U.S. patent application number 13/299907 was filed with the patent office on 2012-03-15 for mono and multi-layer articles and injection molding methods of making the same.
This patent application is currently assigned to The Concentrate Manufacturing Company of Ireland. Invention is credited to Said K. Farha, Gerald A. Hutchinson, Robert A. Lee.
Application Number | 20120061344 13/299907 |
Document ID | / |
Family ID | 34966074 |
Filed Date | 2012-03-15 |
United States Patent
Application |
20120061344 |
Kind Code |
A1 |
Hutchinson; Gerald A. ; et
al. |
March 15, 2012 |
Mono and Multi-Layer Articles and Injection Molding Methods of
Making the Same
Abstract
In preferred embodiments methods and apparatuses can produce
articles that have expandable thermoplastic material. The articles
may be mono- and multilayer. The articles can be formed by various
methods.
Inventors: |
Hutchinson; Gerald A.; (Coto
De Caza, CA) ; Lee; Robert A.; (Bowdon Cheshire,
GB) ; Farha; Said K.; (Pleasantville, NY) |
Assignee: |
The Concentrate Manufacturing
Company of Ireland
Hamilton
BM
|
Family ID: |
34966074 |
Appl. No.: |
13/299907 |
Filed: |
November 18, 2011 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12861757 |
Aug 23, 2010 |
|
|
|
13299907 |
|
|
|
|
11108607 |
Apr 18, 2005 |
|
|
|
12861757 |
|
|
|
|
60563021 |
Apr 16, 2004 |
|
|
|
60575231 |
May 28, 2004 |
|
|
|
60586399 |
Jul 7, 2004 |
|
|
|
60620160 |
Oct 18, 2004 |
|
|
|
60643008 |
Jan 11, 2005 |
|
|
|
Current U.S.
Class: |
215/382 ;
220/669; 264/37.1; 264/516; 428/411.1 |
Current CPC
Class: |
B29K 2105/0076 20130101;
B32B 5/18 20130101; Y10T 428/31786 20150401; B29B 2911/1404
20130101; B32B 2307/718 20130101; Y10T 428/31504 20150401; B29B
2911/14646 20130101; B32B 27/065 20130101; B29K 2023/083 20130101;
B32B 1/02 20130101; B29B 2911/14053 20130101; B29C 49/06 20130101;
B32B 2439/70 20130101; B29C 2049/225 20130101; F16L 2011/047
20130101; B29K 2105/253 20130101; B29L 2009/00 20130101; B32B
2266/025 20130101; B29B 2911/14246 20130101; B32B 27/32 20130101;
B29C 2049/0089 20130101; B32B 27/36 20130101; F16L 55/1157
20130101; Y10T 428/1383 20150115; B29B 2911/1426 20130101; B29K
2105/258 20130101; B29B 2911/14273 20130101; Y10T 428/1393
20150115; B29B 2911/1412 20130101; Y10T 428/31938 20150401; B29B
2911/14026 20130101; B29K 2105/048 20130101; B29K 2105/04 20130101;
B32B 2307/54 20130101; F16L 11/04 20130101; Y10T 428/1379 20150115;
B29B 2911/14253 20130101; B29C 49/04 20130101; B29C 49/22 20130101;
Y10T 428/1352 20150115; B29B 2911/14066 20130101; B29C 49/221
20130101; B29B 2911/14126 20130101; B29C 70/66 20130101; B29K
2105/162 20130101; B29K 2105/165 20130101; B32B 27/325 20130101;
B29K 2623/12 20130101; B29B 2911/1408 20130101; B29L 2031/716
20130101; B32B 2307/304 20130101; B32B 2266/0264 20130101; B29B
2911/14106 20130101; B29B 2911/1406 20130101; B29K 2995/0015
20130101; B29C 44/04 20130101; B29K 2023/086 20130101; B29K 2067/00
20130101; B32B 2274/00 20130101; Y10T 428/249971 20150401; B29B
2911/14266 20130101; B29C 45/1684 20130101; B29B 2911/1402
20130101; B29C 49/12 20130101; B29K 2995/0067 20130101; B32B 5/20
20130101; B32B 27/08 20130101; B29B 2911/14113 20130101; F16L
55/1152 20130101; B29C 2791/006 20130101; B29K 2023/12 20130101;
B32B 2307/7242 20130101; B32B 2307/7265 20130101; B29K 2105/26
20130101; B29C 51/10 20130101; B29L 2023/22 20130101; B65D 1/0215
20130101; B29L 2031/463 20130101; B29C 70/603 20130101; B29B
2911/1424 20130101; B29B 2911/14093 20130101; B29B 2911/1428
20130101; B29L 2031/7158 20130101; B32B 2439/60 20130101 |
Class at
Publication: |
215/382 ;
264/516; 264/37.1; 220/669; 428/411.1 |
International
Class: |
B65D 23/00 20060101
B65D023/00; B32B 9/04 20060101 B32B009/04; B65D 1/40 20060101
B65D001/40; B29C 45/14 20060101 B29C045/14; B29B 17/00 20060101
B29B017/00 |
Claims
1. A method for making an overmolded container comprising:
providing a preform for a container, the preform comprising a
thermoplastic polymer; overmolding an expandable thermoplastic
overmold material over at least a portion of the preform to form an
overmolded preform; and blow molding the overmolded preform to form
an overmolded container.
2. The method of claim 1, wherein the expandable thermoplastic
overmold material inhibits heat transfer through the walls of the
container.
3. The method of claim 1, wherein the expandable thermoplastic
overmold material comprises plastic.
4. The method of claim 1, wherein the expandable thermoplastic
overmold material is crosslinked.
5. The method of claim 1, wherein the overmolded container is a
beverage container.
6. The method of claim 1, wherein the thermoplastic polymer
comprises a polyester.
7. The method of claim 6, wherein the thermoplastic polymer
comprises a polyethylene terephthalate copolymer.
8. The method of claim 1, wherein the overmold material is selected
from ethylene acrylic acid, ethylene vinyl acetate, linear low
density polyethylene, polyethylene, and polypropylene.
9. The method of claim 1, wherein the overmold material is selected
from the group consisting of a polyolefin, a modified polyolefin,
and combinations thereof.
10. The method of claim 1, wherein the overmold material is
selected from the group consisting of acrylic-olefin copolymer,
polyester, and combinations thereof.
11. The method of claim 1, wherein the overmold material has a
density less than 1.00 g/cc.
12. The method of claim 1, wherein the overmold material further
comprises one or more additives.
13. The method of claim 12, wherein the one or more additives are
selected from the group consisting of a colorant, a UV protection
additive, a lubricant, a thermal stabilizer, an antioxidant, and
combinations thereof.
14. The method of claim 1, wherein the blow molding process
comprises preheating the overmolded preform and then stretch blow
molding the preheated preform.
15. The method of claim 1, wherein the overmolded material covers a
majority of the outer surface of the overmolded container.
16. A blow molded container produced by the method of claim 1.
17. A packaged beverage comprising the blow molded bottle of claim
16 and a beverage disposed inside the bottle.
18. A method for recycling an overmolded container comprising:
providing the container of claim 16; and separating the overmolded
layer from the container body.
19. The method of claim 18, wherein the separating process
comprises recycling of the container.
20. An overmolded preform comprising: a thermoplastic polymer
preform suitable for blow molding into a bottle; and an overmold
material, which comprises a crosslinked thermoplastic material,
overmolded over at least a portion of the preform.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No.
12/861,757, filed Aug. 23, 2010, which is a continuation of
application Ser. No. 11/108,607, filed Apr. 18, 2005, now
abandoned, which claims the priority benefit under 35 U.S.C.
.sctn.119(e) of provisional Application Nos. 60/563,021, filed Apr.
16, 2004, 60/575,231, filed May 28, 2004, 60/586,399, filed Jul. 7,
2004, 60/620,160, filed Oct. 18, 2004, and 60/643,008, filed Jan.
11, 2005, each of which is hereby incorporated by reference in its
entirety.
BACKGROUND
[0002] Articles have been commonly used for holding beverages and
foodstuffs. The use of articles, such as plastic containers, as a
replacement for entirely glass or metal containers in the packaging
of beverages has become increasingly popular. The advantages of
plastic packaging include lighter weight, decreased breakage as
compared to glass, and potentially lower costs. The most common
plastic used in making beverage containers today is polyethylene
terephthalate ("PET"). Virgin PET has been approved by the FDA for
use in contact with foodstuffs. Containers made of PET are
generally transparent, thin-walled, lightweight, and have the
ability to maintain their shape by withstanding the force exerted
on the walls of the container by pressurized contents, such as
carbonated beverages. PET resins are also fairly inexpensive and
easy to process.
[0003] Most PET bottles are made by a process that includes the
blow-molding of plastic preforms, which have been made by processes
including injection molding or extrusion process. The PET bottle
may not provide a suitable thermal barrier for limiting thermal
communication through the walls of the PET bottles. It may be
desirable to reduce the heat transfer between the liquid within the
bottle and the environment surrounding the bottle to maintain the
temperature of the liquid within the bottles. Similarly, most
inexpensive containers for holding foodstuffs do not provide an
effective thermal barrier to reduce heat transfer through the
container. It may be desirable to reduce the heat transfer through
containers or packaging.
[0004] Additionally, articles in the form of conduits, food
packaging, and the like may have unsuitable structural, barrier, or
other characteristics. Many times fluids, foods, or beverages, such
as carbonated soda, are stored in a container that may undesirably
affect its contents. Unfortunately, when the food contacts the
surface of some materials of the known articles, the taste of the
food may be adversely altered. It may be desirable to maintain the
taste of the foodstuffs in contact with the article.
SUMMARY
[0005] In a preferred embodiment, there is provided a method for
forming a preform. At least a portion of the preform comprises
expandable material that can expand to form a thermal barrier or
desired finish. The preform is heated to a temperature suitable for
blow molding and at least a portion of the expandable material
expands. The preform is blow molded into a container. In one
arrangement, the preform is a monolayer preform. In another
arrangement, the preform is a multi-layer preform.
[0006] In another embodiment, there is provided a process for
making a foam coated polymer article comprising the acts of
providing a foam coated polymer preform and blow molding the
preform to a desired container shape. In one arrangement, the
process comprises preheating the foam coated polymer preform before
blow molding, causing the foam coating, which comprises
microspheres, to initiate expansion of the microspheres. The
microspheres can expand before blow molding, during blow molding,
and/or after blow molding.
[0007] In one embodiment, a foam coated polymer article comprises
at least one layer of foam surrounding at least a portion of
another layer substantially comprising polyester. The foam
comprises a polymer carrier material and a foaming agent.
[0008] In another embodiment, there is provided a process for
making an article comprising foam. The foam can have a first
component and a second component. The first component can expand
when thermally activated. Optionally, the first component comprises
microspheres that are generally in a first state of expansion. In
one arrangement, the second component is a carrier material mixed
with the first component. When the mixture is heated, the mixture
is expanded to form a generally closed cell foam.
[0009] In one embodiment, the mixture is formed into a preform
having microspheres that are expanded from the first state of
expansion to a second state of expansion. The preform is molded
into a container having the microspheres which are expanded from
the second state of expansion to a third state of expansion. In one
arrangement, a substantial portion of the microspheres are
generally unexpanded in the first position. Optionally, a
substantial portion of the microspheres are generally partially
expanded in the second position. Optionally, a substantial portion
of the microspheres are generally expanded in the third
position.
[0010] In one embodiment, the preform comprises a plurality of
layers and one of the layers comprises an expandable material. The
preform is optionally formed into a container. In one embodiment,
an inner layer of the preform or container comprises material
suitable for contacting foodstuff and/or liquid and defines a
holding chamber of the preform or container. In one arrangement,
the inner layer comprises thermoplastic material. A second layer of
the preform or container comprises expandable material including a
polymer and microspheres. Alternatively, the expandable material
can form an inner layer or liner of the preform or container.
[0011] In one embodiment, the expandable material comprises a
carrier material and a foaming agent. The carrier material is
preferably a material that can be mixed with the microspheres to
form an expandable material. The carrier material can be a
thermoplastic or polymeric material, including, but not limited to,
ethylene acrylic acid ("EAA"), ethylene vinyl acetate ("EVA"),
linear low density polyethylene ("LLDPE"), poly(hydroxyamino
ethers) ("PHAE"), polyethylene terephthalate ("PET") and other
copolymers including polyethylene terephthalate glycol (PETG),
polyethylene ("PE"), polypropylene ("PP"), polystyrene ("PS"),
cellulose material, pulp, mixtures thereof, and the like. In one
embodiment, the foaming agent comprises microspheres that expand
when heated and cooperate with the carrier material to produce
foam. In one arrangement, the foaming agent comprises EXPANCEL.RTM.
microspheres.
[0012] In preferred embodiments, the expandable material has
insulating properties to inhibit heat transfer through the walls of
the container comprising the expandable material. The expandable
material can therefore be used to maintain the temperature of food,
fluids, or the like. In one embodiment, when liquid is in the
container, the expandable material of the container reduces heat
transfer between liquid within the container and the environment
surrounding the container. In one arrangement, the container can
hold a chilled liquid and the expandable material of the container
is a thermal barrier that inhibits heat transfer from the
environment to the chilled fluid. Alternatively, a heated liquid
can be within the container and the expandable material of the
container is a thermal barrier that reduces heat transfer from the
liquid to the environment surrounding the container. Although use
in connection with food and beverages is one preferred use, these
containers may also be used with non-food items.
[0013] In one embodiment, the foam material is extruded to produce
sheets that are formed into containers for holding food, trays,
bottles, and the like. Optionally, the sheets are formed into
clamshells that are adapted to hold food. The foam sheets can be
pre-cut and configured to form a container for holding foodstuff.
The sheets may be formed into a container by one or more processes,
e.g., a thermomolding or thermoforming process.
[0014] In another embodiment, an article is provided comprising
foam material that forms a coating on a paper or wood pulp. based
material or container. In one arrangement, the foam material is
mixed with pulp. Optionally, the foam material and pulp can be
mixed to form a generally homogeneous mixture which can be formed
into a desired shape. The mixture may be heated before, during,
and/or after the mixture is shaped to cause expansion of at least a
portion of the foam material component of the mixture.
[0015] In another embodiment, a preform comprises at least a first
layer comprising material suitable for contacting foodstuff and a
second layer comprising a thermoplastic, such as polypropylene.
Optionally, the first layer comprises a thermoplastic material,
such as PET, and the second layer comprises foam material having
polypropylene and microspheres. Optionally, the first layer
comprises PET and the second layer contains mostly or entirely
polypropylene. Optionally, the first layer comprises phenoxy type
thermoplastic and the second layer contains another material, such
as polypropylene. The preform may be formed into a container by one
or more processes, e.g., a blow molding process.
[0016] In one embodiment, a method of producing a bottle comprises
providing a preform comprising an inner layer of PET and an outer
layer comprising PP. The preform is heated to a temperature not
typically suitable for processing PP. The preform is blow molded
into a bottle after heating the preform. In one arrangement, the
outer layer comprises foam material. In one arrangement, the outer
layer contains mostly or entirely PP.
[0017] In another embodiment, a preform comprises an inner layer
that has a flange that defines at least a portion of an opening of
the preform. An outer layer surrounds the inner layer and defines a
substantial portion of a neck finish of a preform and forms an
outer surface of a body portion of the preform.
[0018] In another embodiment, there is a tube comprising a first
layer and a second layer. In one embodiment, the first layer
comprises a thermoplastic material, such as PET, and the second
layer comprises the same or different thermoplastic material, such
as PP, and a foaming agent. Optionally, the first layer comprises
primarily PET and the second layer comprises PP based foam
material. In one arrangement, the tube is formed by a co-extrusion
process. Optionally, the tube can be blow molded into a container.
Optionally, the tube can be used as a fluid line to deliver
ingestible liquids.
[0019] In another embodiment, a preform comprises an inner layer
and an outer layer. The outer layer surrounds the inner layer and
defines a substantial portion of a neck finish of a preform. The
outer layer also forms an outer surface of a body portion of the
preform
[0020] In another embodiment, an apparatus for molding preforms
comprises a mold core section and a mold cavity section. The mold
cavity section has a delivery system. The mold core section and
mold cavity section cooperate to define a void when the mold core
section and mold cavity section are in a closed position. The
delivery system is configured to deliver tying material into the
void. Optionally, the apparatus also comprises an exhaust system in
fluid communication with the void.
[0021] In another embodiment, a method of forming a preform
comprises positioning a portion of a preform on a mandrel of a
mold. Tie material is delivered from an outlet of a delivery system
formed within a cavity section defining a cavity. At least a
portion of the preform is coated with the tie material.
[0022] In some embodiments, a preform comprises a neck portion and
a body portion. The body portion has a wall portion and an end cap
and comprises a first layer and a second layer, the first layer
comprising an expandable material. In some arrangements, the
expandable material is adapted to expand by heat treatment.
[0023] In some embodiments, a preform comprises a threaded neck
portion and a body portion. The body portion includes a wall
portion and an end cap. The body portion comprises expandable
material forming less than about 40% by weight of the preform. In
some embodiments, the expandable material comprises less than 20%
by weight of the preform. The expandable material can optionally
comprise microspheres and a preferably thermoplastic carrier
material including those selected from the group consisting of
polypropylene, PET, and combinations thereof.
[0024] In some embodiments, a method of producing a preform
comprises forming a first layer of the preform. A second layer of
the preform is formed and comprises a controllable, expandable
material. In some arrangements, the first layer is formed by
injecting a first material preferably comprising polyester through
a gate into a space defined by a cavity mold half and a core mold
half to form an article. The article comprises an inner surface and
an outer surface. The second layer is formed by injecting
expandable material into a second space defined by the outer
surface of the article formed by the first injected material and a
second cavity mold half to form the second layer of the
preform.
[0025] In some embodiments, a method of producing a bottle
comprises providing a preform having a neck portion and a body
portion. The preform is heated so that a portion of the preform at
least partially expands to form foam. The preform is blow molded
into a bottle comprising foam material.
[0026] In some embodiments, an article comprises a neck portion
having threads and a body portion. The body portion comprises a
first layer and a second layer. The first layer has an upper end
that terminates below the threads of the neck portion and comprises
foam material. The second layer is positioned interior to the first
layer. In some embodiments, the article is a preform, bottle,
container, or the like. The second layer can optionally comprise a
material suitable for contacting foodstuffs. For example, the
second layer can comprise a material including at least one
material selected from a group consisting of polyester,
polypropylene, phenoxy-type thermoplastic, and combinations
thereof.
[0027] In some embodiments, a bottle comprises a neck portion and a
body portion. The body portion comprises an inner layer comprising
polyester and an outer layer comprising foam material. The foam
material comprises polypropylene. The inner layer and the outer
layer define at least a portion of a wall of the body portion.
[0028] In some embodiments, a method of making a multilayer preform
comprises providing a substrate preform which has been made by any
of a variety of methods as are known in the art. The substrate
preform is positioned within a cavity defined between a first mold
portion and a second mold portion. First material is injected from
an outlet of the first mold portion into the cavity onto the
substrate preform. The first material is adapted to form a layer on
the substrate preform. A second material is injected from a melt
gate of the first mold portion onto the substrate preform. In some
arrangements, the first material comprises a tie material. In some
embodiments, the first material coats at least a portion,
preferably a substantial portion of a body portion of the substrate
preform. The second material can be injected directly onto the
first material to form an outer layer. Optionally, the unused
portion of the first material can be removed from the cavity by an
exhaust system. In some arrangements, the first mold portion is a
cavity section and the second mold portion is a core section.
[0029] In some embodiments, a method of injecting material into a
mold for molding an article comprises providing an injection mold
being movable between an open position and a closed position. The
mold comprises a core section and a cavity section. Material is
delivered through a first gate of the cavity section. Melt is
delivered through a second gate of the cavity section. In some
arrangements, the article is a preform or closure. The material
delivered through the first gate can optionally comprise a fluid
comprising a tie material.
[0030] In some embodiments, a mold for molding preforms or
containers comprises a core section and a cavity section movable
between an open position and a closed position. The core section
and cavity section define a cavity when the core section and the
cavity section are in the closed position. A gate in the cavity
section is configured to inject melt into the cavity. An outlet in
the cavity section is positioned and configured to inject a first
material from an inlet line into the cavity. An inlet in the cavity
section is positioned and configured to draw in material within the
cavity and deliver the material to an output line. In some
arrangements, the gate is positioned in the area of the cavity
section for molding an end cap of a preform. Optionally, the gate,
the outlet, and the inlet are spaced from each other and are formed
in a molding surface of the cavity section.
[0031] In some embodiments, a mold for molding articles comprises a
first mold section that defines a first molding surface. A second
mold section defines a second molding surface. The first mold
section and the second mold section cooperate to form a cavity in
the shape of an article. A delivery system of the mold has a source
of fluid and a feed line. The feed line is in fluid communication
with the source of fluid and an output. The output is positioned
along one of the first mold section and the second mold section. An
exhaust system has an inlet positioned along one of the first mold
section and the second mold section. The exhaust system comprises
an exhaust line in fluid communication with the cavity. A melt
injection gate is positioned along the second mold section and is
configured to deliver melt into the cavity. In some arrangements,
the delivery system further comprises a valve system configured to
selectively control the amount of fluid delivered into the cavity.
Optionally, the cavity is in the shape of a preform or closure.
[0032] In some embodiments, a mold for producing an article
comprises a core half and a cavity half that are configured to mate
to form a cavity for molding a preform. The cavity half has a gate.
The mold has means for delivering coating material into the cavity
and means for removing coating material delivered by the means for
delivering coating material from the cavity. Optionally, the
article can be a preform or closure. The gate can be spaced from
the means for delivering coating material and the means for
removing coating material.
[0033] In preferred embodiments laminates, preforms, containers,
and articles comprising PETG and polypropylene, and methods of
making the same, are disclosed. In one embodiment polypropylene may
be grafted or modified with maleic anhydride, glycidyl
methacrylate, acryl methacrylate and/or similar compounds to
improve adhesion. In another embodiment polypropylene further
comprises "nanoparticles" or "nanoparticular material." In another
embodiment polypropylene comprises nanoparticles and is grafted or
modified with maleic anhydride, glycidyl methacrylate, acryl
methacrylate and/or similar compounds.
[0034] Preferred articles, preforms, containers, and articles can
be made using various techniques. For example, laminates, preforms,
containers, and articles can be formed through injection molding,
overmolding, blow molding, injection blow molding, extrusion,
co-extrusion, and injection stretch blow molding, and other methods
disclosed herein and/or known to those of skill in the art.
[0035] In some non-limiting embodiments, the articles may comprise
one or more layers or portions having one or more of the following
advantageous characteristics: an insulating layer, a gas barrier
layer, UV protection layers, protective layer (e.g., a vitamin
protective layer, scuff resistance layer, etc.), a foodstuff
contacting layer, a non-flavor scalping layer, non-color scalping
layer a high strength layer, a compliant layer, a tie layer, a gas
scavenging layer (e.g., oxygen, carbon dioxide, etc.), a layer or
portion suitable for hot fill applications, a layer having a melt
strength suitable for extrusion, strength, recyclable
(post-consumer and/or post-industrial), clarity, etc. In one
embodiment, the monolayer or multi-layer material comprises one or
more of the following materials: PET (including recycled and/or
virgin PET), PETG, foam, polypropylene, phenoxy type
thermoplastics, polyolefins, phenoxy-polyolefin thermoplastic
blends, and/or combinations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a preform used as a starting material for forming
containers.
[0037] FIG. 2 is a cross-section of the preform of FIG. 1.
[0038] FIG. 3 is a cross-section of a blow-molding apparatus of a
type that may be used to make a preferred container.
[0039] FIG. 4 is a side view of a container formed from a
preform.
[0040] FIG. 5 is a cross-section of a multilayer preform.
[0041] FIG. 6 is a cross-section of a multilayer container formed
from the multilayer preform of FIG. 5.
[0042] FIG. 7 is an enlarged view of the container of FIG. 6 taken
along 7.
[0043] FIG. 8 is a cross-section of a multilayer preform.
[0044] FIG. 8A is an enlarged view of the preform of FIG. 8 taken
along 8A.
[0045] FIG. 9 is a cross-section of a multilayer preform having a
multilayer neck portion.
[0046] FIG. 10 is a cross-section of a multilayer preform in
accordance with another embodiment.
[0047] FIG. 11 is a cross-section of a multi-layer preform having
an inner layer defining an interior of the preform.
[0048] FIG. 12 is a cross-section of a multi-layer preform having
an inner layer and an outer layer that define a neck portion.
[0049] FIG. 12A is a cross-section of a multi-layer preform having
an inner layer and an outer layer that define a neck portion.
[0050] FIG. 12B is a cross-section of a multi-layer preform having
an inner layer and an outer layer that define a neck portion.
[0051] FIG. 13 is a cross-section of a multi-layer preform having
an inner layer with a flange.
[0052] FIGS. 13A and 13B are enlarged cross-sections of portions of
multi-layer preforms in accordance with some embodiments.
[0053] FIG. 14 is a cross-section of a multi-layer preform having
an outer layer with a coupling structure.
[0054] FIG. 14A is a cross-section of a container made from the
preform of FIG. 14, a closure is attached to the container.
[0055] FIG. 14B is an enlarged view of a portion of the container
and closure of FIG. 14A taken along 14B.
[0056] FIG. 14C is an enlarged view of a portion of the container
and closure in accordance with another embodiment.
[0057] FIG. 15A is a cross-section of a portion of a preform having
a neck portion without threads.
[0058] FIG. 15B is a cross-section of the preform of FIG. 15A.
[0059] FIG. 15C is a cross-section of a portion a multi-piece
preform.
[0060] FIG. 16 is a cross-section of a preform in accordance with
another embodiment.
[0061] FIG. 17 is a cross-section of a preform in accordance with
another embodiment.
[0062] FIG. 18 is a perspective view of a closure suitable for
closing a container.
[0063] FIG. 19 is a cross-section of a multilayer closure having an
inner layer.
[0064] FIG. 20 is a cross-section of a multilayer closure having an
inner layer extending along the sides of the closure.
[0065] FIGS. 21A-21E are cross-sections of multilayer closures.
[0066] FIGS. 22A-22B are cross-sections of sheets.
[0067] FIG. 23 is a perspective view of one preferred embodiment of
a profile.
[0068] FIG. 24 is a side view of one preferred embodiment of
packaging including a container having a label and a closure.
[0069] FIG. 25 is side view of a container and a closure in
accordance with another embodiment.
[0070] FIG. 26A is perspective view of a container.
[0071] FIG. 26B is a perspective view of a tray.
[0072] FIG. 27 is a schematic view of an embodiment of a lamellar
meltstream generation system.
[0073] FIG. 27A is a cross-section of lamellar material made from
the lamellar meltstream generation system of FIG. 27.
[0074] FIG. 28 is a cross-section of a mold of a type that may be
used to make the preform of FIG. 1.
[0075] FIG. 29 is a cross-section of a mold that may be used to
make an outer layer of the preform of FIG. 5.
[0076] FIG. 30 is a cross-section of a mold of a type that may be
used to make an inner layer of the preform of FIG. 11.
[0077] FIG. 31 is a cross-section of a mold of a type that may be
used to make an outer layer of the preform of FIG. 11.
[0078] FIG. 32 is a cross-section of a mold of a type that may be
used to make a closure.
[0079] FIG. 33 is a cross-section of a mold of a type that may be
used to make an outer layer of the closure of FIG. 20.
