.075cm3·mil/100m2/天/atm。
例如屏障层的总屏障厚度可以为整体材料薄片厚度的大约1％至整体材料薄片厚度的大约50％，例如整体材料薄片厚度的大约10至大约40％，整体材料薄片厚度的大约25至大约50％，或者整体材料薄片厚度的大约1至大约30％。
在某些实施方案中，粘合剂层包含接枝有官能团(例如马来酸酐)的聚丙烯，接枝有官能团(例如马来酸酐)的聚乙烯，聚苯乙烯/聚丙烯共聚物(例如互穿共聚物)，聚苯乙烯/聚乙烯共聚物(例如互穿共聚物)，或者它们的任意的组合。在单一的材料薄片中可以使用相似的或不同的粘合剂层。
在某些实施方案中，材料薄片可以包含一个或多个印刷层。
制备容器的方法
用于制备容器的方法可以包括：(i)提供材料薄片，其具有至少2个屏障层和至少2个聚合物层，如上文所述；(ii)将所述的材料薄片形成管；(iii)在密封区域密封所述的管；以及(iv)对所述的管进行吹模，从而形成其中至少2个屏障层在密封区域形成基本连续的屏障的容器。
如图3所示，向仪器300提供一卷材料薄片310。使材料薄片310在管形成部分314形成一个或多个管312。例如材料薄片可以围绕芯棒形成管形。然后，将管312在密封部分316处密封，并通过模具320吹制，从而形成容器322。由于材料薄片310包含至少2个屏障层，所以由其形成的容器322在密封区域具有改进的屏障，例如消除气体泄漏的基本连续的屏障。此外，由这些方法制备的容器在其他的密封区域还可以展示出改进的屏障性质，其中所述的密封区域是在吹模步骤中例如在任何翅焊区域(finweldarea)处创建的。
在某些实施方案中，如图3所示，制备容器的方法还包括将材料薄片310切成多于1个的条带，并将每个条带形成管312。例如可以沿机器方向切开材料薄片。
在某些实施方案中，使用搭接密封来密封所述的管。可以使用本领域普通技术人员已知的方法来密封所述管。例如可以使用热焊接、超声波焊接、感应焊接技术来密封所述管。例如所述的管可以沿着搭接密封在纵向方向上密封。
在某些实施方案中，在加热部分318处加热所述的管312。例如对所述的管进行吹模的步骤可以包括加热所述的管以及紧靠模具吹制所述的管。例如可以紧靠冰冷的模具来吹制所述的管，然后可以将形成的容器由模具上分离并释放下来。可以使用这些方法以成型-填料-密封类型的操作来制造容器，其中所述的容器在连续的工艺中成型、填满产品并密封。
吹模可以有利地用于制造具有多种形状和尺寸的容器。因此，这些方法允许用于制造具有改进的屏障性质的、不同尺寸和形状的容器。
可以参照以下非限定性实例而进一步理解本发明。
实施例
根据上述方法，但是使用具有单一屏障层的材料薄片来制备比较样品，其中所述的单一屏障层夹在2个聚合物层之间。例如图1示出了材料薄片100，其具有夹在2个具有粘合剂层106的聚合物层102之间的单一屏障层104。单一屏障层材料薄片被卷曲成管，使用搭接密封来密封，加热并吹模从而形成容器。这些样品中的一个样品的搭接密封区域的横截面照片示于图5中。如图5可见，比较样品的屏障在密封区域不是连续的。而且，在重叠部分处在屏障层之间存在大的聚合物层间隙。这种非连续的屏障层使得整体屏障性能损失。例如这种性能损失可以允许氧气渗透过容器，降低包装于该容器中的食品或饮料产品的货架期。
图4示出了由单一屏障层材料薄片形成的搭接密封区域。而且，在搭接密封区域401处的屏障层404之间存在大的聚合物层间隙。图8示出了由具有单一屏障层804的材料薄片形成的翅形密封区域801。
根据上述方法，并使用具有3个屏障层的材料薄片来制备样品，其中所述的3个屏障层夹在2个聚合物层之间。将多个屏障层的材料卷成管，使用搭接密封来密封，加热并吹模，从而形成容器。这些样品的一个样品的搭接密封区域的横截面示意图示于图7中。如图7可见，比较样品的屏障704在密封区域是基本连续的。这种基本连续的屏障限制气体透过容器的能力，并限制了挥发物、芳香和风味消散的能力。这些改进的屏障容器为其中包装的食品和饮料产品提供了延长的货架期。
图6示出了由多屏障层材料薄片的另一个实施方案形成的搭接密封区域。如所示，一旦屏障层604在吹模工艺中被加热，屏障层604便定位，从而在搭接密封区域601形成基本连续的屏障。图9示出了由具有多个屏障层904的材料薄片形成的翅形密封区域901。与搭接密封区域类似，由多个屏障层材料薄片形成的翅形密封区域在密封的区域处还展现出改进的屏障，例如消除气体泄漏的基本连续的屏障。
应该理解的是多个上文公开的以及其他的特征和功能、或者它们的备选特征和功能可以理想地结合在许多其他不同的产品或应用中。本领域的那些技术人员随后可以制备许多目前未预见的或意料之外的备选特征和功能，它们的修改、改变或改进，这些备选特征和功能，它们的修改、改变或改进也将涵盖在所附的权利要求书中。

