TWI632183B - 用於絕緣容器之高分子材料 - Google Patents

用於絕緣容器之高分子材料 Download PDF

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Publication number
TWI632183B
TWI632183B TW101121656A TW101121656A TWI632183B TW I632183 B TWI632183 B TW I632183B TW 101121656 A TW101121656 A TW 101121656A TW 101121656 A TW101121656 A TW 101121656A TW I632183 B TWI632183 B TW I632183B
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Taiwan
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formulation
polymer
polypropylene
force
materials
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TW101121656A
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TW201309757A (zh
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克里斯K 雷瑟
約翰B 尤勒
查理斯T 華勒斯
菲利浦A 卓斯克爾
傑森J 帕勒迪諾
米勒C 瑪洛維奇
丹尼爾O 戴維斯
斯維特拉娜I 卡崔達
藍迪A 鮑德斯
傑佛瑞A 曼尼
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比瑞塑料有限公司
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    • B29B7/80Component parts, details or accessories; Auxiliary operations
    • B29B7/88Adding charges, i.e. additives
    • B29B7/94Liquid charges
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    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10Homopolymers or copolymers of propene
    • C08L23/12Polypropene
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Abstract

一種調配物,其包括高分子材料、成核劑、發泡劑及表面活性劑。該調配物可用於形成容器。

Description

用於絕緣容器之高分子材料
本發明係關於可經形成以產生容器之高分子材料,且詳言之絕緣高分子材料。更特定言之,本發明係關於基於高分子之調配物,其可經形成以產生絕緣非芳族高分子材料。
本申請案根據35 U.S.C.§119(e)主張2011年8月31日申請之美國臨時申請案第61/529,632號及2012年3月30日申請之美國臨時申請案第61/618,604號之優先權,該等美國臨時申請案以引用的方式明確併入本文中。
本發明之高分子材料包括高分子樹脂及成泡劑(cell-forming agent)。在說明性實施例中,高分子樹脂及成泡劑之摻合物經擠出或以其他方式形成以產生絕緣泡孔非芳族高分子材料。
在說明性實施例中,根據本發明產生之絕緣泡孔非芳族高分子材料可經形成以產生絕緣杯或其他產物。使用聚丙烯樹脂形成說明性實施例中之絕緣泡孔非芳族高分子材料。
在說明性實施例中,絕緣泡孔非芳族高分子材料包含具有高熔體強度之聚丙烯基礎樹脂、聚丙烯共聚物或均聚物(或兩者)、及包括至少一種成核劑及發泡劑(諸如二氧化碳)之成泡劑。在說明性實施例中,絕緣泡孔非芳族高分子材料進一步包含助滑劑。聚丙烯基礎樹脂具有廣泛分佈 的單峰(非雙峰)分子量分佈。
在說明性實施例中,本發明之基於聚丙烯之調配物經加熱且兩級擠出產生管狀擠出物(在擠出法中),該擠出物可切開得到絕緣泡孔非芳族高分子材料條帶。在說明性實施例中,將惰性氣體形式之發泡劑引入第一級擠出之熔融樹脂中。
在說明性實施例中,使用絕緣泡孔非芳族高分子材料條帶形成絕緣杯。絕緣杯包括具有套筒狀側壁之杯體及與杯體耦接之底面,底面與側壁合作形成儲備食物、液體或任何合適產物之內部區域。杯體亦包括與側壁上端耦接之捲邊及與側壁下端及底面耦接之底面座架。
絕緣泡孔非芳族高分子材料根據本發明經組態以提供能夠在杯體之至少一個選擇區域(例如側壁、捲邊、底面座架及底面座架中所包括之底面固定凸緣)實現局部塑性變形之方式,提供(1)在杯體選擇區域之第一部分具有第一密度之塑性變形第一材料片段及(2)在杯體選擇區域之相鄰第二部分具有相對較低之第二密度的第二材料片段。在說明性實施例中,第一材料片段比第二材料片段薄。
在考慮對目前所認為實施本發明之最佳方式進行例示的說明性實施例後,本發明之其他特徵將對熟習此項技術者顯而易見。
實施方式尤其參考附圖。
可形成根據本發明產生之絕緣泡孔非芳族高分子材料以產生如圖2-9中所示之絕緣杯10。舉例而言,絕緣泡孔非芳族高分子材料包含具有高熔體強度之聚丙烯基礎樹脂、聚丙烯共聚物或均聚物(或兩者)、及包括至少一種成核劑及發泡劑(諸如二氧化碳)之成泡劑。作為另一實例,絕緣泡孔非芳族高分子材料進一步包含助滑劑。聚丙烯基礎樹脂具有廣泛分佈的單峰(非雙峰)分子量分佈。
如圖1中所示,材料形成法100使用本發明之基於聚丙烯之調配物121產生絕緣泡孔非芳族高分子材料條帶82。如例如圖1中所說明,調配物121經加熱且兩級擠出產生管狀擠出物124,該管狀擠出物可經切割以提供絕緣泡孔非芳族高分子材料條帶82。將呈液化惰性氣體形式之發泡劑引入第一級擠出區之熔融樹脂122中。
使用絕緣泡孔非芳族高分子材料形成絕緣杯10。如圖2及4中所示,絕緣杯10包括具有套筒狀側壁18之杯體11及底面20。底面20與杯體11耦接且與側壁18合作形成於其之間儲備食物、液體或任何合適產物之內部區域14。如圖5中所示,杯體11亦包括與側壁18上端耦接之捲邊16及與側壁18下端及底面20耦接之底面座架17。
如例如圖2及6-9中所示,絕緣泡孔非芳族高分子材料根據本發明經組態以提供能夠在杯體11之至少一個選擇區域(例如側壁18、捲邊16、底面座架17及底面座架17中所包括之底面固定凸緣26)實現局部塑性變形之方式,提供(1)在杯體11選擇區域之第一部分具有第一密度之塑性變形第 一材料片段及(2)在杯體11選擇區域之相鄰第二部分具有相對較低之第二密度的第二材料片段。在說明性實施例中,第一材料片段比第二材料片段薄。
本發明之一個態樣提供用於製造絕緣泡孔非芳族高分子材料之調配物。如本文所提及,絕緣泡孔非芳族高分子材料係指具有泡孔形成於其中且在既定厚度下具有理想絕緣特性之擠出結構。本發明之另一態樣提供用於製造絕緣泡孔非芳族高分子材料擠出結構之樹脂材料。本發明之另一態樣提供包含絕緣泡孔非芳族高分子材料之擠出物。本發明之另一態樣提供由絕緣泡孔非芳族高分子材料形成之材料之結構。本發明之另一態樣提供由絕緣泡孔非芳族高分子材料形成之容器。
