CN112789151B - 制品成型的方法 - Google Patents

制品成型的方法 Download PDF

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CN112789151B
CN112789151B CN201980062240.5A CN201980062240A CN112789151B CN 112789151 B CN112789151 B CN 112789151B CN 201980062240 A CN201980062240 A CN 201980062240A CN 112789151 B CN112789151 B CN 112789151B
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cavity
plastic composition
pressure
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P·克拉克
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Bockatech Ltd
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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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/027—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles the foaming continuing or beginning when the mould is opened
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/0407—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by regulating the temperature of the mould or parts thereof, e.g. cold mould walls inhibiting foaming of an outer layer
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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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    • B—PERFORMING OPERATIONS; TRANSPORTING
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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
    • B65D1/40—Details of walls
    • B65D1/42—Reinforcing or strengthening parts or members
    • B65D1/44—Corrugations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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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)
  • Ceramic Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)

Abstract

本发明提供一种由包含聚合物和发泡剂的熔融塑料组合物成型制品的方法。本方法提供了，在注射步骤(c)和保压步骤(d)期间，腔体(8)的至少一个第二区(32)中注射压力和保压压力分别维持在最低压力阈值以上，以维持物理发泡剂作为溶解于聚合物中的气体，以便在该至少一个第二区中基本上不形成气泡，在开模步骤(e)期间，至少一些所述熔融塑料组合物暴露于低于最低压力阈值的外部压力下，以在制品中形成至少一个包含由所述塑料组合物形成的发泡蜂窝状泡沫体的第一部分，和在开模步骤(e)之前，腔体的所述至少一个第二区中的塑料组合物已经被冷却以使其完全固化，从而在制品中形成至少一个包含基本上均匀的固相未发泡塑料组合物的第二部分。

