TWI469897B - 外包裝容器之吹氣模製襯墊及其製造方法 - Google Patents
外包裝容器之吹氣模製襯墊及其製造方法 Download PDFInfo
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Description
本發明是關於襯底(liner-based)儲存與分配系統。本發明更關於用於外包裝、瓶子、容器等的襯墊及其製造方法。更特別地,本發明是關於用於外包裝、瓶子、容器等的彈性射出吹模成型或射出拉吹成型襯墊及其製造方法。
許多製造製程需使用極純的液體,例如酸、溶劑、鹼、光阻、摻質、無機、有機與生物溶液、藥物和放射性化學品。這些產業需控制極純液體中的微粒數量和大小,以確保純度。特別地,由於極純液體應用到微電子製造製程的許多方面,因此半導體製造業者己制定嚴格的微粒濃度規格用於處理化學品和化學品搬運設備。需制定規格是因為若製造製程所用的液體含有大量微粒或氣泡,則微粒或氣泡會沉積在矽的固體表面。如此將導致產品失效及降低品質和可靠度。
故極純液體的儲存、輸送及分配需使用能適當保護盛裝液體的容器。用於產業的兩種典型容器為由玻璃或塑膠組成的簡易硬壁容器和可摺疊襯底容器。硬壁容器因其物理強度、厚壁、成本低廉且容易製作而常使用。然此容器於加壓分配液體時會引起氣-液界面。此將造成氣泡溶入容器內的盛裝液體,例如光阻,以致在液體中產生不當微粒。
或者,相對於直接加壓容器內的液體,可摺疊襯底容器(如ATMI公司販售的NOWPak分配系統)可於分配時利用氣體加壓襯墊來減少氣-液界面。此外,此容器有較佳的再回收利用性,因盛裝液體只接觸可摺疊襯墊,故”牢固的外包裝”可搭配另一襯墊重複使用。然已知襯墊無法提供適當保護來抵抗環境條件。例如,目前的襯底容器不能保護盛裝液體抵擋至少二氣源。氣源之一仍然位於或陷入襯墊的摺痕間。更明確地說,因襯墊具彈性本質且可能不適合外容器,故空隙空氣將流入可摺疊襯墊的摺痕。第二氣源位於多褶襯墊的各褶間。襯墊摺痕間或襯墊各褶間的空隙氣體會污染盛裝液體過久,使氣體得以進入溶液並離開至晶圓上變成氣泡或微粒。
此外,具不適合可摺疊襯墊的容器會受運送時的震動影響,因不當撞擊而於液體中產生更多微粒。此襯墊還會因運送時震動而產生少量針孔。
故此技藝需要製造用於外包裝、瓶子、容器等之襯墊的有效方法,其不包括先前技術之硬壁和可摺疊襯底容器的缺點,且襯墊製作期間具有少量廢棄物。此技藝尚需要更順應外包裝、容器、瓶子等之內部的彈性襯墊。此技藝還需要襯底儲存與分配系統,其可解決襯墊褶痕間與襯墊各褶間的空隙氣體所引起的相關問題。此技藝另需要具較少運送引發失效的彈性襯墊。此技藝又需要具整體型設備埠的氟化高分子阻障襯墊,以確保所含極純液體的純度。
在一實施例中,本發明提出製造用於外包裝之襯墊的方法。方法包括提供高分子襯墊預型體、擴展預型體來實質順應模具、以及摺疊襯墊來插進外包裝。在一些實施例中,提供襯墊預型體包括射出一或多個高分子材料至預型模具而構成預型體。擴展預型體包括將預型體吹模成型或拉吹成型成外包裝尺寸而構成襯墊。在替代實施例中,襯墊經吹模成型或拉吹成型而直接製作於外包裝內。在一些實施例中,方法更包括在吹模成型預型體前,加熱預型體、以及測試襯墊的滲漏情形。氟化高分子可用於預型體。
在另一實施例中,提出製造用於容器之彈性襯墊的方法。方法包括提供氟化高分子預型體、加熱氟化高分子預型體、以及擴展氟化高分子預型體成外包裝尺寸而構成彈性襯墊。
