US20050249905A1 - Polyolefin container having certain shrink characteristics and method of making such containers - Google Patents

Polyolefin container having certain shrink characteristics and method of making such containers Download PDF

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Publication number
US20050249905A1
US20050249905A1 US11/137,046 US13704605A US2005249905A1 US 20050249905 A1 US20050249905 A1 US 20050249905A1 US 13704605 A US13704605 A US 13704605A US 2005249905 A1 US2005249905 A1 US 2005249905A1
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United States
Prior art keywords
acceptable
container
polypropylene
preform
bottle
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/137,046
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English (en)
Inventor
Jiannong Xu
Bemard Vermeersch
W. Lambert
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Milliken and Co
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Milliken and Co
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Filing date
Publication date
Priority claimed from US10/764,234 external-priority patent/US20050161866A1/en
Application filed by Milliken and Co filed Critical Milliken and Co
Priority to US11/137,046 priority Critical patent/US20050249905A1/en
Priority to PCT/US2005/018522 priority patent/WO2005118407A2/fr
Priority to BRPI0511638-4A priority patent/BRPI0511638A/pt
Priority to EP05754304A priority patent/EP1748931A4/fr
Publication of US20050249905A1 publication Critical patent/US20050249905A1/en
Assigned to MILLIKEN & COMPANY reassignment MILLIKEN & COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: XU, JIANNONG, LAMBERT, W. SCOTT, VERMEERSCH, BERNARD
Abandoned legal-status Critical Current

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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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/0005—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor characterised by the material
    • 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
    • B65D1/00—Rigid or semi-rigid 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 or by deep-drawing operations performed on sheet material
    • B65D1/02—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents
    • B65D1/0207—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by material, e.g. composition, physical features
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/78—Measuring, controlling or regulating
    • B29C49/783—Measuring, controlling or regulating blowing pressure
    • B29C2049/7831—Measuring, controlling or regulating blowing pressure characterised by pressure values or ranges
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/78—Measuring, controlling or regulating
    • B29C49/783—Measuring, controlling or regulating blowing pressure
    • B29C2049/7832—Blowing with two or more pressure levels
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/78—Measuring, controlling or regulating
    • B29C49/786—Temperature
    • B29C2049/7861—Temperature of the preform
    • B29C2049/7862—Temperature of the preform characterised by temperature values or ranges
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/78—Measuring, controlling or regulating
    • B29C2049/7879—Stretching, e.g. stretch rod
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/07—Preforms or parisons characterised by their configuration
    • B29C2949/0715—Preforms or parisons characterised by their configuration the preform having one end closed
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/07—Preforms or parisons characterised by their configuration
    • B29C2949/072—Preforms or parisons characterised by their configuration having variable wall thickness
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/07—Preforms or parisons characterised by their configuration
    • B29C2949/081—Specified dimensions, e.g. values or ranges
    • B29C2949/0811—Wall thickness
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/07—Preforms or parisons characterised by their configuration
    • B29C2949/081—Specified dimensions, e.g. values or ranges
    • B29C2949/082—Diameter
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/07—Preforms or parisons characterised by their configuration
    • B29C2949/0861—Other specified values, e.g. values or ranges
    • B29C2949/0862—Crystallinity
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/20—Preforms or parisons whereby a specific part is made of only one component, e.g. only one layer
    • B29C2949/22—Preforms or parisons whereby a specific part is made of only one component, e.g. only one layer at neck portion
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/20—Preforms or parisons whereby a specific part is made of only one component, e.g. only one layer
    • B29C2949/24—Preforms or parisons whereby a specific part is made of only one component, e.g. only one layer at flange portion
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/20—Preforms or parisons whereby a specific part is made of only one component, e.g. only one layer
    • B29C2949/26—Preforms or parisons whereby a specific part is made of only one component, e.g. only one layer at body portion
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/20—Preforms or parisons whereby a specific part is made of only one component, e.g. only one layer
    • B29C2949/28—Preforms or parisons whereby a specific part is made of only one component, e.g. only one layer at bottom portion
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/30—Preforms or parisons made of several components
    • B29C2949/3024—Preforms or parisons made of several components characterised by the number of components or by the manufacturing technique
    • 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
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/30—Preforms or parisons made of several components
    • B29C2949/3032—Preforms or parisons made of several components having components being injected
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/06—Injection blow-moulding
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/08—Biaxial stretching during blow-moulding
    • B29C49/087—Means for providing controlled or limited stretch ratio
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/08—Biaxial stretching during blow-moulding
    • B29C49/10—Biaxial stretching during blow-moulding using mechanical means for prestretching
    • B29C49/12—Stretching rods
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/4205—Handling means, e.g. transfer, loading or discharging means
    • B29C49/42093—Transporting apparatus, e.g. slides, wheels or conveyors
    • B29C49/42095—Rotating wheels or stars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2623/00—Use of polyalkenes or derivatives thereof for preformed parts, e.g. for inserts
    • B29K2623/10—Polymers of propylene
    • B29K2623/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7158—Bottles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]

Definitions

  • Injection stretch blow molding is a process of producing thermoplastic articles, such as liquid containers. This process involves the initial production of a preform articles by injection molding. Then, the preform article that after reheating is subjected to stretching and gas pressure to expand (blow) the preform article against a mold surface to form a container.
  • a first type is a single stage process in which a preform is made on a machine and allowed to cool somewhat to a predetermined blow molding temperature. While still at this elevated temperature, the preform is stretch blow molded into a container on the same machine, as part of a single manufacturing procedure. This is a one step or so-called “single stage” manufacturing procedure.
  • the temperature of the preform is cooled (reduced) following preform formation from about 230° C. to about 120-140° C. The preform is not returned to ambient temperature, but instead is blown to a container while at about 120 to 140° C.
  • Another type of process is a two stage process.
  • preforms first are formed in an injection machine. Then, preforms are cooled to ambient temperature. In some cases, preforms are shipped from one location to another (or from one company to another) prior to stretch blowing the preforms into containers.
  • preforms are heated from an initial ambient temperature to an elevated temperature for stretch blowing on a molding machine to form a container.
  • the injection machine and the molding machine typically are located apart from one another in such a two stage procedure.
  • Two stage manufacturing processes are sometimes referred to as “reheat stretch blow molding” (RSBM) processes, because preform articles formed in the first stage are subsequently reheated during the second stage of manufacture to form finished containers.