[0080] FIG. 34 is a mold system configured to make multi-layer
preforms having tie layers.
[0081] FIG. 35 is a cross-section a mold of the mold system of FIG.
34.
[0082] FIG. 36 is a cross-section of the mold of FIG. 35 taken
along lines 36-36.
[0083] FIG. 37 is a cutaway close up view of the area of FIG. 35
along 37-37.
[0084] FIG. 38 is a cross-section of a modified mold of FIG. 35
taken along lines 36-36.
[0085] FIG. 39 is a cutaway close up view of a modified mold of
FIG. 35 along 37-37.
[0086] FIG. 40 is a cross sectional view of lamellar material.
DETAILED DESCRIPTION
[0087] All patents and publications mentioned herein are hereby
incorporated by reference in their entireties. Except as further
described herein, certain embodiments, features, systems, devices,
materials, methods and techniques described herein may, in some
embodiments, be similar to any one or more of the embodiments,
features, systems, devices, materials, methods and techniques
described in U.S. Pat. Nos. 6,109,006; 6,808,820; 6,528,546;
6,312,641; 6,391,408; 6,352,426; 6,676,883; and 7,588,808; U.S.
Publication Nos. 2002/0100566; 2003/0220036; 2003/0031814;
2003/0012904; 2004/0013833; 2004/0071885; 2006/0065992; and
2006/0073298; U.S. provisional Application Nos. 60/563,021, filed
Apr. 16, 2004; 60/575,231, filed May 28, 2004; 60/586,399, filed
Jul. 7, 2004; 60/620,160, filed Oct. 18, 2004; 60/621,511, filed
Oct. 22, 2004; and 60/643,008, filed Jan. 11, 2005; each of which
is hereby incorporated by reference in its entirety. In addition,
the embodiments, features, systems, devices, materials, methods and
techniques described herein may, in certain embodiments, be applied
to or used in connection with any one or more of the embodiments,
features, systems, devices, materials, methods and techniques
disclosed in the above-mentioned patents and applications.
A. Articles
[0088] In preferred embodiments articles may comprise one or more
formable materials. Articles described herein may be mono-layer or
multi-layer (i.e., two or more layers). In some embodiments, the
articles can be packaging, such as drinkware (including preforms,
containers, bottles, closures, etc.), boxes, cartons, and the
like.
[0089] The multi-layer articles may comprise an inner layer (e.g.,
the layer that is in contact with the contents of the container) of
a material approved by a regulatory agency (e.g., the U.S. Food and
Drug Association) or material having regulatory approval to be in
contact with food (including beverages), drugs, cosmetics, etc. In
other embodiments, an inner layer comprises material(s) that are
not approved by a regulatory scheme to be in contact with food. A
second layer may comprise a second material, which can be similar
to or different than the material forming the inner layer. The
articles can have as many layers as desired. It is contemplated
that the articles may comprise one or more materials that form
various portions that are not "layers."
1. Detailed Description of Drawings
[0090] With reference to FIGS. 1 and 2, a preferred monolayer
preform 30 is illustrated.
[0091] Generally, the preform 30 has a neck portion 32 and a body
portion 34. The illustrated preform 30 can have a single layer
formed of a material that can be blow-molded. The preform 30 is
preferably blow molded into a container for holding liquids, such
as non-carbonated liquids such as fruit juice, water, and the like.
Optionally, the preform 30 can be formed into a container to hold
other liquids, such as carbonated liquids. The illustrated preform
30 can be suitable for forming a 16 oz. beverage bottle that is
especially well suited for holding carbonated beverage. As used
herein, the term "bottle" is a broad term and is used in accordance
with its ordinary meaning and may include, without limitation a
container (typically of glass and/or plastic having a comparatively
narrow neck or mouth), a bottle-shaped container for storing fluid
(preferably a liquid), etc. The bottle may or may not have a
handle.
[0092] The illustrated preform 30 has a neck portion 32 which
begins at an opening 36 (FIG. 2) to the interior of the preform 30
and extends to and includes the support ring 38. As used herein,
the term "neck portion" is a broad term and is used in accordance
with its ordinary meaning and may include, without limitation a
portion of a preform attached to a body portion. The neck portion
may include a neck finish. The neck finish together with the neck
cylinder may form what is referred to herein as the "neck portion."
The neck portion 32 in the illustrated embodiment is further
characterized by the presence of the threads 40, which provide a
way to fasten a cap or closure member to the bottle produced from
the preform 30. Alternatively, the neck portion 32 may not be
configured to engage a closure or may have means other than threads
to engage a closure. The body portion 34 is an elongated and
generally cylindrically shaped structure extending down from the
neck portion 32 and culminating in an end cap 42. The illustrated
end cap 42 is rounded; however, the end cap can have other suitable
shapes. The preform thickness 44 will depend upon the overall
length of the preform 30 and the desired wall thickness and overall
size of the resulting container.
[0093] Referring to FIG. 3, in this blow molding process the
preform 30 is placed in a mold having a cavity corresponding to the
desired container shape. The preform 30 is then heated and expanded
by forcing air or other suitable fluid into the interior of the
preform to stretch the preform so that it fills the cavity, thus
creating a container 37 (FIG. 4). This blow-molding process is
described in detail below. A stretched rod or similar means may
also be used to aid in the blow molding process, as is known in the
art.
[0094] In some embodiments, a blow molding machine can receive warm
articles (e.g., profiles such as sleeves, preforms, etc.) to aid in
the blow molding process, as is known in the art. The mold 28 can
receive warm preforms from an injection molding machine, such as
the injection molding machines described herein. The preforms
manufactured by the injection molding machine can be quickly
transported to the mold 28 via a delivery system. The inherent heat
of the preforms may provide one or more of the following: reduced
blow molding time, reduced energy required to heat preforms to a
temperature suitable for blow molding, and/or the like.
[0095] Optionally, one or more delivery systems can be employed to
transport preforms to and/or bottles away from a mold. For example,
a delivery system may comprise a shuttle system (e.g., a linear or
rotary shuttle system) for transporting preforms to and/or away
from the mold 28. The shuttle system can batch feed preforms to or
remove blow molded bottles from the mold 28. Alternatively, the
delivery system can comprise a reciprocating and/or wheel delivery
system. In some embodiments, a wheel delivery system is used to
rapidly deliver preforms to or remove bottles from the mold 28.
Advantageously, wheel delivery systems can continuously transport
articles to and from the mold 28 thereby increasing output.
[0096] It is contemplated that a delivery system can be used in
combination with molding machine suitable for blow molding
preforms, extrusion blow molding, extruding profiles and the like.
Additionally, a delivery system may comprise a plurality of
systems, such a wheel delivery system and a shuttle system that
cooperate to transport articles.
[0097] Referring to FIG. 4, there is disclosed an embodiment of a
container 37 that can be formed from the preform 30. The container
37 has a neck portion 32 and a body portion 34 corresponding to the
neck and body portions of the preform 30. As described above with
respect to preforms, the neck portion 32 can be adapted to engage
with closures. The illustrated neck portion 32 is characterized by
the presence of the threads 40 which provide a way to fasten a cap
onto the container. Optionally, the wall of the container 37 may
inhibit, preferably substantially prevent, migration of gas (e.g.
CO.sub.2) through the wall of the container 37. In some
embodiments, the container 37 comprises substantially closed cell
foam that may inhibit the migration of fluid through the foam.
[0098] The blow molding operation normally is restricted to the
body portion 34 of the preform with the neck portion 32 including
any threads, pilfer ring, and/or support ring retaining the
original configuration as in the preform. However, any portion(s)
of the preform 30 can be stretch blow-molded. The container 37 can
also be formed by other processes, such as through an extrusion
process or combinations of process (e.g., injection over an
extruded portion). For example, the container 37 can be formed
through an extrusion blow molding process. Thus, the containers
described herein may be formed from preforms, extruded profiles,
etc.
[0099] Referring to FIG. 5, a cross-section of one type of
multilayer preform 50 having features in accordance with a
preferred embodiment is disclosed. The preform 50 preferably
comprises an uncoated (monolayer) preform 39 coated with an outer
layer 52. Preferably, the uncoated preform 39 comprises a polymer
material, such as polypropylene, polyester, and/or other
thermoplastic materials, preferably suitable for contacting food.
In one embodiment, for example, the uncoated preform 39 comprises
substantially polypropylene. In another embodiment, the uncoated
preform 39 comprises substantially polyester, such as PET.
[0100] The multilayer preform 50 has a neck portion 32 and a body
portion 34 similar to the preform 30 of FIGS. 1 and 2. In the
illustrated embodiment, the outer layer 52 is disposed about at
least a portion of the body portion 34. In one embodiment, the
outer layer 52 is disposed about a substantial portion, preferably
the entire portion, of the surface of the body portion 34 of the
inner layer (illustrated as the preform 39 of FIG. 1), terminating
at the bottom of the support ring 38. The outer layer 52 in the
illustrated embodiment does not extend to the neck portion 32, nor
is it present on the interior surface of the inner layer 39 which
is preferably made of a material suitable for contact with the
contents of the resulting container. The outer layer 52 may
comprise either a single material or several layers (e.g.,
microlayers) of one or more materials. Further, the outer layer 52
can be generally homogenous, generally heterogeneous, or somewhere
in between. Although not illustrated, the outer layer 52 can form
other portions of the preform 50. For example, the outer layer 52
can form at least a portion of the inner surface of the preform 50
(such as when the outer layer is injected over a tube or profile
that is open on both ends), or a portion of the neck portion 32.
The outer layer 52 may or may not be suitable for contacting
foodstuffs.
[0101] The overall thickness 56 of the preform is equal to the
thickness of the initial uncoated preform 39 (i.e., the inner layer
54) plus the thickness 58 of the outer layer 52, and is dependent
upon the overall size and desired coating thickness of the
resulting container. However, the preform 50 may have any thickness
depending on the desired thermal, optical, barrier, and/or
structural properties of the container formed from the preform 50.
If a tie layer is included, the overall thickness will include any
thickness of the tie layer. The preforms and containers can have
layers which have a wide variety of relative thicknesses. In view
of the present disclosure, the thicknesses of a given layer and of
the overall preform or container, whether at a given point or over
the entire container, can be chosen to fit a manufacturing process
or a particular end use for the container. In the illustrated
embodiment, the outer layer 52 has a generally uniform thickness.
However, the outer layer 52 and/or inner layer 54 need not to be
uniform and they may have, for example, a thickness that varies
along the longitudinal axis of the preform 50.
[0102] The multilayer preforms can be used to produce the
containers. For example, the preform 50 can be used to form a
container 180 (FIG. 6). In one embodiment, the outer layer 52
cooperates with the inner layer 54 so as to provide a layer or
space 85 therebetween, as shown in FIGS. 6 and 7. The layer 85 can
permit the passage of air between the layers 52, 54 and can
advantageously further insulate the container 83. The passages can
be formed between the layer 52 which loosely surrounds the inner
layer 54. Alternatively, the outer layer 52 can be sized and
configured to snuggly hold the inner layer 54 and so that inner
surface of the layer 52 contacts the outer surface of the layer 54.
In some embodiments, the layer 85 can be a foam layer that is
similar, or dissimilar, to one or more of the layers 52, 54. In yet
another embodiment, the layer 85 can be a layer that couples the
layer 52 to the inner layer 54. For example, the layer 85 can be
crafting or a tie layer that inhibits, preferably that
substantially prevents, relative movement between the layers 52,
54. For example, the layer 85 can be an adhesive layer that limits
relative movement between the layers 52, 54. It is contemplated
that some or none of the layers of the embodiments disclosed herein
can be coupled together with a tie layer or the like.
[0103] In one embodiment, at least one of the layers 52, 54 can be
treated to promote or reduce adhesion between the layers 52, 54.
For example, the outer surface of the inner layer 54 can be
chemically treated so that the outer layer 52 adheres to the inner
layer 54. For example, a tie material can be applied to react and
chemically treat one or more of the layers 52, 54. However, it is
contemplated that any of the layer(s) can be modified to achieve
the desired interaction between the layers of the preform.
Optionally, the layers 52, 54 can be directly adhered together.
[0104] In some embodiments, a container comprises foam material
that preferably has insulating properties to inhibit thermal
transfer through the walls of the container. When liquid is in the
container, such as container 83 of FIG. 6, for example, the foam
material forming a wall 84 of the container 83 can reduce heat
transfer between the liquid contents and the environment
surrounding the container 83. For example, the container 83 can
hold chilled contents, such as a carbonated beverage, and the foam
insulates the container 83 to inhibit temperature changes of the
chilled fluid. Thus, the contents can remain chilled for a desired
duration of time despite an exterior ambient temperature that is
greater than the temperature of the liquid. Alternatively, a heated
material, such as a hot beverage, can be within the container 83
and the wall 84 can insulate the container 83 to inhibit heat
transfer from the liquid to the environment surrounding the
container 83. Further, the foam material of the container 83 can
result in a surface temperature of the container 83 that is within
a desired temperature range so that a person can comfortably grip
the container 83 holding a heated or chilled liquid. The thickness
of the foam layer and the size and configuration of the foam
portion of the container can be varied in order to obtain the
desired thermal properties of the container.
[0105] Referring to FIG. 8, a preferred embodiment of a multilayer
preform 60 is shown in cross-section. One difference between the
coated preform 60 and the preform 50 in FIG. 5 is the relative
thickness of the two layers in the area of the end cap. In the
preform 50, the outer layer 52 is generally thinner than the
thickness of the initial preform throughout the entire body portion
of the preform. In the preform 60, however, the outer layer 52 is
thicker at 62 near the end cap 42 than it is at 64 in the wall
portion 66, and conversely, the thickness of the inner layer 54 is
greater at 68 in the wall portion 66 than it is at 70, in the
region of the end cap 42. This preform design is especially useful
when an outer coating is applied to the initial preform in an
overmolding process to make a multilayer preform, as described
below, where it presents certain advantages including that relating
to reducing molding cycle time. Either layer may be homogeneous or
may be comprised of a plurality of microlayers. In other
embodiments of the preform 60 which are not illustrate, the outer
layer 52 is thinner at 62 near the end cap 42 than it is at 64 in
the wall portion 66, and conversely, the thickness of the inner
layer 54 is less at 68 in the wall portion 66 than it is at 70, in
the region of the end cap 42. At least one of the layers 52, 54 can
optionally compromise a barrier material.
[0106] FIG. 8A is an enlargement of a wall section of the preform
showing the makeup of the layers in a LIM-over-inject embodiment.
The layer 54 is the inner layer of the preform and layer 52 is the
outer layer of the preform. The outer layer 52 comprises a
plurality of microlayers (i.e., lamellar material) of material as
will be made when a LIM system is used. Of course, not all preforms
of FIG. 8 will be of this type.
[0107] Referring to FIG. 9, another embodiment of a multilayer
preform is shown in cross-section. The primary difference between
the coated preform 76 and the preforms 50 and 60 in FIGS. 5 and 8,
respectively, is that the outer layer 52 is disposed on the neck
portion 32 as well as the body portion 34.
[0108] The preforms and containers can have layers which have a
wide variety of relative thicknesses. In view of the present
disclosure, the thickness of a given layer and of the overall
preform or container, whether at a given point or over the entire
container, can be chosen to fit a coating process or a particular
end use for the container. Furthermore, as discussed above in
regard to the layer(s) in FIG. 8, the layers in the preform and
container embodiments disclosed herein may comprise a single
material, more than one materials, or several materials.
[0109] The apparatuses and methods disclosed herein can be also
used to create preforms with three or more layers. In FIG. 10,
there is shown a three-layer embodiment of a preform 132. The
preform shown therein has two coating layers, a middle layer 134
and an outer layer 136. The relative thickness of the layers shown
in FIG. 10 may be varied to suit a particular combination of
materials or to allow for the making of different sized bottles. As
will be understood by one skilled in the art, a procedure analogous
to that disclosed herein would be followed, except that the initial
preform would be one which had already been coated, as by one of
the methods for making coated preforms described herein, including
overmolding.
[0110] FIG. 11 illustrates a cross-section of one type of
multi-layer preform 160 having features in accordance with a
preferred embodiment. The preform 160 preferably comprises an outer
layer 162 and an inner layer 164.
[0111] The multi-layer preform 160 has a neck portion 132 and a
body portion 134 similar to the preforms described above.
Preferably, the outer layer 162 forms the outer surface 165 of the
body portion 134 and the outer surface 166 of the neck portion 132.
The outer surface 166 can be configured to engage a closure. The
outer layer 162 is disposed about a substantial portion, preferably
the entire portion, of the inner layer 164.
[0112] The illustrated outer layer 162 extends from the upper end
168 of the inner layer 164 to an opening 169 of the preform 160.
The inner layer 164 in the illustrated embodiment does not extend
along the neck portion 132. Thus, the outer layer 162 can form
substantially the entire neck portion 132, as shown in FIG. 11. In
other embodiments, the upper end 168 of the inner layer 164 can be
disposed at some point along the neck portion 132. Thus, the inner
layer 164 and outer layer 162 may both define the neck portion. In
one non-limiting embodiment, the outer layer 162 comprises at least
about 70% of neck portion (or neck finish) of the neck portion 132
by weight. In another non-limiting embodiment, the outer layer 62
comprises at least about 50% of the neck portion 132 by weight. In
yet another non-limiting embodiment, the outer layer 162 comprises
more than about 30% of the neck portion 132 by weight.
[0113] The overall thickness 171 of the preform 160 is equal to the
thickness 172 of the outer layer 162 plus the thickness 174 of the
inner layer 164, and is dependent upon the overall size of the
resulting container. In one embodiment, the thickness 172 of the
outer layer 162 is substantially greater than the thickness 174 of
the inner layer 164. The outer layer 162 and inner layer 164, as
illustrated, have generally uniform thicknesses. However, the outer
layer 162 and inner layer 164 may not have uniform thicknesses. For
example, one or both of the layers 162, 164 may have a thickness
that varies along the length of the preform 160.
[0114] The outer layer 162 comprises a first material and the inner
layer 164 preferably comprises another material. For example, the
outer layer 162 can comprise foam material and the inner layer 164
can comprise an unfoamed polymer material, such as PET (e.g.,
virgin or post-consumer/recycled PET), phenoxy, etc. Preferably, a
substantial portion of the outer layer 162 comprises a first
material and a substantial portion of the inner layer 164 comprises
a second material. The first and the second materials can be
different or similar to each other.
[0115] FIG. 12 is a cross-section view of a multi-layer preform
180. The preform 180 is generally similar to the preform 160, and
thus, many aspects of preform 180 will not be described in detail.
The preform 180 comprises an inner layer 184 and an outer layer
183. The inner layer 184 defines a substantial portion of the
interior surface 173 of the preform 180. The inner layer 184 has an
end 188 that is proximate to an opening 191 of the preform 180. In
the illustrated embodiment, the outer layer 183 defines an outer
surface 186 of the neck portion 132, and the inner layer 184
defines the inner surface 187 of the neck portion 132. Of course,
the outer layer 183 can be configured to engage a closure. In the
illustrated embodiment, the outer surface 86 defines threads 189
adapted to receive a threaded cap (e.g., a screw cap).
[0116] Although not illustrated, preforms 160 and 180 can include
more than two layers. For example, the outer layer 162 of the
preform 160 can comprise a plurality of layers comprising one or
more of the following: lamellar material, foam material, PP, PET,
and/or the like. Similarly, the inner layer 164 can comprise a
plurality of layers. One of ordinary skill in the art can determine
the dimensions and number of layers that form the preform described
herein. The layers 183, 184 can be made of similar or different
materials as the layers 162, 164 described above.
[0117] Optionally, a layer can be coated over at least a portion of
the preform to prevent abrasion or wearing, especially if at least
a portion of the preform is made of foam material. For example, a
coating layer can surround the threads of a neck portion made of
foam and can comprise PET, PP, combinations thereof, or other
thermoplastic materials.
[0118] FIG. 13 is a cross-sectional view of a preform 190. The
preform 190 is similar to the preform 180 illustrated in FIG. 12,
except as further detailed below.
[0119] The preform 190 comprises an inner layer 194 that extends
downwardly from the opening 191 and defines the interior of the
preform. The inner layer 194 comprises a flange 193. As used
herein, the term "flange" is a broad term and is used in accordance
with its ordinary meaning and may include, without limitation, one
or more of the following: a lip, an elongated portion, rim,
projection edge, a protrusion, and combinations thereof. The flange
can function as a locking structure. Additionally, the preform may
optionally include a plurality of flanges.
[0120] The flange 193 defines a portion of an inner surface 201 and
at least a portion of an upper surface 195 of the preform. The
flange 193 can have a constant or varying thickness F depending on
the desired properties of the neck portion 132. In some
embodiments, including the illustrated embodiment, the flange 193
is positioned above structure(s) (e.g., threads 192) for receiving
a closure. In some embodiments, the flange 193 defines a portion of
one or more threads, protrusions, recesses, and/or other structures
for engaging a closure.
[0121] With continued reference to FIG. 13, the flange 193 extends
about at least a portion of the periphery of the opening 191 and
defines a layer of material. The flange 193 preferably extends
about the entire periphery of the opening 191. Thus, the flange 193
can be a generally annular flange. When a closure is attached to
the neck portion 132 of a container made from the preform 190, the
upper surface 195 of the flange 193 can form a seal with the
closure to inhibit or prevent foodstuffs from escaping from the
container. The flange 193 can inhibit or prevent separation between
the inner layer 194 and the outer layer 199.
[0122] One or more locking structures 197 of FIG. 13 can inhibit
relative movement between the inner layer 194 and an outer layer
199. As used herein, the term "locking structure" is a broad term
and is used in accordance with its ordinary meaning and may
include, without limitation, one or more of the following:
protrusions, surface treatments (e.g., roughened surface), prongs,
protuberances, barbs, flanges, recesses, projections, textured
pattern, or the like, preferably for inhibiting or reducing
movement between the layers 194 and 199. The locking structure 197
can be formed by the inner layer 194 and/or the outer layer 199. In
the illustrated embodiment, the locking structure 197 is a
protrusion extending from and about the outer surface of the inner
layer 194. In some embodiments, the locking structure 197 is an
annular protrusion extending circumferentially about the outer
surface of the inner layer 194. The locking structure 197 can be
continuous or discontinuous structure. The inner layer 194 can have
one or more locking structures, such as a textured pattern (e.g., a
series of grooves, protuberances, and the like).
[0123] Additionally, the locking structure 197 can be configured to
provide positive or negative draft. For example, the inner layer
194 can comprise a somewhat flexible material (e.g., PET) and a
locking structure 197 that can provide positive draft during mold
removal. In some embodiments, the outer layer 199 comprises a
somewhat rigid material (e.g., olefins) that can provide positive
or negative draft during mold removal.
[0124] The outer layer 199 is configured to receive the locking
structure 197. The locking structure 197 effectively locks the
outer layer 199 to the inner layer 194. Although not illustrated, a
plurality of locking structures 197 can be defined by the layers
194, 199 and may be disposed within the neck portion 132 and/or the
body portion 134 of preform 190. In some embodiments, a tie layer
can be used to couple the inner layer 194 to the outer layer 199.
In one embodiment, the inner layer 194 and the outer layer 199 are
formed of materials that bond or adhere to each other directly. In
other embodiments, the inner layer 194 is tied to the outer layer
199, so that the layers 194 and 199 can be easily separated during,
e.g., a recycling process. However, an article comprising a tie
layer can be recycled in some embodiments.
[0125] The upper end of the outer layer 199 is spaced from the
upper surface 195 of the preform. A skilled artisan can select the
thicknesses of the layers 194, 199 to achieve the desired
structural properties, thermal properties, durability, and/or other
properties of the preform.
[0126] FIGS. 13A and 13B illustrate modified embodiments of a
portion of the preform 190 of FIG. 13. The preform 190 of FIG. 13A
has a flange 193 that extends along a portion of the upper surface
195 of the preform. In some non-limiting embodiments, the length LF
of the flange 193 is less than about 95% of the wall thickness T of
the neck portion 132. In one non-limiting embodiment, the length LF
of the flange 193 is about 50% to 90% of the wall thickness T of
the neck portion. In certain non-limiting embodiments, the length
LF of the flange 193 is about 60%, 70%, 75%, or 80%, or ranges
encompassing such percentages of the wall thickness T of the neck
portion. In another non-limiting embodiment, the length LF of the
flange 193 is about 40% to 60% of the wall thickness T of the neck
portion. In yet another embodiment, the length LF of the flange 193
is less than about 40% of the wall thickness T of the neck
portion.
[0127] FIG. 13B illustrates a portion of a preform having an outer
layer 203 that defines a flange 223. The flange 223 extends
inwardly and defines an upper surface 225. The flange 223 can
define the interior surface of the preform, or be spaced therefrom.
The flange 223 can have a length similar to or different than the
length of the flange 193. The neck portion 132 has threads for
receiving a closure. However, the neck portion can have other
structures (e.g., recesses, ridges, grooves, etc.) for engaging a
closure. The preforms described above can be modified by adding one
or more layers to achieve desired properties. For example, a
barrier layer can be formed on the body portions of the
preforms.
[0128] FIG. 14 illustrates a modified embodiment of a preform 202.
The preform 202 has a neck portion 132 that defines a coupling
structure 207 configured to receive a closure. As used herein, the
term "coupling structure" is a broad term and is used in accordance
with its ordinary meaning and may include, without limitation a
feature, such as a positive (e.g., a projection, protuberance, and
the like) or negative feature (e.g., an indentation, recess, and
the like). A coupling structure may be configured to engage a
closure to hold the closure in a desired position.
[0129] The illustrated coupling structure 207 is in the form of a
recess adapted to receive a portion of a closure device. The
coupling structure 207 can extend about one or more portions of the
preform 202. In other embodiments, the coupling structure 207
extends about the entire periphery or circumference of the preform
202. The coupling structure 207 can have a curved (e.g.,
semi-circular), v-shaped, u-shaped, or any other suitable
cross-sectional profile. Although not illustrated, the structure
207 can be a protrusion, such as an annular protrusion, defined by
an outer layer 203. Optionally, the preform 202 can have a
plurality of coupling structures 207 so that the closures of
various configurations can be attached to a container made from the
preform. The distance between an upper surface 205 and the
structures 207 and the shape of the structure 207 is determined by
the geometry of closure used to seal and close the container made
from the preform 202.
[0130] FIG. 14A illustrates a container 211 produced from a preform
202 of FIG. 14. A closure 213 is attached to the neck portion 132
of the container 111. The closure 213 can be a one-piece or
multi-piece closure. The closure 213 can be temporarily or
permanently attached to the container 211. The entire closure 213
can be removed from the container 211 when the liquid is consumed.
In other embodiments, a portion of the closure 213 can be removed
while another portion of the closure 213 remains attached to the
container 211 during consumption. The closure 213 can be
semi-permanently or permanently attached to the container. If the
closure 213 is semi-permanently attached to the container 211, the
closure 213 can be pulled off the container 211. In one embodiment,
if the closure 213 is permanently attached to the container 211,
the closure 213 and container 211 can form a generally unitary
body.
[0131] As shown in FIG. 14B, the upper surface 205 of the preform
and the closure 213 can form a seal 231, preferably forming either
a hermetic seal or other seal that inhibits or prevents liquid from
escaping between the container 211 and the closure 213. Optionally,
the container 211 can have a gasket or removable seal. For example,
the container 211 can have a removable seal, such as a membrane
adhered to the upper lip of the container, or a portion of the
closure 213 that can be removed. The removable seal can have a tab
or ring for convenient gripping and removal of the seal.
