IT202000016174A1 - MULTILAYER MATERIAL, CONTAINER MADE OF MULTILAYER MATERIAL AND CONTAINER MANUFACTURING PROCESS - Google Patents

Description

DESCRIPTION

Attached to a patent application for INDUSTRIAL INVENTION having the title

?MULTI-LAYER MATERIAL, CONTAINER MADE IN

MULTILAYER MATERIAL AND MANUFACTURING PROCESS OF A

CONTAINER?

The present invention relates to a multilayer material, a container made of multilayer material and a process for manufacturing a container.

The proposed invention finds application in the packaging of various sectors, such as for example the food and beverage industry, the pharmaceutical and cosmetic industry, the agricultural sector.

The trend of recent years? that of making packaging conform to the principle of the three ?Rs?: Reduce, Reuse, Recycle. In particular, with regard to plastic packaging, we observe the progressive replacement of packaging that is not easily recyclable with other recyclable ones. For example, a yogurt pot, traditionally made from HIPS (polystyrene-polybutadiene blend), is ? made, by some packaging companies, in polypropylene, easily recyclable.

Another trend? that of using biodegradable plastic packaging, such as for example PLA (polylactic acid). PLA allows complete biodegradability, although at temperatures and pressures that can only be achieved in an industrial environment.

Other material that is widely used? Mater-Bi, compostable and of interest for various applications, from packaging to home accessories. Inorganic glass, unlike plastic, is a type of material with characteristics that make it very attractive as packaging. In fact, glass has an interesting combination of properties chemical-physical characteristics which differentiates it from plastic materials for packaging, including high specific weight, excellent transparency, high stiffness and mechanical resistance, remarkable stability chemistry, recyclability? complete countless times (without degradation of the material constituents).

Glass packaging is made of non-biodegradable inorganic glass, therefore the possible choices relating to the management of the end of life of the material (return logistics) are as follows:

? reuse of the container as it is;

? material recycling by remelting and making new packaging.

In the case of reuse of the container as it is, the energy and environmental costs of reuse (including collection, cleaning and redistribution) make the process onerous. ? Furthermore, it should be noted that in the re-use of glass voids, given their handling by operating machines and transport on pallets, it is not unusual to observe a progressive damage to the packaging (for example, bottles with engravings and lines), reducing its transparency and therefore changing its appearance compared to the virgin packaging. Since glass is often chosen as a packaging material capable of enhancing the high quality of the product contained in it, its progressive deterioration significantly affects this purpose? making its reuse a very limited procedure today.

In the case of recycling of the material, although this is possible an indefinite number of times because? glass isn't it? subject to degradation as occurs instead in the case of plastic materials, the collection, intended as the management of the entire return logistics or ?reverse logistics?, and the selection require activities? with a high expenditure of energy and environmental impact and can present a certain complexity? due, for example, to the need? to separate glass cullet of different colors in order to use them for their respective and specific applications. Furthermore, remelting requires the achievement of high temperatures (around 1500°C), thus entailing considerable energy and environmental costs.

In this context, the technical task underlying the present invention ? that of proposing a multilayer material, a container made of multilayer material and a process for manufacturing a container, which overcome the above mentioned drawbacks of the prior art.

In particular, the purpose of the present invention is propose a multilayer material and a container made of multilayer material that can be dispersed directly into the environment and reabsorbed by it.

Another purpose of the present invention? propose a multilayer material, a container made of multilayer material and a container manufacturing process that simplify or eliminate the onerousness? and the energy expenditure associated with the recycling of known materials. Another purpose of the present invention? make available a container made of multilayer material that eliminates the problem of return logistics, both in terms of energy, costs and environmental impact. Another purpose of the present invention? make available a container made of multilayer material, in which the contents can be sanitized using UV rays.

Another purpose of the present invention? make available a container made of durable, resistant and high quality multilayer material. The technical task specified and the aims specified are substantially achieved by a multilayer material for use in the manufacture of containers, comprising at least:

? a first layer made of an inorganic vitreous mixture having a phosphate or silicate or borate base;

? a second coating layer applied to the first layer in such a way as to protect it from degrading agents, the second layer being made of polymeric or inorganic based material.

In accordance with an embodiment, the multilayer material further comprises a third coating layer applied to the first layer on the opposite side with respect to the second coating layer so that the first layer is interposed between the second layer and the third layer. The third layer? made of polymeric material or inorganic material.

In accordance with one aspect of the invention, the second layer and/or the third layer ? made of inorganic material starting from alcoholic solutions based on organometallic precursors.