Description

制品成型的方法
本发明涉及泡沫塑料制品例如用于食物的杯子或容器的成型方法。
在包装工业中，常用类型的一次性杯子(例如，外卖咖啡杯)是带有塑料内衬例如低密度聚乙烯(LDPE)的纸杯。由于这些杯子是由两种不同的材料制成的，很难分开和/或成本高昂，因此它们回收就具有挑战性。此外，由于杯子的一侧有纸质材料接合的接缝，因此，当倾斜杯子以饮用杯中的饮料时(特别是杯子与带饮料饮用口的盖子连接使用时)液体可能从杯的接合接缝漏出。
业界已经在努力提供一次性聚丙烯杯。在常规的注射成型中，需要厚壁以在杯中形成一定的隔热。一般来说，多孔结构会提供隔热，将发泡剂添加到热塑性聚合物中以产生泡沫结构来进一步改善隔热并降低发泡壁的密度。
WO-A-2017/134181公开了一种制品和该制品成型的方法，其中所述制品是具有发泡区和未发泡区的聚丙烯杯。由于在发泡区中形成了蜂窝状泡沫体，故其变得半透明。还公开了因为在未发泡区中形成了一些发泡的泡孔，因而其变为半透明的。期望的是，未发泡区中没有蜂窝状泡沫体而使其变的透明，即视觉上清亮。但是，困难的是如何控制工艺以实现透明或视觉上清亮的未发泡区。
本发明的目标是至少部分地克服在制品中同时获得半透明的发泡蜂窝状泡沫区和透明的即视觉上清亮的未发泡区的问题。
本发明提供根据权利要求1的制品的成型方法。
本方法的优选特征在从属权利要求中定义。
本发明方法成型的制品可以具有任何形状、形态或功能。但是，本发明在中空制品例如杯子或任何其它用于容纳液体的容器或器皿的制造中具有特定的应用。
本发明的优点在于通过本方法成型的制品易于回收和再利用，具有由发泡区提供的高水平刚度且还具有由发泡区提供的良好的隔热性，还结合有可提供制品结构和/或美学特性的未发泡区。
未发泡区是透明的或视觉上清亮的。
本发明至少部分地基于本发明人的以下发现，即在注射和保压阶段使压力控制与最小阈值压力相关联能够可靠地确保当制品暴露于减压例如大气压进行膨发形成发泡区过程中制品一些区域不会膨发。
本发明人还发现，尽管其中使用的材料量减少，但通过本发明方法生产的制品仍具有此类制品所需的刚度水平。已经发现，当蜂窝状泡沫塑料组合物(一般是热塑性聚合物如聚烯烃、典型是聚丙烯)缓慢冷却时，因其隔热性质，塑料组合物的结晶度可以增加，这反过来又可以增加泡沫塑料组合物的刚性。通过发泡使第一皮层和第二皮层之间的熔融塑料组合物膨发也为制品提供了良好的隔热性能。
另外，由于整个容器可以由单层可回收材料制成(即没有需要分离的不同材料层)，因此该容器比常用的带塑料衬里的纸杯更易于回收。
而且，由于本发明方法中制品是注塑成型，因此制品中不存在可能会使盛装液体泄漏的接合处。
现在将参考附图仅通过示例的方式来描述本发明的具体实施方案，其中：
图1是通过本发明具体实施方案的方法成型的杯子的侧视图。
图2是图1杯子的第一部分的线A-A的截面图，例示说明本发明方法中在不同阶段时杯子的发泡半透明区的外观；和
图3是图1杯子的第二部分的线B-B的截面图，例示说明本发明方法中在不同阶段时杯子的未发泡透明区的外观。
参照图1，示出了通过本发明方法成型的制品(例如，诸如咖啡杯之类的杯子)的侧视图。
杯子100具有环状侧壁102，其具有环状发泡区104和环状未发泡区106。在本说明书中，术语“环状”是指“总体环状”，不限于几何圆形，涵盖了圆形或非圆形的形状如椭圆形、多边形等。发泡的泡沫体104的厚度通常为1-4mm，可选地为1-3mm。未发泡区106的厚度通常为0.25-0.75mm，可选地为0.25-0.5mm。
发泡区104肉眼可见为半透明的，因为发泡的蜂窝状泡沫体包括泡孔壁会反射可见光的泡孔。然而，如果将颜料以高浓度掺入到热塑性聚合物中，则发泡区104一般看起来会是不透明的纯色。
相反，未发泡区106没有泡孔，或者如果存在任何泡孔，例如有低含量存在，则其泡孔尺寸一般小于0.5微米且因此肉眼不可见，故未发泡区106肉眼可见为透明的。未发泡区106肉眼可见为透明的，因为在制品制造过程中发泡剂(本实施方案中为CO2气体)已经留在聚合物(本实施方案中为聚丙烯)的溶液中。熔融聚合物固化后，都不会有任何因发泡剂作用而形成的泡孔。
本发明涉及可靠制造这类同时包括半透明的发泡区104和透明的未发泡区106的制品的方法。
参看图2，示出了线A-A的截面图，例示说明本发明方法中不同阶段时发泡区104的外观。
在图2和3中，为了清楚说明起见，夸大了距离。
参看图2的左侧，制品的发泡区104是使用具有第一环状外部部件12和第二环状内部部件14的模具2来成型的。第一和第二部件12、14分别具有第一和第二型腔表面22a、24a。模具外部部件12的第一型腔表面22a包括波纹25，第一型腔表面22a中的波纹25具有例如呈正弦波形式的峰和谷。就峰和谷的形状和形态而言，正弦波可具有多种不同的构造。第二型腔表面24a优选是光滑的且没有任何起伏。
将模具2闭合，从而在第一和第二型腔表面22a、24a之间限定出腔体8的第一区30。将包含聚合物和物理发泡剂的熔融塑料组合物50注入腔体8中。物理发泡剂是溶解在聚合物中的气体。
在本发明的实施方案中，塑料组合物的聚合物可包含聚烯烃或多种聚烯烃的混合物，任选地是聚乙烯或聚丙烯；或聚酯，任选地是聚对苯二甲酸乙二酯或聚对苯二甲酸丁二酯；或聚乳酸。在优选的实施方案中，聚合物包括聚丙烯。熔体流动指数(MFI)为10-120的聚丙烯是特别优选的。聚合物的熔体流动指数可根据ASTM D1238测量。
可在本发明的实施方式中使用的发泡剂包括溶解在熔融塑料组合物中的呈气体形式的物理发泡剂。这样的气体可包括例如二氧化碳。气体可任选地进一步包括香料组合物(即香味剂)，其在发泡后仍存在于聚合物材料中以增强消费者体验。