在例示性實施例中,調配物包括至少一種高分子材料。在一個例示性實施例中,主要或基礎高分子包含具有長鏈分支之高熔體強度聚丙烯。長鏈分支藉由用該高分子另一共價鍵結之鏈或(在接枝共聚物情況下)另一類型之鏈置換單體次單位上之取代基(例如氫原子)而出現。舉例而言,在聚合期間之鏈轉移反應可引起高分子分支。長鏈分支為使高分子側鏈長度比線性高分子鏈平均臨界纏結距離長的分支。長鏈分支通常理解為包括至少20個碳原子之高分子鏈,視用於聚合之特定單體結構而定。分支之另一實例為在聚合完成後藉由使高分子交聯來實現。一些長鏈分支高分子在未交聯的情況下形成。高分子鏈分支可對材料特性具有顯著影響。聚丙烯材料之最終選擇可能考慮到最終材 料之特性、調配期間所需之額外材料以及擠出法期間之條件。在例示性實施例中,高熔體強度聚丙烯可為可容納氣體(如下文所述)、產生所需泡孔尺寸、具有所需表面光滑度且具有可接受之氣味含量(若存在)之材料。
合適聚丙烯基礎樹脂之一個說明性實例為DAPLOYTM WB140均聚物(可購自Borealis A/S),一種高熔體強度結構同分異構的經修飾聚丙烯均聚物(如根據以引用的方式併入本文中之ISO 16790所測試,熔體強度=36,使用以引用的方式併入本文中之ISO 11357所測試,熔融溫度=325.4℉(163℃))。
Borealis DAPLOYTM WB140特性(如Borealis產品手冊中所述):
亦可使用具有合適熔體強度、分支及熔融溫度之其他聚丙烯高分子。可使用若干基礎樹脂且混合在一起。
在某些例示性實施例中,第二高分子可與基礎高分子一起使用。第二高分子可為例如具有充足結晶度之高分子。在例示性實施例中,第二高分子可為至少一種結晶聚丙烯均聚物、抗衝擊共聚物、其混合物或其類似物。一個說明性實例為可自Braskem以F020HC購得的高結晶聚丙烯均聚物。另一說明性實例為以PRO-FAX SC204TM市售之高分子(可購自LyndellBasell Industries Holdings,B.V.)。另一說明性實例包括可購自Braskem之Homo PP-INSPIRE 222。在一個態樣中,聚丙烯在10℃/min冷卻速率下可具有高結晶度,亦即結晶相含量超過51%(如使用差示掃描熱量測定所測試)。在例示性實施例中,可使用若干不同第二高分子且混合在一起。
在例示性實施例中,第二高分子可為聚乙烯或可包括聚乙烯。在例示性實施例中,第二高分子可包括低密度聚乙烯、線性低密度聚乙烯、高密度聚乙烯、乙烯-乙酸乙烯酯共聚物、乙烯-丙烯酸乙酯共聚物、乙烯-丙烯酸共聚物、至少兩種上述物之混合物及其類似物。如下文進一步所述,使用非聚丙烯材料可能影響可回收性、絕緣、可微波性、抗衝擊性或其他特性。
一或多種成核劑用以提供且控制成核點,以促進在擠出法期間在熔融樹脂中形成泡孔、氣泡或空隙。成核劑意指在熔融樹脂混合物中提供泡孔形成位點之化學或物理材 料。成核劑可為物理試劑或化學試劑。合適物理成核劑具有所需的粒徑、縱橫比及頂切特性。實例包括(但不限於)滑石、CaCO3、雲母及至少兩種上述物之混合物。成核劑可與引入料斗中之高分子樹脂調配物摻合。或者,成核劑可添加至擠出機中之熔融樹脂混合物中。當達到化學反應溫度時,成核劑起作用使氣泡形成,從而在熔融樹脂中形成泡孔。化學發泡劑之說明性實例為檸檬酸或基於檸檬酸之材料。在分解後,化學發泡劑形成小氣泡,該等小氣泡進一步充當用於自物理或其他類型發泡劑生長較大泡孔之成核點。一個代表性實例為HydrocerolTM CF-40ETM(可購自Clariant Corporation),其含有檸檬酸及結晶成核劑。在說明性實施例中,可添加一或多種催化劑或其他反應劑以加快或促進泡孔形成。
在某些例示性實施例中,可併入一或多種發泡劑。發泡劑意指起作用以使成核點膨脹之物理或化學材料(或材料組合)。成核劑及發泡劑可一起起作用。發泡劑藉由在熔融樹脂中形成泡孔而起作用來減小密度。發泡劑可添加至擠出機中之熔融樹脂混合物中。物理發泡劑之代表性實例包括(但不限於)二氧化碳、氮氣、氦氣、氬氣、空氣、戊烷、丁烷、或上述物之其他烷烴混合物及其類似物。在某些例示性實施例中,可使用增加物理發泡劑溶解度之加工助劑。或者,物理發泡劑可為氫氟碳化物,諸如1,1,1,2-四氟乙烷(亦稱為R134a)或其他鹵烷製冷劑。發泡劑之選擇可能要考慮環境影響。
在例示性實施例中,物理發泡劑通常為氣體,其在壓力下以液體形式經由如圖1所示擠出機之埠引入熔融樹脂。隨著熔融樹脂穿過擠出機及模頭,壓力降低,導致物理發泡劑自液相變為氣相,從而在擠出樹脂中形成泡孔。過量氣體在擠出後噴出,而其餘氣體截留於擠出物泡孔中。
化學發泡劑為降解或反應產生氣體之材料。化學發泡劑可吸熱或放熱。化學發泡劑通常在特定溫度下降解以分解及釋放氣體。在一個態樣中,化學發泡劑可為一或多種選自由以下組成之群之材料:偶氮二甲醯胺;偶氮二異丁腈;苯磺醯肼;4,4-羥苯磺醯基半卡肼;對甲苯磺醯基半卡肼;偶氮二甲酸鋇;N,N'-二甲基-N,N'-二亞硝基對苯二甲醯胺;三肼基三嗪;甲烷;乙烷;丙烷;正丁烷;異丁烷;正戊烷;異戊烷;新戊烷;氟甲烷;全氟甲烷;氟乙烷;1,1-二氟乙烷;1,1,1-三氟乙烷;1,1,1,2-四氟乙烷;五氟乙烷;全氟乙烷;2,2-二氟丙烷;1,1,1-三氟丙烷;全氟丙烷;全氟丁烷;全氟環丁烷;氯甲烷;二氯甲烷;氯乙烷;1,1,1-三氯乙烷;1,1-二氯-1-氟乙烷;1-氯-1,1-二氟乙烷;1,1-二氯-2,2,2-三氟乙烷;1-氯-1,2,2,2-四氟乙烷;三氯單氟甲烷;二氯二氟甲烷;三氯三氟乙烷;二氯四氟乙烷;氯七氟丙烷;二氯六氟丙烷;甲醇;乙醇;正丙醇;異丙醇;碳酸氫鈉;碳酸鈉;碳酸氫銨;碳酸銨;亞硝酸銨;N,N'-二甲基-N,N'-二亞硝基對苯二甲醯胺;N,N'-二亞硝基五亞甲基四胺;偶氮二異丁腈;偶氮環己腈;偶氮二胺基苯;苯磺 醯肼;甲苯磺醯肼;p,p'-氧基雙(苯磺醯肼);二苯碸-3,3'-二磺醯肼;疊氮化鈣;4,4'-二苯基二磺醯疊氮;及對甲苯磺醯疊氮。
在本發明之一個態樣中,當使用化學發泡劑時,化學發泡劑可引入添加至料斗中之樹脂調配物中。
在本發明之一個態樣中,發泡劑可為在分解後形成氣體之可分解材料。該材料之代表性實例為檸檬酸或基於檸檬酸之材料。在本發明之一個例示性態樣中,可使用物理發泡劑及化學發泡劑之混合物。
在本發明之一個態樣中,至少一種助滑劑可併入樹脂混合物中以輔助提高產率。助滑劑(亦稱為加工助劑)為用以描述添加至樹脂混合物且在轉化期間及轉化後向高分子提供表面潤滑之一般類型材料的術語。助滑劑亦可減少或消除模流涎(die drool)。助滑劑材料之代表性實例包括脂肪或脂肪酸之醯胺,諸如(但不限於)芥酸醯胺(erucamide)及油醯胺。在一個例示性態樣中,可使用油醯胺(單一不飽和C-18)至芥酸醯胺(C-22單一不飽和)。助滑劑材料之其他代表性實例包括低分子量醯胺及含氟彈性體。可使用兩種或兩種以上助滑劑之組合。助滑劑可以母料顆粒形式提供且與樹脂調配物摻合。
可視情況併入一或多種額外組分及添加劑,諸如(但不限於)抗衝擊改質劑、著色劑(諸如(但不限於)二氧化鈦)及化合物回收料。
高分子樹脂可與任何其他所需組分摻合且熔融形成樹脂 調配混合物。
除表面地形及形態之外,發現有益於獲得無折痕之高品質絕緣杯的另一因素為絕緣泡孔非芳族高分子條帶之各向異性。縱橫比為泡孔長軸與短軸之比率。如顯微術所證實,在一個例示性實施例中,絕緣泡孔非芳族高分子材料之擠出條帶82在加工方向67(機器或沿著腹板方向)上之平均泡孔尺寸為約0.0362吋(0.92 mm)寬,約0.0106吋(0.27 mm)高。因此,加工方向泡孔尺寸縱橫比為約3.5。交叉方向(交叉腹板或橫向方向)平均泡孔尺寸為約0.0205吋(0.52 mm)寬及約0.0106吋(0.27 mm)高。因此,交叉方向縱橫比為1.94。在一個例示性實施例中,發現對於在杯形成期間承受壓縮力之條帶,泡孔之一個所需平均縱橫比為約1.0至約3.0。在一個例示性實施例中,泡孔之一個所需平均縱橫比為約1.0至約2.0。
加工方向與交叉方向泡孔長度之比率用作擠出條帶各向異性之量度。在例示性實施例中,絕緣泡孔非芳族高分子材料條帶可雙軸定向,各向異性係數範圍介於約1.5至約3。在一個例示性實施例中,各向異性係數為約1.8。