In accordance with one aspect of the invention, the second layer and/or the third layer ? made of organic material starting from polymeric solutions or melts.

The technical task specified and the aims specified are substantially achieved by a container, comprising a body having walls delimiting a cavity interior, characterized in that these walls are made of a multilayer material according to the present invention.

The second layer? arranged externally with respect to the cavity? internal.

In the embodiment in which the multilayer material also includes the third layer, does the latter face the cavity? internal.

According to one embodiment, the body is a hollow tubular having a bottom and an open mouth opposite the bottom. The technical task specified and the aims specified are substantially achieved by a process for manufacturing a container, comprising the steps of:

? preparing an inorganic vitreous mixture having a phosphate or silicate or borate base;

? bring the mixture to a melting temperature Tf characterized by the fact that the viscosity? of the mixture is substantially between 10 and 1,000 [Pa?s];

? bring the mixture to a forming temperature T1 lower than the melting temperature Tf, the forming temperature T1 being characterized by the fact that the viscosity? of the mixture is substantially between 1,000 and 1,000,000 [Pa?s];

? form an intermediate product shaped in such a way as to delimit a cavity? internal;

? applying at least one layer of coating to the outer walls of the intermediate article so as to obtain the container.

In accordance with one embodiment, the step of applying at least one coating layer occurs by immersing the intermediate manufactured article in a solution containing the coating material.

In accordance with an embodiment, the step of applying at least one coating layer occurs by investing the intermediate manufactured article with a vaporized flow of the coating material.

In accordance with one embodiment, the step of applying at least one coating layer comprises the following steps:

? rotate the intermediate product;

? deposit the coating material on the rotating intermediate product.

In accordance with one embodiment, the step of applying at least one coating layer takes place by means of the sol-gel technique.

In accordance with one embodiment, the step of applying at least one coating layer occurs by physical or chemical vapor deposition of a coating material.

In accordance with one aspect of the invention, the coating layer is polymer based.

In accordance with one aspect of the invention, the coating layer is inorganic based.

In accordance with an embodiment, the process also comprises a step of applying a further coating layer to the internal walls of the intermediate article facing the cavity. internal.

Further characteristics and advantages of the present invention will appear more clearly from the indicative, and therefore non-limiting, description of a preferred but not exclusive embodiment of a multilayer material, of a container made of multilayer material and of a container manufacturing process, as illustrated in the attached drawings where:

? figure 1 illustrates an embodiment of a multilayer material, object of the present invention, in sectional view;

? figure 2 illustrates an alternative embodiment of the multilayer material of figure 1, in sectional view;

? Figure 3 is a front view of a container made of the multilayer material object of the present invention;

? figure 4 is a sectional view along the axis AA of the container of figure 3, in accordance with the embodiment of the multilayer material of figure 1;

? figure 5 illustrates a sectional view along the axis AA of the container of figure 3, in accordance with the embodiment of the multilayer material of figure 2.

With reference to the figures, with the number 1 ? indicated a multilayer material for use in the construction of containers.

The multilayer material 1 comprises a first layer 2 made of an inorganic vitreous mixture having a phosphate or silicate or borate base. In the embodiment in which the first layer 2 is made of a phosphate-based inorganic glass mixture, it is characterized in that the concentration of phosphoric anhydride or diphosphorus pentoxide (P2O5) is ? higher than any other constituent. By way of example but not limited to, phosphate-based compositions may include: P2O5, Na2O, K2O, Li2O, CaO, MgO, SrO, ZnO, TiO2, Fe2O3, FeO, CuO, Cu2O, Al2O3, B2O3, SiO2, ZrO2, PbO , BaO, NiO, MnO, CoO.

An example of an inorganic vitreous mixture that can be used? described in the volume ?Bioactive Glasses: Fundamentals, Technology and Applications?, edited by Aldo R. Boccaccini, Delia S. Brauer and Leena Hupa - The Royal Society of Chemistry 2017, in particular in chapter 18 entitled ?Bioactive glasses for nerve repair? (authors: Novajra G, Baino F, Raimondo S, Lousteau J, Milanese D, Vitale-Brovarone).

Another example of a phosphate-based inorganic vitreous mixture, again for biomedical applications, can be found in the publication by the authors Ahmed I, Parsons A, Jones A, Walker G, Scotchford C, Rudd C.: ?Cytocompatibility and effect of increasing MgO content in a range of quaternary invert phosphate-based glasses?, J Biomater Appl 2010;24(6):555e75.?