在又一實施例中,提出用於外包裝的彈性襯墊。襯墊包含實質順應外包裝內部的彈性主體、和整合在彈性主體上的設備埠。藉由摺疊彈性主體、將彈性主體插進外包裝及使彈性主體在外包裝內再膨脹,可將彈性主體移動插入外包裝。彈性主體較佳包含氟化高分子且可包含多層。彈性主體較佳更包含氣體阻障層。襯墊可為任意形狀,並且與外包裝分開。在一些實施例中,襯墊順應外包裝的內部,又不黏結外包裝。
儘管已揭露多個實施例,然熟諳此技藝者在參閱以下實施例詳細說明後可更清楚本發明之其他實施例。將可理解,本發明當可作各種潤飾,其皆不脫離本發明之精神和範圍。故圖式和詳細說明本質上僅為舉例說明,而非用以限定本發明。
本發明是關於新穎且優異的襯底儲存與分配系統。特別地,本發明是關於新穎且優異的襯墊,用於外包裝、瓶子、容器等(以下統稱”外包裝”),及製造此襯墊的方法。更特別地,本發明是關於用於外包裝的彈性射出吹模成型或射出拉吹成型襯墊及其製造方法,其不包括先前技術之可摺疊襯底容器的缺點,且襯墊製作期間具有少量廢棄物。不像先前技術中某些襯墊是由焊接膜和形成摺痕或接縫組成,三維(3D)襯墊更能順應外包裝內部,並且減少運送引發失效。由於彈性3D襯墊的摺痕可實質消除,因此彈性3D襯墊可實質減少或消除當前襯底容器之摺痕間的空隙氣體所引起的相關問題。同樣地,因彈性3D襯墊可製作成多層單褶襯墊,故當前襯底容器之各褶間的空隙氣體所引起的相關問題也可實質消除。彈性3D襯墊可為具整體型設備埠的氟化高分子阻障襯墊,以確保所含極純液體的純度。
襯墊用途實例包括輸送及分配酸、溶劑、鹼、光阻、摻質、無機、有機與生物溶液、藥物和放射性化學品,但不以此為限。然此襯墊更可應用於其他產業來輸送及分配其他產品,例如無酒精飲料、烹飪油、農用化學品、健康與口腔保健產品和化妝品等,但不以此為限。熟諳此技藝者將可理解此襯墊和襯墊製造方法的優勢,從而明瞭襯墊用於不同產業來輸送及分配各種產品的合適性。
第1圖繪示本發明一實施例之彈性3D襯墊20的截面,其置於外包裝10內。外包裝10包括外包裝壁面12、內部腔穴14和開口16。外包裝10可以任何方法製作,例如射出吹模成型、射出拉吹成型、擠出成型等。外包裝10可製作成單一組件或多個組件的組合物。在一些實施例中,外包裝10具有相當簡單的設計,包括大致平滑的外包裝壁面12和內部腔穴14。在其他實施例中,外包裝10具有相當複雜的設計,例如包括凹痕、突出物及/或不同壁面12厚度,但不以此為限。具任一尺寸或形狀的外包裝皆可搭配使用本發明之彈性3D襯墊20。在另一實施例中,外包裝10為實質剛硬,是以外包裝10可自行支撐。在其他實施例中,外包裝10較不剛硬,故需要支撐結構。
在另一實施例中,外包裝10設有流體入口,用以加壓分配襯墊的內容物。流體入口可為獨立的埠、開口、柄等,供流體或空氣或其他氣體引至外包裝10的腔穴14內。流體可經由個別流體入口或透過具流體通道之連接器引入,此連接器放進外包裝10的開口16。流體可輸送到外包裝壁面12與襯墊20之間,以助於分配襯墊20的內容物。若流體包括氣體,則襯墊最好包括阻障層,以免氣體通過襯墊20而進入內容物(此將進一步描述於後)。
襯墊20包括襯墊壁面24、內部腔穴26和開口28。在一實施例中,襯墊20經調整大小及塑形以實質順應外包裝10的內部。因此,襯墊20可具有相當簡單的設計,包括大致平滑的外表面,或者襯墊20可具有相當複雜的設計,例如包括凹痕和突出物,但不以此為限。相較於外包裝壁面12的厚度,襯墊20的襯墊壁面24很薄。例如,在一些實施例中,襯墊20的厚度較佳為1密爾(mil)至10密爾。但本發明之襯墊20可採用任何適合之襯墊厚度,包括小於1密爾或大於10密爾。襯墊20最好具彈性,使得襯墊壁面24例如可利用真空而快速摺疊。如此可輕鬆將襯墊20插進外包裝10。一旦插進外包裝10,彈性更可讓襯墊壁面24再膨脹。襯墊20可摺疊及再膨脹,又不會破壞襯墊壁面24。襯墊壁面24實質上再膨脹成外包裝10的內部大小和形狀。故襯墊20可膨脹或再膨脹,以實質順應外包裝10的內部。