  • RSBM reheat stretch blow molding
  • FIG. 1 shows a typical polypropylene container that may be manufactured according to the process of the invention
  • FIG. 2A is a schematic flow diagram showing the processing steps employed in the first stage of the two stage process, which relates to injection manufacture of preform articles;
  • FIG. 2B illustrates processing steps in the second stage of manufacturing in accord with the invention, wherein a preform article is stretch blow molded to form a container;
  • FIG. 3 is a side view of a conventional thick-walled preform article
  • FIG. 3A shows a side cross-sectional view of the conventional preform article of FIG. 3 ;
  • FIGS. 3B and 3C show a first embodiment of a relatively thin walled preform with an external profile that may be employed in the invention
  • FIG. 4 shows a side view of a second preform that may be used in the invention, i.e. a relatively thin-walled preform article according to the practice of the invention, in which the preform article optionally may have a profile on the inside rather than the outside of the preform article structure;
  • FIG. 4A shows a cross-sectional view of the thin-walled preform article of FIG. 4 ;
  • FIG. 5 is a longitudinal sectional view of an injection molding assembly for the production of a preform article
  • FIG. 6 is an illustration of stage two of the manufacturing process, showing a vertical cross-sectional view of stretch blow mold apparatus that is used to produce the containers from a perform, in this view showing a start up position with the preform article in place;
  • FIG. 7 is a view of the apparatus of FIG. 6 showing the mold closed on the preform article.
  • FIG. 8 shows a fully blown container with a stretch rod and swage in a down position with the container decompressing in the mold.
  • a two-stage process of injection stretch blow molding polypropylene to form a container is disclosed in the practice of the invention.
  • a first stage of this process comprises forming a preform article.
  • a second subsequent stage comprises reheating and blow molding the preform article to form a container.
  • the invention is directed to both preform articles and containers, in addition to the specific method or process for forming these products. Surprisingly beneficial results have been achieved in the practice of the invention.
  • a polypropylene container is made by an injection stretch blow molding two stage process.
  • the container has:
  • a process having at least the following steps. First, a chemical composition comprising at least in part polypropylene is provided. This chemical composition provides a melt flow index in the range of between about 6 and about 50 grams/10 minutes, according to ASTM D 1238 at 230 degrees C./2.16 kg.
  • the chemical composition is injected into a mold at a fill rate of greater than about 5 grams of chemical composition per second. This injection may be made through an orifice or gate, as further described herein.
  • a preform article is formed in a mold. The preform article is removed from the mold. The preform article includes a closed end adapted for subsequent second stage reheating and stretch blow molding. The closed end may be integral with a side wall. The side wall of the preform provides a thickness of less than about 3.5 mm, in one aspect of the invention.
  • melt flow index MFI
  • resins polypropylene chemical compositions
  • the invention has overcome limitations in the art, in part by the unexpected discovery that processing parameters may be established to impart necessary conditions and benefits to form superior polypropylene-based preforms.
  • This invention facilitates efficient and cost-effective production of clear, low haze polypropylene articles from preforms using injection to make a preform, followed in some instances by stretch blow molding to form a container.
  • the advantages of the process disclosed herein comprise, among other things, appropriate selection of melt flow polypropylene resins, appropriate selection of nucleating and clarifying agents, appropriate thickness of performs, appropriate rate or speed of injecting the resin for preform production, and also perhaps the appropriate gate width during preform production. Surprisingly, it has been found that there are ranges for each of these criteria which cause stretch blow molded articles to be produced at high rates with superior clarity.
  • Polypropylene has long been known to exist in several forms, and essentially any known form could be used in the practice of the invention. Thus, the invention is not limited to any particular type of polypropylene.
  • Isotactic propylene iPP
  • sPP syndiotactic polypropylene
  • container articles produced in accordance with the criteria noted above exhibit specific haze to thickness ratios, and such is within the scope of the present invention.
  • the invention provides a vast improvement in polypropylene injection stretch blow-molded article technology whereby efficient methods of producing very clear articles is accorded as proper replacements for previous PET types.
  • the practice of the invention makes it possible to provide injection stretch blow-molded polypropylene articles that may be produced at very high rates and exhibit substantially uniform clarity levels.
  • the invention may provide polypropylene preforms that facilitate production of very low haze container articles with injection stretch blow molding in a very efficient manner.
  • One application of the invention provides improved containers, wherein such containers (or bottles) exhibit low haze levels.
  • DMDBS 1,3-O-2,4-bis(3,4-dimethylbenzylidene) sorbitol
  • Millad® 3988 1,3-O-2,4-bis(3,4-dimethylbenzylidene) sorbitol
  • Such a compound provides highly effective haze reductions within polypropylenes with concomitant low taste and odor problems.
  • Disubstituted DBS compounds are broadly described in U.S. Pat. Nos. 5,049,605 and 5,135,975 to Rekers. As it is, in terms of providing excellent clarity, particularly within the neck and bottom regions of target injection stretch blow-molded polypropylene bottle articles within this invention, DMDBS is a useful compound for such a result.
  • thermoplastic nucleator in terms of high crystallization temperatures is available from Milliken & Company using the tradename HPN-68TM.
  • HPN-68TM thermoplastic nucleating compounds that may be employed in the practice of the invention are disclosed in U.S. Pat. Nos. 6,465,551 and 6,534,574.
  • the HPN-68TM compound is disodium bicyclo[2.2.1]heptanedicarboxylate.
  • the ability to provide highly effective crystallization, or, in this specific situation, control targeted levels of crystallization within polypropylene preforms prior to injection stretch blow molding sometimes is facilitated by utilization of such a nucleating agent. Low amounts of this additive can be provided to produce the desired and intended amorphous-crystalline combination within the target performs.
  • Other nucleating agents can be employed in the practice of the invention.
  • the polypropylene polymers employed in the practice of the invention may include homopolymers (known as HPs), impact or block copolymers (known as ICPs)(combinations of propylene with certain elastomeric additives, such as rubber, and the like), and random copolymers (known as RCPS) made from at least one propylene and one or more ethylenically unsaturated comonomers.
  • HPs homopolymers
  • ICPs impact or block copolymers
  • RCPS random copolymers
  • co-monomers if present, constitute a relatively minor amount, i.e., about 10 percent or less, or about 5 percent or less, of the entire polypropylene, based upon the total weight of the polymer.
  • co-monomers may serve to assist in clarity improvement of the polypropylene, or they may function to improve other properties of the polymer.
  • Co-monomer examples include acrylic acid and vinyl acetate, polyethylene, polybutylene, and other
  • Polypropylene provides an average molecular weight of from about 10,000 to about 2,000,000, preferably from about 30,000 to about 300,000, and it may be mixed with additives such as polyethylene, linear low density polyethylene, crystalline ethylenepropylene copolymer, poly(1-butene), 1-hexene, 1-octene, vinyl cyclohexane, and polymethylpentene, as examples.
  • additives such as polyethylene, linear low density polyethylene, crystalline ethylenepropylene copolymer, poly(1-butene), 1-hexene, 1-octene, vinyl cyclohexane, and polymethylpentene, as examples.
  • Other polymers that may be added to the base polypropylene for physical, aesthetic, or other reasons, include polyethylene terephthalate, polybutylene terephthalate, and polyamides, among others.