当使用二氧化碳作为发泡剂时，CO2气体通过在注塑机的挤出机内的发泡剂产生，然后CO2气体在注射阶段(典型地为300-500bar)进入溶液中，这归因于施加在材料上的压力要高于强迫使CO2进入熔融的热塑性树脂如聚丙烯内溶液所需的压力(典型地是大于75bar)。
熔融塑料组合物以注射压力P注射进行注射。典型地，注射压力P注射至少为150bar。
注射步骤后，在保压步骤中对腔体8施加保压压力P保压。通常，保压压力P保压至少为150bar。
在注射步骤(c)和保压步骤(d)至少之一或二者，将与第一和第二型腔表面22a、24a接触的注入塑料组合物50进行冷却以形成分别与第一型腔表面22a和第二型腔表面24a相邻并接触的第一和第二固体皮层4、6。
在保压步骤(d)之后，在腔体8的至少一个第一区30中，在第一和第二固体皮层4、6之间的至少一些塑料组合物仍保持熔融。
在注射步骤(c)和保压步骤(d)期间，腔体8的第一区30中注射压力P注射和保压压力P保压分别高于最低压力阈值P阈值。典型地，最低压力阈值P阈值为75bar。这样就防止了在第一区30中物理发泡剂部分地从聚合物溶液中释出，以便在注射步骤(c)和保压步骤(d)期间在第一区30中不形成蜂窝状气泡。
参看图2的右侧，此后，在第一和第二固体皮层4、6之间的熔融塑料组合物在腔体8的至少一个第一区30中固化之前，打开模具2。
模腔8的第一区30是厚的，因此熔融的聚合物树脂需要比注射和保压步骤更长的时间周期来冷却和固化。另外，该第一区30可用外部加热器额外加热以使聚合物树脂保持在熔融液相状态。
在开模步骤(e)期间，至少一些熔融塑料组合物暴露于低于最低压力阈值的外部压力例如大气压下，以在制品中形成包含由塑料组合物形成的发泡蜂窝状泡沫体的至少一个第一部分。
因此，开模步骤使得在第一固体皮层和第二固体皮层4、6间的熔融塑料组合物通过发泡而膨发，从而形成发泡蜂窝状泡沫体20。开模步骤包括移去模具2的第一部件12，使第一固体皮层4不再与第一型腔表面22a接触，同时第二固体皮层6仍与第二型腔表面24a接触。在所例示说明的实施方案中，通过移去模具2的外部部件12来实现开模，第一皮层4暴露于大气压下且第二皮层6留在内部部件14上。但是，可以使用任何其它配置来打开模具。
图2的右侧示出了第一固体皮层4、第二固体皮层6和介于第一固体皮层和第二固体皮层4、6间的塑料组合物50，其中塑料组合物10通过发泡而在固体基体40中形成泡孔18得以膨发，然后固化。在图2的右侧，模具的外部部件12已经从制品上移除，且制品留在内部部件14或型芯上。
可以看到，膨发导致第一固体皮层4中成型区域被“吹出”，使成品28在第一和第二固体皮层4、6之间的距离环绕制品一周基本恒定。发泡气体自聚合物溶液中释出而形成发泡的蜂窝状泡沫体。
压力所起的作用是将第一外部固体皮层4与第二内部固体皮层6的距离推大。第一与第二皮层4、6间距离推大是位于保持高浓度发泡剂的区域，所述发泡剂自溶液释出且因此而膨发。发泡的侧壁可以具有在WO-A-2017/134181中公开的棱纹结构。
参看图3，示出了线B-B的截面图，例示说明本发明方法中在相应阶段的未发泡区106的外观。
对应图2，参看图3的左侧，制品的未发泡区106是使用具有第一环状外部部件12和第二环状内部部件14的模具2成型的。
将模具2闭合，从而在第一和第二型腔表面22b、24b之间限定出腔体8的第二区32。第一和第二型腔表面22b、24b形成窄腔区32且优选是光滑和没有任何起伏的。
在注射步骤(c)和保压步骤(d)期间，腔体8的第二区32中注射压力和保压压力分别维持在最低压力阈值以上，以维持物理发泡剂作为溶解于聚合物中的气体，以便在第二区32中基本上不形成气泡。
在开模步骤(e)之前，将腔体8第二区32中的塑料组合物冷却以使其完全固化，从而在制品中形成包含基本上均匀的固相未发泡塑料组合物的至少一个未发泡区106。
型腔8的此第二区32是薄的，因此熔融的聚合物树脂冷却和固化所需时间周期比注射步骤和保压步骤的短。此第二区32还可通过外部冷却器进行额外冷却以使聚合物树脂从熔融液相转变成固相。
因此，任选地，在注射步骤(c)和开模步骤(e)之间，对腔体8的至少一个第二区32进行冷却步骤(f)，将至少一个第二区32中塑料组合物的温度在至少一个第二区32的整个腔体8厚度上冷却至低于塑料组合物的熔融温度。
在注射步骤(c)和保压步骤(d)至少之一或二者，将腔体8第二区32中与第一和第二型腔表面22b、24b接触的注入塑料组合物冷却，成型为分别与第一和第二型腔表面22b、24b相邻并接触的第一和第二固体皮层4、6，以及厚度贯穿腔体8第二区32宽度40的固体壁38。
在腔体8的至少一个第二区32中的保压步骤(d)之后，介于第一和第二固体皮层4、6之间的整个厚度塑料组合物被固化。
参看图3的右侧，此后，在腔体8的至少一个第二区32中的介于第一和第二固体皮层4、6之间的熔融塑料组合物已固化之后，打开模具2。
在开模步骤之后，在第一和第二固体皮层4、6之间的固体塑料组合物不可能通过发泡进一步膨发，且不能形成发泡的蜂窝状泡沫体。因此，未发泡106区肉眼可见是透明的。
在本发明第一方面和第二方面二者中，制品可以是杯子或容器，例如咖啡杯或适合于用微波炉加热汤的容器。制品可以是一次性的或可重复使用的，并且在两种情况下都是可回收的，因为该制品由单一聚合物例如聚丙烯组成。
例示说明的实施方案的各种修改对于本领域技术人员而言将是显而易见的，且旨在将其包括在本发明的范围内。