若杯之周長與擠出條帶82之加工方向67對準,泡孔縱橫比超過約3.0,則通常在杯之內表面上形成深度超過約200微米之深折痕,使得該杯不可用。出乎意料地發現,在一個例示性實施例中,若杯之周長在擠出條帶82之交叉方向上對準,其可以低於約2.0之泡孔縱橫比表徵,則在杯內部未形成深折痕,表明擠出條帶82之交叉方向在杯形成期 間更抗壓縮力。
泡孔在杯周長方向(諸如在交叉方向)上具有低於約2.0之縱橫比的擠出條帶壓縮性較大的一個可能原因可歸因於具有較大半徑之泡孔的較低應力集中。另一可能原因可為泡孔之較大縱橫比可意指泡孔壁之細長比較大,細長比與壓曲強度成反比。條帶在壓縮模式中摺疊起皺可近似為泡孔壁壓曲。對於具有較長長度之泡孔壁,細長比(長度比直徑)可較大。減輕壓縮應力之另一可能因素可為在交叉方向上泡孔壁中更有利的高分子鏈填充,使高分子鏈在壓縮力下重排。預期高分子鏈較佳在加工方向67上定向且更緊密填充。
在例示性實施例中,所形成之杯周長係沿著擠出條帶方向對準,且泡孔縱橫比低於約2.0。因此,面向杯內部之結晶域尺寸低於約100埃之擠出條帶表面可提供之有利結果為達到所需表面地形,其中缺陷小於約5微米深。
在本發明之一個態樣中,聚丙烯樹脂(基礎樹脂或所組合之基礎樹脂與次要樹脂)可能具有在約0.01g/cm3至約0.19g/cm3範圍內之密度。在一個例示性實施例中,密度可能在約0.05g/cm3至約0.19g/cm3之範圍內。在一個例示性實施例中,密度可能在約0.1g/cm3至約0.185g/cm3之範圍內。
在一個替代性例示性實施例中,可使用聚乳酸材料代替聚丙烯作為主要高分子,諸如(但不限於)衍生自基於食物之材料(例如玉米澱粉)之聚乳酸材料。在一個例示性實施 例中,聚乙烯可用作主要高分子。
在本發明之一個例示性態樣中,適用於形成絕緣泡孔非芳族高分子材料之材料的一種調配物包括以下:包含高熔體強度長鏈分支聚丙烯之至少一種主要樹脂、包含高結晶聚丙烯均聚物或抗衝擊共聚物之至少一種次要樹脂、至少一種成核劑、至少一種發泡劑及至少一種助滑劑。可視情況併入著色劑。
調配物可經由料斗引入擠出機中,諸如圖1中所示。在擠出法期間,加熱且熔融調配物以形成熔融樹脂混合物。在例示性實施例中,將至少一種物理發泡劑經由擠出機中之一或多個埠引入熔融樹脂混合物中。熔融樹脂混合物及氣體接著擠出穿過模具。
在另一例示性實施例中,調配物可含有至少一種化學發泡劑及至少一種物理發泡劑兩者。
可根據習知設備及方法,由薄片形成杯子或其他容器或結構。
僅出於非限制性說明之目的,將描述自本文中所揭示之材料的例示性實施例形成杯子;然而,容器可為任何多種可能的形狀或結構或用於多種應用,諸如(但不限於)習知飲料杯、貯藏容器、瓶子或其類似物。僅出於非限制性說明之目的,液體飲料將用作可由容器所容納之材料;然而,容器可保留液體、固體、凝膠、其組合或其他材料。
材料形成法100展示於例如圖1中。如圖1所示,材料形成法100將非芳族高分子材料擠出成絕緣泡孔非芳族高分 子材料之薄片或條帶82。舉例而言,材料形成法100使用串聯擠出技術,其中第一擠出機111及第二擠出機112合作擠出絕緣泡孔非芳族高分子材料條帶82。
如圖1中所示,將絕緣泡孔非芳族高分子材料82之調配物121裝入與第一擠出機111耦接之料斗113中。調配物121可呈丸粒、顆粒片(granular flake)、粉末或其他合適形式。絕緣泡孔非芳族高分子材料之調配物121藉由第一擠出機111中所包括之螺桿114自料斗113移動。如圖1所示,調配物121在第一擠出機111之第一擠出區中藉由施加熱105及來自螺桿114之壓力轉化成熔融樹脂122。在例示性實施例中,可在熔融樹脂122形成後將物理發泡劑115引入且混入熔融樹脂122中。在例示性實施例中,如本文中進一步所述,物理發泡劑可為如圖1所示以加壓液體形式經由埠115A引入且與熔融樹脂122混合形成熔融擠出樹脂混合物123之氣體。
如圖1所示,擠出樹脂混合物123藉由螺桿114輸送至第二擠出機112中所包括之第二擠出區中。此處,由第二擠出機112進一步加工擠出樹脂混合物123,隨後排出穿過與第二擠出機112末端耦接之擠出模116,形成擠出物124。隨著擠出樹脂混合物123穿過擠出模116,氣體115由擠出樹脂混合物123中之溶液產生且開始形成泡孔並膨脹,以便形成擠出物124。如圖1中所示之例示性實施例,擠出物124可藉由環形擠出模116來形成,以便形成管狀擠出物。如圖1所示,切割機117接著切割擠出物124,形成絕緣泡 孔非芳族高分子材料之薄片或條帶82。
擠出物意指退出擠出模之物質。擠出物可呈以下形式,諸如(但不限於)薄片、條帶、管、細線、丸粒、顆粒或作為如本文所述之基於高分子之調配物擠出穿過擠出機模具之結果的其他結構。僅出於說明目的,薄片將稱為可形成的代表性擠出物結構,但意欲包括本文中所述之結構。擠出物可進一步形成任何多種最終產物,諸如(但不限於):杯子、容器、托盤、包裹物、絕緣泡孔非芳族高分子材料條帶之捲筒或其類似物。
舉例而言,絕緣泡孔非芳族高分子材料條帶82捲繞形成絕緣泡孔非芳族高分子材料捲且儲存以供後來用於杯成形法。然而,待與杯成形法串聯使用之絕緣泡孔非芳族高分子材料條帶82屬於本發明之範疇。在一個說明性實例中,絕緣泡孔非芳族高分子材料條帶82與具有薄膜及印刷於該薄膜上之墨水層的表層一起層壓,得到高品質圖形。
如圖2及3所示,使用絕緣泡孔非芳族高分子材料條帶82形成絕緣杯10。如圖2所示,絕緣杯10包括例如具有套筒狀側壁18之杯體11及與杯體11耦接從而與側壁18合作形成用於儲存食物、液體或任何合適產品之內部區域14的底面20。如圖2及7中所示,杯體11亦包括與側壁18上端耦接之捲邊16及與側壁18下端及底面20耦接之底面座架17。
杯體11由如本文中所揭示之絕緣泡孔非芳族高分子材料條帶82形成。根據本發明,絕緣泡孔非芳族高分子材料條帶82經由施加壓力及熱(但在例示性實施例中,組態可能 未施加熱)經組態以提供能夠在杯體11至少一個選擇區域實現局部塑性變形之方式,在不破壞絕緣泡孔非芳族高分子材料薄片的情況下,得到位於杯體11選擇區域第一部分且具有第一密度的塑性變形第一薄片片段及位於杯體11選擇區域相鄰第二部分且具有低於該第一密度之第二密度的第二薄片片段,以便維持杯體11之預定絕緣特徵。
如圖2、5及6所示,能夠藉由絕緣泡孔非芳族高分子材料實現局部塑性變形之杯體11選擇區域中的第一區域101在套筒狀側壁18中。如圖2、5及6所示,套筒狀側壁18包括立式內部突出部514、立式外部突出部512及立式圍籬513。立式內部突出部514經配置以自底面20向上延伸且經組態以提供杯體11之選擇區域中的第一區域101中具有第一密度之第一薄片片段。如圖6所示,立式外部突出部512經配置以自底面20向上延伸且沿著立式外部突出部512與立式內部突出部514之間的界面I與立式內部突出部514配對。立式圍籬513經配置以使立式內部突出部514及立式外部突出部512與周圍內部區域14互連。如圖2-5所示,立式圍籬513經組態以提供杯體11之選擇區域中的第一區域101中具有第二密度之第二薄片片段,且與立式內部突出部514及立式外部突出部512合作形成套筒狀側壁18。
如圖2、4、5及7所示,能夠藉由絕緣泡孔非芳族高分子材料薄片實現局部塑性變形之杯體11選擇區域中的第二區域102在杯體11所包括之捲邊16中。捲邊16與套筒狀側壁18之上端耦接,與底面20間隔置放且構造內部區域14之開 口。如圖2、4、5及7所示,捲邊16包括內部捲式突出部164、外部捲式突出部162及捲緣163。內部捲式突出部164經組態以提供杯體11選擇區域中的第二區域102中之第一薄片片段。內部捲式突出部164與套筒狀側壁18中所包括之立式外部突出部512上端耦接。外部捲式突出部162與套筒狀側壁18中所包括之立式內部突出部514上端耦接且與內部捲式突出部164面向外的外表面耦接。捲緣163經配置以使內部捲式突出部164及外部捲式突出部162各相對面向的側邊互連。如圖2所示,捲緣163經組態以提供在杯體11之選擇區域中的第二區域102中具有第二密度之第二薄片片段且與內部捲式突出部164及外部捲式突出部162合作形成捲邊16。
