US20080099961A1 - Method and Installation for the Production of Containers - Google Patents
Method and Installation for the Production of Containers Download PDFInfo
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- US20080099961A1 US20080099961A1 US11/667,958 US66795805A US2008099961A1 US 20080099961 A1 US20080099961 A1 US 20080099961A1 US 66795805 A US66795805 A US 66795805A US 2008099961 A1 US2008099961 A1 US 2008099961A1
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- Prior art keywords
- installation
- path
- parison
- heating
- heating unit
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B13/00—Conditioning or physical treatment of the material to be shaped
- B29B13/02—Conditioning or physical treatment of the material to be shaped by heating
- B29B13/023—Half-products, e.g. films, plates
- B29B13/024—Hollow bodies, e.g. tubes or profiles
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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
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/64—Heating or cooling preforms, parisons or blown articles
- B29C49/68—Ovens specially adapted for heating preforms or parisons
-
- 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
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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
- 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
- B29C2035/0838—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 laser
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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
- 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
- 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
-
- 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
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/64—Heating or cooling preforms, parisons or blown articles
- B29C49/6409—Thermal conditioning of preforms
- B29C49/6436—Thermal conditioning of preforms characterised by temperature differential
- B29C49/6445—Thermal conditioning of preforms characterised by temperature differential through the preform length
- B29C49/645—Thermal conditioning of preforms characterised by temperature differential through the preform length by cooling the neck
-
- 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
- B29C49/64—Heating or cooling preforms, parisons or blown articles
- B29C49/68—Ovens specially adapted for heating preforms or parisons
- B29C49/6835—Ovens specially adapted for heating preforms or parisons using reflectors
Definitions
- the invention relates to the production of containers.
- It relates more particularly to a method and an installation for producing containers—especially bottles—from thermoplastic parisons.
- Such a method involves a first step during which the parisons are heated, within an appropriate heating unit, then a second step during which the parisons are introduced, hot, into a multiple-mold blow-molding or stretch-blow-molding unit where they are shaped into containers.
- the containers thus formed will be directed either toward a storage unit to await subsequent filling or directly toward a filling unit.
- a container parison comprises a neck, intended to take the closure that seals the container that is to come and which is already at its final dimensions, extended by a body, the shaping of which will lead to the actual container proper.
- the heating of the parisons is generally performed within an oven equipped with an array of tubular halogen lamps past which the parisons progress, while being rotated on themselves. More specifically, an oven contains several elementary modules, each containing several lamps, each of the lamps being controlled individually so that, ultimately, on leaving the oven, the temperature of the body of each of the parisons is above the glass transition temperature of their constituent material and a heating profile is obtained on each parison, which profile is predetermined such that the distribution of material is optimized in the container that is to be obtained.
- This method of heating does have a certain number of disadvantages.
- the heating profile (that is to say the plot of temperatures measured along the length of the parison) cannot be obtained precisely; given the diffusion effect, the radiation from the lamps interferes with each other which means that seeking precisely to regulate the intensity of the combined radiation at a given distance from the lamps is an extremely fanciful notion.
- this orientation of the parisons entails, on entering the heating unit, an operation of inverting the preforms, because the preforms are generally introduced into the oven neck up, and also an operation of inverting either the preforms before they are introduced into the mold when the stretch-blow-molding step is performed neck up (which is the more common scenario), or of the containers as they leave the installation so that they can be stored or filled.
- inverting operations entail installing and operating appropriate devices which make the installation more complicated and have a negative impact on cost.
- the method according to the invention for producing a container from a thermoplastic parison involves:
- the invention also proposes an installation for producing containers from thermoplastic parisons, which comprises a heating unit for heating the parisons with a view to forming the containers from the parisons thus heated.
- the installation defines a path that the parisons are intended to follow within the heating unit, which comprises at least one source of coherent electromagnetic radiation directed toward a region situated on the path of the parisons.
- the radiation can thus be concentrated on to a localized part of the parison, making it possible to obtain a temperature profile close to a predetermined profile, the almost-total absence of diffusion and thermal convection allowing the parison to be heated while it is oriented neck up without this neck experiencing incident heating liable to alter its dimensions.
- the beam of electromagnetic radiation (such as a laser emitted for example by a laser diode) is preferably directed toward the body of the parison.
- the radiation is preferably emitted in the near infrared, in other words at a wavelength ranging between about 700 nm and 1600 nm.
- the heating of the parison is preferably performed by means of a plurality of adjacent and/or superposed beams of electromagnetic radiation.
- heating may be performed by means of a plurality of juxtaposed and/or superposed laser diodes, for example, in the form of one or more arrays.
- the or each beam may be linear or planar; it is, for example, directed in a predetermined overall direction, while the parison, at least locally is made to follow a path either substantially perpendicular or substantially parallel to the direction of the beam.
- the parison is preferably rotated about a predetermined axis, for example, an axis that coincides with an axis of revolution of the parison, so as to obtain uniform heating around the circumference of this parison.
- the neck of the parison may be ventilated in order to remove the overflow of hot air.
- the beam is reflected at least once off a reflective surface.
- the heating unit comprises, for example, a chamber comprising a first wall and a second wall facing one another and substantially parallel to the path of the parisons, these walls being positioned one on each side of this path and together delimiting an internal volume, the first wall being equipped with a plurality of superposed parallel slits facing each of which there is positioned, on the opposite side to the internal volume, a row of radiation sources.
- the second wall at least has, on the same side as the internal volume, a reflective internal surface.
- the heating unit may comprise a ventilation system able to generate an air flow passing through a region situated vertically in line with said chamber.
- the installation comprises two successive heating units of this type.
- the heating unit comprises a plurality of successive chambers positioned along the path, each chamber having two cylindrical walls facing each other and positioned one on each side of the path and together defining an internal cavity, each wall having several adjacent reflective facets facing toward the cavity, the source of electromagnetic radiation being directed toward one of these facets.
- the heating unit for example comprises an opaque screen adjacent to one of the facets, to absorb the beam after it has been reflected several times off the facets.
- the heating unit preferably comprises means for rotating the parisons about their axis of revolution.
- FIG. 1 is a schematic view of an installation for producing containers from thermoplastic parisons
- FIGS. 2 and 3 are perspective views of a block and of an array of laser diodes which may be chosen to equip an installation according to the invention
- FIG. 4 is a schematic perspective view showing the internal structure of an array of laser diodes
- FIG. 5 is a diagram illustrating the compared efficiency of three different laser sources for heating a PET
- FIG. 6 is a schematic perspective view illustrating a heating unit for an installation for producing containers according to a first embodiment
- FIG. 7 is an elevation in cross section illustrating the heating unit of FIG. 6 ;
- FIG. 8 is a schematic perspective view showing a container parison exposed to a laser beam in a heating unit as depicted in FIG. 7 ;
- FIG. 9 is a schematic perspective view illustrating a heating unit for an installation for producing containers according to a second embodiment
- FIG. 10 is a schematic perspective view similar to FIG. 9 also illustrating a heating unit according to a variant of the second embodiment
- FIG. 11 is a schematic plan view, from above, illustrating the heating unit for an installation for producing containers according to a third embodiment
- FIG. 12 is a plan view, from above, on a larger scale, of a detail of the heating unit depicted in FIG. 11 ;
- FIG. 13 is a view illustrating, in perspective, the detail depicted in FIG. 12 .
- FIG. 1 depicts an installation 1 for producing containers, such as bottles, from parisons 2 , in this instance preforms, made of thermoplastic. It is recalled here that the term “parison” covers not only a preform, but also any intermediate part between the preform and the finished container. Some methods actually involve two successive shaping steps, namely a first step of forming an intermediate container from the preform then, after a certain time has elapsed, a second step of forming the finished container from the intermediate container.