在另一實施例中,當襯墊20膨脹或填充時,其形狀不同於外包裝10的形狀,但與之相配而可放置於內。襯墊在此指稱”任意形狀襯墊”。襯墊20亦可為可拆除式或可拆接外包裝壁面12的內部。襯墊壁面24不需黏結或以其他方式接合外包裝壁面12。然在一些實施例中,襯墊壁面24黏結外包裝壁面12,此亦不脫離本發明之精神和範圍。接合襯墊壁面24與外包裝壁面12可防止因液體分配導致襯墊摺疊起來而“阻塞”襯墊,及避免完全使用內容物。
襯墊20可提供阻障層來抵擋出自襯墊壁面24與外包裝壁面12間之空間的驅動氣體,例如氣體阻障層。在一些實施例中,襯墊20使用一或多個高分子製作,包括塑膠、尼龍、乙烯-乙烯醇(EVOH)、聚烯烴、或其他天然或加工高分子。在另一實施例中,襯墊20使用氟化高分子製作,例如聚氯三氟乙烯(PCTFE)、聚四氟乙烯(PTFE)、氟化乙烯丙烯(FEP)和過氟烷氧化物(PFA),但不以此為限。在一些實施例中,襯墊20包含多層。例如,在一些實施例中,襯墊20包括內面層、核心層和外層,或包括任何適當層數。多層可包含一或多個不同高分子或其他適合材料。例如,內面層可使用氟化高分子(如PCTFE、PTFE、FEP、PFA等)製作,核心層可為使用諸如尼龍、EVOH、聚萘二酸乙二醇酯(PEN)、PCTFE等材料製作的氣體阻障層。外層亦可以任何適合材料製作,且視內面層和核心層的選用材料而定。
根據本發明之方法,襯墊20可製作成單一組件,故可消除襯墊的焊接點與接縫、和焊接點與接縫相關的課題。例如,焊接點與接縫造成製造製程變複雜及削弱襯墊。此外,一些最好用於某些襯墊的材料不適合焊接。
襯墊20可以任何適合製造方法製作,例如射出吹模成型、射出拉吹成型等。採行射出吹模成型或射出拉吹成型的製造製程比起其他製程更能讓襯墊有精確的形狀。利用射出拉吹成型來製造襯墊20的實施例將參照第2圖流程圖加以描述並進一步說明於第3A-3E圖。應理解第2圖所示製造襯墊20之實施例的所有步驟不需全然進行,而可省略一些步驟或增添附加步驟,此亦不脫離本發明之精神和範圍。方法包括藉由射出高分子或氟化高分子鑄模30至預型模具34的射出腔穴32,以形成襯墊預型體36(步驟42)。鑄模溫度和留在鑄模內的時間長短視製造襯墊預型體36的選用材料而定。在一些實施例中,多重射出技術用來形成具多層之預型體36。射出腔穴32的形狀對應具整體型設備埠22的襯墊預型體36(第3B圖)。高分子或氟化高分子經固化,而將形成之襯墊預型體36移出預型模具34。在替代實施例中,包括多層預型體的預製預型體用於本發明之預型體36。
在一些實施例中,如第3C圖所示,在拉吹成型前,清潔及加熱襯墊預型體36,以調理襯墊預型體36(步驟44)。如第3D圖所示,接著將襯墊預型體36插進實質具有外包裝10之內部負像的襯墊鑄模38。如第3E圖所示,接著吹製或拉吹襯墊預型體36成襯墊鑄模38的映像,以構成具整體型設備埠22的襯墊20。在其他實施例中,襯墊預型體36可在外包裝10本身中進行吹模成型或拉吹成型,而於外包裝10內形成襯墊20。吹模成型空氣速度、和吹模成型溫度與壓力視用來製造襯墊預型體36的材料而定。
