CN1331653C - 制造空心制品的方法,和由该方法获得的空心制品、预成形体和瓶子 - Google Patents

制造空心制品的方法,和由该方法获得的空心制品、预成形体和瓶子 Download PDF

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CN1331653C
CN1331653C CNB028223381A CN02822338A CN1331653C CN 1331653 C CN1331653 C CN 1331653C CN B028223381 A CNB028223381 A CN B028223381A CN 02822338 A CN02822338 A CN 02822338A CN 1331653 C CN1331653 C CN 1331653C
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polyester
bottle
hollow bodies
preform
acid
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CN1585694A (zh
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J－L·勒佩吉
G·罗伯特
P·贝克里奇
G·佩雷兹
D·达拉斯
F·莱特克
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Tergal Industries
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    • 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
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    • 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
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Abstract

本发明涉及利用聚酯注射吹塑法的空心制品的制造，更具体地说，用于包装液体食品如充气饮料或矿泉水或天然水的空心制品的制造。更确切地说，本发明涉及制造具有高的热机械性能的空心制品，如能够在没有显著变形的前提下承受在诸如填充热的液体或制品的内容物的巴氏灭菌之类的过程中容易产生的较强热应力的瓶子。本发明的特征在于该空心制品是通过一种聚酯的注射吹塑获得，该聚酯具有高的粘度指数和较低浓度的与乙二醇和对苯二甲酸单体不同的单体。本发明的空心制品或瓶子尤其可用于利用加热法巴氏杀菌工艺的食品的包装过程，例如例如啤酒包装过程中。

Description

制造空心制品的方法，和由该方法获得的 空心制品、预成形体和瓶子
本发明涉及通过注射模塑/吹塑聚酯来制造空心制品的方法，更具体地，用于包装饮料，如起泡饮料，或矿物或天然水的空心制品。
更具体地说，本发明涉及具有高水平的热机械性能的空心制品的制造，例如能够承受在诸如给它们填充热液体或对它们的内容物巴氏杀菌之类的程序时所遇到的相对较强的热应力而不显著变形的瓶子制造。
几十年以来，聚酯，特别是聚对苯二甲酸乙二醇酯(以缩写PET为大家所熟知)，已经越来越广泛地用于容器的制造领域中，更具体地说，全部类型的饮料的瓶子的制造领域中。
传统上，从聚酯(PET)制造的塑料容器(瓶子)是利用模塑技术，通过注射模塑/吹塑加工熔化聚酯来制造。在实践中，该制造方法主要包括制造预成形体的第一步骤，该预成形体具有在其两端中的一端封闭而它的另一端以瓶子的颈部的形状开放的空心圆柱形管的一般形状，该瓶子是在具有容器(瓶子)的最终形状的模具中的热吹塑的第二步骤中获得的。