如圖2、5及8所示,能夠藉由絕緣泡孔非芳族高分子材料薄片實現局部塑性變形之杯體11選擇區域中的第三區域103在杯體11所包括之底面座架中。底面座架17與套筒狀側壁18下端耦接以與捲邊16間隔置放,且與底面20耦接以在相對於套筒狀側壁18固定的位置處支撐底面20,從而形成內部區域14。底面座架17包括腹板支撐環126、底面固定凸緣26及腹板25。腹板支撐環126與套筒狀側壁18下端耦接,且經組態以提供在杯體11之選擇區域中的第三區域103中具有第二密度之第二薄片片段。底面固定凸緣26與底面20耦接且經配置以由腹板支撐環126圍繞。腹板25經配置以使底面固定凸緣26與腹板支撐環126互連。腹板25經組態以提供在杯體11之選擇區域中的第三區域103中具 有第一密度之第一薄片片段。
如圖2、5及9所示,能夠藉由絕緣泡孔非芳族高分子材料薄片實現局部塑性變形之杯體11之選擇區域中的第四區域104在底面座架17之底面固定凸緣中。底面固定凸緣26包括面對面配置的一串交替立式厚狹板及薄狹板,自腹板25向上朝受套筒狀側壁18及底面20束縛之內部區域14延伸。第一立式厚狹板261經組態以包括自腹板25向上朝內部區域14延伸之右側邊。第二立式厚狹板262經組態以包括自腹板25向上朝內部區域14延伸配置之左側邊,且面對第一立式厚狹板261之右側邊隔開置放。第一立式薄狹板260經配置以使第一立式厚狹板261之左側邊與第二立式厚狹板262之右側邊互連,且與左側邊及右側邊合作界定其間的垂直通道263,該垂直通道263向內通向受底面固定凸緣26及底面20中所包括且位於底面固定凸緣26上方的水平平台21束縛的較低內部區域。第一立式薄狹板260經組態以提供在杯體11之選擇區域中的第四區域104中的第一薄片片段。第一立式厚狹板261經組態以提供在杯體11之選擇區域中的第四區域104中的第二薄片片段。
用以產生絕緣杯10之絕緣泡孔非芳族高分子材料之壓縮性使得絕緣泡孔非芳族高分子材料得以製備絕緣杯10之機械總成,無其他非芳族高分子材料所具有的限制。材料之泡孔性提供如下所述之絕緣特徵,而易塑性變形性允許在不破裂的情況下生成材料。當絕緣泡孔非芳族高分子材料經受壓力負載時所經受之塑性變形用以在已移除壓力負載 後,在絕緣泡孔非芳族高分子材料中形成永久定形。在一些位置中,定位永久定形之位置以便控制絕緣泡孔非芳族高分子材料薄片之聚集。
塑性變形亦可在薄片中形成摺疊線,以便在組裝過程中起作用時控制薄片變形。當變形存在時,由變形所形成之空隙中不存在材料便於使材料易於在變形位置摺疊。
如本文所述形成之絕緣泡孔非芳族高分子材料薄片可能的非預期特徵為在既定厚度下獲得的高絕緣值。參見例如下文實例1及2。
由本發明例示性實施例之絕緣泡孔非芳族高分子材料形成之杯子的可能特徵為該杯子具有較低物質損失。此外,當經受習知廚房類型之微波爐加熱多達若干分鐘的一段時間時,本發明之材料排出明顯較少的廢氣。
由本發明之絕緣泡孔非芳族高分子材料形成之杯子的另一可能特徵為該杯子可置放於習知住宅或市售洗碗機清潔循環(頂部機架(top rack))中且經受該清潔循環,而無顯著結構或材料損壞或對材料性質之不利影響。此特徵是與珠粒發泡聚苯乙烯杯子或容器相比,珠粒發泡聚苯乙烯杯子或容器在類似清潔過程下可能損壞。因此,可清潔且重複使用根據本發明之一個態樣製得之杯子。
由根據本發明不同態樣之絕緣泡孔非芳族高分子材料形成之物品的另一可能特徵為該物品可回收。可回收意指材料(諸如回收料)可添加回到擠出或其他形成過程而無需分離材料組分,亦即由該材料形成之物品在重新進入擠出過 程之前無須操作來移除一或多種材料或組分。舉例而言,若吾人無需在具有層壓於杯外部之印刷膜層的杯子研磨成粒子之前分離出膜層,則該杯子可回收。相比之下,紙包裹之發泡聚苯乙烯杯不可回收,因為聚苯乙烯材料實際不能用作形成發泡聚苯乙烯杯之材料,但該杯材料或許可能形成另一產物。作為另一實例,由具有非苯乙烯印刷膜層黏著於其之非發泡聚苯乙烯材料形成的杯子可視為不可回收,因為其可能需要使聚苯乙烯杯材料與非苯乙烯膜層分離,而不想要作為回收料之一部分引入擠出過程。
由本發明之絕緣泡孔非芳族高分子材料形成之物品的可回收性將產生的可用廢物之量減至最小。相比之下,珠粒發泡聚苯乙烯杯分裂成珠粒且因此通常不易於在使用相同材料形成物品之製造方法中重複使用。而且,由於為產生液體阻力而通常具有擠出塗佈塑膠層或塑膠疊層之紙杯一般不能回收,此係因為不同材料(紙、黏著劑、膜、塑膠)一般實際上不能在商業回收操作中分離。
由根據本發明之一個態樣(非層壓法)之材料形成之杯子或其他物品的可能特徵為絕緣泡孔非芳族聚丙烯薄片(在形成杯子之前或在杯子形成期間,視所用製造方法而定)之外壁表面(或內壁表面或兩者)可印刷高解析度圖形。習知珠粒發泡聚苯乙烯杯之表面通常並未平滑到足以接受除低解析度圖形以外之印刷。同樣,已知無塗層紙杯亦通常不具有對於該等高解析度圖形而言足夠平滑的表面。紙杯可經塗佈以具有所需表面修整且可達到高解析度。紙難以 達到絕緣水平且需要所設計之氣隙併入杯子或與杯子結合以實現絕緣,諸如杯子一部分上及上方之套筒滑件(sleeve slid)。因此,解決辦法為使用低解析度印刷來層壓於已印刷薄膜之外壁,或將印刷套筒(黏結或可移動)插在外壁上方,或塗佈紙以接受高解析度圖形。
由根據本發明之一個態樣的絕緣泡孔非芳族高分子材料形成之杯子的可能特徵為其具有由剛度所量測之非預期強度。剛度為在室溫及高溫(例如藉由用熱液體填充杯子)下進行且量測材料剛度之量度。杯子材料之強度對減少使用者使杯子變形及蓋溢流冒口(popping off)或蓋或側壁密封漏洩的可能性而言為重要的。
如下文所述,如由標準衝擊測試所量測,由本發明之絕緣泡孔非芳族高分子材料形成之杯子的可能特徵為套筒抗諸如由吸管、叉、匙、指甲或其類似物穿孔。當與珠粒發泡聚苯乙烯杯相比時,測試材料顯示實質上較高的抗衝擊性。因此,如本文所述之一個態樣形成的杯子可減少熱液體穿孔及漏洩於使用者之可能性。
如本文所述由根據一個態樣之材料形成的具有壓縮邊及接縫之杯子的特徵為較大數目的該等杯子可以既定套筒長度嵌套,此係因為接縫較薄且側壁角度可減至最小(亦即相對於杯底更接近90°),同時提供可易於去嵌套之充足氣隙。具有實質上比側壁厚之接縫的習知接縫形成杯需要較大側壁角度(及氣隙)以便可去嵌套,導致以既定套筒長度只能嵌套較少杯子。
由根據本發明之一個態樣之材料形成的杯子的特徵為杯邊可具有小於約0.170吋(4.318 mm)之截面輪廓,其可歸因於局部泡孔變形及壓縮。該小輪廓比較大輪廓在審美上更令人喜愛。
由根據本發明之一個態樣之材料形成的杯子的特徵為不同容積之杯子的捲邊直徑可相同,使得一種蓋尺寸用於不同杯尺寸,假設杯邊外徑相同。因此,可減少庫存及使用點不同尺寸之蓋子的數目。
材料調配物可具有使薄片在不破裂的情況下壓縮之特性。
本發明之絕緣泡孔非芳族高分子材料可能形成可裹在其他結構周圍之條帶。舉例而言,可形成可用作包裹材料之根據本發明之一個態樣的材料條帶且裹在管、導管或其他結構周圍以提供經改良之絕緣。薄片或條帶可具有施用於一面或兩面之黏著劑(諸如壓敏黏著劑)層。條帶可捲繞於捲筒上。條帶視情況可具有與其結合之離型襯墊,以便更容易自捲筒解開條帶。可例如藉由使用一或多種聚丙烯或具有足夠可撓性之其他聚烯烴材料調適高分子調配物以提供形成包裹物或可捲繞條帶之所需可撓性,從而能夠使擠出薄片具有足夠可撓性以便捲繞於捲筒上。絕緣泡孔非芳族高分子材料可能形成為可插在杯子上方以便提供額外絕緣之套筒。
在例示性實施例中,由本發明之絕緣泡孔非芳族高分子材料形成之薄片可在模具處切割或剝落且用作主體絕緣 體。