一旦吹製或拉吹成襯墊鑄模38的映像,則固化襯墊20及移出襯墊鑄模38。在一實施例中,將襯墊20移出襯墊鑄模38,如第4圖所示,藉由摺疊襯墊壁面24,例如利用真空摺疊,可使摺疊襯墊40經由襯墊鑄模38的開口41離開襯墊鑄模38(步驟48),而不需將襯墊鑄模38分離成二或多個個別的鑄模組件。用來摺疊襯墊20的真空壓力大小視襯墊20的選用材料和其厚度而定。故在一實施例中,可消除襯墊壁面24的鑄模線。在其他實施例中,可以任何適合方法將襯墊20移出襯墊鑄模38。襯墊20或摺疊襯墊40可經膨漲、再膨脹、摺疊及測試滲漏情形任意適當次數(步驟50)。襯墊20或摺疊襯墊40可在襯墊鑄模38內、外包裝10內、或在襯墊鑄模38或外包裝10外膨漲、再膨脹、摺疊及測試滲漏情形。
在另一實施例中,已將襯墊20或摺疊襯墊40移出襯墊鑄模38後(例如,襯墊非直接吹製在外包裝10中),摺疊襯墊40(若在移出襯墊鑄模38前仍未完成,也可摺疊襯墊20)可放到外包裝10內,如第5圖所示。一旦放到外包裝10內,摺疊襯墊40再膨漲成原本尺寸(步驟52),其實質上為外包裝10的負像,如第6圖所示。於是襯墊20恢復成3D外形,其實質順應外包裝10的內部。
在一些實施例中,因襯墊20實質順應外包裝10的內部,故在運送襯墊20和外包裝10時,外包裝10大致上可承受襯墊20之部分或實質全部的內容物負載量。即,外包裝10可為實質剛性或半剛硬,如此實質順應外包裝10內部的襯墊可輸送襯墊20之部分或實質全部的內容物負載量至外包裝10。因襯墊20可承受較少負載量,故可降低襯墊20上的壓力,進而減少運送引發襯墊滲漏的可能性。
使用時,外包裝10內部的襯墊20可填充或含有極純液體,例如酸、溶劑、鹼、光阻、摻質、無機、有機或生物溶液、藥物、或放射性化學品。亦理解襯墊20當可填充其他產品,例如無酒精飲料、烹飪油、農用化學品、健康與口腔保健產品和化妝品等,但不以此為限。內容物可依需求加壓密封。當期分配襯墊20之內容物時,內容物可經由襯墊開口28和外包裝10的開口16離開,一旦倒空內容物,則可摺疊襯墊20。如上述,氣體入口18可讓空氣進入襯墊壁面24與外包裝壁面12間的外包裝10,以助於分配襯墊20之內容物。在另一實施例中,流體或氣體管線可連接氣體入口18,而驅動流體或驅動器體可用來摺疊襯墊20及分配襯墊20之內容物。若有需要,摺疊襯墊40可移出外包裝10。然後丟棄使用過的摺疊襯墊40。
雖然本發明已以較佳實施例揭露如上,然其並非用以限定本發明,任何熟習此技藝者,在不脫離本發明之精神和範圍內,當可作各種之更動與潤飾,因此本發明之保護範圍當視後附之申請專利範圍所界定者為準。
10...外包裝
12、24...壁面
14、26、32...腔穴
16、28、41...開口
18...入口
20、40...襯墊
22...設備埠
30、38...鑄模
34...模具
36...預型體
雖然說明書結尾的申請專利範圍特別指出及明確主張視為構成本發明的主題,但咸信本發明在參照說明書和所附圖式後將變得更明顯易懂,其中:
第1圖為根據本發明一實施例,置於外包裝內之彈性襯墊的截面側視圖。
第2圖為根據本發明一實施例,製造彈性襯墊的方法流程圖。
第3A圖為射出拉吹成型彈性襯墊方法之射出步驟的截面側視圖,其中襯墊預型體是根據本發明一實施例製作。
第3B圖為根據本發明一實施例,射出拉吹成型彈性襯墊方法之射出步驟的截面側視圖,其中襯墊預型體移出預型模具。
第3C圖為根據本發明一實施例,射出拉吹成型彈性襯墊方法之預型調理步驟的截面側視圖。
第3D圖為根據本發明一實施例,射出拉吹成型彈性襯墊方法之拉吹成型步驟的截面側視圖。