- a parison 2 in the form of a preform is depicted on a large scale in FIG. 8 . It is a molded component in the form of a test specimen exhibiting symmetry of revolution about an axis A and having a neck 3 intended, as far as possible, not to undergo any deformation during the forming of the container, and a body 4 ending in a bottom 5 and intended to be heated and then shaped. Without implying any limitation to such an application, it is assumed in the remainder of the description that the containers are formed directly from preforms, which means that, for the sake of convenience, this term will be used arbitrarily to denote parisons or preforms.
- the containers are, for example, made of polyethylene terephthalate (PET), of polyethylene naphthalate (PEN), or another appropriate thermoplastic.
- PET polyethylene terephthalate
- PEN polyethylene naphthalate
- the installation 1 comprises a feed unit 10 which supplies the preforms 2 to a forming unit 6 .
- the feed unit 10 comprises, for example, a hopper 11 into which the preforms 2 , produced beforehand by molding, are loaded loose, this hopper 11 being connected to an inlet 12 of the forming unit 6 by a sorting machine 13 which isolates and positions the preforms 2 (which are cold, that is to say at ambient temperature) on a slide 14 .
- the preforms 2 are then mounted on a transfer line 15 then heated, as they pass through a heating unit 16 , before being introduced hot into a blow-molding unit 17 (or stretch-blow-molding unit) of the multiple-mold carousel type.
- the containers are then transferred, by means of a conveyer 18 , such as a wheel with cavities, from the molds of the blow-molding unit 17 to an outlet of the forming unit 6 .
- a conveyer 18 such as a wheel with cavities
- the preforms 2 are heated by means of at least one beam 22 of coherent electromagnetic radiation.
- the installation 1 defines, within the heating unit 16 , a predetermined path 23 that the preforms 2 follow during the heating step. More specifically, this path 23 is defined by a conveyer (not depicted) equipped with links articulated to one another and from which the preforms 2 are suspended.
- This driving technique is well known to those skilled in the art and will not be described in detail; let us nonetheless specify that each link comprises attachment means in the form of a hanger, known as a “spinner” in the terms of the art, which fits into or on to the neck 3 of the preform 2 , this hanger having a pinion-shaped part which meshes with a fixed rack running alongside the line, so that as the line advances, the hangers, with their preforms are rotated.
- the heating unit 16 comprises at least one source 24 of coherent electromagnetic radiation directed toward a target region 25 situated on the path 23 of the preforms 2 , and through which these pass, as we shall see later.
- thermoplastic such as a PET (the material from which container preforms for the most common applications are conventionally made) lies in the field of the near infrared, that is to say at wavelengths ranging between 700 nm and 1600 nm.
- a PET preform generally has a wall thickness ranging between 1 mm and 3 mm, entirely dependent on the type of container that is to be obtained.
- a first test was conducted by the inventors on PET test specimens 3 mm thick using three laser sources emitting in the near infrared, namely:
- a laser of the Nd:YAG type (this type of laser comprises a neodymium-doped yttrium aluminum garnet amplifier with a power of 4.4 kW, generating an infrared beam with a wavelength of 1064 nm,
- a laser diode of the hybrid type with a power of 3 kW, generating an infrared beam combining two wavelengths of 808 nm and 940 nm respectively, and
- a laser diode with a power of 500 W generating an infrared beam with a wavelength of 808 nm.
- the diagram in FIG. 5 shows, for each of these lasers, the plot of the time taken for the material to reach the core temperature of 130° C. (this is in fact the temperature to which PET preforms need to be heated), as a function of the transmitted power density.
- heating quality is to be understood as meaning heating which not only gives a lower exposure time, but also gives good accuracy and good diffusion of the radiation through the thickness of the material).
- the first exemplary embodiment uses a planar beam 22 , generated by a laser diode 26 to which a spreading lens is added.
- a laser diode 26 to which a spreading lens is added.
- Various manufacturers offer laser diodes which either come individually or assembled into arrays as depicted in FIGS. 2 and 3 .
- FIG. 2 depicts a block 27 of stacked diodes 26 with a total power of 1200 W, marketed by Thales, under the references TH-C17xx-M1 or TH-C55xx-M1.
- Each diode 26 generates a planar laser beam so that the block generates several superposed planar beams which may be parallel or divergent.
- FIG. 3 depicts an array 28 of diodes 26 with a power of 40 W each, each diode 26 generating a planar beam.
- the array 28 thus generates a planar beam, formed by the juxtaposition of the beams generated by all the diodes.
- An array of this type is marketed by Thales, under the references TH-C1840-P or TH-C1841-R.
- the block 27 and the array 28 are both equipped with an internal water-cooling circuit, the water inlet 29 and outlet 30 pipes of which can be seen in the figures.
- FIG. 4 schematically depicts the structure of an array 28 of diodes 26 .
- the diodes 26 are jointly mounted and soldered onto a support 31 equipped with ducts 32 perpendicular to the beams 22 and through which the cooling fluid runs.
- the heating unit is now described in greater detail according to three distinct exemplary embodiments with reference to FIGS. 6 to 11 .
- the first exemplary embodiment is described with reference to FIGS. 6 to 8 .
- the path 23 represented by a chain line, that the preforms 2 follow within the heating unit 16 is substantially rectilinear and defines a direction L termed the longitudinal direction.
- the heating unit 16 comprises a chamber 33 comprising a first wall and a second wall 34 , 35 which are vertical and face one another and run substantially parallel to the path 23 , being positioned one on each side thereof.
- the walls 34 , 35 together delimit an internal volume 36 through which the preforms 2 pass longitudinally.
- the walls 34 , 35 extend over a height substantially equal to the length of the body 4 of the preform 2 .
- This preform is oriented neck up, the neck 3 protruding out of the chamber 33 above the walls 34 , 35 .
- the chamber 33 is open at the bottom to allow an ascending air flow 37 to circulate to provide the chamber 33 with a certain degree of ventilation in order to remove the heat emitted by the body 4 of the heated parison 2 .
- Each wall 34 , 35 has a respective internal face 38 , 39 facing toward the internal volume 36 and a respective opposite external face 40 , 41 .
- the first wall 34 is equipped with a plurality of superposed horizontal parallel slits 42 facing each of which there is positioned, on the external face 40 side, an array 28 of laser diodes, as described hereinabove.
- the heating unit thus comprises a matrix 43 of laser diodes formed by a plurality of superposed arrays 28 , which runs substantially facing the entire height of the body 4 of the preforms 2 .
- the arrays 28 may be cooled by means of their own circuits, which are connected to a common cooling liquid supply 29 and discharge 30 duct.
- Each diode emits a beam 22 oriented in an overall direction T that is transverse to the path 23 , and runs in a horizontal mid-plane P parallel to this path 23 .
- Each slit 42 subjects the beam 22 passing through it to a diffusion effect which means that the beam 22 has a tendency to diverge on each side of the horizontal midplane P.
- the internal faces 38 , 39 of the walls 34 , 35 are reflective which means that the beam 22 undergoes several successive reflections and therefore crosses the preform 2 several times before it loses its energy. This results in an improvement in the energy efficiency and in a reduction in the time taken to heat the preforms 2 .
- Rotating the preform 2 about its axis A makes it possible, on leaving the heating unit, to obtain a temperature profile that is substantially constant around the circumference of the body 4 .
- the middle arrays 28 will be set to a lower power than the lower and upper arrays 28 so as to keep the central part of the body 4 at a temperature that is lower (for example at around 115° C.) than the temperature of its end parts (which will be raised to around 130° C.).
- the phenomenon of thermal convection in the chamber 33 is limited because of the use of coherent radiation, particularly so that the neck 3 does not experience any heating liable to soften it and cause an alteration to its dimensions during the blowing (which, as has been stated, allows the preforms 2 to be oriented neck up), it may prove preferable to ventilate at least the upper part of the chamber 33 , so as to create a cool air flow around the neck 3 .