起始聚酯(PET)具有粒料的形状，它在注射模塑步骤之前熔化。
在聚酯(PET)用作制造容器尤其瓶子的主要原材料的过程中，对于聚酯的限制当中，最大的一种是透明度。这方面的理由是，在熔化和成形之后，PET在冷却时硬化，有一定的发生球粒状结晶的倾向，这使得预成形体的壁变得不透明。
为了克服这一缺点，与聚酯的主要结构单体(对于PET而言的对苯二甲酸和乙二醇)一起，可以使用用作结晶阻滞剂的其它单体并以可变浓度存在于聚酯中，例如以3.5-7.5％的摩尔量(基于二酸单体的全部)。
还重要的是，用于容器(瓶子)的制造中的聚酯(PET)具有良好的热机械性能。这一点的理由是，在聚酯(PET)瓶子中调理的某些液体食品必须用巴氏法灭菌，即在65到75℃或更高下加热20-30分钟。这些瓶子也用于填充热产物的工艺中，这些通常称作热灌装工艺。该聚酯(PET)瓶子因此必须承受热应力。现在，聚酯和尤其PET的玻璃化转变温度，是大约75-80℃。
因此，上述的工艺过程包括在高温下引起变形的步骤，其中的一些是不可逆的和永久的。该术语蠕变用于表示这一不可逆变形。
当用于调理的液体由起泡饮料组成时，用作容器(瓶子)的结构材料的聚酯(PET)的有限热致蠕变的这一技术问题变得严重。这一点的理由是，在饮料中存在的气体会增加施加于容器的壁上的机械应力，因此提高了这一现象的程度。
试图补偿这一情形所提出的建议包括改进获得空心制品的工艺和/或改性所使用的聚酯。
法国专利申请No.2 658 119是以第一种可能性为基础的。它描述了从PET制造容器如瓶子的方法和组合件，对于在它们的使用过程中的较严重的热条件有耐受性。该工艺在于：在冷的模具(5-40℃)中吹塑已加热至高于PET的软化点的温度的无定形PET预成形体的壳体(颈部除外)，而形成体积大于所获得容器的体积的中间容器，然后加热该中间容器的壳体到160-240℃保持1-5分钟，同时加热瓶子的颈部，然后施加受控冷却，最终获得具有收缩的壳体和结晶的颈部的中间容器。该产品再次经2-6秒吹塑到它的规定尺寸而获得具有改进的热机械性能的规定容器。
这一已知的工艺具有使用起来相对难操纵和耗时的缺点，而且在大部分的巴氏杀菌工艺中热机械性能是不足够的。
另外，现在已有市售的聚酯(PET)，据称当加热时，和有时候在压力下具有良好的耐变形性。
这些聚酯的例子已经由KOSA公司以商品名“Polyclear 2201”或由SHELL CHEMI CALS公司以商品名“CLEARTUF P85HF”销售。然而，聚酯的热机械性能的水平(通过测定下面定义的VRB来评价)，需要具有高的壁厚度和特殊形状的空心制品或瓶子的制造，允许它们尤其可用于巴氏杀菌工艺中。
对于本发明的目的，为了评价用给定的聚酯获得的空心制品的耐变形性和耐蠕变性，可使用测量在规定形状和尺寸的瓶子上的蠕变(变形)的试验。这一试验，称作巴氏杀菌试验(Tp)定义如下：
参考瓶子是在附图1中表示的瓶子。所使用的模制品因此包括图1的这一参考瓶子的形状。需要表征的聚酯(PET)是粒料的形式，该试验瓶子是通过注射模塑/吹塑的传统工艺制造的。在第一步骤中，具有在附图2中给出的形状和尺寸的管式预成形体通过注射模塑法制造，然后在第二个步骤中这一预成形体在模具中吹塑而获得瓶子，它的形状和尺寸如图1中所示。通过利用在空心制品制造的所属技术领域的专业人员的知识和经验，注射模塑和吹塑的条件与所使用的聚酯的特性相关地来确定。注射模塑法在装有具有一定形状的模具的BILLION H650/200Probilog 3S压机上进行的。吹塑采用由SIDEL公司以SB08系列2型HPR销售的吹塑机在模具中于10℃的温度下进行的。