Alternatively, the seal 231 can be formed by a membrane or sheet
that can be broken or pieced in order open the container 211. In
some embodiments, an outer layer 203 of the container 211 is formed
of a generally high strength material or rigid material (e.g., PP),
so that the flange 209 can be compressed between the closure 213
and the outer layer 203 to ensure that the integrity of the seal
231 is maintained.
[0132] As shown in FIGS. 14A and 14B, the closure 213 has a body
215 and a cover 218. The body 215 can be connected to the cover 218
by a hinge 221 (e.g., a molded material acting as a living hinge or
other structure to permit movement). A latch or tang 217 (FIG. 14A)
can fasten the cover 218 to the body 215. The latch 217 can be
moved to release the cover 218 in order to open the closure 213.
Alternatively, the cover 218 and body 215 can be separate pieces so
that the cover 218 can be removed from the body 215. When the
closure 213 is in the opened position, contents can be delivered
out of the container 211, preferably delivered while the body 215
remains attached to the neck finish. After the desired amount of
foodstuff has been removed from the container 211, the cover 218
can be returned to the closed position to reseal the container.
[0133] The body 215 of the closure 213 can be releasably coupled to
the neck portion. For example, the body 215 can be snapped onto the
neck portion 132. Alternatively, the body 215 can be permanently
coupled to the neck portion 132. The neck portion 132 comprises one
or more closure attaching structures 227, so that the closure 213
can be snapped onto and off of the container. The neck portion 132
in the illustrated embodiment has a closure attaching structure 227
in the form of a negative feature, such as a recess or indentation.
The body 215 can be permanently coupled to outer layer 203 by a
welding or fusing process (e.g., induction welding), an adhesive,
frictional interaction, and/or the like. The container 211 can be
configured to receive various types of closures, such as BAP.RTM.
closures produced by Bapco Closures Limited (England) (or similar
closures), screw caps, snap closures, and/or the like. A skilled
artisan can design the neck finish of the container 211 to receive
closures of different configurations.
[0134] With continued reference to FIG. 14A, the container 211 is
particularly well suited for hot-fill applications. The container
211 can generally maintain its shape during hot-fill processes.
After blow molding or hot-filling, final dimensions of the neck
portion of the container 211 are preferably substantially identical
to the initial dimensions of the preform. Additionally, this
results in reduced dimensions variations of the threads on the neck
finish. For example, the inner layer 284 can be formed of a
material for contacting foodstuffs, such as PET. The outer layer
203 can comprise moldable materials (e.g., PP, foam material,
crystalline or semi-crystalline material, lamellar material,
homopolymers, copolymers, combinations thereof, and other heat
resistant materials described herein) suitable for hot-filling. The
outer layer 203 provides dimensional stability to the neck portion
132 even during and/or after hot-filling. The width of the outer
layer 203 can be increased or decreased to increase or decrease,
respectively, the dimensional stability of the neck portion 132.
Preferably, one of the layers forming the neck portion 132
comprises a material having high thermal stability; however, the
neck portion 132 can also be made of materials having low
temperature stability, especially for non-hot-fill
applications.
[0135] Additionally, the dimensional stability of the outer layer
203 ensures that the closure 213 remains attached to the container
211. For example, the outer layer 203 may comprise a high strength
material (e.g., PP) and can maintain its shape thereby preventing
the closure 213 from unintentionally decoupling from the container
211.
[0136] With reference to FIG. 14C, the container has a neck portion
that comprises closure attaching structures for a snap fit. The
neck portion in the illustrated embodiment has a closure attaching
structure 227 in the form of a positive feature, such as a
protrusion, flange, or the like suitable for engaging the closure
213. The closure attaching structure 227 can form an annular
protrusion that extends circumferentially about the neck portion.
The closure 213 can have a one-piece or multi-piece construction.
The illustrated container 211 has an upwardly tapered wall forming
the neck finish. The tapered portion of the neck finish can bear
against the closure 213 to form a seal.
[0137] FIG. 15A illustrates a portion of a preform 220 in
accordance with another embodiment.
[0138] The preform 220 has a support ring 222 and a body portion
224 extending downwardly therefrom. The preform 220 has an opening
226 at its upper end. The neck finish of the preform may or may not
have threads. In some embodiments, threads are attached to the neck
region 225 of the preform. It is contemplated that the preform 220
can be formed without a support ring. A support ring and/or threads
may optionally be formed on the preform 220 in subsequent
processes.
[0139] FIG. 15B illustrates the preform 220 after closure attaching
structures 228 have been attached to the neck region 225. It is
contemplated that the threads, structures engaging a snap cap, or
other type of mounting or attaching structure can be attached to
the neck region 225 before or after the preform 220 has been made
into a container. For example, the closure mounting structures 228
can be attached to the preform 220 after the preform has been
molded, preferably blow molded into a container.
[0140] Preforms can have other portions that are attached or
coupled to each other. FIG. 15C illustrates a preform 234 that has
at least a portion of the neck finish 240 that is coupled to a body
242 of the preform. The illustrated preform 234 has a portion 238
that is coupled to the upper end 250 of the lower portion 252 of
the preform 234. The portion 238 may comprise different materials
and/or microstructures than the lower portion 252. In some
embodiments, the portion 238 comprises crystalline material. Thus,
the preform 230 may be suitable for hot fill applications. The
lower portion 252 may be amorphous to facilitate the blow molding
process. In some embodiments, the upper portion 238 comprises a
different material than the lower portion 252. A skilled artisan
can select the material that forms the preform. In some
embodiments, the upper end 250 is positioned below or at the
support ring. The preforms illustrated in FIGS. 15A to 15C can have
monolayer or multilayer walls.
[0141] The preforms, including the monolayer and multiplayer
preforms, described above can have other shapes and configurations.
FIG. 16 illustrates a preform 270 having a tapered body portion 272
and a neck finish 274. The preform 270 can be blow molded to form a
container in the form of a jar, for example. A jar or other similar
container can have a mouth or opening that is larger than the
opening of a bottle. The preform 270 has a support ring 278 and one
or more closure attaching structures 279, preferably configured to
interact with a snap closure or other type of closure. FIG. 17
illustrates an embodiment of a preform with a neck finish without
threads. The preform 280 comprises a body portion 281, which has an
end cap 283, and a neck finish 282. The preform 280 may be suitable
for blow molding into a container. The preforms illustrated in
FIGS. 16 and 17 can be monolayer or multilayer preforms (e.g.,
having layers described above). The preforms described above can be
formed without a neck finish.
[0142] The preforms, such as those depicted in FIGS. 1-18, can be
subjected to a stretch blow-molding process. The blow molding
process is described primarily for the monolayer preform 30,
although the multi-layer preforms (e.g., preforms 50, 60, 76, 80,
132, 160, 180, 290, and 216) can be processed in a similar manner.
The containers described above can be formed by various molding
process (including extrusion blow molding), for example.
2. Detailed Description of Closures
[0143] As described above, closures can be employed to seal
containers. As used herein, the term "closure" is a broad term and
is used in accordance with its ordinary meaning and may include,
without limitation, a cap (including snap cap, flip cap, bottle
cap, threaded bottle cap, pilfer-proof cap), a crown closure, cork
(natural or artificial), punctured seal, a lid (e.g., a lid for a
cup), multi-piece closure (e.g., BAP.RTM. closures produced by
Bapco Closures Limited (England) or similar closure), snap
closures, and/or the like.
[0144] Generally, the closures can have one or more features that
provide further advantages. Some closures can have one or more of
the following: tamper evident feature, tamper resistant feature,
sealing enhancer, compartment for storage, gripping structures to
facilitate removal/placement of the closure, non-spill feature, and
combinations thereof.
[0145] Closures can have a one-piece or multi-piece construction
and may be configured for permanently or temporarily coupling to a
container. For example, the closure illustrated in FIG. 14A has a
multi-piece construction. The closure illustrated in FIG. 18 has a
one-piece construction. The terms "closure" and "cap" may be used
interchangeably herein. It is contemplated that closures can be
used with bottles, boxes (especially boxes used to hold foodstuff,
such as juices, for example), cartons, and other packaging or
articles. As used herein, the term "bottle cap" is a broad term and
is used in accordance with its ordinary meaning and may include,
without limitation, a cap suitable for being attached to a bottle,
such as a glass or plastic bottle (e.g., bottle typically
configured to hold alcoholic beverages or juices) and may or may
not have threads. Bottle caps are typically removed by using a
bottle opener, as in known in the art. The term "threaded bottle
cap" is a broad term and is used in accordance with its ordinary
meaning and may include, without limitation, a cap (e.g., a screw
cap) suitable for being attached to bottle having threads. In view
of the present disclosure, embodiments of closures having threads
may be modified to form bottle caps, or other types of closures for
containers of different configurations. In some embodiments,
closures can threadably engage a container or be attached to a
container by various methods, such as sonic welding, induction
welding, a multi-step molding process, adhesives, thermoforming,
and the like.
[0146] FIG. 18 illustrates one embodiment of a closure 302 that can
be coupled to an article, such as the neck portion of a container.
In the illustrated embodiment, the closure 302 has internal threads
306 (FIG. 19) that are configured to mate with the threads of a
neck portion so that the closure 302 can be removably coupled to a
container. The closure 302 can be fastened to the container (e.g.,
a bottle) to close the opening or mouth of the bottle. The closure
302 includes a main body 310, and an optional tamper evidence
structure or anti-tamper structure, such as a band 313 (or skirt)
coupled to the body 310 by one or more connectors 312. The
connectors 312 can be sized and adapted so that when the closure
302 is removed from a container, the connectors 312 will break,
thus separating the body 310 and the band 313 indicating that the
closure 302 has been removed from the associated container.
Although not illustrated, other types of temper evidence structures
can be employed. A surface 316 of the body 310 can have a surface
treatment, such as grooves, ridges, texture treatment, and/or the
like to facilitate frictional interaction with the closure 302.
[0147] With respect to FIG. 19, the closure 302 comprises the body
310 and may or may not have a liner. The illustrated closure 302
comprises an optional inner closure layer 314. The illustrated
closure inner layer 314 is in the form of a liner contained within
an outer portion 311 of the body 310. The liner 314 can be adapted
to be in contact with foodstuff or liquid and may form a seal with
the lip that forms the opening of the bottle. Thus, the liner 314
forms a substantial portion, or the entire portion, of a contact
area of the closure 304.
[0148] The liner 314 can be a barrier liner, such as an active or
passive barrier liner. The liner 314 can function as a fluid
barrier (e.g., a liquid or gas), flavor barrier, and combinations
thereof. For example, the liner 314 can be a gas barrier that
inhibits or prevents the passage of oxygen, carbon dioxide, and the
like therethrough. In some embodiments, the liner 314 can have
scalping capabilities, such as gas scalping (e.g., oxygen
scalping).
[0149] The liner 314 can be pressed against a lip of a bottle to
prevent liquid from escaping from the container that is sealed by
the closure 302. In one embodiment, the liner 314 is a gas barrier
that prevents or inhibits gas from escaping from the container. In
another embodiment, the liner 314 is a flavor barrier that can
prevent or limit the change of the taste of the fluid within the
container. For example, the liner 314 can be formed of a polymer
(e.g., a thermoplastic material) that can act as a flavor barrier
to ensure that foodstuff in the container maintains a desirable
flavor. Thus, the liner 314 can help to ensure that the body 310
does not impart flavor and/or odor to foodstuff in the
container.
[0150] Many times, a somewhat flavor imparting material and/or
flavor reducing or scalping material (e.g., polyolefins such as
polypropylene or polyethylene) is used to form a container or
closure, such as a cap of a bottle, due to its physical properties
(e.g., durability, toughness, impact resistance, and/or strength).
In certain embodiments polypropylene may exhibit one or more
physical properties which are preferred to the physical properties
of polymers such as PET. Unfortunately, in certain circumstances
polypropylene has a tendency to reduce or scalp the flavor of the
contents of the bottle or to remove desired flavors or aromatic
components from the contents. Thus, a person consuming the food
previously in contact with the PP may be able to recognize a change
in flavor. Advantageously, the liner 314 can comprise a flavor
preserving material so that the food stuff in the container is not
generally affected when the foodstuff contacts the liner 314.
Preferably, the flavor preserving material is a material approved
by the FDA for contacting foodstuff.
[0151] In some non-limiting embodiments, the flavor preserving
material comprises PET (such as virgin PET), phenoxy
type-thermoplastic, and/or the like. The body 310 can therefore be
made of a flavor scalping material, such as polypropylene, to
provide desired physical properties and the liner 314 comprises PET
for an effective flavor barrier to ensure that the contents of
container maintain a desirable taste. It is contemplated that the
liner 314 can be formed of any material suitable for contacting the
food stuff in the container. In some embodiments, the liners 314
can be formed of foam material described herein that may or may not
substantially alter the taste of the contents of the container.
Additionally, the thickness of the liner 314 can be increased to
inhibit gas or other fluids from passing through the liner.
Optionally, the liner 314 can be a monolayer or multilayer
structure. For example, the liner 314 can comprise an inner layer
of PET (i.e., the layer in contact with the container contents) and
an outer layer of foam material.
[0152] The liner 314 can have a layer suitable for contacting
foodstuffs and one or more layers acting as a barrier, similar to
the preforms described herein. In some embodiments, for example,
the liner 314 can comprise a first layer and a second layer wherein
the first layer comprises a foam material and the second layer
comprises a barrier material. Thus, a second layer can reduce or
inhibit the migration of fluid through the liner 314 and the first
layer insulates the closure 302. In some embodiments, the liner 314
comprises a layer of PET and a layer comprising a second material.
The PET layer preferably is the lowermost layer so that it forms a
seal with the lip of a container. The second material can be EVA or
other suitable material for forming a portion of a liner.
[0153] In some embodiments, the liner 314 of FIG. 19 can be
pre-formed and inserted into the body 310. For example, the body
310 can be shaped like a typical screw cap used to seal a bottle.
The liner 314 is formed by cutting out a portion of the sheet,
which is described below. The pre-cut liner 314 can then be
inserted into the body 310 and positioned as shown in FIG. 19.
Alternatively, the liner 314 can be formed within the body 310. For
example, the liner 314 can be formed through a molding process,
such as over-molding. At least a portion of the liner 314 can be
formed by a spray coating process. For example, a monolayer liner
can be sprayed and coated with a polymer (e.g., PET, phenoxy type
thermoplastic, or other materials described herein) resulting in a
multilayer liner.
[0154] A further advantage is optionally provided where the liner
314 can be retained in the body 310 or can be attached to the
container. The liner 314 can be attached to the body 310 such that
the liner 314 remains coupled to the body 310 after the body has
been separated from the container. Alternatively, the liner 314 can
be coupled to the container so that the body 310 and liner are
separable. For example, the liner 314 can be transferred to the
body 310 to the opening of a container by a welding process, such
as an induction welding process.
[0155] A further advantage is optionally provided where at least a
portion of the closure 302 is formed of material to provide a
comfortable gripping surface so that a user can comfortably grip
the closure 302. The body 310 may comprise a material for
sufficient rigidity, (e.g., PP), compressibility for a comfortable
grip (e.g., foam material), and/or the like. In some embodiments,
the outer portion 311 of the body 310 can comprise foam to increase
the space occupied by the outer portion 311 and can provide the
user with greater leverage for easy opening and closing of the
closure 302. For example, the closure 302 can have an internally
threaded surface that is configured to threadably mate with an
externally threaded surface of the container. The enlarged outer
portion 311 can provide increased leverage such that the user can
easily rotate the closure 302 onto and off of a container.
Advantageously, a similar, or same, amount of material that forms a
conventional cap can be used to form the enlarged diameter
closure.
[0156] In some embodiments, at least a portion of one of the
portions 311 and liner 314 can be formed of foam material to
achieve a very lightweight closure due to the low density of the
foam material. The reduced weight of the closure 302 can desirably
reduce the transportation cost of the closure 302. Additionally, a
foam material of the closure 302 can reduce the amount of material
that is used to form the closure, since the foam material may have
a substantial number of voids.
[0157] The closures described below can be similar to or different
than the closure illustrated in FIG. 19. With respect to FIG. 20,
the closure 330 has a body 331 that comprises an inner portion 332
and an outer portion 334. The illustrated wall 335 comprises the
portions 332, 334. The inner portion 332 may define at least a
portion of the interior of the closure 330 and can optionally
define one or more of the threads 336. The inner portion 332 can be
formed by an injection molding process, spray coating process, or
other process described herein for forming a portion of an article.
In some non-limiting embodiments, the inner portion 332 comprises
polyolefin (e.g., PET), phenoxy type thermoplastics, and/or other
materials described herein. FIGS. 21A to 21E illustrate
non-limiting embodiments of closures. FIG. 21A illustrates a
closure 340 that has an outer portion 342 and an inner portion 344
that forms at least a portion of the interior of the closure 340.
That is, the outer portion 342 and the inner portion 344 each can
define a portion (e.g., the threads) of the interior surface of the
closure 340. The inner portion 344 is set into the outer portion
342; however, in other embodiments the inner portion 344 is not set
into the outer 342. FIG. 21B illustrates a closure 350 that
comprises an inner portion 354 comprising a plurality of layers
356, 358. FIG. 21C illustrates a closure 360 comprising a plurality
of layers. An outer layer 362 forms the outer surface (including
the top and wall) of the closure 360. An intermediate layer 364 can
comprise one or more layers. An inner layer 366 defines a threaded
contact surface 368.
[0158] The closures can have portions or layers of varying
thicknesses. As shown in FIG. 21D, at least one of the portions or
layers of a closure 370 comprises a thickened portion. The
illustrated closure 370 has an inner portion 374 with an upper
thickened portion 372 that has a thickness greater than the
thickness of the wall portion 376.
[0159] FIG. 21E illustrates a multilayer closure 380 that comprises
a band 382 connected to an inner portion 383 of the closure 380 by
one or more connectors 384. The closures illustrated in FIGS. 18 to
21E may have any suitable structure(s) or design for coupling to
containers. For example, the closures of FIGS. 18 to 21E may have a
similar configuration as the closure 213 (FIG. 14A). It is
contemplated that the closures of FIGS. 18-21E described herein can
be attached to containers by threadable engagement, welding or
fusing process (e.g., induction welding), an adhesive, by
frictional interaction, or the like. The closures of FIGS. 18-21E
are illustrated with bands. However, the closures may not have
bands, or they may have other anti-tamper indicators or structures.
Although the closures of FIGS. 18-21E are illustrated as screw
closures, other types of closures (e.g., closures of a multi-piece
construction, such as closures with a lid that opens and closes, a
closure with a nipple, and or the like) have similar
constructions.
[0160] The closures can have one or more compartments configured
for storage. The compartments can contain additives that can be
added to the contents of the associated container. The additives
can affect the characteristics of the container's contents and can
be in a solid, gas, and/or liquid state. In some embodiments, the
additives can affect one or more of the following: aroma (e.g.,
additives can comprise scented gases/liquids), flavor, color (e.g.,
additives can comprise dies, pigments, etc.), nutrient content
(e.g., additives can comprise vitamins, protein, carbohydrates,
etc.), and combinations thereof. The additives can be delivered
from the closure into the contents within the container for
subsequent ingestion and preferably enhance the desirability of the
contents and the consumption experience. The compartment can
release the additives during removal of the closure so that the
mixture is fresh. However, the compartment can be opened before or
after the closure is removed from the container. In some
embodiments, the closure has a compartment that can be broken
(e.g., punctured) after the closure has been separated from a
container. The compartment can be broken by a puncturing process,
tearing, and the like. The compartment can have a structure for
releasing its contents. The structure can be a pull plug, snap cap
or other suitable structure for releasing the compartment's
contents.
[0161] The containers can also be closed with a seal that is
separate from the closure. The seal can be applied to the container
before the closure is attached. A sealing process can be employed
to attach the seal to the neck finish of a container after the
container has been filled. The seal can be similar to or different
than the liners that are attached to the closures. The seals can be
hermetic seals (preferably spill proof) that ensure the integrity
of the containers' contents. In some embodiments, the seal can
comprise foil (preferably comprising metal, such as aluminum foil)
and is applied to a container by a welding process, such as
induction welding. However, the seal can be attached to a container
using other suitable attachment processes, for example an adhesive
may be used.
[0162] The closures can have an inner surface suitable for engaging
closuring mounting structures (e.g., threads, snap cap fittings,
and the like). The inner surface can provide a somewhat lubricious
surface to facilitate removal of the closure from a container. For
example, the closures can have a lubricious or low friction
material (e.g. olefin polymers) to engage the material forming the
container. If a closure is formed of PET, for example, the closure
may stick or lock with a PET container. Thus, the closure
(including snap caps, twist caps, and the like) may require a
relatively high removal torque. Advantageously, a closure with a
lubricious or low friction material can reduce the removal torque
in order to facilitate removal of the closure. The lubricious or
low friction material preferably provides enough friction such that
closure can remain coupled to an associated container while also
permitting convenient closure removal. Thus, the lubricious or low
friction material can be selected to achieve the desired removal
torque.
[0163] With reference to FIG. 20, the closure 330 can include an
inner portion 332 comprising a lubricious or low friction material
(e.g., an olefin or other material having a low coefficient of
friction) and an outer portion 334 comprising a polymer, such as an
olefin polymer, foam material, PET, and other materials described
herein. The closures described herein can comprise lubricious or
low friction material that can interface with a container and
achieve a desired removal torque. The lubricious or low friction
material forming the closure can be selected based on the material
forming the container in order to produce the desired frictional
interaction. It is contemplated that the molds described herein can
be modified with an edge gate to form the inner most layer of the
closure for engaging a container.
[0164] 3. Detailed Description of Mono and Multilayer Profiles and
Sheets
[0165] FIGS. 22A and 22B are cross-sectional views of sheets. The
sheets can have a somewhat uniform thickness or varying thickness.
The sheet of FIG. 22A is a monolayer sheet 389. The sheet of FIG.
22B is a multilayer sheet 390 comprising two layers. The sheets can
have any number of layers of any desired thickness based, for
example, on the use of the sheets. For example, the sheets 389, 390
can be used to form packaging, such as a label. At least a portion
of the sheets 389, 390 may comprise foam material. For example, the
sheets 389, 390 may comprise foam material to provide insulation to
the packaging to which the label is attached. Optionally, the sheet
390 can comprise one or more tie layers. For example, the sheet 390
may comprise a tie layer between the layers 392, 394.
[0166] The sheets can be used in various applications and may be
formed into various shapes. For example, the sheets can be cut,
molded (e.g., by thermoforming or casting), and/or the like into a
desired shape. A skilled artisan can select the desired shape,
size, and/or configuration of the sheets based on a desired
application.
[0167] FIG. 23 illustrates a multilayer profile 402. The profile
402 is in the form of a conduit having a substantially tubular
shape. The shape of the profile 402 can be generally circular,
elliptical, polygonal (including rounded polygonal), combinations
thereof, and the like. The illustrated profile 402 has a generally
circular cross sectional profile.
[0168] In some embodiments, the profile 402 can be a conduit
adapted for delivering fluids, preferably adapted for drinking
liquids. The profile 402 can have an inner layer 404 and an outer
layer 406. In some embodiments, at least one of the layers 404, 406
can comprise a plurality of layers (e.g., lamellar material).
[0169] The profile 402 can be a conduit that comprises a material
suitable for contacting foodstuff and one or more additional
materials having desirable physical properties (e.g., structural
and thermal properties). Advantageously, the inner layer 404 that
is in direct contact with the fluid preferably does not
substantially change the flavor of the foodstuff in which it
contacts. For example, many times fluid transfer lines of beverage
dispensing systems have flavor scalping polyolefins.
Advantageously, the inner layer 404 preferably does not
substantially change the flavor of the fluid passing through a
lumen 408 of the profile 402. In some embodiments, the outer layer
406 can provide improved physical characteristics of the profile
402. In another embodiment, the outer layer 406 can provide
increased insulation and/or structural properties of the profile
402. For example, in one embodiment the outer layer 406 can provide
increased impact resistance. In some embodiments, the outer layer
406 can reduce heat transfer through the walls of the profile 402.
In some embodiments, the outer layer 406 can have a high tensile
strength so that highly pressurized fluid can be passed through the
profile 402. Thus, the inner layer serves as a substantially inert
food contact surface while the outer layer(s) serve as an insulator
and/or withstand external influences.
[0170] Of course, the profile 402 can be employed in various other
applications. For example, the profile 402 can be used in hospitals
(e.g., as a delivery line for medicinal fluids, manufacturing
processes, equipment, fluid systems (e.g., ingestible fluid
dispensing systems), and/or the like.
4. Detailed Description of Packaging
[0171] One or more of the articles described herein can be employed
alone or in combination in various applications, such as packaging.
FIG. 24 illustrates a packaging system 416 comprising a container
420 that can be made from the preforms described herein. A closure
422 can be attached to a neck finish 432 of the container 420 to
close the container.
[0172] FIG. 24 also illustrates a label 440 attached to the
container 420 in the form of a bottle. The label 440 can engage the
bottle 420 and can be a monolayer or multilayer. The label 440 can
optionally comprise foam material.
[0173] The label 440 is preferably coupled to the outer surface 442
of the container 420. The label 440 can be removably attached the
outer surface 442. The label 440 can be attached during and/or
after the formation of the container 420. In the illustrated
embodiment, the label 440 is a generally tubular sleeve that
surrounds at least a portion of the bottle 420. The label 440 can
have any shape or configuration suitable for being attached to the
bottle and displaying information. Although not illustrated, the
label 440 can be attached to glass bottles, metal cans, or the
like. Further, the label 440 can be attached to other structures or
packages. For example, the label 440 can be attached to a box,
carton, bottle (plastic bottle, glass bottle, and the like), can,
and other items discussed herein. Additionally, the label 440 can
be printed upon. Optionally, an outer surface 446 of the label 440
can be treated to achieve a suitable printing surface.
[0174] An adhesive can be used to attach the label 440 to an
article. In one embodiment, after the label is attached to the
article, foam material of the label 440 may be expanded to achieve
a thermal barrier, a fluid barrier, a protective layer, and/or
desired structural properties. The foam material is preferably
expanded by heating the label 440. The material of the label 440
can be foamed before and/or after the label 440 is placed on the
container 420. Of course, the foam material of the label 440 can be
directly adhered to an article without the use of adhesives.
[0175] FIG. 25 illustrates another embodiment of a container
comprising a formable material. The container 450 can be similar or
different than the containers described above. In the illustrated
embodiment, the container 450 comprises a closure 452, a body 454,
and a handle 456 attached to the body 454. The body 454 can be
substantially rigid or flexible. The handle 456 is preferably
configured and sized to be comfortably gripped by a user. The wall
of the body 454 can be a mono-layer or multi-layer wall. The
container 450 can have any shape, including a shape similar to
typical containers used for holding ingestible liquids. The
container 450 can be formed by an extrusion blow-molding
process.
[0176] With respect to FIG. 26A, container 460 is packaging (e.g.,
food packaging) that preferably comprises foam material. In one
embodiment, a sheet (e.g., the sheets 389 or 390) is used to form
at least a portion of the container 460 by, e.g., a thermoforming
process. The container 460 can be in the form of a flexible pouch,
food container, or any other suitable structure.
[0177] For example, in one arrangement the sheets are formed into
clamshell packages that are adapted to hold food, such as
hamburgers. In another arrangement, the sheets are configured to
form boxes (e.g., pizza boxes). In another embodiment, the material
and the dimensions of the container 460 can be determined based on
the desired structural properties, thermal properties, and/or other
characteristics. For example, the container 460 may comprise foam
material for effective thermal insulation of the container 460. In
another example, the container 460 can have thick walls so that the
container 460 is generally rigid.