- the heating unit 16 is equipped with a ventilation system 44 generating an air flow 45 which, vertically in line with the chamber 33 , circulates transversely in order to remove the heat energy drained away by the upward air flow 37 due to natural thermal convection.
- This ventilation system 44 for example comprises a fan 46 arranged in a casing 47 positioned on the external face 41 side of the second wall 35 and having an opening 48 extending vertically in line with an upper edge 49 of the wall 35 , able to route the air flow 37 from the fan 46 transversely.
- Each preform 2 is heated as follows.
- the preform 2 originating from the feed unit 10 enters the heating unit 16 along the longitudinal path 23 locally defined by the conveyer.
- the preform 2 is rotated about its axis A.
- the laser beams 22 emitted by the diodes 26 strike it along the entire path that it follows through the chamber 33 .
- the body 4 of the preform 2 is quickly raised to a temperature of around 120° C., while its neck 3 is kept at ambient temperature.
- the preform 2 is transferred to the stretch-blow-molding unit 18 to be shaped into a container.
- This second example comprises a first embodiment illustrated in FIG. 9 , whereby the installation 1 comprises a single heating unit 16 , and a second embodiment which, illustrated in FIG. 10 , constitutes a variant of the first in that the installation 1 comprises two successive heating units 16 .
- the path 23 followed by the preforms 2 within the heating unit 16 is locally rectilinear, in a longitudinal direction L, between an upstream transfer region 50 where the cold preforms 2 are brought into the heating unit 16 by an upstream transfer wheel 51 , and a downstream transfer region 52 , where the hot preforms 2 are removed from the heating unit 16 by a downstream transfer wheel 53 .
- the heating unit 16 comprises several superposed laser sources 24 positioned at a downstream end of the path 23 , along the axis thereof.
- the sources 24 here consist of collimating lenses 54 each connected by an optical fiber 55 , to a diode laser generator 56 and together form a vertical block 57 of a height substantially equal to the bodies 4 of the preforms 2 .
- the lenses 54 are oriented in such a way as to generate longitudinal (linear or planar) beams 22 which strike the preforms 2 in succession before encountering an opaque screen 58 forming an energy sink, positioned transversely in the continuation of the path 23 , beyond the upstream transfer wheel 51 .
- each preform 2 is progressively heated by the laser beams 22 whose energy, transferred successively to the preforms 2 that they strike and pass through is, first of all, from the point of view of the preform, low at the exit of the upstream transfer wheel 51 , then increases as the preform 2 gradually nears the sources 24 before reaching a maximum in the vicinity of these sources before the preform 2 is taken up by the downstream transfer wheel 53 .
- the laser adopted here is a diode laser of the type set out hereinabove (cf. ⁇ 1), with an individual power of 500 W.
- the heating unit 16 comprises a confinement chamber 59 comprising two walls 60 , 61 facing each other and positioned one on each side of the path 23 , between the upstream 51 and downstream 53 transfer wheels.
- These walls 60 , 61 have reflective internal faces which confine the laser beams 22 by reflecting their transverse components resulting from the diffraction through the preforms 2 . Thus energy losses are limited while at the same time improving the safety of the installation.
- the heating unit 16 may be equipped with a ventilation system similar to the one described hereinabove in the first exemplary embodiment.
- the installation 1 comprises two heating units 16 , similar to the heating unit 16 described hereinabove in the first embodiment and positioned in succession in the path of the preforms 2 , namely a first heating unit 16 a designed to raise the preforms 2 to an intermediate temperature (that is to say to a temperature between ambient temperature, which corresponds to the initial temperature of the preforms, around 20° C., and the final temperature, prior to forming, of around 120° C.), and a second heating unit 16 b designed to raise the preforms 2 to their final temperature (of around 120° C.).
- a first heating unit 16 a designed to raise the preforms 2 to an intermediate temperature (that is to say to a temperature between ambient temperature, which corresponds to the initial temperature of the preforms, around 20° C., and the final temperature, prior to forming, of around 120° C.)
- a second heating unit 16 b designed to raise the preforms 2 to their final temperature (of around 120° C.).
- the path 23 a followed by the preforms 2 within the first heating unit 16 a is locally rectilinear, in a longitudinal direction L between an upstream transfer region 51 where the cold preforms 2 are supplied to the first heating unit 16 a by an upstream transfer wheel 51 , and an intermediate transfer region 62 where the warm preforms 2 are transferred from the first heating unit 16 a to the second 16 b.
- the heating units 16 a , 16 b are arranged parallel to one another, and the path 23 b followed by the preforms in the intermediate transfer region 62 is curved. This arrangement makes it possible to avoid interference between the beams 22 of the first heating unit 16 a and those of the second 16 b.
- the path 23 c followed by the preforms 2 within the second heating unit 16 b is, also, locally rectilinear and longitudinal, between the intermediate transfer region 62 and a downstream transfer region 52 where the hot preforms 2 are taken up transversely by a downstream transfer wheel 53 .
- Each heating unit 16 a , 16 b comprises a block 27 of superposed laser diodes of a height substantially equal to that of the bodies 4 of the preforms 2 and arranged at a downstream e nd of the corresponding path 23 a , 23 c along the axis thereof.
- the blocks 27 of diodes are, for example, of the kind set out hereinabove (cf. ⁇ 1) and illustrated in FIG. 2 .
- the first heating unit 16 a comprises an opaque screen 58 forming an energy sink, that the laser beams 22 strike once they have passed in succession through the preforms 2 present on the path 23 a , and which is positioned transversely in the continuation of the path 23 a beyond the upstream transfer wheel 51 .
- the second heating unit 16 b also comprises such an opaque screen 58 , for its part positioned in the continuation of the path 23 c , on the same side as the intermediate transfer region 62 .
- each heating unit 16 a , 16 b comprises a confinement chamber 59 of which the reflective walls 60 , 61 , positioned one on each side of the corresponding path 23 a , 23 c , prevent the lateral dispersion of the laser beams 22 .
- the preforms 2 are first of all raised to an intermediate temperature, for example of around 80° C., within the first heating unit 16 a , and then, from there, are raised to a final temperature of about 120° C. within the second heating unit 16 b before being transferred to the stretch-blow-molding unit 18 .
- the third exemplary embodiment is now described with reference to FIGS. 11 to 13 .
- the path 23 of the parisons 2 within the heating unit 16 is substantially circular and, as can be seen in FIG. 11 , the heating unit 16 comprises a plurality of adjacent chambers 63 arranged along the path 23 and through which the preforms 2 pass in succession.
- the path 23 is defined between an upstream transfer wheel 51 which brings the preforms 2 from the feed unit 10 , and a downstream transfer wheel 53 carrying the stretch-blow-molding molds.
- Each chamber 63 has two cylindrical walls facing each other, namely an internal wall 64 and an external wall 65 , positioned one on each side of the path 23 , and together defining an internal cavity 66 in which the preform 2 is positioned, its axis A therefore being temporarily coincident with an axis of symmetry of the chamber 63 .
- Each wall 64 , 65 has several adjacent reflective facets 64 a , 64 b , 64 c , 65 a , 65 b , 65 c facing toward the cavity 66 , each facet 64 a , 64 b , 64 c of one wall 64 being positioned facing a corresponding facet 65 a , 65 b , 65 c of the wall 65 opposite, these facets 64 a , 64 b , 64 c , 65 a , 65 b , 65 c not being exactly parallel with their pair but together defining an angle a of a few degrees, as can be seen in FIG. 12 .
- An upstream gap 67 and a downstream gap 68 are defined between the walls 64 , 65 , through which gaps 67 , 68 each preform 2 in turn enters and then leaves.