  • Resin compositions utilized to produce the preform articles and injection stretch blow-molded containers of the invention can be obtained by adding a specific amount of a nucleating agent/clarifying agent directly to the polypropylene, either in dry form or in molten form, and mixing them by any suitable means while in molten form to provide a substantially homogenous formulation.
  • a concentrate containing as much as about 20 percent by weight of a nucleator/clarifier in a polypropylene masterbatch may be prepared and be subsequently mixed with the resin.
  • the desired nucleator/clarifier may be present in any type of standard polypropylene additive form, including, without limitation, powder, prill, agglomerate, liquid suspension, and the like, particularly comprising dispersion aids such as polyolefin (e.g., polyethylene) waxes, stearate esters of glycerin, waxes, mineral oil, and the like.
  • dispersion aids such as polyolefin (e.g., polyethylene) waxes, stearate esters of glycerin, waxes, mineral oil, and the like.
  • any form may be exhibited by such a combination or composition including such combination made from blending, agglomeration, compaction, and/or extrusion.
  • the produced resins are then utilized to form preforms, as noted herein, which are then subsequently utilized to form the desired container articles in an injection stretch blow molding procedure.
  • organoleptic improvement additives be added for the purpose of reducing the migration of degraded benzaldehydes from reaching the surface of the desired article.
  • organoleptic improvement additive is intended to encompass such compounds and formulations as antioxidants (to prevent degradation of both the polyolefin and possibly the target alditol derivatives present within such polyolefin), acid neutralizers (to prevent the ability of appreciable amounts of residual acids from attacking the alditol derivatives), and benzaldehyde scavengers (such as hydrazides, hydrazines, and the like, to prevent the migration of foul tasting and smelling benzaldehydes to the target polyolefin surface).
  • Polypropylene compositions having an melt flow index (MFI) of between about 6 and about 60 are useful in the practice of the invention. Furthermore, MFI values of between about 13 and about 35 are particularly useful in the practice of the invention, as further described below.
  • MFI melt flow index
  • the thickness and design of the target preform is important for a number of reasons.
  • the thickness of such an article should be thin, as compared with the thickness of previously produced polypropylene preforms. This facilitates low haze results as noted above, and also facilitates utilization within prior PET injection stretch blow molding machinery.
  • the side wall thickness of preforms desirably may be less than about 3.5 mm for effective results. In some applications, side wall thickness of between about 1.5 mm and 3.5 is very useful. Some applications may use a thickness of as much as 4.0 mm, as set forth in Table A.
  • a gate as further described herein, comprises the opening through which liquid chemical composition (polypropylene and additive mixture) is admitted into the preform mold cavity.
  • the gate diameter employed during preform production is particularly important, and may be related to other processing variables.
  • a gate diameter of 1.5 mm may be used.
  • a gate diameter of 3.8 mm has been used.
  • Other gate sizes could be used as well, but each factor or factor must be adjusted to account for gate diameter. Gate diameters between about 1.5 mm and 3.8 mm can be advantageously employed in the practice of the invention.
  • FIG. 1 shows a stretch blow molded polypropylene container that may be manufactured in accordance with the practice of the invention.
  • Container 10 (sometimes referred to herein as a “bottle”) is shown.
  • the container 10 of FIG. 1 has a relatively concave bottom 11 , a cylindrical main sidewall 12 , a conical upper portion 13 , and a thickened externally threaded neck 14 on the convergent end of the upper portion 13 .
  • a neck ring 15 provides a physical point of reference, and may be used to carry the container 10 along processing machinery during manufacture and subsequent filling of the container 10 .
  • the container 10 may be of any desired size or shape with sizes of from 0.5 to 4 liters being very useful, for example.
  • the neck 14 usually is rigid to support a pressure retaining screw type cap (not shown). Thus, the neck 14 may be many times the thickness of the sidewall 12 . Furthermore, the conical upper portion 13 may be gradually thickened as it approaches neck 14 .
  • FIG. 2A a flow schematic is provided showing the steps in the first stage of a two-stage stretch blow molding process.
  • a two stage (two step) procedure is provided for production of containers 10 .
  • FIG. 2A shows the first stage of the manufacturing procedure, that is, the injection molding process of preforms production.
  • a chemical composition containing polypropylene is acquired from a source, such as a polypropylene manufacturer.
  • the polypropylene-containing chemical composition may comprise a homopolymer, copolymer or other polymeric composition.
  • the chemical composition may contain various additives, including (for example) nucleating agents, antioxidants, lubricants, s-scavengers, UV absorbers and the like, as further described herein.
  • the polypropylene chemical composition is provided into an injection machine and heated. The heated chemical composition then is injected at a relatively high rate of speed through a valve or “gate”, and into the mold of the injection machine. A preform article is formed in a mold. The preform article is cooled and removed from the mold.
  • FIG. 2B shows a second stage of a two-stage stretch blow molding process.
  • a preform article (which may or may not have been manufactured at a location distant from the stretch blow molding apparatus) is converted to a container 10 .
  • a preform article (usually at ambient temperature) is provided in a stretch blow molding machine. Then, the preform article is heated from ambient temperature to an elevated temperature.
  • the elevated temperature employed is also known as the “orientation” temperature, and it is typically in the range of about 120-130° C. for random copolymers.
  • the inner surface temperature of the preform needs to be sufficiently high to ensure that containers have the best optical properties. This has been found to be one important variable in the stretch blow molding process which sometimes determines whether the container will be transparent or hazy.
  • the preform article is sufficiently softened, the preform is stretch blow molded into a container 10 .
  • the formed container 10 is cooled and removed from the stretch mold apparatus.
  • FIGS. 3-3A show a thick-walled polypropylene preform having a relatively thick side wall 80 (in this example, the side wall thickness is about 5 mm).
  • the preform article 60 shown in FIG. 3 includes a closed end 62 and an open end 72 . Furthermore, a neck 66 is shown, with threads 68 at the base of the neck 66 . A main body portion 64 with side wall 80 is shown. It is common for polypropylene-based preforms 60 such as that shown in FIG. 3 to have a side wall 80 having a thickness of about 5 mm, or more.
  • This preform article 60 happens to also be “stepped out” or tapered at each end, on its exterior profile.
  • a “profile” is found on the exterior of many preform articles.
  • the size of the threads at the open end 72 are fixed, and cannot be subject to variation.
  • FIG. 3B and corresponding FIG. 3C show a first embodiment of a thin walled preform article that may be employed in the practice of the invention. It should be noted that the invention may include the use of “stepped out” preforms with an exterior profile, such as shown in FIGS. 3 B/ 3 C so long as the preforms are less than about 3.5 mm in side wall width.
  • one discovery of the invention is that thin-walled preforms, in conjunction with processing conditions presented herein, provide surprisingly unexpected results as compared to conventional thick walled preforms.
  • FIGS. 3 B/ 3 C a preform 90 having thin side wall 91 is shown.