Tp巴氏杀菌试验的细节在于使用已由2.7倍体积的CO2碳酸化的水来填充如此制造的参考瓶子达到给定的水平。加满的瓶子完全地浸于恒温控制到75℃的水浴达10min。瓶子然后浸入恒温控制到60℃的水浴中达20min。它然后利用喷水被冷却到大约20℃的温度(在环境温度下的水)。
在试验之前和之后，测量瓶子的全部尺寸，以便确定在高度，肩直径，瓶身直径，底部直径，底部深度上的变化百分数。在巴氏杀菌试验之前和之后，也通过测量容器的体积来测定瓶子的体积变化。这一测量通过称量填充该容器到口边所需要的水的量来进行。
因数VRB表示以百分数表达的体积差异，基于瓶子的初始体积。
根据这一Tp试验，标准聚酯瓶子具有在5和10％之间的VRB，对应于不可接受的蠕变。对于某些聚酯，尤其以上提到的市售的聚酯，获得了2.0-2.5％的VRB的水平。
然而，这一类型的水平仍然证明是不令人满意的，尤其对于在起泡饮料或具有高气体含量的饮料的领域中的应用。
本发明主要目标之一是提供由注射模塑/吹塑法的传统制造过程所获得的、具有高水平的热机械性能的聚酯容器。
为此目的，本发明提供了由注射模塑/吹塑加工以对苯二甲酸乙二醇酯的重复单元为基础的聚酯的方法来制造空心容器的方法，包括注射模塑加工预成形体的第一个步骤和在与容器对应的成形模具中吹塑加工该预成形体的第二个步骤，特征在于该聚酯具有
●粘度值VN≥95ml/g，优选VN≥100ml/g；
●至多3.5％(基于二酸单体的总摩尔数)的摩尔量的与乙二醇和对苯二甲酸不同的单体。
游离或结合了的二甘醇的摩尔量不超过2.5％，基于二酸单体的摩尔数。
与乙二醇和对苯二甲酸不同的单体的摩尔量优选低于3％，有利地低于2.5％。
同样地，二甘醇的摩尔量优选低于2％，有利地低于1.5％。
利用在单体A(乙二醇)和单体B(对苯二甲酸或该酸的酯，例如对苯二甲酸二甲酯)之间的反应获得了对苯二甲酸乙二醇酯的重复单元。
本发明也提供由上述方法获得的并具有由低于或等于2％的VRB所说明的耐热致蠕变性的空心制品或容器，如瓶子，烧瓶，坛子，使得这些空心制品可用于液体产品，特别是食品象水，碳酸软饮料，起泡饮料，啤酒，和更特别地需要巴氏杀菌步骤的食品的包装和保存。
根据1986年6月15日的标准ISO 1628/5，在25℃下对于具有0.5g的聚合物/100ml的由邻-二氯苯和苯酚(50/50重量)组成的溶剂的聚合物溶液来测定粘度值VN。
测量组成空心制品或瓶子的壁的聚酯来测量所述粘度值VN。为了进行这一测量，从瓶子上切下一片，然后切成足够小而能够溶解的碎片。
在空心制品的制造过程中聚酯的粘度值一般受到较小影响。然而，从瓶子的壁测量的粘度值可以低于或高于从被加入到注射模塑步骤中的粒料测量的粘度值。在这两种值之间的差距一般小于从瓶子测量的粘度值的10％。
这些考虑同样地适用于从构成在注射模塑步骤之后获得的预成形体的壁的聚酯所测量的粘度值。
根据本发明的一个特征，与单体A和B不同的起始单体有利地具有阻止结晶的效果，特别在注塑制品(例如预成形体)的冷却过程中，减缓或阻止聚酯的结晶，从而在结晶过程中获得非常小的晶体并因此避免了可见光的散射，这是获得具有可接受的机械性能的透明制品(该制品的壁没有生雾或“雾化”)的主要条件。
这些结晶阻止剂是在聚酯的聚合之前或过程中被加入到单体A、B的混合物中的双官能化合物，如二酸和/或二醇。