[0178] FIG. 26B illustrates another article comprising formable
material. In one embodiment, the article 462 is in the form of a
tray that is configured to receive foodstuff. The tray 462 can be
formed from a sheet through thermoforming. Optionally, the tray 462
can be adapted to fit within a container or box.
[0179] The tray 462 (or other articles described herein) can be
configured for thermal processing. In some embodiments, the tray
462 can be used for heating and reheating. The tray 462 can hold
foodstuffs so that the foodstuffs can be heated by, for example, a
heat lamp, microwave oven, oven, toaster, heated water, and the
like. The microstructure of the tray 462 can be adapted based on
the type and method of thermal processing. For example, the tray
462 may comprise crystalline material (e.g., crystalline PET) to
enhance thermal stability. During the thermoforming process one or
more layers of the tray can be heated above a predetermined
temperature to cause crystallization of at least a portion of one
of the layers. Thus, at least a portion of the tray 462 can be
crystallized during the manufacturing process. In some embodiments,
the tray 462 can comprise a mono or multilayer sheet. The tray 462
can have a first layer of thermoplastic material and a second layer
(e.g., a foam layer). The first layer can comprise crystalline
material (e.g., amorphous, partially crystallized, or fully
crystallized). The tray 462 can be used to hold food for use in a
microwave oven. Of course, other articles, such as containers like
pizza boxes, can have a similar configuration.
[0180] Articles can also be in the form of a can. The can may
comprise polymer materials as disclosed herein. The can may
comprise a metal layer and one or more layers of another material.
In some embodiments, a metal can (e.g., aluminum can) can be coated
with foam material such as a thermoplastic material. At least a
portion of the exterior and/or the interior of the can may be
coated with foam material.
B. Crystalline Neck Finishes
[0181] Plastic bottles and containers, in some embodiments,
preferably comprise one or more materials in the neck, neck finish
and/or neck cylinder that are at least partially in the crystalline
state. Such bottles and preforms can also comprise one or more
layers of materials.
[0182] In some embodiments, bottles are made by a process which
includes the blow-molding of plastic preforms. In some
circumstances, it is preferred that the material in the plastic
preforms is in an amorphous or semi-crystalline state because
materials in this state can be readily blow-molded where fully
crystalline materials generally cannot. However, bottles made
entirely of amorphous or semi-crystalline material may not have
enough dimensional stability during a standard hot-fill process. In
these circumstances, a bottle comprising crystalline material would
be preferred, as it would hold its shape during hot-fill
processes.
[0183] In some embodiments, a plastic bottle has the advantages of
both a crystalline bottle and an amorphous or semi-crystalline
bottle. By making at least part of the uppermost portion of the
preform crystalline while keeping the body of the preform amorphous
or semi-crystalline (sometimes referred to herein as
"non-crystalline"), one can make a preform that will blow-mold
easily yet retain necessary dimensions in the crucial neck area
during a hot-fill process. Some embodiments have both crystalline
and amorphous or semi-crystalline regions. This results in a
preform which has sufficient strength to be used in widespread
commercial applications.
[0184] One or more embodiments described herein generally produce
preforms with a crystalline neck, which are typically then
blow-molded into beverage containers. The preforms may be
monolayer; that is, comprised of a single layer of a base material,
or they may be multilayer. The material in such layers may be a
single material or it may be a blend of one or more materials. In
one embodiment, an article is provided which comprises a neck
portion and a body portion. The neck portion and the body portion
are a monolithic first layer of material. The body portion is
primarily amorphous or semi-crystalline, and the neck portion is
primarily crystalline.
[0185] Referring to FIG. 1, the preferred preform 30 is depicted.
The preform 30 may be made by injection molding as is known in the
art or by methods disclosed herein. The preform 30 has the neck
portion 32 and a body portion 34, formed monolithically (i.e., as a
single, or unitary, structure). Advantageously, in some
embodiments, the monolithic arrangement of the preform, when
blow-molded into a bottle, provides greater dimensional stability
and improved physical properties in comparison to a preform
constructed of separate neck and body portions, which are bonded
together.
[0186] By achieving a crystallized state in the neck portion of the
preform during the molding step, the final dimensions are
substantially identical to the initial dimensions, unlike when
additional heating steps are used. Therefore, dimensional
variations are minimized and dimensional stability is achieved.
This results in more consistent performance with regard to
closures, such as the threads on the neck finish and reduces the
scrap rate of the molding process.
[0187] While a non-crystalline preform is preferred for
blow-molding, a bottle having greater crystalline character is
preferred for its dimensional stability during a hot-fill process.
Accordingly, a preform constructed according to some embodiments
has a generally non-crystalline body portion and a generally
crystalline neck portion. To create generally crystalline and
generally non-crystalline portions in the same preform, one needs
to achieve different levels of heating and/or cooling in the mold
in the regions from which crystalline portions will be formed as
compared to those in which generally non-crystalline portions will
be formed. The different levels of heating and/or cooling may be
maintained by thermal isolation of the regions having different
temperatures. This thermal isolation between the thread split, core
and/or cavity interface can be accomplished utilizing a combination
of low and high thermal conduct materials as inserts or separate
components at the mating surfaces of these portions.
[0188] Some preferred processes accomplish the making of a preform
within the preferred cycle times for uncoated preforms of similar
size by standard methods currently used in preform production.
Further, the preferred processes are enabled by tooling design and
process techniques to allow for the simultaneous production of
crystalline and amorphous regions in particular locations on the
same preform.
[0189] In one embodiment, there is provided a mold for making a
preform comprising a neck portion having a first mold temperature
control system (e.g., cooling/heating channels), a body portion
having a second temperature control system, and a core having a
third temperature control system, wherein the first temperature
control system is independent of the second and third temperature
control systems and the neck portion is thermally isolated from the
body portion and core.
[0190] The cooling of the mold in regions which form preform
surfaces for which it is preferred that the material be generally
amorphous or semi-crystalline, can be accomplished by chilled fluid
circulating through the mold cavity and core. In some embodiments,
a mold set-up similar to conventional injection molding
applications is used, except that there is an independent fluid
circuit or electric heating system for the portions of the mold
from which crystalline portions of the preform will be formed.
Thermal isolation of the body mold, neck finish mold and core
section can be achieved by use of inserts having low thermal
conductivity. The neck, neck finish, and/or neck cylinder portions
of the mold preferably are maintained at a higher temperature to
achieve slower cooling, which promotes crystallinity of the
material during cooling.
[0191] The above embodiments as well as further embodiments and
techniques regarding preforms that have both crystalline and
amorphous or semi-crystalline regions are described in U.S. Pat.
No. 6,217,818 to Collette et al; U.S. Pat. No. 6,428,737 to
Collette et al.; U.S. Patent Publication No. 2003/0031814A1 to
Hutchinson et al.; and PCT Publication No. WO 98/46410 to Koch et
al.
C. Detailed Description of Some Preferred Materials
1. General Description of Preferred Materials
[0192] Furthermore, the articles described herein may be described
specifically in relation to a particular material, such as
polyethylene terephthalate (PET) or polypropylene (PP), but
preferred methods are applicable to many other thermoplastics,
including those of the of the polyester and polyolefin types. Other
suitable materials include, but are not limited to, foam materials,
various polymers and thermosets, thermoplastic materials such as
polyesters, polyolefins, including polypropylene and polyethylene,
polycarbonate, polyamides, including nylons (e.g. Nylon 6, Nylon
66, MXD6), polystyrenes, epoxies, acrylics, copolymers, blends,
grafted polymers, and/or modified polymers (monomers or portion
thereof having another group as a side group, e.g. olefin-modified
polyesters). These materials may be used alone or in conjunction
with each other. More specific material examples include, but are
not limited to, ethylene vinyl alcohol copolymer ("EVOH"), ethylene
vinyl acetate ("EVA"), ethylene acrylic acid ("EAA"), linear low
density polyethylene ("LLDPE"), polyethylene 2,6- and
1,5-naphthalate (PEN), polyethylene terephthalate glycol (PETG),
poly(cyclohexylenedimethylene terephthalate), polystyrene,
cycloolefin, copolymer, poly-4-methylpentene-1, poly(methyl
methacrylate), acrylonitrile, polyvinyl chloride, polyvinylidine
chloride, styrene acrylonitrile, acrylonitrile-butadiene-styrene,
polyacetal, polybutylene terephthalate, ionomer, polysulfone,
polytetrafluoroethylene, polytetramethylene 1,2-dioxybenzoate and
copolymers of ethylene terephthalate and ethylene isophthalate.
[0193] As used herein, the term "polyethylene terephthalate glycol"
(PETG) refers to a copolymer of PET wherein an additional
comonomer, cyclohexane di-methanol (CHDM), is added in significant
amounts (e.g. approximately 40% or more by weight) to the PET
mixture. In one embodiment, preferred PETG material is essentially
amorphous. Suitable PETG materials may be purchased from various
sources. One suitable source is Voridian, a division of Eastman
Chemical Company. Other PET copolymers include CHDM at lower levels
such that the resulting material remains crystallizable or
semi-crystalline. One example of PET copolymer containing low
levels of CHDM is Voridian 9921 resin.
[0194] In some embodiments polymers that have been grafted or
modified may be used. In one embodiment polypropylene or other
polymers may be grafted or modified with polar groups including,
but not limited to, maleic anhydride, glycidyl methacrylate, acryl
methacrylate and/or similar compounds to improve adhesion. In other
embodiments polypropylene also refers to clarified polypropylene.
As used herein, the term "clarified polypropylene" is a broad term
and is used in accordance with its ordinary meaning and may
include, without limitation, a polypropylene that includes
nucleation inhibitors and/or clarifying additives. Clarified
polypropylene is a generally transparent material as compared to
the homopolymer or block copolymer of polypropylene. The inclusion
of nucleation inhibitors helps prevent and/or reduce crystallinity,
which contributes to the haziness of polypropylene, within the
polypropylene. Clarified polypropylene may be purchased from
various sources such as Dow Chemical Co. Alternatively, nucleation
inhibitors may be added to polypropylene. One suitable source of
nucleation inhibitor additives is Schulman.
[0195] Optionally, the materials may comprise microstructures such
as microlayers, microspheres, and combinations thereof. In certain
embodiments preferred materials may be virgin, pre-consumer,
post-consumer, regrind, recycled, and/or combinations thereof.
[0196] As used herein, "PET" includes, but is not limited to,
modified PET as well as PET blended with other materials. One
example of a modified PET is "high IPA PET" or IPA-modified PET,
which refer to PET in which the IPA content is preferably more than
about 2% by weight, including about 2-10% IPA by weight, also
including about 5-10% IPA by weight. PET can be virgin, pre or
post-consumer, recycled, or regrind PET, PET copolymers and
combinations thereof.
[0197] In embodiments of preferred methods and processes one or
more layers may comprise barrier layers, UV protection layers,
oxygen scavenging layers, oxygen barrier layers, carbon dioxide
scavenging layers, carbon dioxide barrier layers, and other layers
as needed for the particular application. As used herein, the terms
"barrier material," "barrier resin," and the like are broad terms
and are used in their ordinary sense and refer, without limitation,
to materials which, when used in preferred methods and processes,
have a lower permeability to oxygen and carbon dioxide than the one
or more of the layers. As used herein, the terms "UV protection"
and the like are broad terms and are used in their ordinary sense
and refer, without limitation, to materials which have a higher UV
absorption rate than one or more layers of the article. As used
herein, the terms "oxygen scavenging" and the like are broad terms
and are used in their ordinary sense and refer, without limitation,
to materials which have a higher oxygen absorption rate than one or
more layers of the article. As used herein, the terms "oxygen
barrier" and the like are broad terms and are used in their
ordinary sense and refer, without limitation, to materials which
are passive or active in nature and slow the transmission of oxygen
into and/or out of an article. As used herein, the terms "carbon
dioxide scavenging" and the like are broad terms and are used in
their ordinary sense and refer, without limitation, to materials
which have a higher carbon dioxide absorption rate than one or more
layers of the article. As used herein, the terms "carbon dioxide
barrier" and the like are broad terms and are used in their
ordinary sense and refer, without limitation, to materials which
are passive or active in nature and slow the transmission of carbon
dioxide into and/or out of an article. Without wishing to be bound
to any theory, applicants believe that in applications wherein a
carbonated product, e.g. a soft-drink beverage, contained in an
article is over-carbonated, the inclusion of a carbon dioxide
scavenger in one or more layers of the article allows the excess
carbonation to saturate the layer which contains the carbon dioxide
scavenger. Therefore, as carbon dioxide escapes to the atmosphere
from the article it first leaves the article layer rather than the
product contained therein. As used herein, the terms "crosslink,"
"crosslinked," and the like are broad terms and are used in their
ordinary sense and refer, without limitation, to materials and
coatings which vary in degree from a very small degree of
crosslinking up to and including fully crosslinked materials such
as a thermoset epoxy. The degree of crosslinking can be adjusted to
provide the appropriate degree of chemical or mechanical abuse
resistance for the particular circumstances. As used herein, the
term "tie material" is a broad term and is used in its ordinary
sense and refers, without limitation, to a gas, liquid, or
suspension comprising a material that aids in binding two materials
together physically and/or chemically, including but not limited to
adhesives, surface modification agents, reactive materials, and the
like.
2. Preferred Materials
[0198] In a preferred embodiment materials comprise thermoplastic
materials. A further preferred embodiment includes "Phenoxy-Type
Thermoplastics." Phenoxy-Type Thermoplastics, as that term is used
herein, include a wide variety of materials including those
discussed in WO 99/20462. In one embodiment, materials comprise
thermoplastic epoxy resins (TPEs), a subset of Phenoxy-Type
Thermoplastics. A further subset of Phenoxy-Type Thermoplastics,
and thermoplastic materials, are preferred hydroxy-phenoxyether
polymers, of which polyhydroxyaminoether copolymers (PHAE) is a
further preferred material. See for example, U.S. Pat. Nos.
6,455,116; 6,180,715; 6,011,111; 5,834,078; 5,814,373; 5,464,924;
and 5,275,853; see also PCT Application Nos. WO 99/48962; WO
99/12995; WO 98/29491; and WO 98/14498. In some embodiments, PHAEs
are TPEs.
[0199] Preferably, the Phenoxy-Type Thermoplastics used in
preferred embodiments comprise one of the following types: (1)
hydroxy-functional poly(amide ethers) having repeating units
represented by any one of the Formulae Ia, Ib or Ic:
##STR00001##
[0200] (2) poly(hydroxy amide ethers) having repeating units
represented independently by any one of the Formulae IIa, IIb or
IIc:
##STR00002##
[0201] (3) amide- and hydroxymethyl-functionalized polyethers
having repeating units represented by Formula III:
##STR00003##
[0202] (4) hydroxy-functional polyethers having repeating units
represented by Formula IV:
##STR00004##
[0203] (5) hydroxy-functional poly(ether sulfonamides) having
repeating units represented by
[0204] Formulae Va or Vb:
##STR00005##
[0205] (6) poly(hydroxy ester ethers) having repeating units
represented by Formula VI:
##STR00006##
[0206] (7) hydroxy-phenoxyether polymers having repeating units
represented by Formula VII:
##STR00007##
[0207] and (8) poly(hydroxyamino ethers) having repeating units
represented by Formula VIII:
##STR00008##
[0208] wherein each Ar individually represents a divalent aromatic
moiety, substituted divalent aromatic moiety or heteroaromatic
moiety, or a combination of different divalent aromatic moieties,
substituted aromatic moieties or heteroaromatic moieties; R is
individually hydrogen or a monovalent hydrocarbyl moiety; each
Ar.sub.1 is a divalent aromatic moiety or combination of divalent
aromatic moieties bearing amide or hydroxymethyl groups; each
Ar.sub.2 is the same or different than Ar and is individually a
divalent aromatic moiety, substituted aromatic moiety or
heteroaromatic moiety or a combination of different divalent
aromatic moieties, substituted aromatic moieties or heteroaromatic
moieties; R.sub.1 is individually a predominantly hydrocarbylene
moiety, such as a divalent aromatic moiety, substituted divalent
aromatic moiety, divalent heteroaromatic moiety, divalent alkylene
moiety, divalent substituted alkylene moiety or divalent
heteroalkylene moiety or a combination of such moieties; R.sub.2 is
individually a monovalent hydrocarbyl moiety; A is an amine moiety
or a combination of different amine moieties; X is an amine, an
arylenedioxy, an arylenedisulfonamido or an arylenedicarboxy moiety
or combination of such moieties; and Ar.sub.3 is a "cardo" moiety
represented by any one of the Formulae:
##STR00009##
[0209] wherein Y is nil, a covalent bond, or a linking group,
wherein suitable linking groups include, for example, an oxygen
atom, a sulfur atom, a carbonyl atom, a sulfonyl group, or a
methylene group or similar linkage; n is an integer from about 10
to about 1000; x is 0.01 to 1.0; and y is 0 to 0.5.
[0210] The term "predominantly hydrocarbylene" means a divalent
radical that is predominantly hydrocarbon, but which optionally
contains a small quantity of a heteroatomic moiety such as oxygen,
sulfur, imino, sulfonyl, sulfoxyl, and the like.
[0211] The hydroxy-functional poly(amide ethers) represented by
Formula I are preferably prepared by contacting an
N,N'-bis(hydroxyphenylamido)alkane or arene with a diglycidyl ether
as described in U.S. Pat. Nos. 5,089,588 and 5,143,998.
[0212] The poly(hydroxy amide ethers) represented by Formula II are
prepared by contacting a bis(hydroxyphenylamido)alkane or arene, or
a combination of 2 or more of these compounds, such as
N,N'-bis(3-hydroxyphenyl) adipamide or
N,N'-bis(3-hydroxyphenyl)glutaramide, with an epihalohydrin as
described in U.S. Pat. No. 5,134,218.
[0213] The amide- and hydroxymethyl-functionalized polyethers
represented by Formula III can be prepared, for example, by
reacting the diglycidyl ethers, such as the diglycidyl ether of
bisphenol A, with a dihydric phenol having pendant amido,
N-substituted amido and/or hydroxyalkyl moieties, such as
2,2-bis(4-hydroxyphenyl)acetamide and 3,5-dihydroxybenzamide. These
polyethers and their preparation are described in U.S. Pat. Nos.
5,115,075 and 5,218,075.
[0214] The hydroxy-functional polyethers represented by Formula IV
can be prepared, for example, by allowing a diglycidyl ether or
combination of diglycidyl ethers to react with a dihydric phenol or
a combination of dihydric phenols using the process described in
U.S. Pat. No. 5,164,472. Alternatively, the hydroxy-functional
polyethers are obtained by allowing a dihydric phenol or
combination of dihydric phenols to react with an epihalohydrin by
the process described by Reinking, Barnabeo and Hale in the Journal
of Applied Polymer Science, Vol. 7, p. 2135 (1963).
[0215] The hydroxy-functional poly(ether sulfonamides) represented
by Formula V are prepared, for example, by polymerizing an
N,N'-dialkyl or N,N'-diaryldisulfonamide with a diglycidyl ether as
described in U.S. Pat. No. 5,149,768.
[0216] The poly(hydroxy ester ethers) represented by Formula VI are
prepared by reacting diglycidyl ethers of aliphatic or aromatic
diacids, such as diglycidyl terephthalate, or diglycidyl ethers of
dihydric phenols with, aliphatic or aromatic diacids such as adipic
acid or isophthalic acid. These polyesters are described in U.S.
Pat. No. 5,171,820.
[0217] The hydroxy-phenoxyether polymers represented by Formula VII
are prepared, for example, by contacting at least one
dinucleophilic monomer with at least one diglycidyl ether of a
cardo bisphenol, such as 9,9-bis(4-hydroxyphenyl)fluorene,
phenolphthalein, or phenolphthalimidine or a substituted cardo
bisphenol, such as a substituted bis(hydroxyphenyl)fluorene, a
substituted phenolphthalein or a substituted phenolphthalimidine
under conditions sufficient to cause the nucleophilic moieties of
the dinucleophilic monomer to react with epoxy moieties to form a
polymer backbone containing pendant hydroxy moieties and ether,
imino, amino, sulfonamido or ester linkages. These
hydroxy-phenoxyether polymers are described in U.S. Pat. No.
5,184,373.
[0218] The poly(hydroxyamino ethers) ("PHAE" or polyetheramines)
represented by Formula VIII are prepared by contacting one or more
of the diglycidyl ethers of a dihydric phenol with an amine having
two amine hydrogens under conditions sufficient to cause the amine
moieties to react with epoxy moieties to form a polymer backbone
having amine linkages, ether linkages and pendant hydroxyl
moieties. These compounds are described in U.S. Pat. No. 5,275,853.
For example, polyhydroxyaminoether copolymers can be made from
resorcinol diglycidyl ether, hydroquinone diglycidyl ether,
bisphenol A diglycidyl ether, or mixtures thereof.
[0219] The hydroxy-phenoxyether polymers are the condensation
reaction products of a dihydric polynuclear phenol, such as
bisphenol A, and an epihalohydrin and have the repeating units
represented by Formula IV wherein Ar is an isopropylidene
diphenylene moiety. The process for preparing these is described in
U.S. Pat. No. 3,305,528, incorporated herein by reference in its
entirety. One preferred non-limiting hydroxy-phenoxyether polymer,
PAPHEN 25068-38-6, is commercially available from Phenoxy
Associates, Inc. Other preferred phenoxy resins are available from
InChem.RTM. (Rock Hill, S.C.), these materials include, but are not
limited to, the INCHEMREZT.TM. PKHH and PKHW product lines.
[0220] Generally, preferred phenoxy-type materials form stable
aqueous based solutions or dispersions. Preferably, the properties
of the solutions/dispersions are not adversely affected by contact
with water. Preferred materials range from about 10% solids to
about 50% solids, including about 15%, 20%, 25%, 30%, 35%, 40% and
45%, and ranges encompassing such percentages. Preferably, the
material used dissolves or disperses in polar solvents. These polar
solvents include, but are not limited to, water, alcohols, and
glycol ethers. See, for example, U.S. Pat. Nos. 6,455,116,
6,180,715, and 5,834,078 which describe some preferred phenoxy-type
solutions and/or dispersions.
[0221] One preferred phenoxy-type material is a
polyhydroxyaminoether copolymer (PHAE), represented by Formula
VIII, dispersion or solution. The dispersion or solution, when
applied to a container or preform, greatly reduces the permeation
rate of a variety of gases through the container walls in a
predictable and well known manner. One dispersion or latex made
thereof comprises 10-30 percent solids. A PHAE solution/dispersion
may be prepared by stirring or otherwise agitating the PHAE in a
solution of water with an organic acid, preferably acetic or
phosphoric acid, but also including lactic, malic, citric, or
glycolic acid and/or mixtures thereof. These PHAE
solution/dispersions also include organic acid salts produced by
the reaction of the polyhydroxyaminoethers with these acids.
[0222] In other preferred embodiments, phenoxy-type thermoplastics
are mixed or blended with other materials using methods known to
those of skill in the art. In some embodiments a compatibilizer may
be added to the blend. When compatibilizers are used, preferably
one or more properties of the blends are improved, such properties
including, but not limited to, color, haze, and adhesion between a
layer comprising a blend and other layers. One preferred blend
comprises one or more phenoxy-type thermoplastics and one or more
polyolefins. A preferred polyolefin comprises polypropylene. In one
embodiment polypropylene or other polyolefins may be grafted or
modified with a polar molecule or monomer, including, but not
limited to, maleic anhydride, glycidyl methacrylate, acryl
methacrylate and/or similar compounds to increase
compatibility.
[0223] The following PHAE solutions or dispersions are examples of
suitable phenoxy-type solutions or dispersions which may be used if
one or more layers of resin are applied as a liquid such as by dip,
flow, or spray coating, such as described in WO 04/004929 and U.S.
Pat. No. 6,676,883. One suitable material is BLOX.RTM. experimental
barrier resin, for example XU-19061.00 made with phosphoric acid
manufactured by Dow Chemical Corporation. This particular PHAE
dispersion is said to have the following typical characteristics:
30% percent solids, a specific gravity of 1.30, a pH of 4, a
viscosity of 24 centipoise (Brookfield, 60 rpm, LVI, 22.degree.
C.), and a particle size of between 1,400 and 1,800 angstroms.
Other suitable materials include BLOX.RTM. 588-29 resins based on
resorcinol have also provided superior results as a barrier
material. This particular dispersion is said to have the following
typical characteristics: 30% percent solids, a specific gravity of
1.2, a pH of 4.0, a viscosity of 20 centipoise (Brookfield, 60 rpm,
LVI, 22.degree. C.), and a particle size of between 1500 and 2000
angstroms. Other variations of the polyhydroxyaminoether chemistry
may prove useful such as crystalline versions based on hydroquinone
diglycidylethers. Other suitable materials include
polyhydroxyaminoether solutions/dispersions by Imperial Chemical
Industries ("ICI," Ohio, USA) available under the name OXYBLOK. In
one embodiment, PHAE solutions or dispersions can be crosslinked
partially (semi-crosslinked), fully, or to the exact desired degree
as appropriate for the application by adding an appropriate cross
linker material. The benefits of crosslinking include, but are not
limited to, one or more of the following: improved chemical
resistance, improved abrasion resistance, low blushing, low surface
tension. Examples of cross linker materials include, but are not
limited to, formaldehyde, acetaldehyde or other members of the
aldehyde family of materials. Suitable cross linkers can also
enable changes to the T.sub.g of the material, which can facilitate
formation of specific containers. Other suitable materials include
BLOX.RTM. 5000 resin dispersion intermediate, BLOX.RTM. XUR 588-29,
BLOX.RTM. 0000 and 4000 series resins. The solvents used to
dissolve these materials include, but are not limited to, polar
solvents such as alcohols, water, glycol ethers or blends thereof.
Other suitable materials include, but are not limited to, BLOX.RTM.
R1.
[0224] In one embodiment, preferred phenoxy-type thermoplastics are
soluble in aqueous acid. A polymer solution/dispersion may be
prepared by stirring or otherwise agitating the thermoplastic epoxy
in a solution of water with an organic acid, preferably acetic or
phosphoric acid, but also including lactic, malic, citric, or
glycolic acid and/or mixtures thereof. In a preferred embodiment,
the acid concentration in the polymer solution is preferably in the
range of about 5%-20%, including about 5%-10% by weight based on
total weight. In other preferred embodiments, the acid
concentration may be below about 5% or above about 20%; and may
vary depending on factors such as the type of polymer and its
molecular weight. In other preferred embodiments, the acid
concentration ranges from about 2.5 to about 5% by weight. The
amount of dissolved polymer in a preferred embodiment ranges from
about 0.1% to about 40%. A uniform and free flowing polymer
solution is preferred. In one embodiment a 10% polymer solution is
prepared by dissolving the polymer in a 10% acetic acid solution at
90.degree. C. Then while still hot the solution is diluted with 20%
distilled water to give an 8% polymer solution. At higher
concentrations of polymer, the polymer solution tends to be more
viscous.
[0225] Examples of preferred copolyester materials and a process
for their preparation is described in U.S. Pat. No. 4,578,295 to
Jabarin. They are generally prepared by heating a mixture of at
least one reactant selected from isophthalic acid, terephthalic
acid and their C.sub.1 to C.sub.4 alkyl esters with 1,3
bis(2-hydroxyethoxy)benzene and ethylene glycol. Optionally, the
mixture may further comprise one or more ester-forming dihydroxy
hydrocarbon and/or bis(4-.beta.-hydroxyethoxyphenyl)sulfone.