  • a preform article 115 having a relatively thin side wall may be employed, as further described herein and as shown in FIGS. 4-4A .
  • the geometry of the preform article 115 of FIG. 3 shows a tapered neck 114 , and a main body portion 102 with side walls 101 and 104 that are approximately parallel to each other along their length. Furthermore, a closed end portion 116 tapers from the main body portion 102 . Threads 110 are provided adjacent the open end 103 of preform article 115 .
  • a transition area 105 represents the tapering region of the side wall 101 into the neck 114 .
  • a preform article 115 of the invention is shown in which the outer wall surfaces 109 a - b of the preform article are generally parallel and straight, forming a substantially symmtrical tube on its outer dimension from a point near the closed end 116 to a point near the open end 103 .
  • the inner wall 108 of the preform 115 is profiled due to a transition zone 105 .
  • the preform article 115 engages a mold so as to make a container 10 of the appropriate geometry.
  • profiled it is meant that a given wall has a changing angle or slope which deviates from 180 degrees.
  • the invention may in some embodiments take advantage of a profiled inner wall 108 , as opposed to a profiled exterior wall, as is common in the conventional devices (see FIGS. 3-3A ).
  • the use of a profiled inner wall 108 has been found to be a useful feature in application of the preform 115 to container 10 manufacture.
  • One reason for this fact is that it facilitates the use of relatively uniform outer wall dimensions.
  • preforms 115 can be used that have differing inner wall 108 profile for various container sizes, while still exhibiting a common outer dimension or shape. This is useful in manufacturing, to avoid or minimize tooling and/or machinery changes for each size preform 115 that may be used to make containers 10 of various sizes.
  • a relatively uniform outer dimension to the preform articles 115 may provide an advantage that may be realized in the practice of the invention. It should be recognized that the use of a profiled inner wall 108 is not required in the practice of the invention, but is one useful manner of practicing the invention. Thus, preforms having either an exterior profile or an exterior profile may be used in the practice of the invention.
  • FIG. 5 shows a schematic vertical cross-sectional view of an injection molding machine for making preform articles in a first stage.
  • a preform article 115 may be 10 formed in an injection molding unit 120 having a barrel 121 fed by an hopper 122 and ejecting the melt through a round nose nozzle 123 .
  • a chemical composition i.e. polypropylene-containing pellets or portions, with optional additives or optional nucleating agents, etc) is provided into inlet hopper 122 .
  • Barrel 121 rotatably mounts a melting and mixing screw 124 with a non-return valve nose 125 .
  • Heater bands 126 may be provided in the barrel 121 .
  • Crystalline polypropylene stretch blow mold formulations are fed through the hopper 122 into the barrel 121 where they are advanced by the melting and mixing screw 124 to a molten condition at the valve end 125 whereupon the screw is advanced to the dotted line position where the valve nose 125 will force the molten material through the nozzle orifice 127 .
  • Gate 137 a received a determined the amount of liquid flow that proceeds into the molding cavity 135 .
  • Other similar apparatus could be used to form a preform, which achieves the same or similar result as that shown in FIG. 5 .
  • the apparatus includes a two-part mold 130 with a first core part 131 and a second molding cavity defining part 132 .
  • the part 131 has a cylindrical core 133 with a hemispherical end 134 .
  • the part 132 has a molding cavity 135 with a hemispherical bottom end 136 fed by a conduit 137 .
  • the end wall of the part 132 has a recess 138 receiving the rounded nose of the nozzle 123 .
  • the molten plastics material ahead of the valve 125 may be ejected through the orifice 127 by moving the screw rod to the dotted line position as shown in FIG. 5 .
  • the molten material will flow through the conduit 137 into the mold cavity 135 .
  • the surface of core 133 and the molding cavity surfaces 135 and 136 typically are polished, but may be treated as well to facilitate the ejection of preforms 115 .
  • Steel is a desired metal for manufacture of such mold surfaces 135 .
  • Chilled mold temperatures from about 11-20 degrees C. may be employed.
  • the gate 137 a refers is the opening between the point at which the liquid polypropylene is injected and the actual core 134 of the mold cavity 135 .
  • Gate size is a parameter that may vary for different applications.
  • the size of the gate 137 a can be important in the manufacture of preformed articles 115 . This is because the size of the gate 137 a determines the shear forces applied to the molten polypropylene as it is injected into the mold cavity.
  • the size of gate 137 a will affect the filing rate.
  • the size of the gate 137 a will in some cases determine the rate by at which the chemical composition may be injected, which affects the ultimate clarity of the containers 10 produced by the preformed article 115 in the second stage of the container 10 manufacture (see FIG. 2B ).
  • Gate diameter may vary, depending upon the application. The invention is not limited to any particular gate diameter, but it has been found that diameters between about 1.5 mm and about 3.8 mm are useful, and may be found in equipment in the industry. It may be an advantage in the practice of the invention to be capable of employing gate diameter settings that already are in existence and used on existing commercial PET processing equipment.
  • the injection rate usually is relatively slow. Cavity filling time is typically about 1 to about 4.5 total seconds to fill mold cavity 135 . This corresponds generally to an injection rate greater than about 5 grams/second. In other cases, the rate may be between about 5 and about 22 grams per second. Table A shows various parameters that may be advantageously employed in the practice of the invention.
  • the mold 130 Upon solidification of the preform article 115 in the mold 130 , the mold 130 is opened by withdrawing part 131 (and core 133 ) from part 132 . The preform 115 is stripped from the mold.
  • melt flow index also known as the melt flow rate
  • melt flow index is an important factor in the manufacturing of preform articles 115 .
  • melt flow index is measured according to American Society of Testing Materials ASTM D-1238. This testing method is a nationally (or internationally) known standard. It is a standard test method for measuring the melt flow rates of thermoplastics. Unless otherwise indicated herein, all references to melt flow index, melt flow rate, MFI, or MFR, refer to measurements according to this industry standard. For polypropylene, measurements are at 230 degrees C., and using 2.16 kg, as per this standard.
  • the more viscous is a material at a given temperature the lower will be the MFI value of that material.
  • a given polymer or copolymer composition will have an MFI that is specified by a manufacturer.
  • each particular type of polypropylene-containing composition to be employed in the practice of the invention will have a given or predetermined MFI.
  • the MFI is also determined and affected by the length of the polymer chains in a given polypropylene composition. The longer the polymeric chains, the more viscous the material. The more viscous the material, the lower the MFI value will be for a given composition.
  • MFI values are important in determining the speed at which a chemical composition may be fed into an injection mold cavity to form a preform article. This is true because the MFI also will affect the clarity of the final container which is produced from the preform. By clarity, it is meant the degree of haze that will be present in a given container 10 made according to the invention. In general, the higher percentage of haze in the container 10 , the less transparent is the container 10 produced in the invention. Higher levels of haze are undesirable.