Claims (13)

1.一种制品成型的方法，所述方法包括：
(a)提供具有第一部件和第二部件的模具，所述第一部件和第二部件分别有第一型腔表面和第二型腔表面；
(b)关闭所述模具，从而在所述第一型腔表面和第二型腔表面之间限定出腔体；
(c)将包含聚合物和物理发泡剂的熔融塑料组合物注入所述腔体中，其中所述物理发泡剂是溶解在所述聚合物中的气体，所述熔融塑料组合物在注射压力下注入；
(d)注射步骤后，在保压步骤中向所述腔体施加保压压力，其中在所述注射步骤(c)和所述保压步骤(d)至少之一或两者期间，与所述第一型腔表面和所述第二型腔表面接触的注入的熔融塑料组合物被冷却以形成分别与所述第一型腔表面和所述第二型腔表面相邻并接触的第一固体皮层和第二固体皮层，且在所述保压步骤(d)之后，在腔体的至少一个第一区中在所述第一固体皮层和第二固体皮层之间的至少一些塑料组合物保持熔融；
(e)在所述腔体的至少一个第一区中的在所述第一固体皮层和第二固体皮层之间的所述熔融塑料组合物固化之前打开所述模具，以使在所述第一固体皮层和第二固体皮层之间的所述熔融塑料组合物通过发泡而膨发以形成发泡的蜂窝状泡沫体，其中开模步骤包括移去所述模具的第一部件，以使所述第一固体皮层不再与所述第一型腔表面接触，同时保持所述第二固体皮层与所述第二型腔表面接触，
其中在所述注射步骤(c)和所述保压步骤(d)期间，所述腔体的至少一个第二区中注射压力和保压压力分别维持在最低压力阈值以上，以维持物理发泡剂作为溶解于聚合物中的气体，以便在所述至少一个第二区中基本上不形成气泡，在开模步骤(e)期间，至少一些所述熔融塑料组合物暴露于低于所述最低压力阈值的外部压力下，以在所述制品中形成包含由所述塑料组合物形成的发泡蜂窝状泡沫体的至少一个第一部分，和
其中开模步骤(e)之前，所述腔体的所述至少一个第二区中的所述塑料组合物已经被冷却以使其完全固化，从而在所述制品中形成包含基本上均匀的固相未发泡塑料组合物的至少一个第二部分。
2.根据权利要求1的方法，其中所述至少一个第二部分在可见光下是透明的。
3.根据权利要求2的方法，其中所述至少一个第一部分在可见光下是半透明或不透明的。
4.根据权利要求1至3中任一项的方法，其中所述聚合物是聚丙烯。
5.根据权利要求1至3中任一项的方法，其中所述最低压力阈值是75bar。
6.根据权利要求1至3中任一项的方法，其中所述发泡剂是二氧化碳。
7.根据权利要求1至3中任一项的方法，其中在所述注射步骤(c)期间，所述注射压力为至少150bar。
8.根据权利要求1至3中任一项的方法，其中在所述保压步骤(d)期间，所述保压压力为至少150bar。
9.根据权利要求1至3中任一项的方法，其中在所述开模步骤(e)期间，所述第一固体皮层暴露于大气且所述外部压力为大气压力。
10.根据权利要求1至3中任一项的方法，其中在所述注射步骤(c)和所述开模步骤(e)之间，对所述腔体的所述至少一个第二区进行冷却步骤(f)以将所述至少一个第二区中的所述塑料组合物在所述至少一个第二区的整个腔体厚度上冷却至低于塑料组合物的熔融温度。
11.根据权利要求1至3中任一项的方法，其中所述制品是中空制品，并且所述第一部件和第二部件分别具有第一环状型腔表面和第二环状型腔表面，且在步骤(b)中所述腔体是在第一和第二环状型腔表面之间的环状腔体。
12.根据权利要求11的方法，其中所述第一部件和第二部分分别是形成所述中空制品的外表面和内表面的外部部件和内部部件。
13.根据权利要求12的方法，其中所述中空制品是杯子、瓶子、盆或碗。
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