第3E圖為根據本發明一實施例,射出拉吹成型彈性襯墊方法之另一拉吹成型步驟的截面側視圖,其中襯墊預型體吹製成襯墊模具尺寸。
第4圖為根據本發明一實施例之可摺疊襯墊的截面側視圖。
第5圖為根據本發明一實施例之可摺疊襯墊的截面側視圖,其置於外包裝內。
第6圖為根據本發明一實施例之再膨脹襯墊的截面側視圖,其置於外包裝內。
無(流程圖)
Claims (39)
- 一種製造一外包裝之一襯墊的方法,包含下列步驟:提供一高分子襯墊預型體;擴展該預型體來實質順應一模具而構成該襯墊;以及摺疊該襯墊以插進一外包裝,其中形成的該襯墊經配置以在該外包裝內摺疊、放置,並在該外包裝內膨脹以實質順應該外包裝的該內部。
- 如申請專利範圍第1項所述之方法,更包含下列步驟:放置該襯墊於一外包裝中;以及使該襯墊在該外包裝內膨脹。
- 如申請專利範圍第1項所述之方法,其中該模具具有該外包裝的一負像。
- 如申請專利範圍第1項所述之方法,其中提供該襯墊預型體之該步驟包含射出成型一高分子材料,而構成一襯墊預型體。
- 如申請專利範圍第4項所述之方法,其中提供該襯墊預型體之該步驟包含提供一多層預型體。
- 如申請專利範圍第1項所述之方法,其中該襯墊預型體包含一高分子做為一氣體阻障層。
- 如申請專利範圍第5項所述之方法,其中該多層預型體包含一整合式氣體阻障層。
- 如申請專利範圍第4項所述之方法,其中該襯墊預型體配設一整體型設備埠。
- 如申請專利範圍第1項所述之方法,其中擴展該預型體之該步驟包含吹模成型該預型體。
- 如申請專利範圍第9項所述之方法,更包含在吹模成型該預型體前,加熱該預型體。
- 如申請專利範圍第1項所述之方法,更包含在該摺疊步驟前,測試該襯墊的滲漏。
- 如申請專利範圍第4項所述之方法,其中該高分子材料包含一氟化高分子。
- 如申請專利範圍第2項所述之方法,其中該襯墊經膨脹而實質順應該外包裝的一內部。
- 如申請專利範圍第9項所述之方法,其中吹模成型該預型體包含拉吹成型該預型體。
- 一種製造一外包裝之一彈性襯墊的方法,包含下列步驟:提供一氟化高分子襯墊預型體;加熱該氟化高分子襯墊預型體;實質擴展該氟化高分子襯墊預型體成一外包裝之一尺寸以順應該外包裝的該內部,以構成該彈性襯墊;摺疊該襯墊以插進一外包裝;放置該襯墊於該外包裝中;以及使該襯墊在該外包裝內膨脹。
- 如申請專利範圍第15項所述之方法,其中提供該氟化高分子襯墊預型體之該步驟包含射出成型一氟化高分子材料。
- 如申請專利範圍第16項所述之方法,其中提供該氟化高分子襯墊預型體之該步驟包含提供一多層預型體。
- 如申請專利範圍第15項所述之方法,其中該襯墊預型體包含一氟化高分子做為一氣體阻障層。
- 如申請專利範圍第17項所述之方法,其中該多層預型體包含一整合式氣體阻障層。
- 如申請專利範圍第16項所述之方法,其中該氟化高分子襯墊預型體配設一整體型設備埠。
- 如申請專利範圍第15項所述之方法,其中擴展該預型體之該步驟包含吹模成型該氟化高分子襯墊預型體。
- 如申請專利範圍第21項所述之方法,其中吹模成型該氟化高分子襯墊預型體是在該外包裝內進行。
- 如申請專利範圍第14項所述之方法,其中該襯墊具有多個實質薄壁,使得該襯墊可摺疊及再膨脹。
- 如申請專利範圍第23項所述之方法,其中該襯墊經再膨脹而實質順應該外包裝的一內部。
- 如申請專利範圍第21項所述之方法,其中吹模成型該氟化高分子襯墊預型體包含拉吹成型該氟化高分子襯墊預型體。