Especially preferred copolyester materials are available from
Mitsui Petrochemical Ind. Ltd. (Japan) as B-010, B-030 and others
of this family.
[0226] Examples of preferred polyamide materials include MXD-6 from
Mitsubishi Gas Chemical (Japan). Other preferred polyamide
materials include Nylon 6, and Nylon 66. Other preferred polyamide
materials are blends of polyamide and polyester, including those
comprising about 1-20% polyester by weight, more preferably about
1-10% polyester by weight, where the polyester is preferably PET or
a modified PET. In another embodiment, preferred polyamide
materials are blends of polyamide and polyester, including those
comprising about 1-20% polyamide by weight, more preferably about
1-10% polyamide by weight, where the polyester is preferably PET or
a modified PET. The blends may be ordinary blends or they may be
compatibilized with an antioxidant or other material. Examples of
such materials include those described in U.S. Patent Publication
No. 2004/0013833, filed Mar. 21, 2003, which is hereby incorporated
by reference in its entirety. Other preferred polyesters include,
but are not limited to, PEN and PET/PEN copolymers.
3. Preferred Foam Materials
[0227] As used herein, the term "foam material" is a broad term and
is used in accordance with its ordinary meaning and may include,
without limitation, a foaming agent, a mixture of foaming agent and
a binder or carrier material, an expandable cellular material,
and/or a material having voids. The terms "foam material" and
"expandable material" are used interchangeably herein. Preferred
foam materials may exhibit one or more physical characteristics
that improve the thermal and/or structural characteristics of
articles (e.g., containers) and may enable the preferred
embodiments to be able to withstand processing and physical
stresses typically experienced by containers. In one embodiment,
the foam material provides structural support to the container. In
another embodiment, the foam material forms a protective layer that
can reduce damage to the container during processing. For example,
the foam material can provide abrasion resistance which can reduce
damage to the container during transport. In one embodiment, a
protective layer of foam may increase the shock or impact
resistance of the container and thus prevent or reduce breakage of
the container. Furthermore, in another embodiment foam can provide
a comfortable gripping surface and/or enhance the aesthetics or
appeal of the container.
[0228] In one embodiment, foam material comprises a foaming or
blowing agent and a carrier material. In one preferred embodiment,
the foaming agent comprises expandable structures (e.g.,
microspheres) that can be expanded and cooperate with the carrier
material to produce foam. For example, the foaming agent can be
thermoplastic microspheres, such as EXPANCEL.RTM. microspheres sold
by Akzo Nobel. In one embodiment, microspheres can be thermoplastic
hollow spheres comprising thermoplastic shells that encapsulate
gas. Preferably, when the microspheres are heated, the
thermoplastic shell softens and the gas increases its pressure
causing the expansion of the microspheres from an initial position
to an expanded position. The expanded microspheres and at least a
portion of the carrier material can form the foam portion of the
articles described herein. The foam material can form a layer that
comprises a single material (e.g., a generally homogenous mixture
of the foaming agent and the carrier material), a mix or blend of
materials, a matrix formed of two or more materials, two or more
layers, or a plurality of microlayers (lamellae) preferably
including at least two different materials. Alternatively, the
microspheres can be any other suitable controllably expandable
material. For example, the microspheres can be structures
comprising materials that can produce gas within or from the
structures. In one embodiment, the microspheres are hollow
structures containing chemicals which produce or contain gas
wherein an increase in gas pressure causes the structures to expand
and/or burst. In another embodiment, the microspheres are
structures made from and/or containing one or more materials which
decompose or react to produce gas thereby expanding and/or bursting
the microspheres. Optionally, the microsphere may be generally
solid structures. Optionally, the microspheres can be shells filled
with solids, liquids, and/or gases. The microspheres can have any
configuration and shape suitable for forming foam. For example, the
microspheres can be generally spherical. Optionally, the
microspheres can be elongated or oblique spheroids. Optionally, the
microspheres can comprise any gas or blends of gases suitable for
expanding the microspheres. In one embodiment, the gas can comprise
an inert gas, such as nitrogen. In one embodiment, the gas is
generally non-flammable. However, in certain embodiments non-inert
gas and/or flammable gas can fill the shells of the microspheres.
In some embodiments, the foam material may comprise foaming or
blowing agents as are known in the art. Additionally, the foam
material may be mostly or entirely foaming agent.
[0229] Although some preferred embodiments contain microspheres
that generally do not break or burst, other embodiments comprise
microspheres that may break, burst, fracture, and/or the like.
Optionally, a portion of the microspheres may break while the
remaining portion of the microspheres do not break. In some
embodiments up to about 0.5%, 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%,
40%, 50%, 60% 70%, 80%, 90% by weight of microspheres, and ranges
encompassing these amounts, break. In one embodiment, for example,
a substantial portion of the microspheres may burst and/or fracture
when they are expanded. Additionally, various blends and mixtures
of microspheres can be used to form foam material.
[0230] The microspheres can be formed of any material suitable for
causing expansion. In one embodiment, the microspheres can have a
shell comprising a polymer, resin, thermoplastic, thermoset, or the
like as described herein. The microsphere shell may comprise a
single material or a blend of two or more different materials. For
example, the microspheres can have an outer shell comprising
ethylene vinyl acetate ("EVA"), polyethylene terephthalate ("PET"),
polyamides (e.g. Nylon 6 and Nylon 66) polyethylene terephthalate
glycol (PETG), PEN, PET copolymers, and combinations thereof. In
one embodiment a PET copolymer comprises CHDM comonomer at a level
between what is commonly called PETG and PET. In another
embodiment, comonomers such as DEG and IPA are added to PET to form
microsphere shells. The appropriate combination of material type,
size, and inner gas can be selected to achieve the desired
expansion of the microspheres. In one embodiment, the microspheres
comprise shells formed of a high temperature material (e.g., PETG
or similar material) that is capable of expanding when subject to
high temperatures, preferably without causing the microspheres to
burst. If the microspheres have a shell made of low temperature
material (e.g., as EVA), the microspheres may break when subjected
to high temperatures that are suitable for processing certain
carrier materials (e.g., PET or polypropylene having a high melt
point). In some circumstances, for example, EXPANCEL.RTM.
microspheres may be break when processed at relatively high
temperatures. Advantageously, mid or high temperature microspheres
can be used with a carrier material having a relatively high melt
point to produce controllably, expandable foam material without
breaking the microspheres. For example, microspheres can comprise a
mid-temperature material (e.g., PETG) or a high temperature
material (e.g., acrylonitrile) and may be suitable for relatively
high temperature applications. Thus, a blowing agent for foaming
polymers can be selected based on the processing temperatures
employed.
[0231] The foam material can be a matrix comprising a carrier
material, preferably a material that can be mixed with a blowing
agent (e.g., microspheres) to form an expandable material. The
carrier material can be a thermoplastic, thermoset, or polymeric
material, such as ethylene acrylic acid ("EAA"), ethylene vinyl
acetate ("EVA"), linear low density polyethylene ("LLDPE"),
polyethylene terephthalate glycol (PETG), poly(hydroxyamino ethers)
("PHAE"), PET, polyethylene, polypropylene, polystyrene ("PS"),
pulp (e.g., wood or paper pulp of fibers, or pulp mixed with one or
more polymers), mixtures thereof, and the like. However, other
materials suitable for carrying the foaming agent can be used to
achieve one or more of the desired thermal, structural, optical,
and/or other characteristics of the foam. In some embodiments, the
carrier material has properties (e.g., a high melt index) for
easier and rapid expansion of the microspheres, thus reducing cycle
time thereby resulting in increased production.
[0232] In preferred embodiments, the formable material may comprise
two or more components including a plurality of components each
having different processing windows and/or physical properties. The
components can be combined such that the formable material has one
or more desired characteristics. The proportion of components can
be varied to produce a desired processing window and/or physical
properties. For example, the first material may have a processing
window that is similar to or different than the processing window
of the second material. The processing window may be based on, for
example, pressure, temperature, viscosity, or the like. Thus,
components of the formable material can be mixed to achieve a
desired, for example, pressure or temperature range for shaping the
material.
[0233] In one embodiment, the combination of a first material and a
second material may result in a material having a processing window
that is more desirable than the processing window of the second
material. For example, the first material may be suitable for
processing over a wide range of temperatures, and the second
material may be suitable for processing over a narrow range of
temperatures. A material having a portion formed of the first
material and another portion formed of the second material may be
suitable for processing over a range of temperatures that is wider
than the narrow range of processing temperatures of the second
material. In one embodiment, the processing window of a
multi-component material is similar to the processing window of the
first material. In one embodiment, the formable material comprises
a multilayer sheet or tube comprising a layer comprising PET and a
layer comprising polypropylene. The material formed from both PET
and polypropylene can be processed (e.g., extruded) within a wide
temperature range similar to the processing temperature range
suitable for PET. The processing window may be for one or more
parameters, such as pressure, temperature, viscosity, and/or the
like.
[0234] Optionally, the amount of each component of the material can
be varied to achieve the desired processing window. Optionally, the
materials can be combined to produce a formable material suitable
for processing over a desired range of pressure, temperature,
viscosity, and/or the like. For example, the proportion of the
material having a more desirable processing window can be increased
and the proportion of material having a less undesirable processing
window can be decreased to result in a material having a processing
window that is very similar to or is substantially the same as the
processing window of the first material. Of course, if the more
desired processing window is between a first processing window of a
first material and the second processing window of a second
material, the proportion of the first and the second material can
be chosen to achieve a desired processing window of the formable
material.
[0235] Optionally, a plurality of materials each having similar or
different processing windows can be combined to obtain a desired
processing window for the resultant material.
[0236] In one embodiment, the rheological characteristics of a
formable material can be altered by varying one or more of its
components having different Theological characteristics. For
example, a substrate (e.g., PP) may have a high melt strength and
is amenable to extrusion. PP can be combined with another material,
such as PET which has a low melt strength making it difficult to
extrude, to form a material suitable for extrusion processes. For
example, a layer of PP or other strong material may support a layer
of PET during co-extrusion (e.g., horizontal or vertical
co-extrusion). Thus, formable material formed of PET and
polypropylene can be processed, e.g., extruded, in a temperature
range generally suitable for PP and not generally suitable for
PET.
[0237] In some embodiments, the composition of the formable
material may be selected to affect one or more properties of the
articles. For example, the thermal properties, structural
properties, barrier properties, optical properties, rheology
properties, favorable flavor properties, and/or other properties or
characteristics disclosed herein can be obtained by using formable
materials described herein.
4. Additives to Enhance Materials
[0238] An advantage of preferred methods disclosed herein are their
flexibility allowing for the use of multiple functional additives.
Additives known by those of ordinary skill in the art for their
ability to provide enhanced CO.sub.2 barriers, O.sub.2 barriers, UV
protection, scuff resistance, blush resistance, impact resistance
and/or chemical resistance may be used.
[0239] Preferred additives may be prepared by methods known to
those of skill in the art. For example, the additives may be mixed
directly with a particular material, they may be
dissolved/dispersed separately and then added to a particular
material, or they may be combined with a particular material to
addition of the solvent that forms the material
solution/dispersion. In addition, in some embodiments, preferred
additives may be used alone as a single layer.
[0240] In preferred embodiments, the barrier properties of a layer
may be enhanced by the addition of different additives. Additives
are preferably present in an amount up to about 40% of the
material, also including up to about 30%, 20%, 10%, 5%, 2% and 1%
by weight of the material. In other embodiments, additives are
preferably present in an amount less than or equal to 1% by weight,
preferred ranges of materials include, but are not limited to,
about 0.01% to about 1%, about 0.01% to about 0.1%, and about 0.1%
to about 1% by weight. Further, in some embodiments additives are
preferably stable in aqueous conditions. For example, derivatives
of resorcinol (m-dihydroxybenzene) may be used in conjunction with
various preferred materials as blends or as additives or monomers
in the formation of the material. The higher the resorcinol content
the greater the barrier properties of the material. For example,
resorcinol diglycidyl ether can be used in PHAE and hydroxyethyl
ether resorcinol can be used in PET and other polyesters and
Copolyester Barrier Materials.
[0241] Another additive that may be used are "nanoparticles" or
"nanoparticulate material." For convenience the term nanoparticles
will be used herein to refer to both nanoparticles and
nanoparticulate material. These nanoparticles are tiny, micron or
sub-micron size (diameter), particles of materials which enhance
the barrier properties of a material by creating a more tortuous
path for migrating gas molecules, e.g. oxygen or carbon dioxide, to
take as they permeate a material. In preferred embodiments
nanoparticulate material is present in amounts ranging from 0.05 to
1% by weight, including 0.1%, 0.5% by weight and ranges
encompassing these amounts.
[0242] One preferred type of nanoparticulate material is a
microparticular clay based product available from Southern Clay
Products. One preferred line of products available from Southern
Clay products is Cloisites nanoparticles. In one embodiment
preferred nanoparticles comprise monmorillonite modified with a
quaternary ammonium salt. In other embodiments nanoparticles
comprise monmorillonite modified with a ternary ammonium salt. In
other embodiments nanoparticles comprise natural monmorillonite. In
further embodiments, nanoparticles comprise organoclays as
described in U.S. Pat. No. 5,780,376, the entire disclosure of
which is hereby incorporated by reference and forms part of the
disclosure of this application. Other suitable organic and
inorganic microparticular clay based products may also be used.
Both man-made and natural products are also suitable.
[0243] Another type of preferred nanoparticulate material comprises
a composite material of a metal. For example, one suitable
composite is a water based dispersion of aluminum oxide in
nanoparticulate form available from BYK Chemie (Germany). It is
believed that this type of nanoparticular material may provide one
or more of the following advantages: increased abrasion resistance,
increased scratch resistance, increased T.sub.g, and thermal
stability.
[0244] Another type of preferred nanoparticulate material comprises
a polymer-silicate composite. In preferred embodiments the silicate
comprises montmorillonite. Suitable polymer-silicate
nanoparticulate material are available from Nanocor and RTP
Company.
[0245] In preferred embodiments, the UV protection properties of
the material may be enhanced by the addition of different
additives. In a preferred embodiment, the UV protection material
used provides UV protection up to about 350 nm or less, preferably
about 370 nm or less, more preferably about 400 nm or less. The UV
protection material may be used as an additive with layers
providing additional functionality or applied separately as a
single layer. Preferably additives providing enhanced UV protection
are present in the material from about 0.05 to 20% by weight, but
also including about 0.1%, 0.5%, 1%, 2%, 3%, 5%, 10%, and 15% by
weight, and ranges encompassing these amounts. Preferably the UV
protection material is added in a form that is compatible with the
other materials. For example, a preferred UV protection material is
Milliken UV390A ClearShield.RTM. UV390A is an oily liquid for which
mixing is aided by first blending the liquid with water, preferably
in roughly equal parts by volume. This blend is then added to the
material solution, for example, BLOX.RTM. 599-29, and agitated. The
resulting solution contains about 10% UV390A and provides UV
protection up to 390 nm when applied to a PET preform. As
previously described, in another embodiment the UV390A solution is
applied as a single layer. In other embodiments, a preferred UV
protection material comprises a polymer grafted or modified with a
UV absorber that is added as a concentrate. Other preferred UV
protection materials include, but are not limited to,
benzotriazoles, phenothiazines, and azaphenothiazines. UV
protection materials may be added during the melt phase process
prior to use, e.g. prior to injection molding or extrusion, or
added directly to a coating material that is in the form of a
solution or dispersion. Suitable UV protection materials are
available from Milliken, Ciba and Clariant.
[0246] In preferred embodiments, CO.sub.2 scavenging properties can
be added to the materials. In one preferred embodiment such
properties are achieved by including an active amine which will
react with CO.sub.2 forming a high gas barrier salt. This salt will
then act as a passive CO.sub.2 barrier. The active amine may be an
additive or it may be one or more moieties in the thermoplastic
resin material of one or more layers.
[0247] In preferred embodiments, O.sub.2 scavenging properties can
be added to preferred materials by including O.sub.2 scavengers
such as anthroquinone and others known in the art. In another
embodiment, one suitable O.sub.2 scavenger is AMOSORB.RTM. O.sub.2
scavenger available from BP Amoco Corporation and ColorMatrix
Corporation which is disclosed in U.S. Pat. No. 6,083,585 to Cahill
et al., the disclosure of which is hereby incorporated in its
entirety. In one embodiment, O.sub.2 scavenging properties are
added to preferred phenoxy-type materials, or other materials, by
including O.sub.2 scavengers in the phenoxy-type material, with
different activating mechanisms. Preferred O.sub.2 scavengers can
act either spontaneously, gradually or with delayed action until
initiated by a specific trigger. In some embodiments the O.sub.2
scavengers are activated via exposure to either UV or water (e.g.,
present in the contents of the container), or a combination of
both. The O.sub.2 scavenger is preferably present in an amount of
from about 0.1 to about 20 percent by weight, more preferably in an
amount of from about 0.5 to about 10 percent by weight, and, most
preferably, in an amount of from about 1 to about 5 percent by
weight, based on the total weight of the coating layer.
[0248] In another preferred embodiment, a top coat or layer is
applied to provide chemical resistance to harsher chemicals than
what is provided by the outer layer. In certain embodiments,
preferably these top coats or layers are aqueous based or
non-aqueous based polyesters or acrylics which are optionally
partially or fully crosslinked. A preferred aqueous based polyester
is polyethylene terephthalate, however other polyesters may also be
used. In certain embodiments, the process of applying the top coat
or layer is that disclosed in U.S. Patent Pub. No. 2004/0071885,
entitled Dip, Spray, And Flow Coating Process For Forming Coated
Articles, the entire disclosure of which is hereby incorporated by
reference in its entirety.
[0249] A preferred aqueous based polyester resin is described in
U.S. Pat. No. 4,977,191 (Salsman), incorporated herein by
reference. More specifically, U.S. Pat. No. 4,977,191 describes an
aqueous based polyester resin, comprising a reaction product of
20-50% by weight of waste terephthalate polymer, 10-40% by weight
of at least one glycol an 5-25% by weight of at least one
oxyalkylated polyol.
[0250] Another preferred aqueous based polymer is a sulfonated
aqueous based polyester resin composition as described in U.S. Pat.
No. 5,281,630 (Salsman), herein incorporated by reference.
Specifically, U.S. Pat. No. 5,281,630 describes an aqueous
suspension of a sulfonated water-soluble or water dispersible
polyester resin comprising a reaction product of 20-50% by weight
terephthalate polymer, 10-40% by weight at least one glycol and
5-25% by weight of at least one oxyalkylated polyol to produce a
prepolymer resin having hydroxyalkyl functionality where the
prepolymer resin is further reacted with about 0.10 mole to about
0.50 mole of alpha, beta-ethylenically unsaturated dicarboxylic
acid per 100 g of prepolymer resin and a thus produced resin,
terminated by a residue of an alpha, beta-ethylenically unsaturated
dicarboxylic acid, is reacted with about 0.5 mole to about 1.5 mole
of a sulfite per mole of alpha, beta-ethylenically unsaturated
dicarboxylic acid residue to produce a sulfonated-terminated
resin.
[0251] Yet another preferred aqueous based polymer is the coating
described in U.S. Pat. No. 5,726,277 (Salsman), incorporated herein
by reference. Specifically, U.S. Pat. No. 5,726,277 describes
coating compositions comprising a reaction product of at least 50%
by weight of waste terephthalate polymer and a mixture of glycols
including an oxyalkylated polyol in the presence of a glycolysis
catalyst wherein the reaction product is further reacted with a
difunctional, organic acid and wherein the weight ratio of acid to
glycols in is the range of 6:1 to 1:2.
[0252] While the above examples are provided as preferred aqueous
based polymer coating compositions, other aqueous based polymers
are suitable for use in the products and methods describe herein.
By way of example only, and not meant to be limiting, further
suitable aqueous based compositions are described in U.S. Pat. No.
4,104,222 (Date et al.), incorporated herein by reference. U.S.
Pat. No. 4,104,222 describes a dispersion of a linear polyester
resin obtained by mixing a linear polyester resin with a higher
alcohol/ethylene oxide addition type surface-active agent, melting
the mixture and dispersing the resulting melt by pouring it into an
aqueous solution of an alkali under stirring. Specifically, this
dispersion is obtained by mixing a linear polyester resin with a
surface-active agent of the higher alcohol/ethylene oxide addition
type, melting the mixture, and dispersing the resulting melt by
pouring it into an aqueous solution of an alkanolamine under
stirring at a temperature of 70-95.degree. C., said alkanolamine
being selected from the group consisting of monoethanolamine,
diethanolamine, triethanolamine, monomethylethanolamine,
monoethylethanolamine, diethylethanol amine, propanolamine,
butanolamine, pentanolamine, N-phenylethanolamine, and an
alkanolamine of glycerin, said alkanolamine being present in the
aqueous solution in an amount of 0.2 to 5 weight percent, said
surface-active agent of the higher alcohol/ethylene oxide addition
type being an ethylene oxide addition product of a higher alcohol
having an alkyl group of at least 8 carbon atoms, an
alkyl-substituted phenol or a sorbitan monoacylate and wherein said
surface-active agent has an HLB value of at least 12.
[0253] Likewise, by example, U.S. Pat. No. 4,528,321 (Allen)
discloses a dispersion in a water immiscible liquid of water
soluble or water swellable polymer particles and which has been
made by reverse phase polymerization in the water immiscible liquid
and which includes a non-ionic compound selected from C.sub.4-12
alkylene glycol monoethers, their C.sub.1-4 alkanoates, C.sub.6-12
polyakylene glycol monoethers and their C.sub.1-4 alkanoates.
[0254] The materials of certain embodiments may be crosslinked to
enhance thermal stability for various applications, for example hot
fill applications. In one embodiment, inner layers may comprise
low-crosslinking materials while outer layers may comprise high
crosslinking materials or other suitable combinations. For example,
an inner coating on a PET surface may utilize non or low
cross-linked material, such as the BLOX.RTM. 588-29, and the outer
coat may utilize another material, such as EXP 12468-4B from ICI,
capable of crosslinking to ensure maximum adhesion to the PET.
Suitable additives capable of crosslinking may be added to one or
more layers. Suitable crosslinkers can be chosen depending upon the
chemistry and functionality of the resin or material to which they
are added. For example, amine crosslinkers may be useful for
crosslinking resins comprising epoxide groups. Preferably
crosslinking additives, if present, are present in an amount of
about 1% to 10% by weight of the coating solution/dispersion,
preferably about 1% to 5%, more preferably about 0.01% to 0.1% by
weight, also including 2%, 3%, 4%, 6%, 7%, 8%, and 9% by weight.
Optionally, a thermoplastic epoxy (TPE) can be used with one or
more crosslinking agents. In some embodiments, agents (e.g. carbon
black) may also be coated onto or incorporated into the TPE
material. The TPE material can form part of the articles disclosed
herein. It is contemplated that carbon black or similar additives
can be employed in other polymers to enhance material
properties.
[0255] The materials of certain embodiments may optionally comprise
a curing enhancer. As used herein, the term "curing enhancer" is a
broad term and is used in its ordinary meaning and includes,
without limitation, chemical cross-linking catalyst, thermal
enhancer, and the like. As used herein, the term "thermal enhancer"
is a broad term and is used in its ordinary meaning and includes,
without limitation, transition metals, transition metal compounds,
radiation absorbing additives (e.g., carbon black). Suitable
transition metals include, but are not limited to, cobalt, rhodium,
and copper. Suitable transition metal compounds include, but are
not limited to, metal carboxylates. Preferred carboxylates include,
but are not limited to, neodecanoate, octoate, and acetate. Thermal
enhancers may be used alone or in combination with one or more
other thermal enhancers.
[0256] The thermal enhancer can be added to a material and may
significantly increase the temperature of the material during a
curing process, as compared to the material without the thermal
enhancer. For example, in some embodiments, the thermal enhancer
(e.g., carbon black) can be added to a polymer so that the
temperature of the polymer subjected to a curing process (e.g., IR
radiation) is significantly greater than the polymer without the
thermal enhancer subject to the same or similar curing process. The
increased temperature of the polymer caused by the thermal enhancer
can increase the rate of curing and therefore increase production
rates. In some embodiments, the thermal enhancer generally has a
higher temperature than at least one of the layers of an article
when the thermal enhancer and the article are heated with a heating
device (e.g., infrared heating device).
[0257] In some embodiments, the thermal enhancer is present in an
amount of about 5 to 800 ppm, preferably about 20 to about 150 ppm,
preferably about 50 to 125 ppm, preferably about 75 to 100 ppm,
also including about 10, 20, 30, 40, 50, 75, 100, 125, 150, 175,
200, 300, 400, 500, 600, and 700 ppm and ranges encompassing these
amounts. The amount of thermal enhancer may be calculated based on
the weight of layer which comprises the thermal enhancer or the
total weight of all layers comprising the article.
[0258] In some embodiments, a preferred thermal enhancer comprises
carbon black. In one embodiment, carbon black can be applied as a
component of a coating material in order to enhance the curing of
the coating material. When used as a component of a coating
material, carbon black is added to one or more of the coating
materials before, during, and/or after the coating material is
applied (e.g., impregnated, coated, etc.) to the article.
[0259] Preferably carbon black is added to the coating material and
agitated to ensure thorough mixing. The thermal enhancer may
comprise additional materials to achieve the desire material
properties of the article.
[0260] In another embodiment wherein carbon black is used in an
injection molding process, the carbon black may be added to the
polymer blend in the melt phase process.
[0261] In some embodiments, the polymer comprises about 5 to 800
ppm, preferably about 20 to about 150 ppm, preferably about 50 to
125 ppm, preferably about 75 to 100 ppm, also including about 10,
20, 30, 40, 50, 75, 100, 125, 150, 175, 200, 300, 400, 500, 600,
and 700 ppm thermal enhancer and ranges encompassing these amounts.
In a further embodiment, the coating material is cured using
radiation, such as infrared (IR) heating. In preferred embodiments,
the IR heating provides a more effective coating than curing using
other methods. Other thermal and curing enhancers and methods of
using same are disclosed in U.S. Published Application
2006/0099363, entitled "Catalyzed Process for Forming Coated
Articles," the disclosure of which is hereby incorporated by
reference it its entirety.
[0262] In some embodiments the addition of anti-foam/bubble agents
is desirable. In some embodiments utilizing solutions or dispersion
the solutions or dispersions form foam and/or bubbles which can
interfere with preferred processes. One way to avoid this
interference, is to add anti-foam/bubble agents to the
solution/dispersion. Suitable anti-foam agents include, but are not
limited to, nonionic surfactants, alkylene oxide based materials,
siloxane based materials, and ionic surfactants. Preferably
anti-foam agents, if present, are present in an amount of about
0.01% to about 0.3% of the solution/dispersion, preferably about
0.01% to about 0.2%, but also including about 0.02%, 0.03%, 0.04%,
0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.25%, and ranges
encompassing these amounts.