作为结晶阻止剂的单体可提及的例子是二酸类间苯二酸，萘二羧酸，环己烷二羧酸，环己烷二乙酸，琥珀酸，戊二酸，己二酸，壬二酸，癸二酸。对于二醇的例子，可提到含有3到20个碳原子的脂族二醇，具有6到20个碳原子的环脂族二醇，含有6到14个碳原子的芳族二醇和它们的混合物，例如二甘醇，三甘醇，下列物质的各种异构体：1，4-环己烷二甲醇，1，3-丙二醇，1，4-丁二醇，1，5-戊二醇，(2，4)-3-甲基戊二醇，1，4，2-甲基戊二醇，(1，3)-2，2，4-三甲基戊二醇，(1，3)-2-乙基-己二醇，(1，3)-2，2-二乙丙二醇，1，3-己烷-二醇，1，4-二(羟基乙氧基)苯，2，2-双(4-羟基-环己基)丙烷，2，4，4-二羟基-1，1，3，3-四甲基环丁烷，2，2-双(3-羟基乙氧基苯基)-丙烷，2，2-双(4-羟基丙氧基苯基)丙烷和这些的混合物。
对于作为结晶阻止剂并且在聚合物的开始不存在但由聚合产生的单体，最典型的例子是聚酯固有地存在的二甘醇，因为它在合成过程中通过在两个乙二醇分子之间的相互缩合反应而形成。该二甘醇可以是游离形式或与高分子聚酯链相结合。
制备聚酯的方法在于羧二酸的二醇-酯化的产物或二酯的二醇-酯基转移的产物中任何一种的高温缩合。这一缩合是在熔体中进行的。为了获得聚对苯二甲酸乙二醇酯(PET)，所缩合的产物是对苯二甲酸二甲酯(DMT)的乙二醇(EG)-酯基转移产物或提纯对苯二甲酸(PTA)的乙二醇-酯化产物。
就称作“对苯二甲酸二甲酯”(DMT)的途径而言，这包括酯基转移反应。熔融的DMT溶于过量存在的乙二醇(EG)中，EG/DMT的摩尔比率是约1.9到2.2，该反应是在大气压力下在约130℃到250℃的温度下进行。这需要催化剂如乙酸锰的存在。由反应所释放的甲醇通过蒸馏除去。过量存在的乙二醇在酯基转移反应之后通过蒸馏被除去。酯基转移催化剂，它也是聚酯的降解的催化剂，在反应之后借助于含磷化合物来封闭。从酯基转移形成的产物是对苯二甲酸双(BHET)酯和低聚物的混合物。
称作“直接酯化”或“PTA”的其它途径包括对苯二甲酸的乙二醇-酯化反应。它在130℃到280℃的温度下进行。乙二醇以约1到3的摩尔比率EG/对苯二甲酸存在。这一反应获得具有对苯二甲酸或对苯二甲酸羟乙酯形式的末端官能团的低聚物的混合物。
这些方法的使用是在文献中描述的大量研究的主题。以上所述的条件不构成对本发明范围的任何限制。
缩聚和有时候固相聚合的步骤是利用缩合的聚合步骤。它们一般借助于金属化合物，例如由锑、钛或锗的化合物来催化。它们可以通过在现有技术中描述的任何缩聚催化剂来催化。
在所获得的聚酯中存在的成核剂的量优选是低的，以便避免在预成形体的制造过程中的球粒状结晶。这一特征可以通过处理聚酯除去这些试剂，例如通过过滤或通过以合适的酯化和缩聚条件(温度，压力，催化剂浓度)进行聚酯的制造来获得。
制备高粘度值(特别高于0.95dl/g)的聚酯的方法一般包括后缩合的步骤，优选在固相中，优选在大约190℃和230℃之间的温度下在惰性气体之下或在非氧化性条件下进行。
然而，得到具有高VN的聚酯的其它方法都能够使用，例如在专利申请WO00/32676中描述的那些，通过使用在分散介质中的后缩合的方法，从低聚合度的预聚物开始，或在合适反应器中的熔化介质中的后缩合，例如，描述在ANTEC′95中分发的论文中，记录在该会议的会议录的第250-258页上。
按照已知的方式选择获得聚酯的条件，从而获得具有最低的可能的二甘醇含量的聚酯。
如此获得的聚酯切粒然后被加入到用于预成形体的制造的传统注射模塑工艺中，该预成形体所具有的形状和尺寸取决于在后续的吹塑步骤中所制造的空心制品。这些预成形体同样地由本发明提供。
这在后续的吹塑步骤可以整合到注射模塑步骤中，该预成形体不经历再加热，或可以是具有将预成形体预热到高于聚合物的Tg的温度的单独的一个步骤。这些工艺非常广泛地描述在文献中并在工业中大规模地使用。
除了降低的蠕变和透明度的技术规格以外，该聚酯(PET)有利地在容器(聚酯形成它的结构材料)的壁中具有降低的乙醛含量。这一点的理由是该乙醛是从聚酯的降解产生的产物，它会不利地影响在容器或空心制品中所含有的产品的味道。该乙醛是在聚酯的制造过程中和在容器(瓶子)的制造过程中，特别在预成形体的注射模塑步骤中，在高温下形成的。