- the heating unit 16 comprises, for each chamber 63 , an opaque screen 58 adjacent to one facet 64 c of the internal wall 64 , on the same side as the downstream gap 68 .
- the heating unit 16 comprises a block 27 of stacked laser diodes positioned facing one 64 a of the facets of the internal wall 64 , bordering the upstream gap 67 .
- the laser diodes, directed toward this facet 64 a are designed each to generate a beam 22 that is either linear or contained in a vertical plane that is transverse with respect to the path 23 of the preforms 2 , the beam 22 making an acute angle with the normal to the facet 64 a ( FIG. 12 ).
- each beam 22 undergoes several successive reflections off the facets 64 a , 65 a , 64 b , 65 b , 64 c , 65 c before striking the screen 58 which, as it forms an energy sink, completely absorbs the beam 22 ( FIG. 12 ).
- each beam 22 thus strikes it several times in distinct regions distributed at its circumference, as can be seen in FIG. 12 .
- each preform 2 passes in succession through all the chambers 63 and the diodes can be set in such a way that their power increases along the path 23 , the temperature of the preforms 2 therefore increasing as they gradually progress through the heating unit 16 .
- the preforms 2 may be rotated about their axis of revolution A, their progress within the heating unit 16 preferably being stepwise, each preform 2 for example remaining in each chamber 63 for a fraction of a second.
- Tests have in fact demonstrated a laser energy penetration into the materials commonly used in this application, that is superior to that of the radiation of the halogen lamps conventionally employed for heating, thus improving the uniformity of the temperature of the material through the thickness of the preform.
- the precision of the heating makes it possible to obtain a vertical heating profile which more precisely matches the desired profile. More specifically, this precision makes it possible to achieve heating profiles which hitherto were impossible to obtain. That in particular means that the design of the preforms can be revised so that the weight (which in practice means the wall thickness) of the preforms can be distributed differently according to the desired temperature profile for a particular profile of the container.
- the small amount of heating of the ambient air additionally means that the preforms can be kept in the neck up orientation throughout the container production process, thus avoiding inverting operations.
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- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Containers Having Bodies Formed In One Piece (AREA)
Abstract
The invention relates to a method of producing a container from a thermoplastic blank (2), comprising: a step in which the blank (2) is heated using at least one beam (22) of coherent electromagnetic radiation, and a step in which the container is formed from the blank (2) thus heated. The invention also relates to an installation (1) which is used to produce containers (2) and which comprises a unit (16) for heating the blanks (2) in order to form containers from the blanks (2) thus heated. The inventive installation (1) defines a path (23) along which the blanks (2) travel inside the heating unit (16). In addition, the heating unit (16) comprises at least one coherent electromagnetic radiation source (26) which is directed towards a zone (25) that is located on the aforementioned path (23).
Description
- The invention relates to the production of containers.
- It relates more particularly to a method and an installation for producing containers—especially bottles—from thermoplastic parisons.
- Such a method involves a first step during which the parisons are heated, within an appropriate heating unit, then a second step during which the parisons are introduced, hot, into a multiple-mold blow-molding or stretch-blow-molding unit where they are shaped into containers.
- On leaving the blow-molding or stretch-blow-molding unit, the containers thus formed will be directed either toward a storage unit to await subsequent filling or directly toward a filling unit.
- Let us remember that a container parison comprises a neck, intended to take the closure that seals the container that is to come and which is already at its final dimensions, extended by a body, the shaping of which will lead to the actual container proper.
- The heating of the parisons is generally performed within an oven equipped with an array of tubular halogen lamps past which the parisons progress, while being rotated on themselves. More specifically, an oven contains several elementary modules, each containing several lamps, each of the lamps being controlled individually so that, ultimately, on leaving the oven, the temperature of the body of each of the parisons is above the glass transition temperature of their constituent material and a heating profile is obtained on each parison, which profile is predetermined such that the distribution of material is optimized in the container that is to be obtained.
- This method of heating does have a certain number of disadvantages.
- First, its energy efficiency (that is to say the ratio of the power absorbed by the parisons to the power consumed by the lamps) is extremely low, of the order of 11 to 15%. This is because of the spatial diffusion of the radiation emitted by the lamps, only a fraction of which reaches the body of the parisons. The low value displayed by this efficiency has a negative impact on production rates.
- Next, the heating profile (that is to say the plot of temperatures measured along the length of the parison) cannot be obtained precisely; given the diffusion effect, the radiation from the lamps interferes with each other which means that seeking precisely to regulate the intensity of the combined radiation at a given distance from the lamps is an extremely fanciful notion.
- In order to alleviate this disadvantage, there has already been the idea to make the parisons file past the lamps at the closest possible range. However, this then gives rise to an undesirable problem of overheating at the surface of the parisons, which phenomenon cannot be lessened unless an expensive ventilation system is fitted and operated.
- Furthermore, there is also a significant phenomenon of thermal convection whereby the ascending air streams transfer some of the emitted radiation to the capital part of the parison. Now, the neck of this parison needs to be kept at a modest temperature so that it maintains its original dimensions.
- Hence, in order to limit the incident heating of the neck by thermal convection, it has become judicious to orient the parisons neck down. As such a precaution proved to be insufficient in certain instances, it was combined with ventilation of the neck. Whatever the case, this orientation of the parisons entails, on entering the heating unit, an operation of inverting the preforms, because the preforms are generally introduced into the oven neck up, and also an operation of inverting either the preforms before they are introduced into the mold when the stretch-blow-molding step is performed neck up (which is the more common scenario), or of the containers as they leave the installation so that they can be stored or filled. These inverting operations entail installing and operating appropriate devices which make the installation more complicated and have a negative impact on cost.
- In order in particular to alleviate the aforementioned disadvantages, the method according to the invention for producing a container from a thermoplastic parison involves:
- a step of heating the parison performed by means of at least one beam of coherent electromagnetic radiation, then
- a step of forming the container from the parison thus heated.
- The invention also proposes an installation for producing containers from thermoplastic parisons, which comprises a heating unit for heating the parisons with a view to forming the containers from the parisons thus heated. The installation defines a path that the parisons are intended to follow within the heating unit, which comprises at least one source of coherent electromagnetic radiation directed toward a region situated on the path of the parisons.
- The radiation can thus be concentrated on to a localized part of the parison, making it possible to obtain a temperature profile close to a predetermined profile, the almost-total absence of diffusion and thermal convection allowing the parison to be heated while it is oriented neck up without this neck experiencing incident heating liable to alter its dimensions.
- More specifically, the beam of electromagnetic radiation (such as a laser emitted for example by a laser diode) is preferably directed toward the body of the parison. The radiation is preferably emitted in the near infrared, in other words at a wavelength ranging between about 700 nm and 1600 nm.
- The heating of the parison is preferably performed by means of a plurality of adjacent and/or superposed beams of electromagnetic radiation. In practice, heating may be performed by means of a plurality of juxtaposed and/or superposed laser diodes, for example, in the form of one or more arrays.
- The or each beam may be linear or planar; it is, for example, directed in a predetermined overall direction, while the parison, at least locally is made to follow a path either substantially perpendicular or substantially parallel to the direction of the beam.
- In the heating step, the parison is preferably rotated about a predetermined axis, for example, an axis that coincides with an axis of revolution of the parison, so as to obtain uniform heating around the circumference of this parison.
- Furthermore, the neck of the parison may be ventilated in order to remove the overflow of hot air.
- According to one embodiment, in the heating step, the beam is reflected at least once off a reflective surface.
- The heating unit comprises, for example, a chamber comprising a first wall and a second wall facing one another and substantially parallel to the path of the parisons, these walls being positioned one on each side of this path and together delimiting an internal volume, the first wall being equipped with a plurality of superposed parallel slits facing each of which there is positioned, on the opposite side to the internal volume, a row of radiation sources.