[0263] In another embodiment foaming agents may be added to the
coating materials in order to foam the coating layer. In a further
embodiment a reaction product of a foaming agent is used. Useful
foaming agents include, but are not limited to azobisformamide,
azobisisobutyronitrile, diazoaminobenzene,
N,N-dimethyl-N,N-dinitroso terephthalamide,
N,N-dinitrosopentamethylene-tetramine, benzenesulfonyl-hydrazide,
benzene-1,3-disulfonyl hydrazide, diphenylsulfon-3-3, disulfonyl
hydrazide, 4,4'-oxybis benzene sulfonyl hydrazide, p-toluene
sulfonyl semicarbizide, barium azodicarboxylate, butylamine
nitrile, nitroureas, trihydrazino triazine, phenyl-methyl-urethane,
p-sulfonhydrazide, peroxides, ammonium bicarbonate, and sodium
bicarbonate. As presently contemplated, commercially available
foaming agents include, but are not limited to, EXPANCEL.RTM.,
CELOGEN.RTM., HYDROCEROL.RTM., MIKROFINE.RTM., CEL-SPAN.RTM., and
PLASTRON.RTM. FOAM.
[0264] The foaming agent is preferably present in the coating
material in an amount from about 1 up to about 20 percent by
weight, more preferably from about 1 to about 10 percent by weight,
and, most preferably, from about 1 to about 5 percent by weight,
based on the weight of the coating layer. Newer foaming
technologies known to those of skill in the art using compressed
gas could also be used as an alternate means to generate foam in
place of conventional blowing agents listed above.
[0265] The tie-layer is preferably a polymer having functional
groups, such as anhydrides and epoxies that react with the carboxyl
and/or hydroxyl groups on the PET polymer chains. Useful tie-layer
materials include, but are not limited to, DuPont BYNEL.RTM.,
Mitsui ADMER.RTM., Eastman's EPOLINE, Arkema's LOTADER and
ExxonMobil's EVELOY.RTM..
D. Methods and Systems for Making Lamellar Material
[0266] A multi component layer or article can also be made from a
lamellar meltstream that preferably comprises at least two
components. A lamellar meltstream, as that term is used herein,
includes without limitation, a meltstream comprising at least two
layers in which the layers in the meltstream are generally
parallel. Although a lamellar meltstream may have as few as two
layers, a lamellar meltstream may comprise, and preferably
comprises, a plurality of thin layers. Where the lamellar
meltstream is made from two materials, the meltstream is preferably
comprised of generally alternating thin layers of the two
materials. The materials used to form the lamellar meltstream are
preferably polymers, such as thermoplastics, including polyester,
polyolefin, phenoxy-type materials and other materials as described
herein. The layer materials may also include blends of two or more
materials. The layer materials may also incorporate additives such
as nanoparticles, oxygen scavengers, UV absorbers, compatibilizers,
and the like. In one embodiment, the lamellar meltstream comprises
recycled polyester such as recycled PET and a barrier material.
[0267] One method of forming a lamellar meltstream uses a system
similar to that disclosed in several patents to Schrenk, U.S. Pat.
Nos. 5,202,074, 5,540,878, and 5,628,950, the disclosures of which
are hereby incorporated in their entireties by reference, although
the use of that method as well as other methods for obtaining
lamellar meltstreams are presently contemplated. Referring to FIG.
27, a schematic of an embodiment of a lamellar meltstream
generation system 482 is shown. The system in FIG. 27 illustrates
one embodiment of a two material system, but it will be understood
that a system for three or more materials will operate in a similar
fashion. The two materials which are to form the layers are placed
in separate hoppers or inlets 484 and 485, which feed two separate
extruders, 486 and 487 respectively. In a preferred embodiment, the
extruders 486 and 487 are screw-type extruders that can apply a
combination of heat and pressure to turn raw materials into a melt.
The materials are extruded at rates and thicknesses to provide the
desired relative amounts of each material and the meltstreams of
the extruders combined to form a two layer meltstream 488 comprised
of a layer from each cylinder preferably arranged so that one layer
lies on top of the other layer.
[0268] The two layer meltstream 488 output from combined cylinders
is then preferably applied to a layer multiplication system 490. In
the illustrated layer multiplication system 490, the two layer
meltstream 488 is multiplied into a multi-layer meltstream 492,
which has 10 layers in the illustrated embodiment as shown in FIG.
27A. The illustration in FIG. 27A is schematic and somewhat
idealistic in that although the layers of the lamellar material on
average are preferably generally parallel to each other, the
lamellar material may include layers that are not parallel to each
other and/or layers may be generally parallel at some points and
not parallel at others.
[0269] Layer multiplication may be done by any of a number of ways.
In one embodiment, one first divides a section of meltstream into
two pieces perpendicular to the interface of the two layers. Then
the two pieces are flattened so that each of the two pieces is
about as long as the original section before it was halved in the
first step, but only half as thick as the original section. Then
the two pieces are recombined into one piece having similar
dimensions as the original section, but having four layers, by
stacking one piece on top of the other piece so that the sublayers
of the two materials are parallel to each other (i.e. stacking in a
direction perpendicular to the layers of the meltstream). These
steps of dividing, flattening, and recombining the meltstream may
be done several times to create more thinner layers. The meltstream
may be multiplied by performing the dividing, flattening and
recombining a number of times to produce a single melt stream
consisting of a plurality of sublayers of the component materials.
In this two material embodiment, the composition of the layers will
alternate between the two materials. Other methods of layer
generation include performing steps similar to those outlined
above, but flattening the meltstream prior to dividing or following
recombination. Alternatively, in any of these embodiments one may
fold the meltstream back onto itself rather than dividing it into
sections. Combinations of dividing and folding may also be used,
but it is noted that folding and dividing will achieve slightly
different results because folding will cause one layer to be
doubled back upon itself. The output from the layer multiplication
system passes out an opening 494 such as a nozzle or valve, and is
used to form an article or a multi-component layer in an article,
such as by injecting or placing the lamellar meltstream into a
mold.
[0270] In the illustrated two-material embodiment, the composition
of the layers generally alternates between the two materials.
However, in other embodiments any suitable number of materials can
be combined into a component meltstream and then fed to layer
multiplication system 490 which can produce a lamellar meltstream
with any desired number and/or size of repeating blocks or stacks
of materials. For example, in one embodiment, the system 482
comprises three extruders that simultaneously deliver material to
the layer multiplication system 490. The layer multiplication
system 490 can form a stack of layers formed of the three
materials.
[0271] When a lamellar meltstream includes one or more materials
which provide gas barrier properties, it is preferred that the
lamellar meltstream be used in a manner which orients it such that
the layers of the meltstream are generally parallel to one or more
broad surfaces of the article. For example, in a preform or
container, the layers are preferably generally parallel to the
length of the wall section or body portion. Although parallel is
preferred, other orientations may be used and are within the scope
of this disclosure. For example, one or more portions of the wall
of a container can have layers that are parallel to each other and
the surface of the wall while one or more other portions have
layers that are not parallel to each other. The desired tortuous
path through the wall of a container is determined by the
orientation and configuration of the layers of which form the
container. For example, layers that are generally parallel to each
other and the wall section can increase substantially the length of
the path through the wall to be traversed by a gas molecule.
Alternatively, layers that are generally parallel to each other and
transverse to the wall result in a shorter or reduced tortuous
fluid path through the wall and would thus have lower barrier
properties than the same meltstream oriented in a parallel
fashion.
[0272] The articles, such as containers and preforms disclosed
herein can be formed using a lamellar meltstream output from a
system such as the one illustrated. In some embodiments, the
lamellar melt comprises materials that have generally similar melt
temperatures, T.sub.m, for convenient processing and molding.
However, the lamellar melt may comprise materials that have
substantially different T.sub.m. For example, the lamellar material
can comprise materials which have T.sub.m within a range of about
500.degree. F. (about 260.degree. C.). The materials of the
lamellar material can be selected based on the material's thermal
properties, structural properties, barrier properties, rheology
properties, processing properties, and/or other properties. The
lamellar melt can be formed and cooled, preferably before one or
more of its components substantially degrade. A skilled artisan can
select materials to form the lamellar material to achieve the
desired material stability suitable for the processing
characteristics and chosen end use.
E. Methods and Apparatuses for Making Preferred Articles
[0273] The monolayer and multilayer articles (including packaging
such as closures, preforms, containers, bottles) can be formed by a
molding process (e.g., injection molding including co-injection
molding). One method of producing multi-layered articles is
referred to herein generally as overmolding, and sometimes as
inject-over-inject ("IOI"). The name refers to a procedure which
uses injection molding to inject one or more layers of material
over an existing layer, which preferably was itself made by
injection molding. The terms "overinjecting" and "overmolding" are
used herein to describe the coating process whereby a layer of
material is injected over an existing layer or preform.
[0274] One overmolding method for making preforms involves using an
injection molding machine in conjunction with a mold comprising a
mandrel or core and a cavity. A first layer of a preform is molded
between the mandrel and a first cavity of the mold by injecting a
molten polymer (i.e. polymer melt) into the void space in the mold.
The first layer remains on the mandrel when the mandrel is pulled
out of the cavity, moved, and inserted into a second mold cavity. A
second layer of a material is then injected over the existing first
preform layer. The mandrel and accompanying preform are then
removed from the second cavity and the preform is removed from the
mandrel.
[0275] In some embodiments, the overinjecting process is performed
while the underlying layer has not yet fully cooled. The underlying
layer may have retained inherent heat from an injection molding
process that formed the underlying layer. In some embodiments, the
underlying layer can be at room temperature or any other
temperature suitable for overmolding. For example, articles at room
temperature can be overmolded with one or more layers of material.
These articles may have been stored for an extended period of time
before being overmolded.
[0276] Overinjecting may be used to place one or more layers of
material(s) such as those comprising PP, expandable/foam material,
PET (including recycled PET, virgin PET), lamellar material,
barrier materials, combinations thereof, and/or other materials
described herein over a substrate (i.e., the underlying layer). In
some non-limiting embodiments, the substrate is in the form of a
preform, preferably having an interior surface for contacting
foodstuff. In some embodiments, the substrate preform comprises PET
(such as virgin PET), phenoxy type thermoplastic, combinations
thereof, and/or the like.
[0277] Articles may comprises one or more layers or portions having
one or more of the following advantageous characteristics: an
insulating layer, a barrier layer, a foodstuff contacting layer, a
non-flavor scalping layer, a high strength layer, a compliant
layer, a tie layer, a gas scavenging layer, a layer or portion
suitable for hot-fill applications, a layer having a melt strength
suitable for extrusion. In some embodiments, monolayer or
multi-layer material comprises one or more of the following
materials: PET (including recycled and/or virgin PET), PETG, foam,
polypropylene, phenoxy type thermoplastics, polyolefins,
phenoxy-polyolefin thermoplastic blends, and/or combinations
thereof. For the sake of convenience, articles are described
primarily with respect to preforms, containers, and closures.
[0278] In some embodiments, articles can comprise foam material.
Foam material can be prepared by combining a foaming agent and a
carrier material. In one embodiment, the carrier material and the
foaming agent are co-extruded for a preferably generally homogenous
mixture of foam material. The amount of carrier material and the
foaming agent can be varied depending on the desired amount of one
or more of the following: expansion properties, structural
properties, thermal properties, feed pressure, and the like. In
some non-limiting embodiments, the expandable/foam material
comprises less than about 10% by weight, also including less than
about 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, or 1% by weight, of the
foaming agent. In some non-limiting embodiments, the
expandable/foam material comprises about 1-6% by weight of the
foaming agent. In another non-limiting embodiment, the
expandable/foam material comprises about 3-6% by weight of the
foaming agent. In another non-limiting embodiment, the
expandable/foam material comprises about 2-8% by weight of the
foaming agent. It is contemplated that the expandable/foam material
may comprise any suitable amount of foaming agent including those
above and below the particular percentages recited above, depending
on the desired properties of the foam material.
[0279] In some embodiments, carrier material (e.g., polypropylene
pellets) and a foaming agent in the form of microspheres,
preferably EXPANCEL.RTM. microspheres or similar material, are fed
into a hopper. The carrier material and the microspheres are heated
to melt the carrier material for effective mixing of the materials.
When the mixture is heated, the microspheres may expand or become
enlarged. Preferably, the temperature of the mixture is in a
temperature range to not cause full expansion or bursting of a
substantial portion of the microspheres. For example, if the
temperature of the mixture reaches a sufficiently high temperature,
the gas within the microspheres may expand such that microspheres
break or collapse. The melted foam material can be co-extruded and
is preferably rapidly quenched to limit the amount of expansion of
the microspheres.
[0280] When the foam material is heated for processing (e.g.,
extruding, injecting, etc.), the microspheres according to one
embodiment may partially expand from their initial generally
unexpanded position. When such microspheres are partially expanded,
they retain the ability to undergo further expansion to increase
the size of the microspheres. Preferably, the pressure and
temperature are such that the microspheres are not fully expanded
during extrusion in order to allow further expansion of the
microspheres during blow molding, for example. Additionally, the
pressure of the foam material can be increased to reduce, or
substantially prevent, the expansion of the microspheres. Thus, the
pressure and the temperature of the foam material can be varied to
obtain the desired amount of expansion of the microspheres.
Partially expanded microspheres can undergo further expansion when
they are reheated (e.g., during the blow molding cycle) as
described herein.
[0281] It is contemplated that articles described herein can be
prepared or modified by any suitable method, including but not
limited to (1) dip or flow coating, (2) spray coating, (3) flame
spraying, (4) fluidized bed dipping, (5) electrostatic powder
spray, (6) overmolding (e.g., inject-over-inject), and/or (7)
injection molding (including co-injection). For example, preferred
methods and apparatuses for performing the methods are disclosed in
U.S. Pat. No. 6,352,426 and U.S. Publication No. 2004-0071885 which
are incorporated by reference in their entirety and form part of
the disclosure of this application. It is also contemplated that
these methods and apparatuses can be used to form other articles
described herein. The preforms disclosed herein can be blow molded
using methods and apparatus disclosed in the references (e.g., U.S.
Pat. No. 6,352,426) incorporated by reference into the present
application.
1. Methods and Apparatus for Preparing an Article Comprising
Foam
[0282] A article, such as the preform 30 can be formed through
injecting molding by utilizing an injection mold. FIG. 28
illustrates a mold 501 which has a cavity 500 defined by the core
499 and the mold cavity section 504. The mold 501 can form an
article that comprises expandable/foam material. In some
embodiments, including the illustrated embodiment, the foam
material is passed along a line 509 and passes through a gate 508
and into the cavity 500. The foam material can fill the cavity 500
to form the preform 30. The foam material within the cavity 500 can
be rapidly cooled or quenched to limit expansion of the foaming
agent and can reduce cycle times to increase production. The mold
can have a gate or needle valve 511 to prevent backflow of the
expanding foam.
[0283] The back pressure of the melt may not be high enough to
cause the foaming agent in the form of microspheres to break.
However, the back pressure should prevent the microspheres from
over expanding in order to allow for blow molding the preform into
the desired shape and/or to allow for further expansion of the
microspheres. The temperature of the melt can be varied depending
on the back pressure of the melt. For example, a melt at a high
temperature can cause the microspheres to expand. To inhibit or
prevent the expansion of the microspheres, the back pressure can be
increased to account for the increased pressure within each of the
microspheres. However, if the pressure of the melt is too high, the
microspheres may break or collapse. Thus, the pressure of the melt
is preferably maintained in a range so that a substantial portion
of the microspheres do not fully expand or break. In other
embodiments, however, some or all of the spheres may break upon
full expansion to form the foam (e.g., open celled foam).
[0284] In some embodiments, the melt may undergo at least partial
expansion before it is injected into the mold cavity 500. For
example, after a shot of melt is injected into the cavity 500, the
screw of the extruder can be retracted to accumulate melt for the
next shot. After recovery, the screw can be decompressed to reduce
the pressure of the melt to achieve controllable expansion of the
microspheres in the melt. In one embodiment, the melt is not under
pressure so that the microspheres can freely expand. However,
pressure can be applied to the melt to selectively control the
expansion of the microspheres. Accordingly, the microspheres in the
melt can be partially or fully expanded before the melt is injected
into the cavity 500. Preferably, the microspheres are in a state of
expansion such that the microspheres can undergo further expansion
during, e.g., the preheat process for blow molding. The melt having
microspheres may be injected into the cavity 500 to form a preform
having expanded microspheres. The preform having expanded
microspheres can then be formed into the container having generally
evenly distributed microspheres.
[0285] The cavity 500 can be heated to result in a generally even
distribution of the microspheres of the preform. The heat can cause
generally uniform expansion of the foam material. In some
embodiments, the melt may comprises polypropylene and microspheres
and is injected into the cavity 500, which can be at a temperature
of about 100.degree. F. (37.8.degree. C.) to about 250.degree. F.
(121.1.degree. C.). The heated cavity 500 can ensure that the
microspheres are generally evenly distributed throughout the
preform. In another embodiment, the cavity 500 can be maintained at
a temperature of about 150.degree. F. (65.6.degree. C.) to about
225.degree. F. (107.2.degree. C.). In yet another embodiment, the
cavity 500 can be maintained at a temperature of less than about
200.degree. F. (93.3.degree. C.). The cavity 500 can be cooled at
any suitable time to achieve the desired distribution of the
microspheres. In another embodiment, the melt comprises
polyethylene and microspheres. The cavity 500 can be at a
temperature of about 75.degree. F. (23.9.degree. C.) to about
125.degree. F. (51.7.degree. C.) to form a preform, preferably
generally evenly distributed microspheres. The preform may have
evenly distributed microspheres can then be molded into a container
which, in turn, has evenly distributed microspheres. The
temperatures noted above are dependent upon the particular
materials used. In view of the present disclosure, a skilled
artisan can select material(s), processing parameters, and design
to the mold to produce various types of articles.
[0286] The speed of the melt passing through the line 509 and the
cavity 500 can cause frictional heat and thus cause expansion of
the microspheres in addition to the heat of the melt. The
illustrated mold of FIG. 28 has high heat transfer material 507
that can rapidly cool the melt passing through the cavity 500 to
retard the expansion of the microspheres. The high heat transfer
material 507 can form a portion or the entire mold cavity section
504. Thus, operating parameters (e.g., the flow speed, pressure,
temperature, mixture ratios, viscosity, and the like) can be varied
depending on the shape, size, and other characteristics of the
mold.
[0287] In some embodiments, the preform in the cavity 500 can be
rapidly cooled or quenched to retard, or even to stop, the
expansion of the microspheres. This allows that the microspheres,
which may be partially expanded, to form a tight structure that can
be expanded during blow molding. After the preform is sufficiently
cooled, it can be conveniently handled without further expansion of
the microspheres. In one embodiment, the cavity 500 is maintained
at a temperature suitable for controlling the expansion rate of the
microspheres during the molding process. In one non-limiting
embodiment, the cavity 500 is maintained at a temperature of about
40.degree. F. (4.4.degree. C.) to about 180.degree. F.
(82.2.degree. C.) to reduce or stop the expansion of the
microspheres. The temperature of the cavity 500 can be selected
based on, e.g., the molding materials, the size and configuration
of the preform, the size of the space filled by the foam material,
and/or processing parameters. The processing temperature of the
material can be chosen or determined by a skilled artisan given the
composition of foam (carrier material, foaming agent,
microspheres), degree of expansion desired, and/or other
parameters.
a. Preparing Articles By Blow Molding Process
[0288] Articles comprising form can be produced by blow-molding
processes. An article in the form of the preform 30 can be stretch
blow-molded to form a container, such as the container 37 (FIG. 4),
and preferably cause expansion of the microspheres. The preform 30
can be subjected to a stretch blow-molding process in the mold
illustrated in FIG. 3. The preform 30 comprising expandable
material is placed in the mold 28 having a cavity corresponding to
the desired container shape. The preform 30 is then heated and
expanded by stretching the preform 30 to fill the cavity within the
mold 28, thus creating a container. The stretching can be
accomplished by, e.g., forcing air into the interior portion of the
preform 30. The blow molding operation normally is restricted to
the body portion 34.
[0289] Before the preform 30 is stretched, the preform 30 is
preferably preheated to the blow temperature range for the blow
molding process. If the temperature of the preform 30 reaches the
expansion temperature range, the microspheres of the preform 30 may
expand. The expansion temperature range can be achieved before,
during, or after the stretching of the preform 30. Preferably, the
microspheres of the preform 30 are heated to their expansion
temperature range to cause at least partial expansion of the
microspheres before the preform 30 is blow molded.
[0290] After the temperature of the preform 30 is raised to the
blow temperature range, air is passed into the interior portion of
the preform 30 to expand the preform into the desired shape of the
container 37. The expansion temperature range is preferably
generally similar to the blow temperature range such that the
microspheres can expand during the heating or reheating for blow
molding. The expandable material is expanded as the air forces the
preform to stretch and mold to the desired shape. In another
embodiment, the preform 30 can be blow molded into the desired
shape and then the temperature of the container 37 can reach the
expansion temperature range so as to cause expansion of the foam
material of the container 37. To increase the rate of expansion of
the microspheres, the temperature during the blow molding cycle can
be increased and/or the blow pressure can be reduced. To decrease
the rate of expansion of the microspheres, the temperature during
the blow molding cycle can be decreased and/or the blow pressure
can be increased. Thus, the preform can be heated/chilled and the
pressure can be set as desired.
[0291] With reference to FIG. 3, the walls 33 of the mold 28 can be
temperature controlled to achieve the desired expansion of the foam
material of the preform 30/container 37. In one embodiment, the
mold 28 has a temperature control system to control the temperature
of the walls 33. The temperature control system can have
heating/cooling channels or any suitable system for effectively
controlling the temperature of the walls 33.
[0292] In some embodiments, for example, the walls 33 are heated to
cause expansion of the microspheres of the container 37. After the
preform 30 is blow molded to form the container 37, the heated
walls 33 continue the expansion of the microspheres in the wall of
the container 37, thereby reducing the density of the wall. In this
manner, the microspheres in the walls of the container 37 can be
expanded or enlarged to provide a more effective thermal barrier
due to the highly expanded microspheres.
[0293] The walls 33 of the mold 28 can be cooled to retard, or
prevent, the expansion or further expansion of the microspheres.
The walls 33 may be heated during one or more portions and cooled
during one or more portions of the production cycle. The walls 33
can be heated during a heat cycle to promote expansion of the
microspheres as discussed above. After the microspheres have
expanded as desired, the mold walls 33 are preferably cooled to
decrease, or preferably stop, the further expansion of the
microspheres. Thus, the walls 33 can be heated during a first
portion and cooled during a second portion of the blow-molding
process. However, the walls 33 can be heated and/or cooled at any
suitable time during the blow-molding process. For example, in
another embodiment the walls 33 of the mold 28 are cooled during
the stretching of the preform 30 from its initial position to the
desired container shape. The preform 30 can be heated, blown, and
stretched until the wall of the preform contacts the chilled walls
33. Preferably, the expandable material forming the preform 30
undergoes localized expansion as the preform is stretched. When the
preform 30 thermally communicates with the walls 33, heat is
transferred from the stretched preform 30 to the mold 28 to cool
the wall 84 of the shaped preform. As the preform 30 is cooled, the
expansion of the microspheres can be reduced or stopped. The
pressure within the mold 28 can be increased to decrease the rate
of expansion of the microspheres. The pressure within the mold 28
can be decreased to increase the rate of expansion of the
microspheres.
[0294] The walls 33 of the mold 28 can have a surface treatment or
structures for achieving a desired foaming reaction during the blow
molding process which may result in a textured surface of the
container 37. For example, the surface of the walls 33 can be rough
or gritty so that when the outer surface of container 37 contacts
the wall 33 during blow molding, the outer surface of the container
37 will have a textured foam surface. The textured surface of the
wall 33 can promote further expansion of the microspheres after at
least a portion of the container contacts the wall 33 of the mold
28. However, the surface of the wall 33 can have any treatment to
achieve a suitable outer surface texture of the container 82. In
another embodiment, for example, the wall 33 of the mold 28 can
have a reduced friction finish, such as a vapor honed finish, for
easy release of the container 37 from the mold 28. The reduced
friction finish can be a substantially smooth surface to facilitate
release of the container. The mold 28 can be used to produce
multilayer containers, such as the container 82 of FIG. 6.
2. Preferred Methods and Apparatuses for Preparing Preforms
[0295] Articles having mono or multilayers can be formed through
injection molding processes, such as by co-injection, overmolding,
and the like. It is contemplated that combinations of injection
molding can be performed to produce different configurations of
articles.
a. Preferred Methods and Apparatuses For Co-Injection Molding
[0296] FIG. 28 illustrates the mold 501 that can be used to inject
or co-inject to form monolayer or multilayer, respectively,
articles. Multilayer preforms can be formed by a co-injection
procedure in which a plurality of materials are co-injected into
the cavity 500. In some embodiments, a first material and a second
material are co-injected into the cavity 500 to form a multilayer
preform. In the embodiment illustrated in FIG. 11, a first material
that forms the inner layer 164 and a second material that forms the
outer layer 162 can be co-injected through the gate 508. To
terminate the inner layer 164 along the interior surface of the
preform 160, the flow of the first material forming the inner layer
164 can be stopped before the melt stream comprising the first
material proceeds throughout the entire cavity 500. Thus, one or
more materials can be delivered through the gate 508 at different
flow rates, simultaneously or at different times, in various
amounts, and the like to form a desired article.
[0297] The preform 160 can have a thin inner layer 164 relative to
the outer layer 162. This is especially advantageous if the
material forming the inner layer 164 is substantially more
expensive than the material forming the outer layer 162. For
example, some types of phenoxy type thermoplastics may be more
expensive than readily available materials, such as PET, so that
the amount of phenoxy type thermoplastics can be used in minimal
amounts to reduce the material cost of the preform 160.
[0298] The preform 180 of FIG. 12 also can be formed through a
co-injection process using the mold 501. A skilled artisan will
readily recognize that the layers of the preforms 160, 180 can be
varied to achieve the desired properties of the preform. FIGS. 12A
and 12B illustrate alternative embodiments of multilayer preforms.
FIG. 12B illustrates a preform 180B that comprises an inner layer
184B and/or outer layer 182B that may have a varying thickness. The
illustrated layers 182B, 184B comprise a thickened portion in the
body portion of the preform. The inner layer 184B has a slightly
thickened body portion relative to the neck finish. The thickness
of the outer layer 182B is generally greater than the thickness of
the inner layer 184B. Although not illustrated, the preform 190 of
FIG. 13 also can have the inner layer 194 and the outer layer 199
of varying thicknesses.
[0299] It is contemplated that the preforms of FIGS. 11-14 can be
overmolded with a material (e.g., barrier material), preferably to
form a layer that extends from the support ring along the body
portion of the preform. U.S. Pat. No. 6,312,641 is hereby
incorporated by reference in its entirety and describes methods,
systems and articles formed by one or more molding processes. In
view of the present disclosure, various combinations of systems can
be used to produce a wide variety of articles by employing a
co-injection processes.
b. First Preferred Method and Apparatus for Overmolding
[0300] Articles having multiple layers can be formed through
injection molding process, such as by an overmolding process. FIG.
29 illustrates an example of a mold 520 for overmolding. The mold
520 has a core half 522 and a cavity half 524 illustrated in the
closed position prior to overinjecting. The cavity half 524
comprises a cavity in which the uncoated article in the form of a
substrate (e.g., the preform 528) is placed. The overmolding
process is can be used to deposit one or more layers on the
substrate.
[0301] The preform 528 can be a mono or multilayer preform. The
illustrated preform is a monolayer preform that may comprise one or
more of the following: PET (e.g., virgin PET and/or recycled PET),
polyester, PP, phenoxy type thermoplastics, thermoplastics and/or
the like. The preform 528 can also be similar to the preforms
disclosed in the applications or patents incorporated by reference
into the present application.