In the embodiment in which the first layer 2 is made of a silicate-based inorganic glassy mixture, it is characterized by the fact that the concentration of silicon oxide (SiO2) is ? higher than any other constituent. By way of non-exhaustive example, silicate-based compositions may include: SiO2, Na2O, K2O, Li2O, CaO, MgO, SrO, ZnO, TiO2, Fe2O3, FeO, CuO, Cu2O, Al2O3, B2O3, P2O5, ZrO2, PbO , BaO, NiO, MnO, CoO.

In the embodiment in which the first layer 2 is made of a boric-based inorganic glassy mixture, it is characterized by the fact that the concentration of boric anhydride (B2O3) is ? higher than any other constituent. By way of non-exhaustive example, boric-based compositions may include: B2O3, Na2O, K2O, Li2O, CaO, MgO, SrO, ZnO, TiO2, Fe2O3, FeO, CuO, Cu2O, Al2O3, SiO2, P2O5, ZrO2, PbO , BaO, NiO, MnO, CoO.

As shown in figure 1, this first layer 2? applied a second coating layer 3 in such a way as to protect it from degrading agents. In fact, phosphate, silicate or borate-based glass has the characteristic of being biodegradable, with a speed? of degradation that can? be modulated and controlled by varying the composition of the blend itself. To avoid degradation of the first layer 2 during use of the material, at least one coating layer is suitably applied (the second layer 3, in fact) to protect it from atmospheric agents and/or substances that could attack the glass from the outside of the container .

The second layer 3 pu? be made of polymeric or inorganic based material.

In the case of polymer-based material, ? different compositions can be used. By way of example, the polymeric materials that can be used can be thermoplastic or thermosetting, of fossil origin or from renewable sources. Thermoplastics include polyolefins (polyethylene, polypropylene), polyesters (polyethylene terephthalate, polylactic acid), polyamides (nylon) and polycarbonates. Among the thermosetting materials, acrylate and epoxy systems can be mentioned. Can the polymeric coating materials be varied according to the needs? applications and production.

In the case of inorganic-based material, for example ? It is possible to use alcoholic solutions based on organometallic precursors, usually metal alkoxides or metalloids.

In accordance with one aspect of the invention, the first layer 2 has a thickness which can vary between approximately 1 and 1,000,000 times with respect to the second layer 3. The high amplitude of the interval depends on the fact that the first layer 2 in inorganic glass can? have variable thickness depending on the type of manufactured article (e.g. phial or bottle, or hollow container to contain liquids or even heavy solids) and the thickness of the second layer 3 varies both according to the material deposited and according to the deposition technique used.

In the embodiment of figure 2, the multilayer material 1 comprises a third coating layer 4 applied to the first layer 2 on the opposite side with respect to the second coating layer 3. The first layer 2 is so? interposed between the second layer 3 and the third layer 4.

In accordance with one aspect of the invention, the first layer 2 has a thickness which can vary between approximately 1 and 1,000,000 times compared to the third layer 4. The high amplitude of the interval depends on the fact that the first layer 2 in inorganic glass can? have variable thickness depending on the type of manufactured article (e.g. phial or bottle, or hollow container to contain liquids or even heavy solids) and the thickness of the fourth layer 4 varies both according to the material deposited and according to the deposition technique used.

The third layer 4 ? made of a material based on polymer or inorganic, as already? described for the second layer 3.

The second layer 3 and the third layer 4 can have identical or different compositions.

A container made of the material described above, and subject of the present invention, is described below.

The container 10 comprises a body 11 having walls 12 delimiting a cavity internal 13.

In accordance with an embodiment, described and illustrated herein, the body 11 is a hollow tubular having a bottom 11a and an open mouth 11b on the opposite side with respect to the bottom 11a. In other words, container 10 ? a bottle, a preform for forming bottles, a vial, etc. Alternatively, the container ? a jar, a tray, a vase, a bottle, etc.

In general, the body 11 of the container 10 has an internally hollow three-dimensional shape, which can have various shapes such as cylindrical, conical, prismatic, etc.

Originally, the walls 12 of the body 11 are made of the multilayer material 1 described above. As shown in figure 4, the second layer 3 of the multilayer material 1 is arranged externally with respect to the cavity? internal 13. In other words, the second layer 3 protects the first layer 2 from the external environment in which the container 10 is located.

In the embodiment in which the multilayer material 1 also includes the third layer 4, illustrated in figure 5, this third layer 4 faces the cavity? internal 13. In other words, the third layer 4 protects the first layer 2 from a substance (filling fluid or solid) contained in the cavity? internal 13. A manufacturing process of a container, object of the present invention, is described below.