- According to one embodiment, the second wall at least has, on the same side as the internal volume, a reflective internal surface.
- In order to ventilate the neck of the parison, the heating unit may comprise a ventilation system able to generate an air flow passing through a region situated vertically in line with said chamber.
- According to an embodiment variant, the installation comprises two successive heating units of this type.
- According to another embodiment, with the path of the parisons being substantially circular, the heating unit comprises a plurality of successive chambers positioned along the path, each chamber having two cylindrical walls facing each other and positioned one on each side of the path and together defining an internal cavity, each wall having several adjacent reflective facets facing toward the cavity, the source of electromagnetic radiation being directed toward one of these facets.
- The heating unit, for example comprises an opaque screen adjacent to one of the facets, to absorb the beam after it has been reflected several times off the facets.
- Whatever the embodiment adopted, the heating unit preferably comprises means for rotating the parisons about their axis of revolution.
- Other objects and advantages of the invention will emerge from the description given hereinafter with reference to the attached drawings in which:
-
FIG. 1 is a schematic view of an installation for producing containers from thermoplastic parisons; -
FIGS. 2 and 3 are perspective views of a block and of an array of laser diodes which may be chosen to equip an installation according to the invention; -
FIG. 4 is a schematic perspective view showing the internal structure of an array of laser diodes; -
FIG. 5 is a diagram illustrating the compared efficiency of three different laser sources for heating a PET; -
FIG. 6 is a schematic perspective view illustrating a heating unit for an installation for producing containers according to a first embodiment; -
FIG. 7 is an elevation in cross section illustrating the heating unit ofFIG. 6 ; -
FIG. 8 is a schematic perspective view showing a container parison exposed to a laser beam in a heating unit as depicted inFIG. 7 ; -
FIG. 9 is a schematic perspective view illustrating a heating unit for an installation for producing containers according to a second embodiment; -
FIG. 10 is a schematic perspective view similar toFIG. 9 also illustrating a heating unit according to a variant of the second embodiment; -
FIG. 11 is a schematic plan view, from above, illustrating the heating unit for an installation for producing containers according to a third embodiment; -
FIG. 12 is a plan view, from above, on a larger scale, of a detail of the heating unit depicted inFIG. 11 ; and -
FIG. 13 is a view illustrating, in perspective, the detail depicted inFIG. 12 . -
FIG. 1 depicts aninstallation 1 for producing containers, such as bottles, fromparisons 2, in this instance preforms, made of thermoplastic. It is recalled here that the term “parison” covers not only a preform, but also any intermediate part between the preform and the finished container. Some methods actually involve two successive shaping steps, namely a first step of forming an intermediate container from the preform then, after a certain time has elapsed, a second step of forming the finished container from the intermediate container. - A
parison 2 in the form of a preform is depicted on a large scale inFIG. 8 . It is a molded component in the form of a test specimen exhibiting symmetry of revolution about an axis A and having aneck 3 intended, as far as possible, not to undergo any deformation during the forming of the container, and abody 4 ending in abottom 5 and intended to be heated and then shaped. Without implying any limitation to such an application, it is assumed in the remainder of the description that the containers are formed directly from preforms, which means that, for the sake of convenience, this term will be used arbitrarily to denote parisons or preforms. - The containers are, for example, made of polyethylene terephthalate (PET), of polyethylene naphthalate (PEN), or another appropriate thermoplastic.
- As depicted in
FIG. 1 , theinstallation 1 comprises afeed unit 10 which supplies thepreforms 2 to a formingunit 6. Thefeed unit 10 comprises, for example, ahopper 11 into which thepreforms 2, produced beforehand by molding, are loaded loose, thishopper 11 being connected to aninlet 12 of the formingunit 6 by a sortingmachine 13 which isolates and positions the preforms 2 (which are cold, that is to say at ambient temperature) on aslide 14. - The
preforms 2 are then mounted on atransfer line 15 then heated, as they pass through aheating unit 16, before being introduced hot into a blow-molding unit 17 (or stretch-blow-molding unit) of the multiple-mold carousel type. - The containers are then transferred, by means of a
conveyer 18, such as a wheel with cavities, from the molds of the blow-molding unit 17 to an outlet of the formingunit 6. - Within the
heating unit 16, thepreforms 2 are heated by means of at least onebeam 22 of coherent electromagnetic radiation. - For this, the
installation 1 defines, within theheating unit 16, apredetermined path 23 that thepreforms 2 follow during the heating step. More specifically, thispath 23 is defined by a conveyer (not depicted) equipped with links articulated to one another and from which thepreforms 2 are suspended. This driving technique is well known to those skilled in the art and will not be described in detail; let us nonetheless specify that each link comprises attachment means in the form of a hanger, known as a “spinner” in the terms of the art, which fits into or on to theneck 3 of thepreform 2, this hanger having a pinion-shaped part which meshes with a fixed rack running alongside the line, so that as the line advances, the hangers, with their preforms are rotated. - The
heating unit 16 comprises at least onesource 24 of coherent electromagnetic radiation directed toward atarget region 25 situated on thepath 23 of thepreforms 2, and through which these pass, as we shall see later. - The description which follows first of all sets out the choice of the
source 24 of electromagnetic radiation for heating the preforms (§ 1), and then, describes theheating unit 16 and the corresponding heating method, in three exemplary embodiments (§ 2). - Tests have shown that, across the light spectrum, the radiation that is of use for heating a thermoplastic such as a PET (the material from which container preforms for the most common applications are conventionally made) lies in the field of the near infrared, that is to say at wavelengths ranging between 700 nm and 1600 nm.
- Several lasers available on the market have proved satisfactory in application to the heating of thermoplastics (the tests conducted by the inventors were conducted using a PET).
- A PET preform generally has a wall thickness ranging between 1 mm and 3 mm, entirely dependent on the type of container that is to be obtained.
- A first test was conducted by the inventors on
PET test specimens 3 mm thick using three laser sources emitting in the near infrared, namely: - 1. first of all, a laser of the Nd:YAG type (this type of laser comprises a neodymium-doped yttrium aluminum garnet amplifier with a power of 4.4 kW, generating an infrared beam with a wavelength of 1064 nm,
- 2. secondly, a laser diode of the hybrid type, with a power of 3 kW, generating an infrared beam combining two wavelengths of 808 nm and 940 nm respectively, and
- 3. thirdly, a laser diode with a power of 500 W generating an infrared beam with a wavelength of 808 nm.
- The diagram in
FIG. 5 shows, for each of these lasers, the plot of the time taken for the material to reach the core temperature of 130° C. (this is in fact the temperature to which PET preforms need to be heated), as a function of the transmitted power density. - It can be seen that, while the efficiency of the Nd:YAG laser seems to be superior to that of the diode lasers, the plots are, nonetheless, similar, which shows that the laser can be chosen on the basis of parameters other than efficiency alone, particularly on the basis of the shape of the beam, the size of the source and, of course, its cost.
- Furthermore, it has been found that the choice of laser is also dependent on the need to safeguard the material from uncontrolled crystallization. A compromise is therefore needed. Although the Nd:YAG has proven its efficiency, the diode laser will take preference over it, being less expensive and less bulky, for an imperceptible difference in efficiency in the application to the heating of thermoplastic preforms.
- While tests have shown that the domain adopted for the radiation is that of the near infrared, they have also shown that, before 1000 nm, the choice in wavelength has little impact on the heating quality (“heating quality” is to be understood as meaning heating which not only gives a lower exposure time, but also gives good accuracy and good diffusion of the radiation through the thickness of the material).
- By contrast, for the same wavelength, the following parameters: beam shape, energy profile, power density, have an important effect on the heating quality.