对于某些应用，用于实施本发明的方法的聚酯具有足够低的乙醛含量，从而在成品容器的壁中获得低于或等于6ppm的乙醛浓度。对于其它应用，这一特征不是必要的。
用上述聚酯生产的空心制品具有耐蠕变的突出性能，特别在高温下，即在高于约60℃的温度下。抗蠕变性的这些突出性能也使得，在瓶子或容器在较高温度下贮存的同时，尤其在具有环境温度一般高于30℃的热带气候的国家中，瓶子或容器的变形的减少。这一点的理由是堆积常常用于储存这些容器。另外，聚合物的其它性能，特别是它的透明度，不受影响。
空心制品，更具体地说由本发明的方法获得的瓶子的抗蠕变性因此通过一种试验来说明，该试验对填充液体(充碳酸气的水)的瓶子在所述温度下的变形进行测量。上面描述的试验在于测量和计算当处于一定温度下时瓶子的体积的变化。这一变化称作“全满体积”或VRB的变化并以初始体积为基被表达为百分率变化。
由本发明的方法获得的空心制品或瓶子具有低于2％，优选低于1.8％的VRB。这一抗蠕变性使得这些容器或瓶子甚至可用于具有高的气体含量并需要瓶子巴氏杀菌步骤(为了在食品的消费之前的足够长的时间中确保该食品的保藏)的那些食品的包装。
本发明的制造方法同样地通过针对预成形体的自由吹塑试验来说明，该试验在于通过在120℃的油浴中浸泡4分钟来加热图2的预成形体，然后在从油浴中出来之后立即(以防止它的冷却)在4巴的压力下自由吹塑该预成形体。吹塑的瓶子的体积通过测量为了填充它到瓶口边缘所需要的水的重量来测定。
在吹塑试验中，根据本发明获得的预成形体具有远低于用目前使用的聚酯所生产的预成形体获得的体积的体积。
作为能够包装在本发明的瓶子中的食品的非限制性例子，可提及起泡饮料或未加甜味剂的饮料或通常不称作“fizzy drinks”的饮料，啤酒，牛奶，油，起泡的或不起泡的天然水和泉水。
本发明的其它优点和细节从下面给出的实施例(这些单纯是为了说明目的)和附图中清楚地看出，其中
-图1表示了为了测定VRB的试验的操作所用的参考瓶子的侧视中剖面图，和
-图2表示用于制造在图1中表示的瓶子的预成形体的侧视中剖面图。
在下面的实施例中，使用下面方法来测定按照单体类，尤其按照二酸单体计算的二甘醇浓度：
在聚合物的甲醇分解作用之后的色谱分析(GPC)。
由GPC鉴别的结构通过耦联气相色谱分析/红外光谱/质谱分析(GC/IR/MS)来证实。
甲醇分解作用：约300mg(研磨或未研磨)的精确称量的试样被放入到具有10ml的Norma pur甲醇和5滴的钛酸四丁基酯(TBOT)(ALDRICH产品编号：24，411-2)的0.6％(w/v)甲醇溶液的锆制Parr罐(bomb)中。
Parr罐在通风烘箱中在190℃下加热16小时。在冷却之后，内容物定量地滗析到50ml容量瓶中。Parr罐用10ml的丙酮漂洗3次，将漂洗溶液加入到该容量瓶中。将内标物(2ml(利用精确的移液管移取)1，4-丁二醇在丙酮中的称量到0.1mg的1.5g/50ml的溶液)加入到容量瓶中。该容量瓶用丙酮填充到50ml液面。这一溶液用于通过使用通常在色谱分析中使用的技术来进行色谱分析，以测定不同单体的浓度。需要测定所存在的全部化合物的响应因数。
为了完成所分析的化合物的鉴别，该方法结合了红外线分析和质谱分析。
实施例1
从对苯二甲酸和乙二醇开始所获得的、具有2.6％的间苯二酸摩尔含量的共聚酯可通过传统的聚合过程来获得。
在熔体中聚合之后，聚酯具有2.4％的二甘醇摩尔含量，聚酯通过在真空下加热到220℃保持足以获得101.0ml/g的粘度值的一段时间而在固相中进行后缩合。这一聚酯被称作聚合物A。
实施例2
在固相聚合之后获得的实施例1的共聚酯与实施例1相同地进行后缩合，不同的是获得114.1ml/g的粘度值需要较长的时间。该聚酯被称作聚酯B。
实施例3