The process comprises the step of preparing an inorganic vitreous mixture based on phosphate or silicate or borate. In particular, the inorganic glassy material is characterized by the fact that the concentration of, respectively, phosphoric anhydride (P2O5), silicon oxide (SiO2) or boric anhydride (B2O3) ? higher than any other constituent, therefore it gives the name to the corresponding vitreous family, being its main lattice former.

The mixture is then brought to a melting temperature Tf characterized by the fact that the viscosity? of the mixture is substantially between 10 and 1000 [Pa?s].

After that? the temperature of the mixture is lowered from the melting temperature Tf to a forming temperature T1. So, the forming temperature T1 ? lower than the melting temperature Tf and ? characterized by the fact that the viscosity? of the mixture is substantially between 1,000 and 1,000,000 [Pa?s].

At the forming temperature T1, the process comprises the step of forming an intermediate product shaped in such a way as to delimit a cavity internal 13. In other words, the intermediate artifact already has? the final shape of the container 10.

In accordance with an embodiment, the intermediate artefact ? blow molding. In particular, the blend ? subjected to the injection of a gas at high pressure which gives the product its shape.

In accordance with another embodiment, the intermediate artefact ? molding format. The best techniques common ones that can be used in this context are press molding and blow molding. These techniques are of known type and will not be further described.

Once the intermediate product has been formed, at least one layer 3 of coating is applied to its external walls so as to obtain the container 10.

Coating layer 3 can? be made of polymeric or inorganic based material.

In the case of polymer-based material, ? different compositions can be used. By way of example, the polymeric materials that can be used can be thermoplastic or thermosetting, of fossil origin or from renewable sources. Thermoplastics include polyolefins (polyethylene, polypropylene), polyesters (polyethylene terephthalate, polylactic acid), polyamides (nylon) and polycarbonates. Among the thermosetting materials, acrylate and epoxy systems can be mentioned. Can the polymeric coating materials be varied according to the needs? applications and production.

In the case of inorganic-based material, for example ? It is possible to use alcoholic solutions based on organometallic precursors, usually metal alkoxides or metalloids.

In accordance with one embodiment, the coating layer 3 is applied by immersing the intermediate product in a solution containing the coating material. In particular, by varying the speed? of extraction, the permanence time of the product in the solution, the concentration and composition of the solution ? it is possible to obtain coatings with controlled thickness. This technique? also known as ?dipping?.

In accordance with another embodiment, the application of the coating layer 3 takes place by investing the intermediate manufactured article with a vaporized flow of the coating material. In particular, the nebulised drops form a homogeneous and uniform film on the surface of the product, at the same time the solvent evaporates leaving a thin film of solid coating. This technique? also known as ?spraying?. In accordance with another embodiment, the application of the coating layer 3 comprises the following steps:

? rotate the intermediate product;

? deposit the coating material on the rotating intermediate product.

This technique? also known as ?spinning?.

The foregoing embodiments of the process can be used with both a polymer-based and an inorganic-based coating material.

The following embodiments, however, can only be used with an inorganic-based coating material.

In accordance with one embodiment, the coating layer 3 is applied by sol-gel technique. This technique? of known type: the starting colloidal solution (sol) constitutes the reactive basis for the subsequent formation of a gel (a continuous inorganic lattice containing an interconnected liquid phase) through hydrolysis and condensation reactions. The evaporation of the liquid phase d? origin to a transparent and protective inorganic coating layer, the characteristics of which vary according to the starting precursor.

In accordance with another embodiment, the application of the coating layer 3 takes place by physical or chemical vapor deposition of a coating material.

A physical vapor deposition process (known by the acronym PVD, from the English Physical Vapor Deposition) consists of an atomic deposition in which the material is evaporated from a solid or liquid source in the form of atoms or molecules and transported in vapor form through a vacuum or plasma environment to the substrate where it condenses.

A process of chemical vapor deposition (known by the acronym CVD, from the English ?Chemical Vapor Deposition?) ? a synthesis technique which allows a deposit to be obtained on a solid support starting from a molecular precursor, introduced in gaseous form and which decomposes on the surface of the substrate. The transport of the precursor takes place through the use of a carrier gas such as oxygen, argon, hydrogen or nitrogen, thanks to which the gaseous decomposition products are then also removed from the system.

In accordance with one aspect of the invention, the process comprises the application of a further coating layer 4 to the internal walls of the intermediate product facing the cavity. internal 13.

The further layer 4 of coating can? be made of polymeric or inorganic based material.