- As we shall see hereinafter, the first exemplary embodiment uses a
planar beam 22, generated by alaser diode 26 to which a spreading lens is added. Various manufacturers offer laser diodes which either come individually or assembled into arrays as depicted inFIGS. 2 and 3 . -
FIG. 2 depicts ablock 27 of stackeddiodes 26 with a total power of 1200 W, marketed by Thales, under the references TH-C17xx-M1 or TH-C55xx-M1. Eachdiode 26 generates a planar laser beam so that the block generates several superposed planar beams which may be parallel or divergent. -
FIG. 3 depicts anarray 28 ofdiodes 26 with a power of 40 W each, eachdiode 26 generating a planar beam. Thearray 28 thus generates a planar beam, formed by the juxtaposition of the beams generated by all the diodes. An array of this type is marketed by Thales, under the references TH-C1840-P or TH-C1841-R. - As can be seen in
FIGS. 2 and 3 , theblock 27 and thearray 28 are both equipped with an internal water-cooling circuit, thewater inlet 29 andoutlet 30 pipes of which can be seen in the figures. -
FIG. 4 schematically depicts the structure of anarray 28 ofdiodes 26. Thediodes 26 are jointly mounted and soldered onto asupport 31 equipped withducts 32 perpendicular to thebeams 22 and through which the cooling fluid runs. - The heating unit is now described in greater detail according to three distinct exemplary embodiments with reference to
FIGS. 6 to 11 . - The first exemplary embodiment is described with reference to
FIGS. 6 to 8 . - As can be seen in
FIG. 6 , thepath 23, represented by a chain line, that thepreforms 2 follow within theheating unit 16 is substantially rectilinear and defines a direction L termed the longitudinal direction. - In this example, the
heating unit 16 comprises achamber 33 comprising a first wall and asecond wall path 23, being positioned one on each side thereof. -
- The
walls internal volume 36 through which thepreforms 2 pass longitudinally. - As can be seen in
FIG. 7 , thewalls body 4 of thepreform 2. This preform is oriented neck up, theneck 3 protruding out of thechamber 33 above thewalls chamber 33 is open at the bottom to allow an ascendingair flow 37 to circulate to provide thechamber 33 with a certain degree of ventilation in order to remove the heat emitted by thebody 4 of theheated parison 2. - Each
wall internal face 38, 39 facing toward theinternal volume 36 and a respective oppositeexternal face - The
first wall 34 is equipped with a plurality of superposed horizontalparallel slits 42 facing each of which there is positioned, on theexternal face 40 side, anarray 28 of laser diodes, as described hereinabove. - As can be seen in
FIG. 6 , the heating unit thus comprises amatrix 43 of laser diodes formed by a plurality of superposedarrays 28, which runs substantially facing the entire height of thebody 4 of thepreforms 2. Thearrays 28 may be cooled by means of their own circuits, which are connected to a common coolingliquid supply 29 anddischarge 30 duct. - Each diode emits a
beam 22 oriented in an overall direction T that is transverse to thepath 23, and runs in a horizontal mid-plane P parallel to thispath 23. - Each slit 42 subjects the
beam 22 passing through it to a diffusion effect which means that thebeam 22 has a tendency to diverge on each side of the horizontal midplane P. - Furthermore, the internal faces 38, 39 of the
walls beam 22 undergoes several successive reflections and therefore crosses thepreform 2 several times before it loses its energy. This results in an improvement in the energy efficiency and in a reduction in the time taken to heat thepreforms 2. - To produce the
matrix 43 of diodes, it is possible to use severalsuperposed arrays 28 of 40 W diodes of the type explained hereinabove (cf. § 1) and illustrated inFIG. 3 . - In
FIG. 7 , the angle of divergence of thebeam 22 is exaggerated in order to demonstrate this dual phenomenon of divergence and reflection. - Rotating the
preform 2 about its axis A makes it possible, on leaving the heating unit, to obtain a temperature profile that is substantially constant around the circumference of thebody 4. - Furthermore, it is possible to regulate the power of the
diodes 26 in such a way as to obtain the desired temperature profile which is non-uniform over the length of thepreform 2, for example, with a view ultimately to obtaining a container of curved shape. In such an example, themiddle arrays 28 will be set to a lower power than the lower andupper arrays 28 so as to keep the central part of thebody 4 at a temperature that is lower (for example at around 115° C.) than the temperature of its end parts (which will be raised to around 130° C.). - Although the phenomenon of thermal convection in the
chamber 33 is limited because of the use of coherent radiation, particularly so that theneck 3 does not experience any heating liable to soften it and cause an alteration to its dimensions during the blowing (which, as has been stated, allows thepreforms 2 to be oriented neck up), it may prove preferable to ventilate at least the upper part of thechamber 33, so as to create a cool air flow around theneck 3. - Hence, as has been depicted in
FIG. 7 , theheating unit 16 is equipped with aventilation system 44 generating anair flow 45 which, vertically in line with thechamber 33, circulates transversely in order to remove the heat energy drained away by theupward air flow 37 due to natural thermal convection. Thisventilation system 44 for example comprises afan 46 arranged in acasing 47 positioned on theexternal face 41 side of thesecond wall 35 and having anopening 48 extending vertically in line with anupper edge 49 of thewall 35, able to route theair flow 37 from thefan 46 transversely. - Each
preform 2 is heated as follows. - The
preform 2 originating from thefeed unit 10 enters theheating unit 16 along thelongitudinal path 23 locally defined by the conveyer. - The
preform 2 is rotated about its axis A. Thelaser beams 22 emitted by thediodes 26 strike it along the entire path that it follows through thechamber 33. Initially at ambient temperature, thebody 4 of thepreform 2 is quickly raised to a temperature of around 120° C., while itsneck 3 is kept at ambient temperature. - On leaving the
chamber 33, thepreform 2 is transferred to the stretch-blow-molding unit 18 to be shaped into a container. - The second exemplary embodiment is now described with reference to
FIGS. 9 and 10 . This second example comprises a first embodiment illustrated inFIG. 9 , whereby theinstallation 1 comprises asingle heating unit 16, and a second embodiment which, illustrated inFIG. 10 , constitutes a variant of the first in that theinstallation 1 comprises twosuccessive heating units 16. - According to the first embodiment, the
path 23 followed by thepreforms 2 within theheating unit 16 is locally rectilinear, in a longitudinal direction L, between anupstream transfer region 50 where thecold preforms 2 are brought into theheating unit 16 by anupstream transfer wheel 51, and adownstream transfer region 52, where thehot preforms 2 are removed from theheating unit 16 by adownstream transfer wheel 53. - The
heating unit 16 comprises several superposedlaser sources 24 positioned at a downstream end of thepath 23, along the axis thereof. Thesources 24 here consist of collimating lenses 54 each connected by anoptical fiber 55, to adiode laser generator 56 and together form avertical block 57 of a height substantially equal to thebodies 4 of thepreforms 2. - As can be seen in
FIG. 9 , the lenses 54 are oriented in such a way as to generate longitudinal (linear or planar) beams 22 which strike thepreforms 2 in succession before encountering anopaque screen 58 forming an energy sink, positioned transversely in the continuation of thepath 23, beyond theupstream transfer wheel 51. - Thus, along the
path 23, eachpreform 2 is progressively heated by thelaser beams 22 whose energy, transferred successively to thepreforms 2 that they strike and pass through is, first of all, from the point of view of the preform, low at the exit of theupstream transfer wheel 51, then increases as thepreform 2 gradually nears thesources 24 before reaching a maximum in the vicinity of these sources before thepreform 2 is taken up by thedownstream transfer wheel 53. - It is thus possible to heat the
preforms 2 gradually using only a block of laser sources, rather than a matrix as explained in the first example described above. - However, in order to avoid excessively rapid dissipation of the energy of the laser beams, it is preferable to use laser diodes of a higher power. Thus, the laser adopted here is a diode laser of the type set out hereinabove (cf. § 1), with an individual power of 500 W.