本發明之調配物及絕緣泡孔非芳族高分子材料符合可形成為包括許多(若非全部)以下特徵之物品(諸如杯子)之材料的長期以來的需要:絕緣效能、易於回收、抗穿孔性、抗碎性、可微波性及如本文所述之其他特徵。其他調配物未能提供獲得如隨附申請專利範圍中所反映之此等特徵之組合之材料。此失敗為與競爭性設計選擇有關之特徵的結果。舉例而言,其他調配物已產生材料且基於設計選擇由此等材料形成之結構絕緣,但抗穿孔性較差、不能有效回收且缺乏可微波性。比較而言,本文中所揭示之調配物及材料藉由使用絕緣泡孔非芳族高分子材料克服其他調配物及材料之不足。此處參考2012年6月7日申請的名為INSULATED CONTAINER的美國申請案第13/491,007號,其揭示內容係關於由該等絕緣泡孔非芳族高分子材料形成之物品(諸如杯子),該申請案之全文併入本文中。
實例
僅出於說明之目的闡述以下實例。除非另外規定,否則該等實例中出現的份數及百分比數係以重量計。本發明中所引用或提及之所有ASTM、ISO及其他標準測試法之全文以引用的方式併入本文中。
實例1-調配物及擠出
使用DAPLOYTM WB140聚丙烯均聚物(可購自Borealis A/S)作為聚丙烯基礎樹脂。使用可購自Braskem之F020HC(一種聚丙烯均聚物樹脂)作為次要樹脂。兩種樹脂 與以下物質摻合:HydrocerolTM CF-40ETM作為主要成核劑、滑石作為次要成核劑、CO2作為發泡劑、助滑劑及二氧化鈦作為著色劑。百分比為:79.9%主要樹脂:高熔體強度聚丙烯Borealis WB140
HMS15%次要樹脂:F020HC(Braskem)
0.1%主要成核劑:Clariant Hyrocerol CF-40ETM
2%次要成核劑:滑石
1%著色劑:TiO2 PE(或者可使用PP)
2%助滑劑:AmpacetTM 102823 LLDPE(線性低密度聚乙烯),可購自Ampacet Corporation
添加調配物至擠出機料斗中。擠出機加熱調配物形成熔融樹脂混合物。向此混合物中添加1.1 lbs/hr CO2
0.7 lbs/hr R134a
將具有R134a之二氧化碳注入樹脂摻合物中以使樹脂膨脹且減小密度。由此形成之混合物經由模頭擠出成薄片。接著切割薄片且形成杯子。
實例1-測試結果
根據實例1形成之材料的測試結果展示該材料具有約0.1902 g/cm3之密度及約0.089吋(2.2606 mm)之標稱薄片規格。
可微波性
使用此材料產生之用12盎司室溫水填充的容器在FISO Microwave Station(1200瓦)微波爐中加熱2.5分鐘,無灼燒 或燒焦或對杯子的其他可見影響。比較而言,在同一微波爐中加熱之紙杯在90秒以內燒焦或灼燒。
剛度 測試法
樣品處於73℉(22.8℃)及50%相對濕度下。使用含有荷重計之水平測力計對杯子硬度/剛度進行測試,以量測當暴露於以下測試條件時杯子的抵抗力:(a)杯子上的測試位置為自杯邊向下1/3;(b)測試移動距離為0.25吋(6.35 mm);及(c)測試移動時間為10秒。
測試結果
當平均壁厚為約0.064吋(1.6256 mm)、平均密度為約0.1776 g/cm3及平均杯子重量為約9.86 g時,材料之剛度展示於下表1-2中。
絕緣 測試法
使用如下典型工業杯絕緣測試法:
‧用膠將(杯外部)表面溫度熱電偶附接於杯子。
‧用玻璃膠帶將熱電偶膠帶附接於杯子,以使得熱電偶在杯子中間與接縫相對。
‧加熱水或其他水性液體至接近沸點,諸如在微波中。
‧連續攪拌具有球溫度計之熱液體,同時觀測液體溫度。
‧記錄熱電偶溫度。
‧當液體達到200℉時,將液體傾入杯子中至幾乎充滿。
‧將蓋子置放於杯子上。
‧記錄表面溫度最少5分鐘。
材料厚度為約0.089吋(2.2606 mm)。密度為約0.1902 g/cm3
測試結果
使用由上文所述之調配物形成且具有約0.190 g/cm3之密度及約0.089吋之壁厚的杯子。將200℉(93.3℃)之熱液體置放於杯子中。
測試結果
在杯外壁上測得之溫度為約140.5℉(60.3℃),下降約59.5℉(33℃)。經五分鐘時間最大溫度經觀察為在約140.5℉(60.3℃)下之峰值。溫度愈低,杯材料之絕緣特性愈佳,此係因為材料減少自液體傳遞至杯材料外部之熱傳遞。
易碎性
易碎性可定義為對撕裂或穿孔導致碎裂之抵抗性。
測試法
使用ASTM D1922-93中所述之埃爾曼多夫測試法(Elmendorf test method)。撕裂半徑為1.7吋(43.18 mm)。
測試結果
測試結果展示於下表3-4中。當與EPS相比時,本發明之一個例示性實施例中所形成之材料提供優越的撕裂力抵抗性。
注意不存在發泡聚苯乙烯橫向方向測試所獲得之資料,此係因為發泡聚苯乙烯因製造方法不具有材料定向(亦即加工方向或橫向方向)。本發明測試材料之範圍(計算如下:下限=平均值-(3×標準差);上限=平均值+(3×標準差))在加工方向上為約213公克-力至約351公克-力且在橫向方 向為約143公克-力至約281公克-力。比較而言,所測試之發泡聚苯乙烯材料的範圍為約103公克-力至約121公克-力。
抗穿孔性 測試法
測定穿刺杯側壁及底部所需之力及移動距離。以設定為每分鐘10吋(254 mm)移動速度之壓縮模式使用Instron儀器。使用在Instron底座上之杯穿孔測試夾具。此夾具使杯子套在符合杯內部之形狀上,使頂面垂直於Instron測試儀之移動。夾具之一吋直徑孔應向上安置。Instron移動部分應裝配0.300吋(7.62 mm)直徑穿孔器。在測試夾具中,穿孔器與孔洞對準。將杯子置放在夾具上方且記錄穿刺杯側壁所需之力及移動距離。在三個均勻隔開之位置重複側壁穿孔測試,而非在杯子接縫上進行穿孔測試。測試杯底部。除不使用夾具以外,此舉應以與側壁測試相同之方式進行。杯子僅倒置於Instron基座上,同時在杯底部中心上使穿孔器向下。
測試結果
典型側壁穿孔及底部穿孔之結果展示於下表5中。
抗緩慢穿孔性-吸管 測試法
使用如ASTM D-3763-86中所述之抗緩慢穿孔性測試法,本發明之一個例示性實施例中所形成之材料提供與發泡聚苯乙烯相比優越的抗穿孔性。測試結果展示於下表6-9中。
測試結果
實例2-調配物及擠出
使用以下調配物:81.70% Borealis WB140HMS主要聚丙烯
0.25% Amco A18035 PPRO滑石填充之濃縮物
2% Ampacet 102823製程助劑(Process Aid)PE MB線性低密度聚乙烯助滑劑
0.05% Hydrocerol CF-40E化學發泡劑
1% Colortech 11933-19著色劑
15% Braskem F020HC高結晶度均聚物聚丙烯
每小時引入3.4 lbs CO2至熔融樹脂中。
所形成條帶之密度範圍介於約0.155 g/cm3至約0.182 g/cm3
添加調配物至擠出機料斗中。擠出機加熱調配物形成熔融樹脂混合物。向此混合物中添加CO2以使樹脂膨脹及減小密度。由此形成之混合物經由模頭擠出成條帶82。接著切割條帶且形成絕緣杯10。
實例2-測試結果
在例示性實施例中,當擠出材料時,經擠出之絕緣泡孔非芳族高分子材料管具有在不同冷卻條件下形成之兩個表 面。將進一步作為擠出管外表面提及之一個表面與空氣接觸且不具有限制膨脹之物理障礙。擠出管表面之外表面藉由吹送壓縮空氣以每秒等於或大於12℉之冷卻速率冷卻。相對側上之表面將作為擠出管內部提及。擠出管表面內部為在物理限制擠出管內部之分流板(torpedo)心軸金屬冷卻表面上以腹板或加工方向拉伸擠出管時形成,且藉由水及壓縮空氣之組合以每秒小於10℉之冷卻速率冷卻。在例示性實施例中,冷卻水溫度為約135℉(57.22℃)。在例示性實施例中,冷卻空氣溫度為約85℉(29.44℃)。由於冷卻機制不同,擠出管外表面及擠出管表面內部具有不同表面特徵。已知冷卻速率及方法影響聚丙烯之結晶過程,從而改變聚丙烯形態(晶疇尺寸)及形貌(表面輪廓及平滑性)。
如本文所述之擠出薄片之例示性實施例的非預期特徵為薄片在彎曲形成圓形物品(諸如杯子)時形成顯著平滑、無折痕及折皺表面之能力。甚至杯內部表面平滑且無折皺,此處壓縮力通常易使材料(尤其具有大泡孔尺寸之低密度材料)壓出折痕。在例示性實施例中,由顯微術所偵測之絕緣泡孔非芳族高分子材料擠出薄片表面之平滑度使得當該薄片在杯形成期間經受延伸及壓縮力時,杯表面外部及內部中天然存在之壓痕(折痕或折皺)深度可小於約100微米。在一個例示性實施例中,平滑度可小於約50微米。在一個例示性實施例中,平滑度可為約5微米或5微米以下。在約10微米及10微米以下之深度下,杯表面上之微小折皺肉眼通常看不見。