In the case of polymer-based material, ? different compositions can be used. By way of example, the polymeric materials that can be used can be thermoplastic or thermosetting, of fossil origin or from renewable sources. Thermoplastics include polyolefins (polyethylene, polypropylene), polyesters (polyethylene terephthalate, polylactic acid), polyamides (nylon) and polycarbonates. Among the thermosetting materials, acrylate and epoxy systems can be mentioned. Can the polymeric coating materials be varied according to the needs? applications and production.

The techniques for applying the further (internal) coating layer 4 are similar to those described above for the application of the external coating layer 3.

From the description given, the characteristics of the multilayer material, of the container made of the multilayer material and of the manufacturing process of a container, according to the present invention, are clear. how clear are the advantages.

In particular, the use of the multilayer material composed of a phosphate or silicate or borate based vitreous mixture makes it possible to create a container which can be dispersed directly into the environment as it has characteristics which make it reabsorbable by it.

In particular, the phosphate base confers particular advantages to it as the phosphorus is not? harmful to humans and in pi? it also has nutrients and/or active ingredients for the environment.

Also, there? allows to overcome the return logistics problems related to the recovery and recycling of the glass mentioned.

Furthermore, when the coating layers reach very small thicknesses with respect to the vitreous mixture layer, the filling product is sterilizable inside the container from the outside using UV rays.

Claims (16)

1. Multilayer material (1) for use in the construction of containers, comprising at least: ? a first layer (2) made of an inorganic vitreous mixture having a phosphate or silicate or borate base; ? a second coating layer (3) applied to said first layer (2) in such a way as to protect it from degrading agents, said second layer (3) being made of polymeric or inorganic based material. 2. Multilayer material (1) according to claim 1, comprising a third coating layer (4) applied to the first layer (2) on the opposite side with respect to the second coating layer (3) in such a way that said first layer (2) is interposed between the second layer (3) and the third layer (4), said third layer (4) being made of polymeric material or inorganic material. 3. Multilayer material (1) according to claim 1 or 2, wherein said second layer (3) and/or said third layer (4) ? made of inorganic material starting from alcoholic solutions based on organometallic precursors. 4. Multilayer material (1) according to claim 1 or 2, wherein said second layer (3) and/or said third layer (4) ? made of organic material starting from polymeric solutions or melts. 5. Container (10) comprising a body (11) having walls (12) delimiting a cavity? interior (13), characterized in that the walls (12) of said body are made of a multilayer material (1) according to any one of the preceding claims, said second layer (3) being arranged externally with respect to said cavity? internal (13). 6. Container (10) according to claim 5, wherein when the multilayer material (1) comprises the third layer (4), said third layer (4) faces the cavity? internal (13). 7. Container (10) according to claim 5 or 6, wherein said body (11) is a hollow tubular having a bottom (11a) and an open mouth (11b) on the opposite side with respect to the bottom. 8. Manufacturing process of a container (10), including the steps of: ? preparing an inorganic vitreous mixture having a phosphate or silicate or borate base; ? bring the mixture to a melting temperature Tf characterized by the fact that the viscosity? of the mixture is substantially between 10 and 1,000 [Pa?s]; ? bring the mixture to a forming temperature T1 lower than the melting temperature Tf, said forming temperature T1 being characterized by the fact that the viscosity? of the mixture is substantially between 1,000 and 1,000,000 [Pa?s]; ? form an intermediate product shaped in such a way as to delimit a cavity? internal (13); ? applying at least one layer (3) of coating to the external walls of said intermediate product so as to obtain the container (10). 9. Process according to claim 8, wherein the step of applying at least one coating layer (3) takes place by immersing the intermediate manufactured article in a solution containing said coating material. 10. Process according to claim 8, wherein the step of applying at least one coating layer (3) takes place by investing the intermediate manufactured article with a vaporized flow of said coating material. The process according to claim 8, wherein the step of applying at least one coating layer (3) comprises the following steps: ? rotate the intermediate product; ? deposit the coating material on the rotating intermediate product. 12. Process according to claim 8, wherein the step of applying at least one coating layer (3) takes place by means of the sol-gel technique. The process according to claim 8, wherein the step of applying at least one coating layer (3) takes place by physical or chemical vapor deposition of a coating material. 14. Process according to any one of claims 8 to 11, wherein said coating layer (3) is polymer based. 15. Process according to any one of claims 8 to 14, wherein said coating layer (3) is inorganic based. 16. Process according to any one of claims from 8 to 15, comprising a step of applying a further coating layer (4) to the internal walls of said intermediate manufactured article facing the cavity? internal (13).