  • One unexpected result of the invention is that it has been found that using a given polymeric composition having a predetermined melt flow index, and injecting that composition at a fill rate of greater than about 5 grams per second, a highly desired preform article may be formed. Furthermore, it has been found that the sidewall thickness of the preform is very important in container manufacture. In the practice of the invention, a preform article 115 with a side wall thickness of less than about 3.5 millimeters has proved to be very desirable. This achieves a high productivity of container manufacture while still maintaining a low degree of haze, i.e. a clear container. Cycle time necessary to make a preform article 115 is significantly reduced by using a preform design with a minimum side wall thickness.
  • Hot plastic polypropylene is capable of cooling in the preform mold more quickly using a reduced wall thickness for the preform stage. This facilitates faster preform cycle times, thereby increasing the number of preform articles 115 that can be made in a given period of time, increasing manufacturing capacity and efficiency.
  • Stage two (step 2 ) of manufacture is shown generally in FIG. 2B , and FIGS. 6-8 .
  • a preform article 115 is taken at ambient temperature, and then uniformly heated.
  • the preform article 115 is placed in a stretch blow mold apparatus 140 in a position with its open end 103 resting on a platform 141 on a base 142 surrounding a reciprocal swage 143 .
  • the closed end 116 of the preform 115 is shown near the center of FIG. 6 .
  • the apparatus freely receives the retracted end of the stretch rod 144 of the apparatus 140 .
  • the molding dies 145 of the apparatus 140 are in an opened condition. Threaded neck forming wall portions 146 are shown, as well as tapered cone forming portions 147 , cylindrical main body forming portions 148 , and concave bottom forming portions 149 .
  • a rotary system is employed to transfer preforms using transfer wheels equipped with grippers into a blow mold cavity.
  • rotary stretch blow molding equipment is known in the art, and may be applied in the practice of the invention. From the open position of FIG. 6 the apparatus 140 is closed to the position of FIG. 7 with the mold halves 145 coming together and with the swage 143 extended into the open end of the preform 115 so that the neck and thread forming portions 146 of the die can mold the thick neck 114 of the bottle on the preform 115 . The projection of the swage 143 into the position of FIG. 7 also moves the stretch rod 144 against the closed end 116 of the preform 115 .
  • the apparatus 140 is further activated to eject the stretch rod 144 beyond the swage 143 into closely spaced relation from the bottom forming portion 149 of the dies 145 thereby effecting a stretching of the preform 115 to the full height of the dies.
  • the stretch rod 144 and the swage 143 are retracted from the container 10 .
  • the gas pressure in the bottle is released, and the dies 45 are separated.
  • a blowing agent is introduced into the preform article 115 forming an axially elongated and hoop stretched balloon in the closed die.
  • the balloon (not shown) is blown into a finished container 10 , as shown in FIG. 8 , with the polypropylene material biaxially stretched to produce a strong container 10 .
  • Roughness on the inner container 10 surface has a negative influence on the container clarity. If, during reheating of the preform 115 (within the window of process stability), the temperature in the skin-layer (at the side of the core) is insufficiently high, the material undesirably may be ruptured apart during the stretch blow molding (stage two) process, resulting in a rough inner container 10 surface and containers 10 having low clarity. Additionally, it has been observed that a low amount of “pre-blowing” (intermediate shape of the stretched and pre-blown preform part, i.e. before the final pressure is applied) may contribute to a relatively rough inner container 10 surface (i.e. undesirable high haze) for the same reason. More specifically the primary pressure, flow of air and pre-blow time usually need to be sufficiently high to prevent that the material gets ruptured apart what gives the part an undesirable high haze.
  • variables that are important in the practice of the invention include, for example, injection speed, MFI of the polypropylene-containing resin, the preform article thickness. In some instances, the gate diameter used during injection of the preform article is a factor. These factors may be optimized and correlated to each other for a given container application, as in the Critical Filling Rate Model set forth below. It is possible using the practice of the invention to maximize productivity of the preform and to maximize productivity polypropylene containers in a two-stage stretch blow molding process.
  • a preform thickness may be of a value less than about 3.5 mm. Thickness is measured along side walls 101 , 104 as shown in FIG. 4A , measured as the maximum or thickest portion of the side wall. In yet another embodiment of the invention, the preform thickness may be in the range of about 2-3.5 mm. Furthermore, in the practice of the invention it has been found that an injection fill rate into the cavity mold of greater than about 5 grams of chemical composition (resin) per second is quite useful. Furthermore, in other aspects of the invention it is advantageous to use a cavity mold fill rate of between 5 and 22 grams per second.
  • Table A shows a correlation between processing variables in the practice of the invention.
  • the MFI values and preform wall thickness values are correlated to the optimized injection mold filling rate in the practice of the invention. It is important to note in Table A that for a given preform wall thickness an increase in the MFI value allows an operator to use a higher injection mold filling rate while still obtaining containers 10 of sufficient clarity.
  • a greater preform wall thickness at a given level of MFI value enables an operator employing the invention to use an injection mold filling rate which is greater, resulting in faster production, reduced cycle times, and good container clarity.
  • Table A reports values for a (valve) gate thickness of 1.5 mm.
  • the use of a wider gate such as about 3.8 mm can result in a filling rate of about 13 g/sec at a MFI value of 13. This compares to the data in Table A in which a MFI of 13 at a (valve) gate diameter of 1.5 mm was successfully employed using an injection speed of about 5-6 g/sec.
  • a (valve) gate diameter of 3.8 mm at MFI value 20 may result in an injection speed of about 22 g/sec. This value of 22 g/sec may be compared to the injection speed shown in Table A (valve diameter 1.5 mm) of 5-7 g/s.
  • the invention makes it possible to achieve a rate of container production of at least about 1500 containers per hour per mold.