在一個例示性實施例中,由包含表層及絕緣泡孔非芳族高分子材料條帶之薄片形成的絕緣杯自杯頂延伸至杯底具有約200微米深的典型折痕(深折皺)。在一個例示性實施例中,由僅包含絕緣泡孔非芳族高分子材料條帶(無表層)之薄片形成的絕緣杯自杯頂延伸至杯底具有約200微米深的典型折痕。當擠出管內部在壓縮模式中面向杯內部時,通常形成約100微米至約500微米深的該等折痕。折痕及深折皺可呈現令人不滿意的表面品質問題,使得最終的杯子不可用或不合需要。折痕可在薄片包括表層或不包括表層的情形下形成。
在例示性實施例中,絕緣泡孔非芳族高分子材料可擠出成條帶。然而,顯微圖像展示擠出條帶內存在兩個不同層,亦即,無光澤的擠出管外層及有光澤的擠出管內層。兩層之間的差異為歸因於晶疇尺寸差異之表面反射。若使用黑色標記物給由顯微鏡檢查之表面上色,則消除反射且兩表面之間的差異可最少或不可偵測。
在一個例示性實施例中,製備無任何表層之樣品條帶。使用黑色標記物消除層間任何反射差異。圖像展示泡孔尺寸及泡孔分佈在整個條帶厚度中相同。當泡孔壁在壓縮力下崩潰時,約200微米深的折痕視為表面中之摺疊。
在TA Instruments DSC 2910上於氮氣氛圍中進行之差示掃描熱量測定分析展示,隨著冷卻速率增加,條帶之高分子基質材料之結晶溫度及結晶度降低,如下表10中所示。
差示掃描熱量測定資料顯示結晶及隨後二次加熱熔融溫度及結晶度百分比對於結晶期間冷卻速率之依賴性。絕緣泡孔非芳族高分子材料條帶之例示性實施例可具有約160℃(320℉)至約172℃(341.6℉)之熔融溫度、約108℃(226.4℉)至約135℃(275℉)之結晶溫度及約42%至約62%之結晶度百分比。
在例示性實施例中,在每分鐘10℃之加熱及冷卻速率下由差示掃描熱量測定所測定之擠出薄片具有約162℃(323.6℉)之熔融溫度、約131℃(267.8℉)之結晶溫度及約46%之結晶度。
出乎意料地發現,擠出管外表面在壓縮模式中有利地起作用而不產生可感知的折痕,且因此杯子(或其他結構)宜 由擠出管外表面面向絕緣杯內部來製成。擠出管內層及擠出管外層對壓縮力之抵抗性差異可歸因於層形態之差異,此係因為該等層在不同冷卻速率下結晶。
在形成擠出薄片之例示性實施例中,擠出管內表面可藉由水冷法及壓縮空氣之組合來冷卻。擠出管外表面可藉由使用具有循環水及空氣出口之分流板由壓縮空氣冷卻。較快冷卻速率可導致形成較小尺寸結晶。通常冷卻速率愈快,則所形成之較小結晶的相對量愈大。在Panalytical X'pert MPD Pro繞射儀上,使用在45 KV/40 mA下之Cu輻射對絕緣泡孔非芳族高分子材料之例示性擠出薄片進行X射線繞射分析。已證實,擠出管外表面具有約99埃之晶疇尺寸,而擠出管內表面具有約114埃之晶疇尺寸。在例示性實施例中,絕緣泡孔非芳族高分子材料之擠出條帶可具有低於約200埃之晶疇尺寸。在例示性實施例中,絕緣泡孔非芳族高分子材料之擠出條帶可具有較佳低於約115埃之晶疇尺寸。在例示性實施例中,絕緣泡孔非芳族高分子材料之擠出條帶可具有低於約100埃之晶疇尺寸。
剛度 測試法
測試法與實例1中剛度測試所述相同。
測試結果
剛度測試結果展示於下表11中。
絕緣 測試法--壁溫
使用由上文所述之調配物形成之具有約0.18g/cm3之密度及約0.074吋(1.8796mm)之壁厚的絕緣杯。將200℉(93.3℃)之熱液體置放於杯子中。
測試結果
在杯外壁量測之溫度為約151℉(66.1℃),下降約49.0℉(27.2℃)。經五分鐘時間之最大溫度經觀察為在約151℉(66.1℃)下之峰值。
以熱導率形式進行絕緣測試。
測試法-熱導率
此測試量測在環境溫度及93℃(199.4℉)下量測之整體熱導率(W/m-K)。使用ThermTest TPS 2500 S Thermal Constants Analyzer儀器,採用ISO/DIS 22007-2.2之測試法 且使用低密度/高絕緣選項。所有量測均使用具有Kapton®絕緣之TPS感測器#5501 0.2521吋半徑(6.403 mm半徑)。使用0.02瓦功率,進行20秒測試。記錄使用點100-200之資料。
測試結果
測試結果展示於下表12中。
雖然上文僅詳細描述若干例示性實施例,但熟習此項技術者應易於瞭解,在例示性實施例中可進行許多變化,而本質上不背離新穎教示及優勢。因此,所有該等變化均意欲包括於如下文申請專利範圍所界定之本發明之範疇內。
除非上下文中另外明確規定,否則如本說明書及隨附申請專利範圍中所使用之單數形式「一」及「該」包括複數指示物。本文中可將範圍表示為自「約」一特定值及/或至「約」另一特定值。當表示該範圍時,另一實施例包括自該一特定值及/或至該另一特定值。類似地,當值藉由使用先行詞「約」表示為近似值時,應瞭解該特定值形成另一實施例。此外,應瞭解該等範圍中之每一者之端點既與另一端點顯著相關,又顯著獨立於另一端點。
「視情況」意指隨後描述之事件或情況可能發生或可能 不發生,且意指描述包含該事件或情況發生之情形及其不發生之情形。
在本說明書之描述及申請專利範圍中,詞語「包含(comprise)」及該詞語之變化形式,諸如「包含(comprising)」及「包含(comprises)」,意指「包括(但不限於)」,且不意欲排除例如其他添加劑、組分、整數或步驟。「例示性」意指「實例」且不意欲指示較佳或理想實施例。「諸如」並非以限制性意義使用,而是出於說明性目的。
揭示可用於執行所揭示之方法、設備及系統之組分。對於所有方法、設備及系統,本文揭示此等組分及其他組分,且應瞭解當揭示此等組分之組合、子集、相互作用、群組等,而此等組分之各不同個體及共同組合及排列之特定參考物可能未明確揭示時,每一者特定涵蓋且描述於本文中。此種情況應用於本申請案之所有態樣,包括(但不限於)所揭示方法中之步驟。因此,若存在可進行之多種其他步驟,則應瞭解該等其他步驟之每一者可與所揭示方法之任何特定實施例或實施例之組合一起進行。
熟習此項技術者顯而易知可在不背離範疇或精神的情況下進行不同變化及變化。熟習此項技術者自考量本文中所揭示之說明書及實踐將顯而易知其他實施例。本說明書及實例意欲視為僅具例示性。
此外,應注意本文中所提及之任何公開案及手冊係以全文引用的方式併入本文中。
10‧‧‧絕緣杯
11‧‧‧杯體
14‧‧‧內部區域
16‧‧‧捲邊
17‧‧‧底面座架
18‧‧‧套筒狀側壁
20‧‧‧底面
21‧‧‧水平平台
25‧‧‧腹板
26‧‧‧底面固定凸緣
67‧‧‧加工方向
82‧‧‧絕緣泡孔非芳族高分子材料條帶
100‧‧‧材料形成法
101‧‧‧調配物/第一區域
102‧‧‧熔融樹脂/第二區域
103‧‧‧擠出樹脂混合物/第三區域
104‧‧‧擠出物/第四區域
105‧‧‧熱
111‧‧‧第一擠出機
112‧‧‧第二擠出機
113‧‧‧料斗
114‧‧‧螺桿
115A‧‧‧埠
116‧‧‧擠出模
117‧‧‧切割機
121‧‧‧調配物
122‧‧‧熔融樹脂
123‧‧‧擠出樹脂混合物
124‧‧‧管狀擠出物
126‧‧‧腹板支撐環
162‧‧‧外部捲式突出部
163‧‧‧捲緣
164‧‧‧內部捲式突出部
260‧‧‧第一立式薄狹板
261‧‧‧第一立式厚狹板
262‧‧‧第二立式厚狹板
263‧‧‧垂直通道
512‧‧‧立式外部突出部
513‧‧‧立式圍籬
514‧‧‧立式內部突出部
I‧‧‧界面