Claims (21)

1.一种制备容器的方法，其包括：
提供材料薄片，该材料薄片包含至少2个屏障层和至少2个聚合物层；
将所述的材料薄片形成管；
在密封区域密封所述的管；以及
对所述的管进行吹模，从而形成其中所述的至少2个屏障层在所述的密封区域形成基本连续的屏障的容器。
2.权利要求1所述的方法，其中所述的至少2个聚合物层的2个聚合物层为外部层，并且所述的至少2个屏障层为设置于所述的外部层之间的内部层。
3.权利要求2所述的方法，其中：
所述的材料薄片进一步包含至少2个粘合剂层；
第一所述的至少2个粘合剂层设置于第一所述的外部层和第一所述的内部层之间；以及
第二所述的至少2个粘合剂层设置于第二所述的外部层和第二所述的内部层之间。
4.权利要求1所述的方法，其进一步包括：
将所述的材料薄片切成多于1个的条带，然后将所述的材料薄片形成管，其中将所述的材料薄片形成管包括将所述的多于1个条带的每一个均形成管。
5.权利要求4所述的方法，其中所述的材料薄片沿着机器方向切开。
6.权利要求1所述的方法，其中将所述的材料薄片形成管包括围绕芯棒使所述的材料薄片成型。
7.权利要求1所述的方法，其中所述的管在纵向上密封。
8.权利要求1所述的方法，其中将所述的管密封包括将所述的管搭接密封。
9.权利要求1所述的方法，其中将所述的管吹模包括加热所述的管，并紧靠模具吹制所述的管。
10.权利要求1所述的方法，其中所述的至少2个聚合物层包含热塑性聚合物。
11.权利要求1所述的方法，其中所述的至少2个聚合物层包含聚丙烯、聚苯乙烯、聚乙烯、聚对苯二甲酸乙二醇酯、聚乳酸或它们的任意的组合。
12.权利要求1所述的方法，其中所述的至少2个屏障层包含乙烯乙烯醇、尼龙、聚偏氯乙烯或它们的任意的组合。
13.权利要求1所述的方法，其中所述的材料薄片是共挤出的或层压的。
14.权利要求2所述的方法，其中所述的材料薄片进一步包含设置于所述的内部层之间的内部聚合物层。
15.权利要求1所述的方法，其中所述的材料薄片的厚度为大约0.2mm至大约3.0mm。
16.权利要求1所述的方法，其中所述的至少2个屏障层的总厚度为所述的材料薄片的厚度的大约1％至所述的材料薄片的厚度的大约50％。
17.权利要求1所述的方法，其中所述的至少2个屏障层的每一个屏障层的氧气传输速率为大约0.01cm3·mil/100m2/天/atm至大约0.1cm3·mil/100m2/天/atm。
18.权利要求1所述的方法，其中所述的至少2个聚合物层的总厚度为所述的材料薄片的厚度的大约1％至所述的材料薄片的厚度的大约95％。
19.权利要求1所述的方法，其中所述的至少2个粘合剂层包含接枝有官能团的聚丙烯，接枝有官能团的聚乙烯，聚苯乙烯/聚丙烯共聚物，聚苯乙烯/聚乙烯共聚物，或者它们的任意的组合。
20.权利要求1所述的方法，其包含2个聚合物层、3个屏障层和4个粘合剂层，其中所述的2个聚合物层为外部层。
21.制备容器的方法，其包括：
提供材料薄片，该材料薄片具有设置于至少2个聚合物层之间的至少2个乙烯乙烯醇屏障层；
将所述的材料薄片形成管；
在密封区域搭接密封所述的管；
加热所述的管；以及
紧靠模具吹制所述的管，从而形成其中所述的至少2个乙烯乙烯醇屏障层在所述的密封区域形成基本连续的屏障的容器。
CN201480044890.4A 2013-08-12 2014-08-07 用于制造多屏障层吹模容器的方法 Expired - Fee Related CN105555501B (zh)

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CA2920332A1 (en) 2015-02-19
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