[0302] A support ring 538 of the preform 528 can rest on a ledge
536 and is held in place by the core half 522, which exerts
pressure on the support ring 538, thus sealing the neck portion off
from the body portion of the substrate preform. The core half 522
of the mold comprises a core 540. The core 540 selectively
heats/cools the interior of the preform 528, while channels 544 can
heat/cool the cavity half 524. For example, the cooling is done by
fluid circulating through channels 546 in the core half 522 of the
mold 520.
[0303] As the preform 528 sits in the mold cavity, the body portion
of the preform is substantially centered within the cavity and is
preferably completely surrounded by a void space or cavity 550. The
preform, thus positioned, acts as an interior die mandrel in the
subsequent injection procedure. The melt of the overmolding
material is then introduced into the mold cavity 550 from an
injector via gate 554 and flows around the preform 528, preferably
surrounding at least the body portion of the preform 528. Following
overinjection, the overmolded layer will take the approximate size
and shape of the cavity 550.
[0304] The coating material may be heated to form a melt of a
viscosity compatible with use in an injection molding apparatus.
The temperature for this, the inject temperature, will differ among
materials, as melting ranges in polymers and viscosities of melts
may vary due to the history, chemical character, molecular weight,
degree of branching and other characteristics of a material.
[0305] The mold 520 can be used to form the coated preforms
disclosed herein such as the preform 50. The preform 50 of FIG. 5
can have one of the layers 52, 54 comprising substantially PET,
phenoxy type thermoplastics (including phenoxy and
polyoletin-phenoxyblends), polypropylene, lamellar material, and/or
other thermoplastics. In some embodiments, the other of the layers
52, 54 of the preform 50 can comprise another material, such as
foam. The expandable/foam material can comprise a carrier material
(e.g., PP, PET, and/or ethylene acrylic acid) that mixed with a
foaming agent (e.g., microspheres, such as EXPANCEL.RTM.
microspheres) for producing a foam material. For example, the inner
layer 54 can comprise PET and the outer layer 52 can comprise
expandable/foam material. The substrate preform can comprise PET.
Foam material can be delivered through a line 552 and the gate 554
into the cavity 550. The injected expandable/foam material is then
cooled for subsequent removal. In view of the present disclosure, a
skilled artisan can select material(s) based on the material(s)'
properties and desired articles made therefrom.
i. Preparing Multilayer Articles by Blow Molding
[0306] Multilayer articles can be blow molded in a similar manner
as monolayer articles, except as described in further detail below.
For the sake of convenience, blow molding of multilayer articles
will be described with respect to the preform 50. Of course, other
multilayer preforms can be blow molded in a similar manner,
especially multilayer preforms comprising foam material.
[0307] The preform 50 is placed in a mold (e.g., the mold 28 of
FIG. 3) having a cavity corresponding to the desired container
shape. The preform 50 is then heated and expanded by forcing air
into the interior of the preform to stretch the preform so that it
fills the cavity, thus creating a multilayer container. Optionally,
the preform 50 can be stretched with a stretch rod or other means
of stretching the preform.
[0308] In some embodiments, the preform 50 comprises material
having similar or different processing windows. The preform may
comprise an inner layer 54 comprising PET and an outer layer 52
comprising another material, such as PP (including foamed and
non-foamed PP). The outer layer 52 can be made of mostly or
entirely of PP. Advantageously, the inner layer 54 and the outer
layer 52 can be blow molded within a processing window that is
dramatically wider than the processing window of preforms made
entirely of PP. Advantageously, the processing window may be
widened irrespective of the thicknesses of the inner layer 54 and
outer layer 52. Optionally, a layer 85 can be used to enhance
adhesion between the inner layer 54 and the outer layer 52. In one
embodiment, a coupling agent or crafting (e.g., adhesive) forms the
layer 85 and provides adhesion between the inner layer 54 and the
outer layer 52.
[0309] In some embodiments, the layer 52 can be expandable material
formed through overmolding by using injection molding to inject at
least one layer of expandable material over an existing preform
(e.g., a preform comprising PET, phenoxy type thermoplastics,
etc.). The inner layer 54 and the carrier material of the foam
layer 52 may have a similar T.sub.g so that both layers 52, 54 can
be processed within their preferred blowing temperature ranges. As
discussed above, the expansion temperature range may be the
temperature range that causes expansion of the microspheres. The
expansion temperature range can be varied by changing the pressure
applied to the expandable material. Preferably, the expansion
temperature range is similar or within the blowing temperature
range of the layers 52, 54. During the blow molding process the
temperature of the preform can be within the expansion temperature
range to cause at least partial expansion of the microspheres.
Thus, the foaming agent of the foam layer 52 can expand (1) during
the reheat of the preform for blow molding, (2) during the
stretching of the preform to the shape of the container, (3) after
the container is generally formed, and/or (4) combinations of (1),
(2), and/or (3).
[0310] In some embodiments, a multi-layer preform can be
blow-molded into a container that has an inner layer suitable for
engaging with liquid within the container. For example, a preform
or container can have an inner layer or coating (e.g., as a plasma
layer of silicon oxide, certain types of phenoxy, and the like)
which is suitable for use in contact with drinking liquids,
foodstuff, or the like. This layer can be applied to the container
(e.g., a container 37 or container 83) at any suitable time during
the production of the containers. For example, the plasma layer can
be applied to the preform or to the shaped container.
c. Second Preferred Method and Apparatus for Overmolding
[0311] The methods and apparatus described herein can be modified
to make other preforms disclosed herein. For example, FIG. 30
illustrates a mold that can be used to form an underlying layer of
a substrate preform, prior to injecting material. The preform may
or may not have a neck finish. For example, the preform can be a
neckless preform. A mold 560 has a core section 561 and a cavity
section 566 having a cavity section surface 568. The mold 560
comprises a cavity 570 defined by a core 562 of the core section
561 and the cavity section 566. A line 572 can feed melt through a
gate 574 and into the cavity 570.
[0312] The cavity 570 has a shape corresponding to the desired
shape of a portion of a preform.
[0313] In the illustrated embodiment, the cavity 570 is configured
and sized to mold the inner layer 164 of the preform 160 of FIG.
11. However, the cavity 570 can be sized and configured for forming
any desired article. For example, the cavity 570 can have a shape
corresponding to the shape of an inner layer, such as the inner
layers of any of the preforms described above. Melt can be injected
into the cavity 570 in the manner described above to form a molded
article. The molded article can be removed from the cavity section
566 and then inserted into another cavity section (e.g., a cavity
section 580 of FIG. 31) for an overmolding process.
[0314] The overmolding is carried out by using an injection molding
process using equipment similar to that used to form the inner
layer 164. As shown in FIG. 31, after the layer 164 is formed in
the mold 560 of FIG. 30 the core 562 can be inserted into the
cavity section 580. The layer 164 and the cavity section 580 can
define a void or cavity 582 corresponding to the shape of the outer
layer 162 of the preform 160 of FIG. 11. Generally, the melt is
passed along a line 584 and passes through a gate 586 and into the
cavity 582. The melt can fill the cavity 582 to form the outer
layer 162. After the preform 160 has cooled a sufficient amount, it
can be removed from the mold cavity 582. Following overinjection,
the overmolded outer layer 162 will take the approximate size and
shape of the cavity 582.
[0315] To carry out the overmolding procedure, one preferably heats
the initial layer 164 which is to be overmolded preferably to a
temperature above its T.sub.g. In the case of PET, that temperature
is preferably about 100 to 200.degree. C., more preferably about
180.degree. C. to about 225.degree. C. If a temperature at or above
the temperature of crystallization for PET is used, which is about
120.degree. C., care should be taken when cooling the PET in the
preform. The cooling should be sufficient to minimize
crystallization of the PET in the preform, especially in the body
portion, so that the PET is in the preferred amorphous and/or
semi-crystalline state. Alternatively, the initial inner layer 164
may be very recently injection molded and not fully cooled, as to
be at an elevated temperature as is sometimes preferred for the
overmolding process.
[0316] The overmolding material is heated to form a melt of a
viscosity compatible with use in an injection molding apparatus.
For the some materials such as foam and PP, the inject temperature
is preferably in the range of about 375.degree. F. to 550.degree.
F.
[0317] After the overmolding process, the multilayer preform is
preferably cooled at least to the point where it can be displaced
from the mold or handled without being damaged, and removed from
the mold where further cooling may take place. If the body portion
of the preform has been heated to a temperature near or above the
temperature of crystallization for the material forming the body
portion, the cooling should be fairly rapid and sufficient to
ensure that the material is primarily in the semi-crystalline state
when the preform is fully cooled. As a result of this process, a
strong and effective bonding takes place between the initial layer
164 and the subsequently applied outer layer 162 material. The neck
finish may have a greater proportion of crystalline material for
increased dimensional stability, especially during subsequent
process (e.g., blow molding, hot filling, and the like). In view of
the present disclosure, a skilled artisan can select the type and
design of the molds to make mono and multilayer articles described
herein. The molds and processes for other preform embodiments,
including those from above, in view of the disclosure herein.
Additional details of molding processes (e.g., by an
inject-over-inject molding process) can be found in U.S. Pat. No.
6,352,426 incorporated by reference herein.
[0318] 3. Methods and Apparatus for Preparing a Closure
[0319] A closure, such as the closures illustrated in FIGS. 18-21E
can be formed by utilizing an injection mold. The molds of FIGS. 31
and 32 are generally similar to the molds illustrated in FIGS. 28
to 31, except as further detailed below.
[0320] FIG. 31 illustrates a mold 700 that is configured to form at
least a portion of a closure. The mold 700 is defined by a core
section 702 having a core 704 and a cavity section 706. In one
embodiment, the material (e.g., PET including virgin and/or
recycled PET, PP, phenoxy type thermoplastic, expandable/foam
material, PP, and/or other suitable material(s)) is passed along a
line 709 and passes through a gate 708 and into a cavity 710, which
is defined by the core 704 and the cavity section 706. The material
can fill the cavity 710 to form at least a portion of a closure.
The illustrated cavity 710 is sized and configured in the shape of
the inner layer of a body of a closure. However, the cavity 710 can
be configured to form the entire closure. The cavity 710 also
optionally includes a portion 711 for forming a band and connectors
between the body and band of the closure.
[0321] The closures described above having multi-layers can be
formed through an overmolding process. FIG. 33 illustrates a mold
730 for overmolding. The underlying layer or substrate 732 formed
by the mold 700 (FIG. 32) can be positioned in the mold 730 (FIG.
33). The mold 730 has a core section 734 and a cavity section 736
illustrated in the closed position prior to overinjecting. A split
ring 740 can engage a portion of the body 742 and a band 744 of the
substrate 732. The cavity section 736 comprises a cavity 738 in
which the uncoated substrate 732 is placed.
[0322] The illustrated substrate 732 is a monolayer portion of a
closure; however, the substrate 732 can be a multilayer substrate.
In some non-limiting embodiments, the substrate 732 can comprise
one or more of the following: PET (e.g., virgin PET and/or recycled
PET), polyester, PP, phenoxy, thermoplastics (including phenoxy
type thermoplastics, lamellar materials, combinations thereof,
and/or the like. The substrate 732 can also be a standard closure
that is used to close bottles. A skilled artisan can select the
size and configuration of the substrate 732 based on the desired
end use of the closure.
[0323] As the substrate 732 sits in the mold cavity, the body 742
of the substrate 732 is preferably centered within the cavity and
is completely surrounded by a void space 750. The substrate 732,
thus positioned, acts as an interior die in the subsequent
injection procedure. The melt of the overmolding material is then
introduced into the mold cavity from the injector via gate 752 and
flows around the substrate 732, preferably surrounding at least the
body portion of the substrate 732. Following overinjection, the
overmolded layer will take the approximate size and shape of the
void space 750.
[0324] The mold 730 can be used to form the coated or multilayer
closures disclosed herein. In some non-limiting embodiments, the
closures of FIGS. 18-21E and 24 can have one or more layers
comprising substantially PET, phenoxy type thermoplastics,
polypropylene, foam material, and/or other thermoplastics.
Optionally, at least one of the layers of the closure can comprise
a expandable/foam material. In some embodiments, the closure 302
(FIG. 19) can have the layer 314 of a first material (e.g., PET)
and an outer layer of PP (e.g., foamed or non-foamed PP).
[0325] The methods and apparatuses disclosed in the references
incorporated by reference into the present application can be
modified to produce closures. For example, the molding machines,
apparatuses, and methods disclosed in U.S. Pat. No. 6,352,426 (see,
e.g., FIGS. 10-15, 17-24) can modified to produce closures. For
example, the molds can comprise high heat transfer material,
cooling channels, tie layer systems, gas insertion systems, and/or
the like.
F. Methods and Apparatuses for Depositing Material on a
Substrate
[0326] Systems for making articles can have one or more apparatuses
or systems for depositing a plurality of materials. The molds
described above can have one or more delivery systems for
depositing material on a substrate, such as an article in the form
of a preform, closure, and the like. The deposited material can
form at least portion of a tie layer or other layer (e.g., barrier
layer). For the sake of convenience, the delivery systems described
herein are primarily discussed with respect to molding apparatuses,
such as injection molding machines for producing preforms. However,
delivery systems can be used to delivery other materials (e.g.,
barrier materials, plastics including thermoplastics, foam
material, and the like) onto substrates in the form of closures,
containers (e.g., bottles), sheet, tubes, etc.
[0327] With reference to FIG. 34, a delivery system 1004 of molding
system 1008 can be used in different types of molding systems, such
as injection molding system or compression molding system, for
example. Molding apparatuses may have a delivery system 1004 for
enhancing adhesion between materials and/or to aid in the release
of the molded article.
[0328] FIG. 33 illustrates a molding system 1000 for producing mono
and/or multilayer preforms. The molding system 1000 has the
delivery system 1004 and a mold 1002 that is similar to the mold
501 illustrated in FIG. 28, except as further detailed below.
[0329] The mold 1002 of FIGS. 34 and 35 is adapted for an
overmolding process. The illustrated mold 1002 is configured to
overmold a plurality of preforms and comprises a core section 1052
and the cavity section 1054 that cooperate to define a cavity 1008
when the mold 1002 is in the illustrated closed position of FIG.
35.
[0330] With respect to FIGS. 34 and 35, the mold 1002 comprises the
fluid delivery system 1004 for inserting material, preferably tie
material, into the cavity 1008. The fluid delivery system 1004 has
a feed line 1010 that receives fluid, preferably pressurized fluid,
from a fluid source. An exhaust system 1012 comprises an exhaust
line 1016 that is connected to the mold cavity 1008 and a vent 1020
(FIG. 33). The fluid delivery system 1004 injects fluid, preferably
tie fluid, through the feed line 1010 and into the cavity 1008 to
coat at least a portion of a substrate 1022 (FIG. 35). The
illustrated substrate 1022 is in the form of a preform. The preform
is then overmolded with a layer of material. The tie fluid
preferably forms a tie layer that adheres an overmolded layer to
the substrate preform 1022.
[0331] The fluid can be removed from the cavity 1008 by passing the
fluid through the exhaust line 1016 and out of the vent 1020 (FIG.
34). In some embodiments, a flow or pressurization device (e.g., a
pump) can be disposed at some point along the exhaust line 1016 to
create a low pressure or vacuum (i.e., suction) to promote the flow
of the tie fluid. The suction can be applied with pressurized or
non-pressurized tie fluid. The pressurized tie fluid provided by
the feed line 1010 and the vacuum can result in selectively
controlled flow rates within the cavity 1008. In some embodiments,
the tie fluid is delivered into the cavity 1008 and then a vacuum
is drawn to remove unused tie fluid. However, the exhaust system
1012 may not have device for creating a vacuum. For example, the
exhaust system 1012 may be vented to the atmosphere directly, or
through a scrubber to remove any potentially ecologically harmful
materials such as VOCs.
[0332] The delivery system 1004 can be used to deliver material,
preferably coating material, into the mold 1002. In some
embodiments, the material is a non-tie coating material. As used
herein, the term "coating material" is a broad term and is used in
accordance with its ordinary meaning and may include, without
limitation, tie fluid or material, polymer melt, adhesives, and the
like which form a layer on all or part of the surface of the
article or layer in the mold. The coating material can provide
desired properties to a substrate. In some preferred embodiments,
the coating material being adapted to form a structural layer
(e.g., a tie layer, polymer layer, barrier layer) on a surface.
[0333] As used herein, the term "tie fluid" is a broad term and is
used in accordance with its ordinary meaning and may include,
without limitation, a fluid that can be deposited on the preform to
form a tie, adhesive, or crafting layer and may promote adhesion
between materials. For example, the tie fluid can be chemical
substance that may promote adhesion between thermoplastic polymers,
foams, plastics, other materials described herein, and combinations
thereof. The tie fluid can comprise one or more anhydride polymers
(e.g., maleic anhydride), acrylate group containing polymers, epoxy
group containing polymers, acids, bases, organic solvents, chemical
etchants, adhesives, cross-linking agents, and/or other substances
for promoting adhesion, phenoxy, and/or phenoxy/polyolefin blends.
The tie fluid can comprise one or more of the following: a mist,
gas, plasma, particles, liquid, and/or combinations thereof. The
tie fluid can be selected based on the materials contacted by the
tie fluid. In some embodiments, the tie fluid forms a tie layer
adapted or configured to adhere a foam layer to a PET layer. In
some embodiments, the tie fluid forms a tie layer which causes a PP
layer to adhere more strongly to a PET layer. Additives (e.g.,
chemicals, microparticles, binders, or the like) can be added to
the tie fluid to enhance adhesion characteristics of the tie fluid.
Thus, the tie fluid can form a tie layer, such as the tie layer of
the container 83 of FIG. 6. In some embodiments, the tie fluid
comprises one or more of the tie materials described above. In some
instances, the terms "tie fluid" and "tie material" are used
interchangeably herein.
[0334] As shown in FIGS. 35 and 37, the delivery system 1004 may be
formed at a joint 1024 between members of the mold cavity surface
1018. An outlet or outlet 1028 is positioned along the mold cavity
surface 1018 and preferably spaced from a gate 1040. The gate 1040
can be configured to inject material (e.g., melt, molten polymer,
and the like) into the cavity 1008. The illustrated outlet 1028 is
formed circumferentially around at least a portion the cavity 1008.
The outlet 1028 is sufficiently small that substantially no molten
material will enter during melt injection. Alternatively, the
outlet 1028 may comprise one or more individual openings or
apertures. Optionally, the feed line 1010 has a valve system 1030
(FIG. 34) for selectively controlling the flow of fluid through the
feed line 1010. The valve system 1030, if present, can be located
at any point along the feed line 1010. In some embodiments,
including the illustrated embodiment of FIG. 34, a valve system
1030 is positioned upstream of a plurality of cavities 1008. The
valves selectively permit or inhibit flow through the feed line
1010 to the cavities. The valve system 1030 is preferably embedded
in the material forming the cavity section 1054. Although not
illustrated, the valve system 1030 can be located proximate to an
outlet (e.g., the outlet 1028) of the feed line 1010.
[0335] The valve system 1030 can be operated in response to
pressure, such as positive or negative pressures and can comprise
one or more valves, such as a lift type check valve. In one
embodiment, the lift type check valve is a ball check valve having
a ball and seat arrangement. Pressure within the feed line 1010 may
lift the ball away from the seat, but pressure in the opposite
direction will force the ball against the seat and prevent flow in
the reverse direction. Typically there is also a spring to bias the
ball into contact with the seat. When the pressure within the feed
line 1010 overcomes the bias of the spring, the ball can be
displaced from the seat allowing flow to the cavity 1008 (FIG. 35).
In some embodiments, negative pressure can cause fluid to flow
through the valve system 1030. For example, if there is a negative
pressure in the cavity 1008, it can cause fluid through the valve
system 1030. Alternatively, the valve system 1030 can be
mechanically controlled independent of pressure. For example, the
valve system 1030 can comprise one or more valves (e.g., gate
valves, globe valves, and the like). The valve system 130 can be
operated to deliver a determined amount of tie fluid to the cavity
1008.
[0336] The outlet 1028 of FIG. 35 can be located at any point along
the mold cavity surface 1018. The position of the outlet 1028 can
be determined on the desired fluid flow about the preform. For
example, the illustrated mold 1002 of FIG. 35 has the outlet 1028
positioned near or at the portion of the mold cavity 1008
corresponding to the end cap of the preform. The fluid provided by
the feed line 1010 can flow around the end cap of the preform and
proceeds upwardly along the cavity 1008 to the exhaust line 1016,
thereby depositing material on at least a portion of the preform.
The illustrated mold 1002 is configured to deposit tie fluid on the
body portion of the preform. As shown in FIG. 37, the outlet 1028
is preferably formed by a step 1036 of between about 0.05 mm (0.002
inches) and about 0.127 mm (0.005 inches) and most preferably about
0.076 mm (0.003 inches) in depth. Because of its small size, the
outlet 1028 generally will not fill with melt during injection but
will enable fluid (tie fluid, air, and/or other fluids) to be
delivered out of the outlet 1028. In some embodiments, fluid (e.g.,
air, tie fluid, etc.) can pass through the outlet 1028 to clear out
any material within the outlet 1028. Although not illustrated, the
outlet 1028 can be positioned at other locations along the surface
1018. For example, the outlet 1028 can be position at a location
along the surface 1018 corresponding to the body, neck finish,
and/or support ring of the preform. For example, the outlet 1028
can be positioned near the end cap region of the mold, below the
support ring of the preform, at the neck finish of the preform, or
at body portion of the preform. Additionally, a plurality of
outlets 1028 can be positioned along the surface 1018. A skilled
artisan can select the size, configuration, and placement of the
outlet 1028 to achieve the desired deposition of material on the
substrate. The outlets 1028 can be positioned on the same or
opposing side of the preform as an inlet configured to receive
unused tie fluid. For example, an outlet 1028 can be diametrically
spaced from an inlet. In the illustrated embodiment, the inlet 1029
and the outlet 1028 are positioned on the same side of the
preform.
[0337] With reference to FIGS. 34 and 35, the exhaust line 1016 is
configured to draw in fluid from the cavity 1008 (FIG. 35). The
exhaust line 1016 then delivers the tie fluid to the vent 1020, or
recirculation system so that fluid can be passed through the cavity
1008 again. The exhaust line 1016 can have a valve system 1038 that
can be similar to the valve system 1030 and therefore will not be
described in further detail.
[0338] In operation, after the preform is positioned in the mold
1002, the valve system 1030 permits fluid to flow through the feed
line 1010 and into the cavity 1008. As shown in FIGS. 36 and 37,
the tie fluid TF can flow through the cavity 1008 and coat at least
a portion of the exterior surface of the preform. Preferably, the
tie fluid TF coats a substantial portion of the preform forming the
interior surface defining the cavity 1008. In some embodiments,
including the illustrated embodiment, the tie fluid TF forms a thin
layer of material on most of the body portion of the preform, or a
generally uniform continuous or discontinuous coating. However, the
tie fluid TF can coat any portion of the preform exposed to the
fluid. For example, the thread finish and the body portion can be
coated with the tie fluid, if the cavity 1008 is defined by both
the thread finish and the body portion of the preform.
[0339] To enhance coating of the preform, the mold 1002 can
selectively control the temperature of the preform. In one
embodiment, the core 1040 of FIG. 35 heats or cools the preform to
promote coating of the preform. A skilled artisan can select the
desired temperature of the preform depending on the properties of
the tie fluid that coats the preform. Alternatively, the preforms
can be electrostatically charged to promote coating of the preform.
In other embodiments, the preform can be physically or chemically
roughened or textured to enhance coating of the preform.
Optionally, the mold cavity surfaces 1018 can be thermally
controlled to enhance coating of the preform. For example, the mold
cavity surface 1018 can be chilled to ensure that gases in the
cavity 1008 generally remain in gas phase.
[0340] Optionally, the temperature of the tie material can be
selectively controlled. For example, the tie material may include
tie fluid that is heated to reduce the viscosity of the tie fluid
to facilitate spreading of the tie fluid. Heaters and/or chillers
can be employed to control the temperature of the tie material.
[0341] As the delivery system 1004 feeds tie fluid into the cavity
1008, the tie fluid coats the preform and may flow out of the
cavity 1008 and into the exhaust system 1012. After the preform has
been coated, or after a predetermined period of time, the delivery
system 1004 can reduce, or preferably stop the flow of fluid into
the cavity 1008. The coating on the preform can form a tie layer
for tying the substrate preform 1022 to a material that is
subsequently injected through the gate 1040 into the cavity 1008.
If the tie material is a solvent/solute, the flow can be reduced or
stopped and the cavity 1008 can be vented. The feed line 1010 can
deliver a gas or vapor (e.g., air, inert gases such as nitrogen, or
other gases) to purge the cavity 1008. The exhaust system 1012 can
optionally provide a negative pressure causing gas or vapor in the
cavity 1008 to be removed. In this manner, one or more solvents can
be removed in order to achieve desirable characteristics of the tie
layer and/or overmolded material.
[0342] During melt injection, the valve system 1030 is preferably
closed. The melt injected through the gate 1040 proceeds up along
and fills the cavity 1008. In some embodiments, excess tie fluid is
pushed out of the mold cavity 1008 by the injected melt stream.
Thus, the melt stream can cause tie fluid to be removed from the
cavity 1008. For example, if the tie fluid is a gas, the gas can be
forced out of the cavity 1008 by the advancing melt stream. The tie
coating formed on the preform can be spread on the preform by the
melt stream. As the melt stream proceeds along the cavity 1008, the
melt stream can push and spread the tie material about the surface
of the preform to ensure that at least a portion of the body
portion, preferably most or all of the body portion, is coated with
a tie material. A skilled artisan can determine the appropriate
location of the outlet 1028 based on the properties of the tie
layer and melt stream to achieve the desired tie layer in the
container produced from the preform.
[0343] With reference to FIG. 35, during the injection of the melt
stream, the valve system 1038 can be opened to allow tie fluid to
escape from the cavity 1008. The valve system 1038 can be closed
after a predetermined amount of melt stream has been injected to
prevent or inhibit melt from entering the exhaust line 1016.
Additionally, the inlet 1029 of the exhaust line 1016 can have a
small size so that melt will not substantially enter therein, but
will enable fluid (tie fluid, air, and/or other fluids) to be
delivered into the exhaust line 1016.
[0344] Optionally, when injection is complete, pressurized fluid,
preferably air, is supplied to the outlet 1028 in order to defeat a
vacuum that may form between a preform and the cavity wall. The
supply of air is delivered to the outlet 1028 at a pressure between
about 75 psi (about 0.52 MPa) and 150 psi (about 1.03 MPa) and most
preferably about 100 psi (about 0.69 MPa). In other embodiments,
the preform is removed from the mold cavity 1018 without the aid of
pressurized fluid from the feed line 1010. Additionally, similar
delivery systems may be utilized in other portions of the mold,
such as the thread area, for example but without limitation.
[0345] Optionally, the core section 1052 and the cavity section
1054 can cooperate to form a seal to inhibit or prevent the tie
fluid from escaping into the environment surrounding the mold 1002
illustrated in FIG. 35. Thus, if the tie fluid has volatile organic
compounds (VOCs) or other substances undesirable for inhalation or
the environment, the tie fluid can be contained within the mold
1002. The mold 1002 can circulate and reuse the tie fluid to also
reduce waste. The tie fluid can be vented via the exhaust system
1012 or by another means. If the tie fluid is suitable for release
into the atmosphere, the tie fluid can be vented to the atmosphere.