圖1為本發明之材料形成法之圖解透視圖,展示材料形成法自左至右包括:絕緣泡孔非芳族高分子材料之調配物置放於料斗中,饋送至第一擠出機之第一擠出區中,在此處施加熱及壓力形成熔融樹脂,且展示發泡劑注入熔融樹脂中形成擠出樹脂混合物,將該擠出樹脂混合物饋送至第二擠出機之第二擠出區中,在此處擠出樹脂混合物排出且膨脹形成擠出物,切割該擠出物形成絕緣泡孔非芳族高分子材料條帶;圖2為由包括圖1之絕緣泡孔非芳族高分子材料之材料條帶製成之絕緣杯的透視圖,展示該絕緣杯包括杯體及底面且展示已開裂露出局部塑性變形區域之四個杯體區域,其經提供而在維持杯體內之預定絕緣特徵的同時增加彼等區域之密度;圖3為圖2之絕緣杯體中所包括之一部分側壁的放大剖視圖,展示側壁由薄片製成,該薄片自左至右包括:包括薄膜之表層、墨水層、及黏著層、及圖1之絕緣泡孔非芳族高分子材料條帶;圖4為圖2之絕緣杯的分解組裝圖,展示如圖2所示之絕緣杯自上而下包括底面及杯體,該杯體包括捲邊、側壁及經組態以使底面及側壁互相連接之底面座架;圖5為沿圖2之線5-5截取之剖視圖,展示絕緣杯體中所包括之側壁包括通常均一厚度且底面與杯體中所包括之底面座架耦接; 圖6-9為展示圖2絕緣杯之第一、第二、第三及第四區域之系列圖,該等區域各自包括局部塑性變形;圖6為沿圖2之線5-5截取之部分剖視圖,展示第一區域在杯體側壁中;圖7為沿圖2之線5-5截取之部分剖視圖,展示第二區域在杯體捲邊中;圖8為沿圖2之線5-5截取之部分剖視圖,展示第三區域在杯體底面座架所包括之連接腹板中;圖9為沿圖2之線5-5截取之部分剖視圖,展示第四區域在杯體底面座架所包括之腹板支撐環中;及圖10為展示本發明之絕緣杯在進行溫度測試時隨時間之效能的圖形。

Claims (60)

  1. 一種用於形成絕緣泡孔非芳族高分子結構之調配物,該調配物包含:第一高分子材料,其係為至少一種高熔體強度聚丙烯,第二高分子材料,其係為聚丙烯,至少一種成核劑,及至少一種助滑劑,其中該調配物包含至少94.9重量%之該第一及第二高分子材料,且該第一及第二高分子材料各自為均聚物聚丙烯。
  2. 如請求項1之調配物,其中根據ISO16790,該第一高分子材料具有至少36cN之熔體強度。
  3. 如請求項1之調配物,其中該第一高分子材料具有至少163℃(325.4℉)之熔融溫度。
  4. 如請求項1之調配物,其進一步包含基於聚乙烯之材料,其選自由低密度聚乙烯、線性低密度聚乙烯、高密度聚乙烯、乙烯-乙酸乙烯酯共聚物、乙烯-丙烯酸乙酯共聚物、乙烯-丙烯酸共聚物及其混合物及其組合組成之群。
  5. 如請求項1之調配物,其中該成核劑為選自由化學成核劑、物理成核劑、及其混合物及其組合組成之群之至少一種材料。
  6. 如請求項1之調配物,其中該成核劑為檸檬酸或基於檸檬酸之材料。
  7. 如請求項1之調配物,其中該成核劑為選自由滑石、CaCO3、雲母及至少兩種上述物之混合物組成之群之至少一種材料。
  8. 如請求項1之調配物,其進一步包含至少一種發泡劑。
  9. 如請求項8之調配物,其中該發泡劑為選自由化學發泡劑、物理發泡劑、及其組合組成之群之至少一種材料。
  10. 如請求項8之調配物,其中該至少一種發泡劑引入且混入該調配物中,隨後熔融該調配物。
  11. 如請求項10之調配物,其中該發泡劑為以加壓液體形式引入之至少一種氣體。
  12. 如請求項11之調配物,其中該發泡劑為選自由二氧化碳、氮氣、氦氣、氬氣、空氣、戊烷、丁烷或其他烷烴及其混合物組成之群之至少一種氣體。
  13. 如請求項8之調配物,其中該發泡劑為反應或分解釋放氣體之化學發泡劑。
  14. 如請求項13之調配物,其中該化學發泡劑為CaCO3
  15. 如請求項13之調配物,其中該成核劑進一步包含催化劑。
  16. 如請求項15之調配物,其中該結構具有在加工方向上約0.016吋長及約0.003吋寬之平均泡孔尺寸及在橫向方向約0.017吋長及約0.003吋寬之平均泡孔尺寸。
  17. 如請求項8之調配物,其中該發泡劑為選自由以下組成之群之至少一種材料:偶氮二甲醯胺;偶氮二異丁腈;苯磺醯肼;4,4-羥苯磺醯基半卡肼;對甲苯磺醯基半卡肼;偶氮二甲酸鋇;N,N'-二甲基-N,N'-二亞硝基對苯二甲醯胺;三肼基三嗪;甲烷;乙烷;丙烷;正丁烷;異丁烷;正戊烷;異戊烷;新戊烷;氟甲烷;全氟甲烷;氟乙烷;1,1-二氟乙烷;1,1,1-三氟乙烷;1,1,1,2-四氟乙烷;五氟乙烷;全氟乙烷;2,2-二氟丙烷;1,1,1-三氟丙烷;全氟丙烷;全氟丁烷;全氟環丁烷;氯甲烷;二氯甲烷;氯乙烷;1,1,1-三氯乙烷;1,1-二氯-1-氟乙烷;1-氯-1,1-二氟乙烷;1,1-二氯-2,2,2-三氟乙烷;1-氯-1,2,2,2-四氟乙烷;三氯單氟甲烷;二氯二氟甲烷;三氯三氟乙烷;二氯四氟乙烷;氯七氟丙烷;二氯六氟丙烷;甲醇;乙醇;正丙醇;異丙醇;碳酸氫鈉;碳酸鈉;碳酸氫銨;碳酸銨;亞硝酸銨;N,N'-二甲基-N,N'-二亞硝基對苯二甲醯胺;N,N'-二亞硝基五亞甲基四胺;偶氮環己腈;偶氮二胺基苯;甲苯磺醯肼;p,p'-氧基雙(苯磺醯肼);二苯碸-3,3'-二磺醯肼;疊氮化鈣;4,4'-二苯基二磺醯疊氮;及對甲苯磺醯疊氮。
  18. 如請求項1之調配物,其中該助滑劑為至少一種脂肪酸或基於脂肪酸之材料。
  19. 如請求項1之調配物,其中該助滑劑為選自由芥酸醯胺、油醯胺、及其混合物組成之群之至少一種材料。
  20. 如請求項1之調配物,其進一步包含選自由抗衝擊改質劑、著色劑、發泡劑、化合物回收料及至少兩種上述物之混合物組成之群之至少一種材料。
  21. 如請求項1之調配物,其進一步包含著色劑。
  22. 如請求項1之調配物,其中該結構具有在加工方向上約0.016吋(0.4064mm)長及約0.003吋(0.0762mm)寬之平均泡孔尺寸及在橫向方向約0.017吋(0.4318mm)長及約0.003吋(0.0762mm)寬之平均泡孔尺寸。
  23. 如請求項1之調配物,其中該結構具有在至少一個方向上具有在約1.0至約3.0範圍內之平均泡孔縱橫比的泡孔。
  24. 如請求項1之調配物,其中該結構具有在至少一個方向上具有在約1.0至約2.0範圍內之平均泡孔縱橫比的泡孔。
  25. 如請求項1之調配物,其中該結構在每分鐘10度之加熱及冷卻速率下具有約160℃(320℉)至約172℃(341.6℉)之熔融溫度、約108℃(226.4℉)至約135℃(275℉)之結晶溫度及約42%至約62%之結晶度百分比。
  26. 如請求項1之調配物,其中該結構在每分鐘10度之加熱及冷卻速率下具有約162℃(323.6℉)之熔融溫度、約131℃(267.8℉)之結晶溫度及約46%之結晶度。
  27. 如請求項1之調配物,其中該絕緣泡孔非芳族高分子結構具有在約0.01g/cm3至約0.19g/cm3範圍內之密度。
  28. 如請求項1之調配物,其中該絕緣泡孔非芳族高分子結構具有在約0.05g/cm3至約0.19g/cm3範圍內之密度。
  29. 如請求項1之調配物,其中該絕緣泡孔非芳族高分子結構具有在約0.1g/cm3至約0.185g/cm3範圍內之密度。
  30. 如請求項1之調配物,其中該結構可暴露於約1,200瓦之微波能量高達約2.5分鐘而無可見灼燒或燒焦。
  31. 如請求項1之調配物,其中該結構具有約0.089吋(2.2606mm)之壁厚及約0.1902g/cm3之密度,及在約0.545公斤-力(kg-F)至約0.716公斤-力(kg-F)範圍內之剛度。
  32. 如請求項1之調配物,其中根據如ASTM D3763-86中所述之抗緩慢穿孔性測試法,該材料具有高達約15,210公克-力之平均抗穿孔性。
  33. 如請求項1之調配物,其中根據ASTM D1922-93,該結構在加工方向上具有至少約282公克-力之抗撕裂性。
  34. 如請求項1之調配物,其中根據如ASTM D1922-93中所述之埃爾曼多夫(Elmendorf)測試法,該結構需要至少約282公克-力以在加工方向上撕裂該材料。
  35. 如請求項1之調配物,其中根據如ASTM D1922-93中所述之埃爾曼多夫測試法,該結構需要至少約212公克-力以在橫向方向上撕裂該材料。
  36. 如請求項1之調配物,其中根據如ASTM D1922-93中所述之埃爾曼多夫測試法,該結構需要在約213公克-力至約351公克-力範圍內之力以在加工方向上撕裂該材料。