  • Example 1 Preforms MFI Injection Injection (g/10 Time Speed Example Resin sec) (sec) (g/sec) I-1 RB307MO 1.5 0.5 50.6 I-2 RB307MO 1.5 1.0 25.3 I-3 RB307MO 1.5 1.5 16.9 I-4 RB307MO 1.5 2.0 12.7 I-5 RB307MO 1.5 2.5 10.1 I-6 RB307MO 1.5 3.0 8.4 I-7 RB307MO 1.5 3.5 7.2 I-8 RB307MO 1.5 4.0 6.3 I-9 RE420MO 13 0.5 50.6 I-10 RE420MO 13 1.0 25.3 I-11 RE420MO 13 1.5 16.9 I-12 RE420MO 13 2.0 12.7 I-13 RE420MO 13 2.5 10.1 I-14 RE420MO 13 3.0 8.4 I-15 RE420MO 13 3.5 7.2 I-16 RE420MO 13 4.0 6.3 I-17 RF365MO 20 0.5 50.6 I-18 RF365MO 20 1.0 25.3 I-19 RF365MO 20 1.5 16.9 I-20 RF365MO 20 2.0 12.7 I-21 RF365MO 20 2.5 10.1 I
  • Example 2 Preforms MFI Injection Injection (g/10 Time Speed Example Resin sec) (sec) (g/cc) II-1 RB307MO 1.5 0.5 40.6 II-2 RB307MO 1.5 1.0 20.3 II-3 RB307MO 1.5 1.5 13.5 II-4 RB307MO 1.5 2.0 10.2 II-5 RB307MO 1.5 2.5 8.1 II-6 RB307MO 1.5 3.0 6.8 II-7 RB307MO 1.5 3.5 5.8 II-8 RB307MO 1.5 4.0 5.1 II-9 RE420MO 13 0.5 40.6 II-10 RE420MO 13 1.0 20.3 II-11 RE420MO 13 1.5 13.5 II-12 RE420MO 13 2.0 10.2 II-13 RE420MO 13 2.5 8.1 II-14 RE420MO 13 3.0 6.8 II-15 RE420MO 13 3.5 5.8 II-16 RE420MO 13 4.0 5.1 II-17 RF365MO 20 0.5 40.6 II-18 RF365MO 20 1.0 20.3 II-19 RF365MO 20 1.5 13.5 II-20 RF365MO 20 2.0 10.2 II-21 RF365MO 20 2.5 8.1
  • Example 3 Preforms MFI Injection Injection (g/10 Time Speed Example Resin sec) (sec) (g/cc) III-1 RB307MO 1.5 0.5 34.6 III-2 RB307MO 1.5 1.0 17.3 III-3 RB307MO 1.5 1.5 11.5 III-4 RB307MO 1.5 2.0 10.2 III-5 RB307MO 1.5 2.5 6.9 III-6 RB307MO 1.5 3.0 5.8 III-7 RB307MO 1.5 3.5 4.9 III-8 RB307MO 1.5 4.0 4.3 III-9 RE420MO 13 0.5 34.6 III-10 RE420MO 13 1.0 17.3 III-11 RE420MO 13 1.5 11.5 III-12 RE420MO 13 2.0 10.2 III-13 RE420MO 13 2.5 6.9 III-14 RE420MO 13 3.0 5.8 III-15 RE420MO 13 3.5 4.9 III-16 RE420MO 13 4.0 4.3 III-17 RF365MO 20 0.5 34.6 III-18 RF365MO 20 1.0 17.3 III-19 RF365MO 20 1.5 11.5 III-20 RF365MO 20 2.0 10.2 III-21 RF365MO 20 2.5 6.9
  • Polypropylene bottles (330 ml) were on a two-cavity Chia-Ming stretch blow molding machine designed to blow polypropylene bottles from preforms described in Example 1.
  • This machine is equipped with 3 heater boxes per cavity & uses 1000 Watt IR lamps.
  • Pre-blow pressure was 6 bar & final pressure was 8 bar. After optimization, the bottle productivity for the preforms with 4 mm thickness was 820 bph/cav.
  • Bottle quality was judged at the time of production to be Unacceptable (poorly blown bottle or blown out), Acceptable (a fully blown bottle with moderate optical properties), Average (a fully blown bottle with improved optical properties), or Excellent (a fully blown bottle with outstanding optical clarity).
  • Polypropylene bottles (330 ml) were blown at high speed on a two-cavity Chia-Ming stretch blow molding machine designed to blow polypropylene bottles from preforms described in Example 2.
  • This machine is equipped with 3 heater boxes per cavity & uses 1000 Watt IR lamps.
  • Pre-blow pressure was 6 bar & final pressure was 8 bar.
  • the bottle productivity for the preforms with 3 mm thickness was 1,030 bph/cav.
  • Bottle quality was judged at the time of production to be Unacceptable (poorly blown bottle or blown out), Acceptable (a fully blown bottle with moderate optical properties), Average (a fully blown bottle with improved optical properties), or Excellent (a fully blown bottle with outstanding optical clarity).
  • Polypropylene bottles (330 ml) were blown at high speed on a two-cavity Chia-Ming stretch blow molding machine designed to blow polypropylene bottles from preforms described in Example 3.
  • This machine is equipped with 3 heater boxes per cavity & uses 1000 Watt IR lamps.
  • Pre-blow pressure was 6 bar & final pressure was 8 bar. After optimization, the bottle productivity for the preforms with 2 mm thickness was 1,200 bph/cav.
  • Bottle quality was judged at the time of production to be Unacceptable (poorly blown bottle or blown out), Acceptable (a fully blown bottle with moderate optical properties), Average (a fully blown bottle with improved optical properties), or Excellent (a fully blown bottle with outstanding optical clarity).
  • Polypropylene bottles (500 ml) were blown at high speed (1500 bottles/cavity/hour) on a Sidel SBO-8 Series II stretch blow molding machine designed to blow PET preforms using the polypropylene preforms described in Example 1.
  • Axial stretch ratio is 2.5/1
  • Machine settings were adjusted to accommodate high clarity, high speed bottle production.
  • Preforms were subjected to a pre-blow pressure of 3 Bar for 0.9 seconds with the preform inner temperature set to about 125°-130° C. and the outer temperature set to about 120°-125° C. Heating power distribution was managed in the range of 90%.
  • Bottle quality was judged at the time of production to be Unacceptable (poorly blown bottle or blown out), Acceptable (a fully blown bottle with moderate optical properties), Average (a fully blown bottle with improved optical properties), or excellent (a fully blown bottle with outstanding optical clarity).
  • Polypropylene bottles (500 ml) were blown at high speed (1,500 bottles/cavity/hour) on a Sidel SBO-8 Series-II stretch blow molding machine designed to blow PET preforms using the polypropylene preforms described in Example 2.
  • Axial stretch ratio is 2.5/1
  • Machine settings were adjusted to accommodate high clarity, high speed bottle production.
  • Preforms were subjected to a pre-blow pressure of 4.5 Bar for 0.4 seconds & nozzle for 3 rotations open activated at ‘point zero’.
  • Blowing time is 0.8 sec & Exhaust time is 0.4 sec.
  • Stretch speed is 1,384 m/sec & a standard stretch rod with 14 mm diameter was used.
  • Preform temperature is about 120-130° C.
  • % GP 65%.
  • This example used 100% was ventilation to cool the preform surface.
  • Bottle quality was judged at the time of production to be Unacceptable (poorly blown bottle or blown out), Acceptable (a fully blown bottle with moderate optical properties), Average (a fully blown bottle with improved optical properties), or Excellent (a fully blown bottle with outstanding optical clarity).
  • Polypropylene bottles (500 ml) were blown at high speed (1,500 bottles/cavity/hour) on a Sidel SBO-8 Series-II stretch blow molding machine designed to blow PET preforms using the polypropylene preforms described in Example 3.
  • Axial stretch ratio is 2.5/1
  • Machine settings were adjusted to accommodate high clarity, high speed bottle production.