从对苯二甲酸和乙二醇开始，利用在245℃的温度下的酯化步骤和然后在275℃下在锑存在的缩聚，获得聚酯。所获得的聚合物具有74ml/g的粘度值。
所获得的聚酯在真空中于220℃下进行后缩合而获得89.2ml/g的粘度值。该聚酯被称作聚酯C。
实施例4
在熔体中的聚合之后获得的实施例3的聚酯进行与实施例3相同的后缩合，不同的获得112.0ml/g的粘度值需要较长的时间。该聚酯被称作聚酯D。
根据图1的瓶子是用以上四种聚酯生产的，以通过VRB测量和通过自由吹塑试验测定这些聚酯的抗蠕变性。所获得的结果在下面的表1中给出，它也显示了对于所获得的瓶子和相应的预成形体所测量的粘度值。
表1
 实施例  聚酯            粘度值(ml/g)       Mol％  VRB(％)  自由吹塑体积(ml)   密度
   粒料  预成形体   瓶子   DEG  DEG+IPA
   1   A    100.9    91.9   93.9  2.4   5.0   2.4     1 428  1.362
   2   B    114.1    103.6   98.3  2.4   5.0   2.3     1 157  1.366
   3   C    89.2    82.4   82.6  1.3   1.3   2.6     1 213  1.363
   4   D    112.0    99.9   100.4  1.3   1.3   1.7     734  1.371
这些结果表明，仅仅本发明的聚酯D可以获得具有高水平的热机械性能的瓶子，这些性能允许它们用于液体产品的巴氏杀菌过程中或用于该瓶子的热灌装的过程中。
相反地，不是根据本发明的聚酯A，B，C具有较低水平的热机械性能，该性能对于没有瓶子的形状或瓶壁的厚度的变化的、与巴氏杀菌的工艺相适合的瓶子的制造是不足够的。

Claims (8)

1.由注射模塑和吹塑以对苯二甲酸乙二醇酯的重复单元为基础的聚酯的工艺来制造空心容器的方法，包括注射模塑加工预成形体的第一个步骤和在与容器对应的成形模具中吹塑加工该预成形体的第二个步骤，特征在于该聚酯具有
●粘度值VN≥100ml/g，
●至多3％的摩尔量的与乙二醇和对苯二甲酸不同的单体，基于二酸单体的总摩尔数，和在于
●游离或结合了的二甘醇的摩尔量至多2％，基于二酸单体的摩尔数。
2.根据权利要求1的方法，特征在于这些不同单体的摩尔浓度是至多2.5％。
3.根据权利要求1的方法，特征在于二甘醇的摩尔浓度是至多1.5％。
4.根据权利要求1的方法，特征在于不同单体是选自间苯二酸，萘二羧酸，环己烷二羧酸，环己烷二乙酸，琥珀酸，戊二酸，己二酸，壬二酸，癸二酸，二甘醇，三甘醇，下列物质的异构体：1，4-环己烷二甲醇，1，3-丙二醇，1，4-丁二醇，1，5-戊二醇，(2，4)-3-甲基戊二醇，1，4，2-甲基戊二醇，(1，3)-2，2，4-三甲基戊二醇，(1，3)-2-乙基-己二醇，(1，3)-2，2-二乙基丙二醇，1，3-己二醇，1，4-二(羟基乙氧基)苯，2，2-双(4-羟基-环己基)丙烷，2，4，4-二羟基-1，1，3，3-四甲基环丁烷，2，2-双(3-羟基乙氧基苯基)-丙烷，2，2-双(4-羟基丙氧基苯基)丙烷。
5.根据权利要求1到4中任何一项的方法获得的空心制品。
6.在注射模塑的步骤之后根据权利要求1到4任何一项的方法获得的预成形体。
7.根据权利要求1到4任何一项的方法获得的瓶子，特征在于它具有由根据Tp巴氏杀菌试验测得的低于2％的VRB所说明的抗热蠕变性。
8.根据权利要求7的瓶子，特征在于它通过吹塑加工权利要求6的预成形体而获得。
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