  37. 如請求項1之調配物,其中根據如ASTM D1922-93中所述之埃爾曼多夫測試法,該結構需要在約143公克-力至約281公克-力範圍內之力以在橫向方向上撕裂該材料。
  38. 如請求項1之調配物,其中當形成杯子時,該結構於該杯子以約200℉(93.33℃)之液體填充且蓋子置放於該杯子上時具有約140.5℉(60.28℃)之最大外表面溫度。
  39. 如請求項1之調配物,其中當形成條帶時,該結構具有在21℃下約0.05792W/m-K之平均熱導率及在21℃下約0.00005W/m-K之標準差。
  40. 如請求項1之調配物,其中當形成條帶時,該結構具有在93℃下約0.06680W/m-K之平均熱導率及在93℃下約0.00025W/m-K之標準差。
  41. 如請求項1之調配物,其中該結構為可回收的。
  42. 如請求項1之調配物,其中該結構可於其至少一個表面上接受圖形印刷。
  43. 一種用於形成絕緣泡孔非芳族高分子結構之調配物,該調配物包含第一高分子材料,其係為根據ISO16790具有至少36cN之熔體強度及至少163℃(325.4℉)之熔融溫度的至少一種高熔體強度聚丙烯,第二高分子材料,其係為高結晶聚丙烯均聚物,至少一種成核劑,其選自由化學成核劑、物理成核劑及其組合及其混合物組成之群,至少一種發泡劑,及至少一種助滑劑,其包含脂肪酸或基於脂肪酸之組合物,其中該調配物包含至少94.9重量%之該第一及第二高分子材料,且該第一及第二高分子材料各自為均聚物聚丙烯。
  44. 一種用於形成絕緣泡孔非芳族高分子結構之調配物,該調配物包含第一材料,其係為至少一種高熔體強度聚丙烯高分子,第二材料,其係為高結晶聚丙烯均聚物,至少一種成核劑,其選自由化學成核劑、物理成核劑及其組合組成之群,惰性氣體,及助滑劑,其中該調配物包含至少94.9重量%之該第一及第二材料,且該第一及第二材料各自為均聚物聚丙烯。
  45. 一種用於形成絕緣泡孔非芳族高分子結構之熔融樹脂,該熔融樹脂包含第一高分子材料,其係為根據ISO16790具有至少36cN之熔體強度及至少163℃(325.4℉)之熔融溫度的至少一種高熔體強度聚丙烯,第二高分子材料,其係為高結晶聚丙烯均聚物,至少一種成核劑,其選自由化學成核劑、物理成核劑及其組合組成之群,至少一種發泡劑,其包含選自由化學發泡劑、惰性氣體及其組合組成之群之至少一種組合物,及至少一種助滑劑,其包含脂肪酸或基於脂肪酸之組合物,其中該熔融樹脂包含至少94.9重量%之該第一及第二高分子材料,且該第一及第二高分子材料各自為均聚物聚丙烯。
  46. 一種絕緣泡孔非芳族高分子擠出物,其包含第一高分子材料,其係為根據ISO16790具有至少36cN之熔體強度及至少163℃(325.4℉)之熔融溫度的至少一種高熔體強度聚丙烯,及第二高分子材料,其係為高結晶聚丙烯均聚物,其中該擠出物具有形成於其中之泡孔,且其中該擠出物包含至少94.9重量%之該第一及第二高分子材料,且該第一及第二高分子材料各自為均聚物聚丙烯。
  47. 一種絕緣泡孔非芳族高分子物品,其包含第一高分子材料,其係為根據ISO16790具有至少36cN之熔體強度及至少163℃(325.4℉)之熔融溫度的至少一種高熔體強度聚丙烯,及第二高分子材料,其係為高結晶聚丙烯均聚物,其中該物品具有形成於其中之泡孔,且其中該物品包含至少94.9重量%之該第一及第二高分子材料,且該第一及第二高分子材料各自為均聚物聚丙烯。
  48. 一種由調配物形成之容器,該調配物包含第一材料,其係為根據ISO16790具有至少36cN之熔體強度及至少163℃(325.4℉)之熔融溫度的至少一種高熔體強度聚丙烯,第二材料,其係為高結晶聚丙烯均聚物,至少一種成核劑,其選自由化學成核劑、物理成核劑及其組合組成之群,發泡劑,及助滑劑,其選自由芥酸醯胺、油醯胺、線性低密度聚乙烯及其至少兩者之混合物組成之群,其中該調配物包含至少94.9重量%之該第一及第二材料,且該第一及第二材料各自為均聚物聚丙烯。
  49. 如請求項48之容器,其中該容器包括約0.089吋(2.2606mm)之壁厚及約0.1902g/cm3之密度及在約0.545公斤-力至約0.716公斤-力範圍內之未填充未加蓋剛度。
  50. 如請求項48之容器,其中該容器包括0.089吋(2.2606mm)之壁厚及0.1902g/cm3之密度及在約0.680公斤-力至約1.011公斤-力範圍內之未填充加蓋剛度。
  51. 如請求項48之容器,其中該容器包括約0.089吋(2.2606mm)之壁厚及約0.1902g/cm3之密度,且具有在約200℉(93.33℃)下,在約0.238公斤-力(kg-F)至約0.324公斤-力(kg-F)範圍內之熱填充未加蓋剛度。
  52. 如請求項48之容器,其中該容器包括約0.089吋(2.2606mm)之壁厚及約0.1902g/cm3之密度,且具有在約200℉(93.33℃)下,在約0.227公斤-力(kg-F)至約0.476公斤-力(kg-F)範圍內之熱填充加蓋剛度。
  53. 如請求項48之容器,其中該容器包括約0.089吋(2.2606mm)之壁厚及約0.1902g/cm3之密度,且具有在約35℉(1.67℃)下,在約0.698公斤-力(kg-F)至約0.894公斤-力(kg-F)範圍內之冷填充未加蓋剛度。
  54. 如請求項48之容器,其中該容器包括約0.089吋(2.2606mm)之壁厚及約0.1902g/cm3之密度,且具有在約35℉(1.67℃)下,在約0.837公斤-力(kg-F)至約1.192公斤-力(kg-F)範圍內之冷填充加蓋剛度。
  55. 一種由一調配物形成之絕緣泡孔非芳族高分子包裹材料,該調配物包含第一材料,其係為根據ISO16790具有至少36cN之熔體強度及至少163℃(325.4℉)之熔融溫度的至少一種高熔體強度聚丙烯,第二材料,其係為高結晶聚丙烯均聚物,至少一種成核劑,其選自由化學成核劑、物理成核劑及其組合組成之群,至少一種發泡劑,及助滑劑,其中該調配物包含至少94.9重量%之該第一及第二材料,且該第一及第二材料各自為均聚物聚丙烯,且其中該包裹材料形成可包裹在物件周圍之條帶。
  56. 如請求項55之材料,其中該調配物進一步包含與該條帶之至少一個表面結合的黏著劑。
  57. 如請求項56之材料,其中該調配物進一步包含離型襯墊。
  58. 如請求項55之材料,其中該條帶捲繞形成捲筒。
  59. 一種用於形成絕緣泡孔非芳族高分子材料之結構之方法,該方法包含以下步驟:a.提供第一材料,其係為至少一種高熔體強度聚丙烯高分子,b.提供第二材料,其係為高結晶聚丙烯均聚物,c.提供至少一種成核劑,其選自由化學成核劑、物理成核劑及其組合組成之群,d.添加助滑劑,e.混合步驟a-d中所提供之該等材料形成樹脂混合物,f.加熱該樹脂混合物形成熔融樹脂混合物,g.添加發泡劑至該熔融樹脂混合物中以產生擠出樹脂混合物,其中該擠出樹脂混合物包含至少94.9重量%之該第一及第二材料,且該第一及第二材料各自為均聚物聚丙烯,及h.擠出該擠出樹脂混合物形成具有泡孔形成於其中之結構。
  60. 一種藉由一方法所形成之絕緣泡孔非芳族高分子材料之結構,該方法包含以下步驟:a.提供第一材料,其係為至少一種高熔體強度聚丙烯高分子,b.提供第二材料,其係為高結晶聚丙烯均聚物,c.提供至少一種成核劑,其選自由化學成核劑、物理成核劑及其組合組成之群,d.添加助滑劑,e.混合步驟a-d中所提供之該等材料形成樹脂混合物,f.加熱該樹脂混合物形成熔融樹脂混合物,g.添加發泡劑至該熔融樹脂混合物中以產生擠出樹脂混合物,其中該擠出樹脂混合物包含至少94.9重量%之該第一及第二材料,且該第一及第二材料各自為均聚物聚丙烯,及h.擠出該擠出樹脂混合物形成具有泡孔形成於其中之結構。
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