  • Preforms were subjected to a pre-blow pressure of 4 Bar for 0.4 seconds & nozzle for 3 rotations open activated at ‘point zero’.
  • Blowing time is 0.8 sec & Exhaust time is 0.4 sec.
  • Stretch speed is 1,384 m/sec & a standard stretch rod with 14 mm diameter was used.
  • Preform temperature is about 115-127° C.
  • % GP 45%. Used 100% ventilation to cool the preform surface.
  • Bottle quality was judged at the time of production to be Unacceptable (poorly blown bottle or blown put), Acceptable (a fully blown bottle with moderate optical properties), Average (a fully blown bottle with improved optical properties), or Excellent (a fully blown bottle with outstanding optical clarity).
  • the preforms (ref. Table X) were produced on a two-cavity mold (only one cavity installed) 100 ton Netstal injection molding machine with a variable injection time (0.5-4.0 sec) and a constant cooling time of 10 sec. Melt temperature was 230° C. Temperature of the cooling water was 13° C. The holding pressure time was 4.5 sec. Total cycle time was around 20 sec (not optimized). A valve gate with a diameter of 1.5 mm was used.
  • the preforms have a wall thickness of 3 mm and a bottle weight of about 20.3 g.
  • Polypropylene bottles (330 ml, ref. Table XI) were produced blown at high speed on a two-cavity Chia-Ming stretch blow molding machine designed to blow polypropylene bottles from preforms described in Example 10.
  • This machine is equipped with 3 heater boxes per cavity & uses 1000 Watt IR lamps.
  • Pre-blow pressure was 6 bar & final pressure was 8 bar.
  • the bottle productivity for the preforms with 3 mm thickness was 1,030 bph/cav.
  • Bottle quality was judged at the time of production to be Unacceptable (poorly blown bottle or blown out), Acceptable (a fully blown bottle with moderate optical properties), Average (a fully blown bottle with improved optical properties), or Excellent (a fully blown bottle with outstanding optical clarity).
  • Polypropylene bottles (500 ml, table XII) were produced at high speed (1,500 bottles/cavity/hour) on a Sidel SBO-8 Series-II stretch blow molding machine designed to blow PET preforms using the polypropylene preforms described in Example 10.
  • Axial stretch ratio is 2.5/1
  • Machine settings were adjusted to accommodate high clarity, high speed bottle production.
  • Preforms were subjected to a pre-blow pressure of 4.5 Bar for 0.4 seconds & nozzle for 3 rotations open activated at ‘point zero’.
  • Blowing time is 0.8 sec & Exhaust time is 0.4 sec.
  • Stretch speed is 1,384 m/sec & a standard stretch rod with 14 mm diameter was used.
  • Preform temperature is about 120-130° C.
  • % GP 65%.
  • Bottle quality was judged at the time of production to be Unacceptable (poorly blown bottle or blown out), Acceptable (a fully blown bottle with moderate optical properties), Average (a fully blown bottle with improved optical properties), or Excellent (a fully blown bottle with outstanding optical clarity).
  • the preforms were produced on a two-cavity mold (only one cavity installed) 100 ton Netstal injection molding machine with a variable injection time (0.5-4.0 sec) and a constant cooling time of 10 sec. Melt temperature was 240° C. Temperature of the cooling water was 13° C. The holding pressure time was 8.4 sec. Total cycle time was around 25 sec (not optimized).
  • a valve gate with a diameter of 1.5 mm was used.
  • the preforms have a wall thickness of 3 mm and a bottle weight of about 20.3 g. These preforms were later blown into bottles as explained in subsequent examples.
  • TABLE XIII Example 13 Preforms MFI Injection Injection (g/10 Time Speed Example Resin sec) (sec) (g/cc) XIII-1 HPMT230 30 0.5 50.6 XIII-2 HPMT230 30 1.0 25.3 XIII-3 HPMT230 30 1.5 16.9 XIII-4 HPMT230 30 2.0 12.7 XIII-5 HPMT230 30 2.5 10.1 XIII-6 HPMT230 30 3.0 8.4 XIII-7 HPMT230 30 3.5 7.2 XIII-8 HPMT230 30 4.0 6.3 XIII-9 RF365MO 20 2.5 50.6 XIII-10 RF365MO 20 3.0 25.3 XIII-11 RF365MO 20 3.5 16.9 XIII-12 RF365MO 20 4.0 12.7 XIII-13 RF365MO 20 0.5 10.1 XIII-14 RF365MO 20 1.0 8.4 XIII-15 RF
  • Polypropylene bottles (500 ml) having a narrow neck were produced at high speed (1500 bottles/cavity/hour) on a Sidel SBO-8 Series-II stretch blow molding machine designed to blow PET preforms using the polypropylene preforms described in Example 13.
  • the following stretch ratios were used: axial stretch ratio of 2.63/1, radial stretch ratio of 3.08 and a total stretch ratio of 8.10/1.
  • Machine settings were adjusted to accommodate high clarity, high speed bottle production.
  • the temperature measured at the outer side of the preform was 143.5° C. and 152.5° C. at the inner side of the preform.
  • Bottle quality was judged at the time of production to be Unacceptable (poorly blown bottle or blown out), Acceptable (a fully blown bottle with moderate optical properties), Average (a fully blown bottle with improved optical properties), or Excellent (a fully blown bottle with outstanding optical clarity).
  • the thickness of preforms is measured along the side walls 101 , 104 as shown in FIG. 4A , measured at the widest portion of the side walls 101 , 104 .
  • Thickness of containers such as for purposes of percent haze/thickness ratios is measured at the point at which the haze has been measured (see below), using a Magna-Mike 8500 Hall effect thickness gauge.
  • haze has been measured on a BYK-Gardner hazemeter by ASTM Standard Test Method D1003-61 modified by use of an 0.2′′ aperture.
  • the area in which haze could be measured reliably was in relatively small areas less than about 0.5′′ in area.
  • Samples were obtained from sample containers (bottles) at a relatively flat point approximately mid-way to the bottom of the bottle after the transition point.
  • a thickness modified haze was calculated for each sample where (H/t) is defined as the haze divided by the thickness at the point where the haze was measured.
  • Roughness on the inner container 10 surface has a negative influence on the container clarity. If, during reheating of the preform 115 (within the window of process stability), the temperature in the skin-layer is insufficiently high, the material undesirably may be ruptured apart during the stretch blow molding (stage two) process, resulting in a rough inner container 10 surface and containers 10 having low clarity.
  • Preforms were made with fill rates ranging from 5.5 to 40.2 grams per second utilizing two different resins—Borealis RF365 MO (20 MI RCP) and Atofina 7525 (12 MI RCP). Three different injection valve gates were utilized in the preform production—1.5, 3.0, and 3.8 mm.