- As illustrated in
FIG. 9 , theheating unit 16 comprises aconfinement chamber 59 comprising twowalls path 23, between the upstream 51 and downstream 53 transfer wheels. - These
walls laser beams 22 by reflecting their transverse components resulting from the diffraction through thepreforms 2. Thus energy losses are limited while at the same time improving the safety of the installation. - Although this is not shown in
FIG. 9 , theheating unit 16 may be equipped with a ventilation system similar to the one described hereinabove in the first exemplary embodiment. - According to the second embodiment, the
installation 1 comprises twoheating units 16, similar to theheating unit 16 described hereinabove in the first embodiment and positioned in succession in the path of thepreforms 2, namely a first heating unit 16 a designed to raise thepreforms 2 to an intermediate temperature (that is to say to a temperature between ambient temperature, which corresponds to the initial temperature of the preforms, around 20° C., and the final temperature, prior to forming, of around 120° C.), and a second heating unit 16 b designed to raise thepreforms 2 to their final temperature (of around 120° C.). - The
path 23 a followed by thepreforms 2 within the first heating unit 16 a is locally rectilinear, in a longitudinal direction L between anupstream transfer region 51 where thecold preforms 2 are supplied to the first heating unit 16 a by anupstream transfer wheel 51, and anintermediate transfer region 62 where thewarm preforms 2 are transferred from the first heating unit 16 a to the second 16 b. - In the example depicted in
FIG. 10 , the heating units 16 a, 16 b are arranged parallel to one another, and thepath 23 b followed by the preforms in theintermediate transfer region 62 is curved. This arrangement makes it possible to avoid interference between thebeams 22 of the first heating unit 16 a and those of the second 16 b. - The
path 23 c followed by thepreforms 2 within the second heating unit 16 b is, also, locally rectilinear and longitudinal, between theintermediate transfer region 62 and adownstream transfer region 52 where thehot preforms 2 are taken up transversely by adownstream transfer wheel 53. - Each heating unit 16 a, 16 b comprises a
block 27 of superposed laser diodes of a height substantially equal to that of thebodies 4 of thepreforms 2 and arranged at a downstream e nd of thecorresponding path - The
blocks 27 of diodes are, for example, of the kind set out hereinabove (cf. § 1) and illustrated inFIG. 2 . - As can be seen in
FIG. 10 , the first heating unit 16 a comprises anopaque screen 58 forming an energy sink, that thelaser beams 22 strike once they have passed in succession through thepreforms 2 present on thepath 23 a, and which is positioned transversely in the continuation of thepath 23 a beyond theupstream transfer wheel 51. - The second heating unit 16 b also comprises such an
opaque screen 58, for its part positioned in the continuation of thepath 23 c, on the same side as theintermediate transfer region 62. - Furthermore, as can be seen in
FIG. 10 , each heating unit 16 a, 16 b comprises aconfinement chamber 59 of which thereflective walls corresponding path - Thus, the
preforms 2 are first of all raised to an intermediate temperature, for example of around 80° C., within the first heating unit 16 a, and then, from there, are raised to a final temperature of about 120° C. within the second heating unit 16 b before being transferred to the stretch-blow-molding unit 18. - It should be noted that for particular applications, more than two heating units could be envisioned.
- The third exemplary embodiment is now described with reference to
FIGS. 11 to 13 . - In this example, the
path 23 of theparisons 2 within theheating unit 16 is substantially circular and, as can be seen inFIG. 11 , theheating unit 16 comprises a plurality ofadjacent chambers 63 arranged along thepath 23 and through which thepreforms 2 pass in succession. - The
path 23 is defined between anupstream transfer wheel 51 which brings thepreforms 2 from thefeed unit 10, and adownstream transfer wheel 53 carrying the stretch-blow-molding molds. - Each
chamber 63 has two cylindrical walls facing each other, namely aninternal wall 64 and anexternal wall 65, positioned one on each side of thepath 23, and together defining aninternal cavity 66 in which thepreform 2 is positioned, its axis A therefore being temporarily coincident with an axis of symmetry of thechamber 63. - Each
wall reflective facets cavity 66, eachfacet wall 64 being positioned facing a correspondingfacet wall 65 opposite, thesefacets FIG. 12 . - An
upstream gap 67 and adownstream gap 68 are defined between thewalls gaps preform 2 in turn enters and then leaves. - Furthermore, the
heating unit 16 comprises, for eachchamber 63, anopaque screen 58 adjacent to onefacet 64 c of theinternal wall 64, on the same side as thedownstream gap 68. - For each
chamber 63, theheating unit 16 comprises ablock 27 of stacked laser diodes positioned facing one 64 a of the facets of theinternal wall 64, bordering theupstream gap 67. The laser diodes, directed toward thisfacet 64 a are designed each to generate abeam 22 that is either linear or contained in a vertical plane that is transverse with respect to thepath 23 of thepreforms 2, thebeam 22 making an acute angle with the normal to thefacet 64 a (FIG. 12 ). - Thus, each
beam 22 undergoes several successive reflections off thefacets screen 58 which, as it forms an energy sink, completely absorbs the beam 22 (FIG. 12 ). - When a
preform 2 is positioned at the center of thechamber 63, neck up, eachbeam 22 thus strikes it several times in distinct regions distributed at its circumference, as can be seen inFIG. 12 . - As is apparent from
FIG. 11 , eachpreform 2 passes in succession through all thechambers 63 and the diodes can be set in such a way that their power increases along thepath 23, the temperature of thepreforms 2 therefore increasing as they gradually progress through theheating unit 16. - As before, the
preforms 2 may be rotated about their axis of revolution A, their progress within theheating unit 16 preferably being stepwise, eachpreform 2 for example remaining in eachchamber 63 for a fraction of a second. - It is perfectly conceivable for the progress of the preforms through the
heating unit 16 to be continuous, because of the good ability that the laser beams have to penetrate through the material of which the bodies of the preforms are made. - Of course, irrespective of the embodiment adopted, it is possible to regulate the speed at which the
preforms 2 travel through the heating unit. - In fact, the various settings (rate of travel, power of diodes, length of chamber) will be chosen by the person skilled in the art according to the material to be used for the preforms, and the machine rates dictated by production.
- As we have seen, the method and the installation described hereinabove allow parisons, such as preforms, to be heated both more quickly and more precisely than can be achieved by the known methods and installations.
- This speed means that the size of the heating unit can be limited, while tests have shown it is possible, using coherent electromagnetic beams, to achieve energy efficiencies of 50%, something which seemed unthinkable with the known methods and installations.
- Tests have in fact demonstrated a laser energy penetration into the materials commonly used in this application, that is superior to that of the radiation of the halogen lamps conventionally employed for heating, thus improving the uniformity of the temperature of the material through the thickness of the preform.
- The precision of the heating makes it possible to obtain a vertical heating profile which more precisely matches the desired profile. More specifically, this precision makes it possible to achieve heating profiles which hitherto were impossible to obtain. That in particular means that the design of the preforms can be revised so that the weight (which in practice means the wall thickness) of the preforms can be distributed differently according to the desired temperature profile for a particular profile of the container.
- Furthermore, the small amount of heating of the ambient air additionally means that the preforms can be kept in the neck up orientation throughout the container production process, thus avoiding inverting operations.
Claims (33)
1-34. (canceled)
35. A method for producing a container from a thermoplastic parison, which involves:
a step of heating the parison performed by means of at least one beam of coherent electromagnetic radiation, then
a step of forming the container from the parison thus heated, the method being characterized in that the heating of the parison is performed by means of a plurality of superposed beams of electromagnetic radiation.
36. The method as claimed in claim 35 , in which the heating of the parison is performed by means of a plurality of adjacent beams of electromagnetic radiation.