- 一種用於外包裝的彈性襯墊,該襯墊包含下列步驟: 一彈性主體,其實質順應一外包裝的一內部;以及一設備埠,其整合在該彈性主體上,其中該彈性主體可經調整而折疊,移動插進該外包裝及在插進後在該外包裝內再膨脹以順應該外包裝的該內部。
- 如申請專利範圍第26項所述之彈性襯墊,其中該彈性主體包含一氟化高分子。
- 如申請專利範圍第26項所述之彈性襯墊,其中該彈性主體包含多層。
- 如申請專利範圍第27項所述之彈性襯墊,其中該彈性主體包含一氟化高分子做為一氣體阻障層。
- 如申請專利範圍第28項所述之彈性襯墊,其中該彈性主體包含一整合式氣體阻障層。
- 如申請專利範圍第28項所述之彈性襯墊,其中該多層包含一個以上的材料。
- 如申請專利範圍第26項所述之彈性襯墊,其中該襯墊為一任意形狀襯墊。
- 如申請專利範圍第26項所述之彈性襯墊,其中該襯墊實質上不含一鑄模線。
- 如申請專利範圍第26項所述之彈性襯墊,其中該襯墊是由以下步驟所形成:提供一高分子襯墊預型體;以及擴展該預型體來實質順應一模具而構成該襯墊,該模具具有該外包裝的一負像,如此該襯墊乃製作成一單一組件。
- 一種襯底儲存與分配系統,包含一彈性襯墊和一外包裝,並以下列步驟製造:擴展一高分子襯墊預型體,以實質順應一模具而構成該彈性襯墊;摺疊該彈性襯墊以插進該外包裝;放置該襯墊於該外包裝中;以及使該襯墊在該外包裝內膨脹以順應該外包裝的該內部。
- 如申請專利範圍第35項所述之襯底儲存與分配系統,其中該模具具有該外包裝的一負像。
- 如申請專利範圍第35項所述之襯底儲存與分配系統,其中該彈性襯墊包含一氣體阻障層。
- 如申請專利範圍第35項所述之襯底儲存與分配系統,其中擴展該襯墊預型體之該步驟包含吹模成型該襯墊預型體。
- 如申請專利範圍第38項所述之襯底儲存與分配系統,其中吹模成型該襯墊預型體包含拉吹成型該襯墊預型體。
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EP (1) | EP2229272A4 (zh) |
JP (2) | JP5714909B2 (zh) |
KR (1) | KR101571575B1 (zh) |
CN (2) | CN106003663A (zh) |
SG (1) | SG188849A1 (zh) |
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WO2009076101A1 (en) | 2009-06-18 |
JP2015042568A (ja) | 2015-03-05 |
KR101571575B1 (ko) | 2015-11-24 |
TW200938440A (en) | 2009-09-16 |
SG188849A1 (en) | 2013-04-30 |
CN101970208A (zh) | 2011-02-09 |
JP5714909B2 (ja) | 2015-05-07 |
CN106003663A (zh) | 2016-10-12 |
EP2229272A1 (en) | 2010-09-22 |
JP2011506132A (ja) | 2011-03-03 |
TW201505924A (zh) | 2015-02-16 |
US20110187028A1 (en) | 2011-08-04 |
EP2229272A4 (en) | 2014-02-12 |
KR20110091434A (ko) | 2011-08-11 |
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