  • Haze was measured in the middle of the bottle on the third rib of the bottle from the top using a BYK Gardner hazemeter. In general, it has been found that haze is dependent upon fill rate. There is a strong increase in haze in both of the resins with increasing fill rate. The Borealis resin reaches a minimum % haze at a faster fill rate than does the Atofina resin, indicating an interaction and influence of the Ml of the resin with fill rate.
  • valve gate diameter There is an effect of the valve gate diameter as it can be seen that the change in haze of both of the resins (see attached Table XV).
  • a 3.8 mm valve gate shows a different dependency of % haze on fill time than do the 1.5 and 3.0 mm gates.
  • the resin MI there is an effect of the resin MI on the haze.
  • the 10 MI Atofina resin has a different haze response to the fill rate and gate diameter, than does the 20 MI Borealis resin.
  • FIG. 12 is also illustrative of the effect of pre-blow time and pressure on container percent (%) haze.
  • Pre-blow pressure 1 bar (very hazy in panel) 2 bar (slightly hazy in panel) 4 bar (clear) 5 bar (clear) 7 bar (clear) 10 bar (clear).
  • Pre-blow time 0 sec (very hazy in panel) 0.05 sec (slightly hazy in panel) 0.1 sec (slightly hazy) 0.2 sec (clear) 0.4 sec (OK) 0.8 sec (OK)
  • a polypropylene container is made by an injection stretch blow molding two stage process.
  • the container has:
  • a clear bottle may be produced by two stages, injection molding into a preform and then stretch blow the preform into the final clear bottle. Such bottles exhibit a certain percentage of free shrinkage in the axial direction. This is known as a “free shrinkage test” or “shrinkage test”, for purposes of this specification and claims.
  • Sample D (the comparative example) bottle apparently exhibits the highest shrinkage ratio among all tested. It also has the highest wall thickness among all bottles tested.
  • wall thickness of the preform is one of the critical factors to make good quality and clear ISBM polypropylene bottles with good productivity.
  • the current invention designs the preform with the wall thickness of 3.5 mm or less, while the prior art is above that.
  • the comparative bottle has the wall thickness of 4.9 mm, while the first three bottles out of this invention have the wall thickness of 2.8 mm and 3.5 mm.
  • the shrinkage behavior is similar provided all bottles are made of polypropylene random copolymer.
  • the wall thickness of the shrunk bottle relates closely to the preform wall thickness.
  • the comparable example bottle has the highest shrunk bottle wall thickness, largely due to the fact that the preform is high in wall thickness. This would be one way of differentiating the bottles based on the current inventive preform design or a prior art preform design.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
US11/137,046 2004-01-23 2005-05-25 Polyolefin container having certain shrink characteristics and method of making such containers Abandoned US20050249905A1 (en)

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US11/137,046 US20050249905A1 (en) 2004-01-23 2005-05-25 Polyolefin container having certain shrink characteristics and method of making such containers
PCT/US2005/018522 WO2005118407A2 (fr) 2004-05-28 2005-05-26 Contenant en polyolefine presentant des caracteristiques de retrait determinees et procede pour produire de tels contenants
BRPI0511638-4A BRPI0511638A (pt) 2004-05-28 2005-05-26 recipiente de poliolefina tendo determinadas caracterìsticas de retração, e processo de produção de tais recipientes
EP05754304A EP1748931A4 (fr) 2004-05-28 2005-05-26 Contenant en polyolefine presentant des caracteristiques de retrait determinees et procede pour produire de tels contenants

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US10/764,234 US20050161866A1 (en) 2004-01-23 2004-01-23 Process of making two-stage injection stretch blow molded polypropylene articles
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US11/137,046 US20050249905A1 (en) 2004-01-23 2005-05-25 Polyolefin container having certain shrink characteristics and method of making such containers

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EP1870225A1 (fr) * 2006-06-21 2007-12-26 Total Petrochemicals Research Feluy Conditions d'étirage et de soufflage dans un procédé de moulage par étirage-soufflage
US11873133B2 (en) * 2021-04-20 2024-01-16 Drug Plastics & Glass Company, Inc. Bottle, injection blow molding core rod for the bottle and related method

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US4177239A (en) * 1977-04-20 1979-12-04 Bekum Maschinenfabriken Gmbh Blow molding method
US4357288A (en) * 1980-02-25 1982-11-02 Deacon Machinery, Inc. Method of making clear transparent polypropylene containers
US5066222A (en) * 1989-03-14 1991-11-19 Bekum Maschinenfabriken Gmbh Method and apparatus for heating and conveying plastic preforms prior to mold blowing operations
US5135975A (en) * 1989-09-20 1992-08-04 Milliken Research Corporation Bis(3,4-dialkylbenzylidene) sorbitol acetals and compositions containing same
US5326258A (en) * 1992-04-11 1994-07-05 Bekum Maschinenfabriken Gmbh Method and apparatus for heating preform blanks composed of partly crystalline synthetic resins produced by injection molding
US5783232A (en) * 1996-12-03 1998-07-21 Bekum Maschinenfabriken Gmbh Blow molding machine using reheat method for producing hollow plastic articles
US6129961A (en) * 1998-08-27 2000-10-10 Toyo Boseki Kabushiki Kaisha Polyester resin and production method thereof
US6627278B1 (en) * 1998-11-30 2003-09-30 Fort James Corporation Injection blow-molded disposable tumbler and method of making same

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Publication number Priority date Publication date Assignee Title
US4177239A (en) * 1977-04-20 1979-12-04 Bekum Maschinenfabriken Gmbh Blow molding method
US4357288A (en) * 1980-02-25 1982-11-02 Deacon Machinery, Inc. Method of making clear transparent polypropylene containers
US5066222A (en) * 1989-03-14 1991-11-19 Bekum Maschinenfabriken Gmbh Method and apparatus for heating and conveying plastic preforms prior to mold blowing operations
US5135975A (en) * 1989-09-20 1992-08-04 Milliken Research Corporation Bis(3,4-dialkylbenzylidene) sorbitol acetals and compositions containing same
US5326258A (en) * 1992-04-11 1994-07-05 Bekum Maschinenfabriken Gmbh Method and apparatus for heating preform blanks composed of partly crystalline synthetic resins produced by injection molding
US5783232A (en) * 1996-12-03 1998-07-21 Bekum Maschinenfabriken Gmbh Blow molding machine using reheat method for producing hollow plastic articles
US6129961A (en) * 1998-08-27 2000-10-10 Toyo Boseki Kabushiki Kaisha Polyester resin and production method thereof
US6627278B1 (en) * 1998-11-30 2003-09-30 Fort James Corporation Injection blow-molded disposable tumbler and method of making same

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WO2005118407A2 (fr) 2005-12-15
WO2005118407A3 (fr) 2007-03-01
EP1748931A2 (fr) 2007-02-07
BRPI0511638A (pt) 2008-01-02

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