37. The method as claimed in claim 35 , in which each beam is planar.
38. The method as claimed in claim 35 , in which each beam is directed in a predetermined overall direction and in which, during the heating step, the parison is at least locally made to follow a path substantially perpendicular to the direction of the beam.
39. The method as claimed in claim 35 , in which each beam is directed in a predetermined overall direction and in which, in the heating step, the parison is at least locally made to follow a path substantially parallel to the overall direction of the beam.
40. The method as claimed in claim 35 , in which, in the heating step, the parison is rotated about a predetermined axis.
41. The method as claimed in claim 40 , in which said axis of rotation coincides with an axis of revolution of the parison.
42. The method as claimed in claim 35 , in which, with the parison having a neck and a body, the beam of electromagnetic radiation is directed toward the body of the parison.
43. The method as claimed in claim 42 , in which, during the heating step, the neck of the parison is directed upward.
44. The method as claimed in claim 42 , in which the neck of the parison is ventilated.
45. The method as claimed in claim 35 , in which, in the heating step, the beam is reflected at least once off a reflective surface.
46. The method as claimed in claim 35 , in which said beam is a laser beam.
47. The method as claimed in claim 35 , in which the radiation from the beam is infrared radiation.
48. The method as claimed in claim 47 , in which the wavelength of the radiation is less than or equal to about 1600 nm.
49. The method as claimed in claim 48 , in which the wavelength of the radiation is between about 700 nm and 1600 nm.
50. An installation for producing containers from thermoplastic parisons, which comprises a heating unit for heating the parisons with a view to forming the containers from the parisons thus heated, the installation defining a path but the parisons are intended to follow within the heating unit, characterized in that the heating unit comprises at least one source of coherent electromagnetic radiation directed toward a region situated on the path of the parisons.
51. The installation as claimed in claim 50 , in which, with the path of the parisons being substantially linear, said plurality of sources of radiation is directed transversely with respect to said path.
52. The installation as claimed in claim 51 , in which the heating unit comprises a row of adjacent radiation sources arranged parallel to the path.
53. The installation as claimed in claim 52 , in which the heating unit comprises several superposed rows of radiation sources arranged parallel to the path.
54. The installation as claimed in claim 53 , in which the heating unit comprises a chamber comprising a first wall and a second wall facing one another and substantially parallel to the path of the parisons, these walls being positioned one on each side of this path and together delimiting an internal volume, the first wall being equipped with a plurality of superposed parallel slits facing each of which there is positioned, on the opposite side to the internal volume, a row of radiation sources.
55. The installation as claimed in claim 54 , in which the second wall at least, on the same side as the internal volume, has a reflective internal surface.
56. The installation as claimed in claim 54 , in which the heating unit comprises a ventilation system able to generate an air flow passing through a region situated vertically in line with said chamber.
57. The installation as claimed in claim 50 , in which, with the path of the parisons being substantially linear, said source of radiation is directed parallel to said path.
58. The installation as claimed in claim 56 , which comprises an opaque screen positioned facing the source of radiation.
59. The installation as claimed in claim 56 , which comprises at least two successive heating units.
60. The installation as claimed in claim 50 , in which, with the path of the parisons being substantially circular, the heating unit comprises a plurality of successive chambers positioned along the path, each chamber having two cylindrical walls facing each other and positioned one on each side of the path and together defining an internal cavity, each wall having several adjacent reflective facets facing toward the cavity, the source of electromagnetic radiation being directed toward one of these facets and the facets are not exactly parallel with their pair but together define an angle of a few degrees.
61. The installation as claimed in claim 60 , which comprises an opaque screen adjacent to one of the facets.
62. The installation as claimed in claim 50 , in which, with the parisons having an axis of revolution, the heating unit comprises means for rotating the parisons about their axis.
63. The installation as claimed in claim 50 , in which the source of coherent electromagnetic radiation is a laser source.
64. The installation as claimed in claim 63 , in which the source of coherent electromagnetic radiation is a laser diode.
65. The installation as claimed in claim 64 , in which the laser diode is designed to emit a planar laser beam.
66. The installation as claimed in claim 64 , in which the heating unit comprises at least one block or one array of juxtaposed laser diodes.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/432,824 US8303290B2 (en) | 2004-11-22 | 2009-04-30 | Method and installation for the production of containers |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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FR0412372A FR2878185B1 (en) | 2004-11-22 | 2004-11-22 | PROCESS FOR MANUFACTURING CONTAINERS COMPRISING A HEATING STEP BY MEANS OF A COHERENT ELECTROMAGNETIC RADIATION BEAM |
FR0412372 | 2004-11-22 | ||
PCT/FR2005/002826 WO2006056673A1 (en) | 2004-11-22 | 2005-11-15 | Method and installation for the production of containers |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/FR2005/002826 A-371-Of-International WO2006056673A1 (en) | 2004-11-22 | 2005-11-15 | Method and installation for the production of containers |
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Application Number | Title | Priority Date | Filing Date |
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US12/432,824 Division US8303290B2 (en) | 2004-11-22 | 2009-04-30 | Method and installation for the production of containers |
US12/561,198 Continuation US8354051B2 (en) | 2004-11-22 | 2009-09-16 | Method and installation for the production of containers |
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US20080099961A1 true US20080099961A1 (en) | 2008-05-01 |
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US12/432,824 Active US8303290B2 (en) | 2004-11-22 | 2009-04-30 | Method and installation for the production of containers |
US12/560,417 Abandoned US20100007061A1 (en) | 2004-11-22 | 2009-09-15 | Method and installation for the production of containers |
US12/561,198 Active US8354051B2 (en) | 2004-11-22 | 2009-09-16 | Method and installation for the production of containers |
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US12/432,824 Active US8303290B2 (en) | 2004-11-22 | 2009-04-30 | Method and installation for the production of containers |
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US12/561,198 Active US8354051B2 (en) | 2004-11-22 | 2009-09-16 | Method and installation for the production of containers |
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US (4) | US20080099961A1 (en) |
EP (1) | EP1824659B1 (en) |
JP (1) | JP4555344B2 (en) |
CN (1) | CN101060970B (en) |
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FR3070300A1 (en) * | 2017-08-24 | 2019-03-01 | Sidel Participations | INSTALLATION AND METHOD FOR PRODUCING CONTAINERS FOR PRODUCING THE STARTER |
EP3446852A1 (en) * | 2017-08-24 | 2019-02-27 | Sidel Participations | Installation and method for producing containers, allowing production from the start |
US10960596B2 (en) | 2017-08-24 | 2021-03-30 | Sidel Participations | Facility and method for production of containers, making possible production immediately upon start-up |
CN115534277A (en) * | 2022-09-27 | 2022-12-30 | 江苏新美星包装机械股份有限公司 | Heating device and heating method for plastic preforms |
CN115534276A (en) * | 2022-09-27 | 2022-12-30 | 江苏新美星包装机械股份有限公司 | Conveying and heating device for plastic preforms |
Also Published As
Publication number | Publication date |
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US20100007061A1 (en) | 2010-01-14 |
MX2007006152A (en) | 2007-07-19 |
US20090214690A1 (en) | 2009-08-27 |
US8303290B2 (en) | 2012-11-06 |
CN101060970A (en) | 2007-10-24 |
FR2878185A1 (en) | 2006-05-26 |
FR2878185B1 (en) | 2008-11-07 |
EP1824659B1 (en) | 2013-10-02 |
CN101060970B (en) | 2012-04-18 |
US20100072673A1 (en) | 2010-03-25 |
JP2008520467A (en) | 2008-06-19 |
US8354051B2 (en) | 2013-01-15 |
WO2006056673A1 (en) | 2006-06-01 |
JP4555344B2 (en) | 2010-09-29 |
EP1824659A1 (en) | 2007-08-29 |
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