For example, the tie fluid can escape between, the preform and the
ledge 1056 and then may proceed between the core section 1052 and
the cavity section 1054 and out into the atmosphere.
[0346] The preform can be coated with a tie material before the
mold 1002 is in the fully closed position. The tie material can be
deposited on the substrate preform as the preform is inserted and
advanced into the cavity section 1054. Thus, the preform is coated
with tie material when the preform is proximate to or at least
partially within the cavity section 1054. In some embodiments, the
delivery system 1004 outputs fluid when the mold 1002 is in a
partially or fully opened position. In one embodiment, the delivery
system 1004 injects tie fluid into the cavity 1008 as the mold 1002
is moved from an open position to the illustrated closed position
of FIG. 35. As the preform is advanced into the cavity section
1054, the tie fluid flows upwardly through the cavity 1008 and
coats at least a portion of the preform. Before the mold 1002 is in
the closed position, the tie fluid can escape into the atmosphere.
Thus, the mold 1002 may or may not have an exhaust system 1012. For
example, if the tie material is deposited before the mold 1002 is
in the closed position, the mold 1002 preferably does not have the
exhaust system 1012. If the tie material is deposited after the
mold 1002 is in the closed position, the mold 1002 preferably has
an exhaust system 1012, especially when the tie fluid is not
suitable for venting directly to the atmosphere.
[0347] FIG. 38 illustrates another embodiment of the delivery
system 1004. The delivery system 1004 has a plurality of inlets
1060 for injecting or delivering fluid (e.g., tie fluid, air, etc.)
into the cavity 1008. The fluid can be delivered in response to
positive pressure in the feed line 1010, or drawn into the cavity
1008 under a negative pressure. In the illustrated embodiment, the
mold 1002 has a feed line 1010 connected to each inlet. The
delivery system 1004 having a plurality of outlets 1060 may promote
more uniform coating of the preform 1022.
[0348] The delivery system 1004 of FIG. 39 has an inlet 1061
defined by the end cap region. The position of the inlet 1061
results in generally uniform unidirectional flow through the cavity
1008. In some embodiments, the feed line 1010 delivers tie fluid in
the form of a liquid that douses the end cap of the preform. After
an amount of tie fluid has been delivered, melt can be delivered
into the cavity 1008 through the gate 1040. The melt spreads the
tie material on the surface of the preform.
[0349] Other apparatus disclosed herein can be used to deposit tie
material on articles. For example, the molds of FIGS. 28, 30, 31
can be modified to deposit tie material on the inner layer or
underlying substrate.
[0350] Optionally, the delivery system 1004 can be connected to the
line that delivers melt into a cavity. For example, the feed line
1010 can feed tie fluid into a line through a gate to coat a
substrate. After the substrate is coated, the melt can be injected
through the same line and gate to form an outer layer.
[0351] Additionally, the insertion system of the mold (e.g., the
mold illustrated in FIG. 26) of U.S. Pat. No. 6,352,426 and the
other incorporated applications and patents can inject tie fluid to
both coat a preform and aid in the release of the preform. The
coated substrate preform can then be overmolded. The delivery
system (or insertion systems) can be used to delivery other
materials (e.g., one or more of the materials discloses herein)
onto articles. For the sake of simplicity, the apparatuses were
described delivering a tie fluid. However, it is to be understood
in many cases that other materials may be delivered out by the
apparatuses described above. For example, the tie material or fluid
can be replaced with colorant, chemical, melt, polymer, powder,
coating material, barrier material, and/or any other material
suitable for coating at least a portion of a substrate.
[0352] G. Preferred Articles
[0353] Generally, preferred articles described herein include
articles comprising one or more materials. The material(s) may form
one or more layers of the articles. The layers of the articles may
preferably provide some functionality and may be applied as
multiple layers, each layer having one or more functional
characteristics, or as a single layer containing one or more
functional components. The articles may be in the form of
packaging, such as preforms, closures, containers, etc. The
materials, methods, ranges, and embodiments disclosed herein are
given by way of example only and are not intended to limit the
scope of the disclosure in any way. The articles disclosed herein
can be formed with any suitable material disclosed herein.
Nevertheless, some articles and materials are discussed below. In
view of the present disclosure, embodiments and materials can be
modified by a skilled artisan to produce other alternative
embodiments and/or uses and obvious modifications and equivalents
thereof
1. General Description of Preferred Materials Forming Articles
[0354] a. Non-Limiting Articles Comprising Foam Material
[0355] Articles may comprise foam material. In some non-limiting
embodiments, foam material can form a portion of an article, such
as the body or neck finish of a preform. In some non-limiting
embodiments, foam material comprises less than about 90% by weight,
also including less than about 10%, 20%, 30%, 40%, 50%, 60%, 70%,
80% by weight, of the article (such as a preform, closures,
container, sheet, etc.). In some non-limiting embodiments, the foam
material comprises about 5-30% by weight of the article. In some
non-limiting embodiments, the foam material comprises about 20%-60%
by weight of the article. In some non-limiting embodiments, the
foam material comprises about 10%-30% by weight of the article. In
some embodiments, the foam material comprises more than about 90%
by weight of the article. The foam material can form most or all of
the article. The foam material may result in reduced weight
articles as compared to conventional articles and therefore may
desirably reduce the transportation cost of the articles.
Additionally, foam material can reduce the amount of material that
is used to form the articles, since the foam material may have a
substantial number of voids.
[0356] The foam material can be made from expandable material. For
example, at least a portion of an article can comprise expandable
that has a first density that is reduced when the expandable
material is expanded. In some non-limiting embodiments, a first
material, preferably expandable material, has a first density and
the second material, preferably foam material, made from the first
material has a second density. The second density is less than
about 95%, 90%, 80%, 70%, 50%, 30%, 20%, 10%, 5%, 2%, 1% and ranges
encompassing such percentages of the first density. In some
non-limiting embodiments, the second density is in the range of
about 30% to 60% of the first density. Thus, foam material with a
low density relative to an expandable material can be made.
[0357] It is contemplated that articles may comprise any suitable
amount of foaming agent including those above and below the
particular percentages recited above, depending on the desired use
of the articles.
b. Non-limiting Articles Comprising Phenoxy Type Thermoplastic
Material
[0358] Articles may comprise phenoxy type thermoplastics, such as
phenoxy and blends (e.g., polyolefin-phenoxy blend), PET-phenoxy,
and combinations thereof). In some non-limiting embodiments, the
phenoxy type thermoplastic can form a portion of the article, such
as at least a portion of the interior surface of the preform,
closure, container, etc. In some non-limiting embodiments, the
phenoxy type thermoplastic comprises less than about 30% by weight,
also including less than about 1%, 2%, 5%, 7.5%, 10%, 12%, 15%,
20%, 25%, 50% by weight, of the article. In another non-limiting
embodiment, the phenoxy type thermoplastic comprises about 1-4% by
weight of the article. In another non-limiting embodiment, the
phenoxy type thermoplastic comprises about 1-15% by weight of the
article. In another non-limiting embodiment, the phenoxy type
thermoplastic comprises about 7-25% by weight of the article. In
another non-limiting embodiment, the phenoxy type thermoplastic
material comprises about 5-30% by weight of the article. In some
embodiments, the phenoxy type thermoplastic forms a discrete layer
or a layer blended with another material. In some embodiments, a
discrete layer comprises phenoxy type thermoplastic that forms
about 0.1% to 1% by weight of the article. In some embodiments, a
discrete layer comprise phenoxy type thermoplastic that forms about
0.1% to 1% by weight of the article. In some embodiments, the
phenoxy type thermoplastic is blended with a polymer material
(e.g., PET, polyolefin, combinations thereof) and can comprise more
than about 0.5%, 1%, 2%, 5%, 7.5%, 10%, 12%, 15%, 20%, 25%, 50%,
70% by weight of the article. It is contemplated that these
percentages can be by volume in certain embodiments. The phenoxy
type thermoplastic may result in articles having one or more of the
following properties: desirable flavor scalping, color scalping,
oxygen barrier, recyclable, and/or other properties especially well
suited for food contact. These percentages may result in effective
desirable characteristics while minimizing the amount of phenoxy
type thermoplastic used, thus providing a cost effective
article.
[0359] Various combinations of phenoxy type thermoplastic with
polyethylene, polypropylene, foam material, and the like can be
used to produce preforms, containers, and other packaging of
relatively larger sizes and having desirable characteristics,
especially when the phenoxy type thermoplastic forms the surface of
the packaging that contacts foodstuffs. Phenoxy type thermoplastics
can provide desirable adhesive between a layer comprising PET and a
layer comprising PP.
[0360] It is contemplated that articles may comprise any suitable
amount of phenoxy type thermoplastics including those above and
below the particular percentages recited above, depending on the
desired use of the articles.
2. Articles In the Form of Preforms/Containers
[0361] Foam material may form one or more portions of layers of the
articles (such as packaging including preforms and containers). The
preform 30 of FIG. 1 can comprise a foam material. In some
embodiments, the preform 30 comprises mostly foam material. In some
embodiments, the preform 30 can comprise a phenoxy type
thermoplastic formed through a molding process. For example, the
preform 30 may comprise mostly a phenoxy type thermoplastic. In
some embodiments, the preform 30 may be formed by a co-injection
process, wherein the interior portion and exterior portions of the
preform 30 comprise different materials. The co-injected material
can be compressed into a desired shape. For example, the preform 30
may have an interior portion that comprises one or more of the
following: phenoxy type thermoplastic, PET, PETG, expandable/foam
materials or the like. The outer portion of the preform 30 can
comprise one or more of the following: polyethylene, polypropylene
(including clarified polypropylene), PET, combinations thereof, and
the like. Optionally, a portion of the preform 30 may comprise foam
material.
[0362] In some embodiments, the preform 30 can be coated with a
layer to enhance its barrier characteristics. For example, the
preform 30 can be coated with a barrier material. For example, U.S.
Publication No. 2004/0071885, which is incorporated in its entirety
and describes systems and methods of coating preforms. This system
and other systems disclosed or incorporated herein can be employed
to form a barrier layers described herein. The coated preform can
then be overmolded with another material to form an outer
layer.
[0363] With respect to FIG. 5, the preform 50 can comprises an
uncoated preform 39 coated with a foam layer 52. Preferably, the
uncoated preform 39 comprises a polymer material, such as
polypropylene, polyester, PET, PETG, phenoxy type thermoplastics,
and/or other thermoplastic materials. In one embodiment, for
example, the uncoated preform 39 substantially comprises
polypropylene. In another embodiment, the uncoated preform 39
substantially comprises polyester.
[0364] The foam layer 52 may comprise either a single material or
several materials (such as several microlayers of at least two
materials). In some non-limiting embodiments, the foam layer 52 can
comprise about 2%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%,
and ranges encompassing such percentages of the preform. In some
embodiments, the foam layer 52 comprises about 2% to about 90% of
the preform. In some non-limiting embodiments, the foam layer 52
can comprise about 5% to about 50% of the preform. In some
embodiments, the foam layer 52 comprises about 10% to about 30% of
the preform. In some non-limiting embodiments, the foam layer 52
can comprise about 5% to about 25% of the preform. In some
non-limiting embodiments, the foam layer 52 can comprise less than
about 20% of the preform. It is contemplated that these percentages
can be by weight or by volume in different embodiments. The foam
layer 52 may comprise foam material that is not expanded. The outer
layer 52 of the preform 50 may have a thickness, preferably the
average wall thickness, of about 0.2 mm (0.008 inches) to about 0.5
mm (0.02 inches). In another non-limiting embodiment, the outer
layer 52 has a thickness of about 0.3 mm (0.012 inches). In some
embodiments, the average wall thickness is taken only along the
body portion of the preform 50. In some non-limiting embodiments,
the outer layer 52 comprises less than about 90% of the average
thickness of a wall of the preform 50, also including less than
about 80%, 70%, 60%, 50%, 40%, 30%, 20%, 10%, 9%, 8%, 7%, 6%, 5% of
the average thickness of a wall of the preform 50.
[0365] The foam layer 52 may comprise microspheres that are either
not expanded or partially expanded, for example. Further, the foam
layer 52 can be generally homogenous or generally heterogeneous.
Although not illustrated, the foam layer 52 can form other portions
of the preform 50. For example, the foam layer 52 can form at least
a portion of the inner surface of the preform 50 or a portion of
the neck portion 32.
[0366] In some embodiments, the inner layer 54 can comprise one or
more of the following: polyethylene, PET, polypropylene (e.g.,
foamed polypropylene, non-foamed polypropylene, clarified
polypropylene), combinations thereof, and the like. For example,
the preform 50 can comprise an outer layer 52 of polypropylene
(preferably foamed) and an inner layer 54 comprising PET.
Optionally, a tie layer can be interposed between the layers 52, 54
and may comprise a phenoxy type thermoplastic.
[0367] In some embodiments, a barrier layer can be interposed
between the layers 52, 54. The barrier layer can inhibit or prevent
egress and/or ingress of one or more gases, UV rays, and the like
through the walls of a container made from the preform 50.
[0368] In some embodiments, second layer 54 comprises
polypropylene. The polypropylene may be grafted or modified with
maleic anhydride, glycidyl methacrylate, acryl methacrylate and/or
similar compounds to improve adhesion. In one embodiment, the
polypropylene further comprises nanoparticles. In a further
embodiment, the polypropylene comprises nanoparticles and is
grafted or modified with maleic anhydride, glycidyl methacrylate,
acryl methacrylate and/or similar compounds.
[0369] With reference to FIG. 6, the container 83 can be used as a
carbonated beverage container, the thickness 44, preferably the
average wall thickness, of the outer layer 52 of the container 83
that is about 0.76 mm (0.030 inch), 1.52 mm (0.060 inch), 2.54 mm
(0.10 inch), 3.81 mm (0.15 inch), 5.08 mm (0.2 inch), 6.35 mm (0.25
inch), and ranges encompassing such thicknesses. In some
embodiments, the outer layer is preferably less than about 7.62 mm
(0.3 inch), more preferably about 1.27 mm (0.05 inch) to 5.08 mm
(0.2 inch). The outer layer 52 may comprise foam material having a
thickness more than about 3.81 mm (0.15 inch). In some non-limiting
embodiments, the outer layer 52 has a thickness in the range of
about 0.127 mm (0.005 inch) to about 0.635 mm (0.025 inch).
[0370] In some non-limiting embodiments, the thickness 46 of the
inner layer 54, preferably the average thickness, of the inner
layer 54 is preferably about 0.127 mm (0.005 inch), 0.635 mm (0.025
inch), 1.07 mm (0.040 inch), 1.52 mm (0.060 inch), 2.03 mm (0.080
inch), 2.54 mm (0.100 inch), 3.05 mm (0.120 inch), 3.56 mm (0.140
inch), 4.07 mm (0.160 inch), and ranges encompassing such
thicknesses. In some embodiments, the inner layer 54 of the
container 83 has a thickness of less than about 2.54 mm (0.1 inch)
to provide a cost effective food barrier. In some non-limiting
embodiments, the inner layer 54 has a thickness in the range of
about 0.127 mm (0.005 inch) to about 0.635 mm (0.025 inch). The
overall thickness 48 of the wall of the container can be selected
to achieve the desired properties of the container 83.
[0371] To enhance barrier characteristics of the container 83, the
container 83 can have a barrier layer. On or more barrier layers
can be formed on the interior surface of the inner layer 54,
between the layers 52, 54, on the exterior of the outer layer 52,
and the like. For example, the outer layer 52 of the container (or
the preform that makes the container 83) can be coated with barrier
material by using methods disclosed herein. For example, the
barrier layer can be formed by using apparatuses, methods, and
systems disclosed in U.S. Publication No. 2004/0071885, which is
incorporated in its entirety. Additionally, in some embodiments,
the container 82 comprises substantially closed cell foam that may
inhibit the migration of fluid through the foam. For example, the
foam can be a barrier that inhibits, preferably prevents, migration
of CO.sub.2 gas through the wall 84 of the container 83 formed from
the preform.
[0372] The preform 60 of FIG. 11 has an inner layer 164 that
comprises a first material and the outer layer 162 preferably
comprises another material. In some non-limiting embodiments, the
layer 162 can comprise about 2%, 5%, 10%, 20%, 30%, 40%, 50%, 60%,
70%, 80%, 90%, and ranges encompassing such percentages of the
preform. In some embodiments, the foam layer 162 comprises less
than about 97% of the preform. In some embodiments, the layer 162
comprises about 5% to about 99% of the preform. In some
non-limiting embodiments, the layer 162 can comprise less than
about 90% of the preform. In some non-limiting embodiments, the
layer 162 can comprise about 40% to 80% of the preform. In some
non-limiting embodiments, the layer 162 can comprise about 60% to
90% of the preform. In some non-limiting embodiments, the layer 162
can comprise more than about 60% of the preform. It is contemplated
that these percentages can be by weight or by volume in different
embodiments. In some embodiments, the outer layer 162 can comprise
foam material and the inner layer 164 can comprise a polymer
material, such as PET (e.g., virgin or post-consumer/recycled PET).
The foam layer 162 may comprise foam material that is not expanded.
For example, the foam layer 162 may comprise microspheres that are
either not expanded or partially expanded, for example. The foam
layer 162 may provide a desirable insulating layer when the preform
160 is molded into a container.
[0373] Preferably, a substantial portion of the outer layer 162
comprises foam material and a substantial portion of the inner
layer 164 comprises PET or other material for contacting
foodstuffs. In one non-limiting embodiment, the foam material
comprises PP and expandable microspheres. In yet another
embodiment, the outer layer 162 comprises PP and the inner layer
164 can comprise PET. Preferably, a substantial portion of the
outer layer 162 comprises PP and a substantial portion of the inner
layer 164 comprises PET. In one non-limiting embodiment, the outer
layer 162 comprises generally entirely PP. In yet another
embodiment, substantial portions of the inner layer 164 and outer
layer 162 can comprise foam material. The preforms 76, 132 may
similarly comprise foam material and material suitable for
contacting foodstuffs.
[0374] In some embodiments, the inner layer 164 may comprise one or
more of the following: PET, phenoxy type thermoplastic (including
blends), foam material (e.g., foamed PET), and/or other
coating/layer suitable for contacting foodstuff. The outer layer
162 may comprise one or more of the following: foam material
(including foamed PP, foamed PET, etc.), non-foamed material (e.g.,
phenoxy type-thermoplastics, PET, PP), or other material suitable
for forming the outer portion of a preform. In some embodiments,
the preform 160 comprises a phenoxy type thermoplastic. In some
non-limiting embodiments, the phenoxy type thermoplastic can
comprise less than about 1%, 2.5%, 5%, 10%, 20%, 30%, 50%, 60%,
70%, 80%, 90%, and ranges encompassing such percentages of the
preform. In some embodiments, the phenoxy type thermoplastic
material comprises about 10% to 30% by weight of the preform. In
some embodiments, the phenoxy type thermoplastic material comprises
most of or all of the preform. The weight is for phenoxy type
thermoplastic in a discrete or blend form. It is contemplated that
these percentages can be by weight or by volume in different
embodiments. For example, in some embodiments the layer 164
comprises phenoxy type thermoplastic that forms less than 10% of
the preform. The layer 164 can have a thickness suitable for
forming a food contacting layer. The thickness 174 of the inner
layer 164 is preferably less than about 3.81 mm (0.150 inch) to
form a cost effective food contacting layer. The thickness 174 of
the inner layer 164 may be less than about 0.01 mm (0.0004 inch),
0.02 mm (0.0007 inch), 0.05 mm (0.002 inch), 0.10 mm (0.004 inch),
0.15 mm (0.006 inch), 0.20 mm (0.008 inch), 0.30 mm (0.01 inch),
0.5 mm (0.019 inch), and ranges encompassing such thicknesses. In
some non-limiting embodiments, the inner layer 174 comprising
phenoxy type thermoplastic having a thickness in the range of about
0.01 mm (0.0004 inches) to about 0.05 mm (0.002 inches). In some
embodiments, the preform 160 may be formed by an molding process,
wherein the interior portion and exterior portions of the preform
comprise different materials.
[0375] In some embodiments, the outer layer 162 comprises a first
material and the inner layer 164 preferably comprises another
material. For example, the outer layer 162 can comprise
polypropylene and the inner layer 64 can comprise PETG. In another
embodiment, the polypropylene may be grafted or modified with
maleic anhydride, glycidyl methacrylate, acryl methacrylate and/or
similar compounds to improve adhesion.
[0376] In one embodiment, the polypropylene further comprises
nanoparticles. In a further embodiment, the polypropylene comprises
nanoparticles and is grafted or modified with maleic anhydride,
glycidyl methacrylate, acryl methacrylate and/or similar
compounds.
[0377] The preform 180 (FIG. 12) may have the inner layer 184 that
is similar or identical to the inner layer 164 and the outer layer
182 that is similar or identical to the outer layer 162. The
preform 190 (FIG. 13) may have the inner layer 194 that is similar
or identical to the inner layer 164 and the outer layer 199 that is
similar or identical to the outer layer 162. The materials forming
the inner layer 194 and the outer layer 199 can be selected to
provide desirable interaction with the locking structure 197. The
preform 202 (FIG. 14) may have layers formed of similar or
identical materials as the preform 160.
[0378] The preforms and resulting containers may be particularly
well suited for thermal applications, such as hot-fill processes.
The container 211 of FIG. 14A can generally maintain its shape
during hot-fill processes. After blow molding or hot-filling, the
final dimensions of the neck portion 132 of the container 211 are
substantially identical to the initial dimensions of the preform.
Additionally, this results in reduced dimension variations of the
threads on the neck finish. For example, the inner layer 283 can be
formed of a material for contacting foodstuffs, such as PET. The
outer layer 203 can comprise moldable materials (e.g., mostly or
entirely of PP, PP and a foaming agent, crystalline PET, lamellar
material, homopolymers, copolymers, and other materials described
herein) suitable for hot-filling. The outer layer 203 provides
dimensional stability to the neck finish 132 even during and after
hot-filling. The width of the outer layer 203 can be increased or
decreased to increase or decrease, respectively, the dimensional
stability of the neck finish 132. Preferably, one of the layers
forming the neck finish 132 comprises a material having high
thermal stability; however, the neck finish 132 can also be made of
materials having low temperature stability, especially for
non-hot-fill applications.
[0379] Additionally, the dimensional stability of the outer layer
203 ensures that the closure 213 remains attached to the container
211 of FIG. 14A. For example, the outer layer 203 of PP can
maintain its shape thereby preventing the closure 213 from
unintentionally decoupling from the container 211.
[0380] The preforms described above can be modified by adding one
or more layers to achieve desired properties. For example, a
barrier layer can be formed on the body portions of the
preforms.
3. Articles In the Form of Closures
[0381] Closures may comprise foam material. In some non-limiting
embodiments, the foam material comprises less than about 95% by
weight, also including less than about 5%, 15%, 25%, 35%, 45%, 55%,
65%, 75%, 85%, and ranges encompassing such percentages of the
closure. It is contemplated that these percentages can be by weight
or by volume in different embodiments. In some embodiments, foam
material comprising ranges encompassing these percentages by weight
of the closure. In one non-limiting embodiment, the foam material
comprises about 45-60% by weight of the closure. In another
non-limiting embodiment, the foam material comprises about 15-70%
by weight of the closure. In some embodiments, the closure
comprises mostly or entirely of foam material. For example, the
closure can be a monolayer closure that is made from foam
material.
[0382] With reference to FIG. 19, at least a portion of the closure
302 comprises a foam material. The layer 314 and/or the outer
portion 311 may comprise foam material (e.g., foamed PET, foamed
PP, etc.). In one embodiment, the outer portion 311 comprises foam
material and the layer 314 comprises non-foamed material (such as
PP, PET, etc.).
[0383] Additionally, the inner portion of the closures may comprise
foam material. In some embodiments, the outer portions of closures
may or may not comprise foam material. The closures of FIGS. 21A to
21E may have similar or different inner and outer layers (or outer
portions).
[0384] FIG. 21C illustrates the closure 360 that may have an
intermediate layer 364 formed of materials that have desired
structural, thermal, optical, barrier and/or characteristics. For
example, the layer 364 can be formed of PET, PP, PET, PETG, and/or
the like.
[0385] In one embodiment, a further advantage is provided where the
outer portion of the closure is formed of foam material to provide
a comfortable gripping surface so that a user can comfortably
remove the closure from a container. The outer portion 311 of FIG.
19 can be foam to increase the space occupied by the outer portion
311 and can provide the user with greater leverage for easy opening
and closing of the closure device.
[0386] The closures can have an internally threaded surface that is
configured to threadably mate with an externally threaded surface
of the container. The enlarged outer portion 311 of FIG. 19 can
provide increased leverage such that the user can easily rotate the
closure 302 onto and off of the container. Advantageously, the
similar, or same, amount of material that forms a conventional cap
can be used to form the enlarged diameter closure device. Thus, the
cost of materials for producing the closure 302 can be reduced.
[0387] Closures may comprise phenoxy type thermoplastic materials.
In some non-limiting embodiments, the phenoxy type thermoplastic
material comprises less than about 25% by weight, also including
less than about 1%, 2%, 4%, 5%, 10%, 15%, 20% by weight, of the
closure. In some embodiments, phenoxy type thermoplastic material
comprising ranges encompassing these percentages by weight of the
closure. The weight is for phenoxy type thermoplastic in discrete
or blend form. In one non-limiting embodiment, the phenoxy type
thermoplastic material comprises about 0.5 to 5% by weight of the
closure. In another non-limiting embodiment, the phenoxy type
thermoplastic material comprises about 1 to 6% by weight of the
closure.
[0388] The phenoxy-type thermoplastic can form at least a portion
of the interior surface of the closure. For example, a phenoxy type
thermoplastic layer can be deposited on the interior surface 309 of
the layer 314 (FIG. 19). Optionally, the layer 314 can be made of a
phenoxy-type thermoplastic. The phenoxy-type thermoplastic can form
at least a portion of the layer 344 of the closure 340 (FIG. 21A),
the layer 356 of the closure 350 (FIG. 21B), the layer 366 and/or
layer 364 of the closure 360 (FIG. 21C), the layer 374 of the
closure 370 (FIG. 21D), the layer 383 of the closure 380 (FIG.
21E), for example. Of course, these layers may comprise material
(e.g., lamellar material, PET, PP, and/or the like) that is coated
with a phenoxy-type thermoplastic, such a phenoxy or
polyolefin-phenoxy blend.
[0389] The closures described above can have one or more barrier
layers to enhance its barrier characteristics. For example, an
inner layer, one or more intermediate layers, and/or exterior
barrier layers can be formed by using systems and methods disclosed
in U.S. Publication No. 2004/0071885, which is incorporated in its
entirety and describes systems and methods of forming barrier
layers. In some embodiments, the materials of the closures can be
modified to enhance barrier characteristics. For example, foam
material may have additives (e.g., microparticulates) that improve
the barrier characteristics of the foam material. A skilled artisan
can select the design of the closures to achieve the desired
barrier properties.
4. Articles with Tie Layers
[0390] Exemplary articles can be multilayer articles. A tie layer
can be disposed between one or more portions or layers of the
articles. For example, articles can have a tie layer interposed
between layers of materials. Articles can have a plurality of tie
layers, preferably one of the tie layers is positioned between a
pair of adjacent layers. In some embodiments, a plurality of pairs
of adjacent layers each have interposed therebetween one of the tie
layers.
[0391] The container 83 of FIG. 6 can have a tie layer 85 (FIG. 7)
between the layer 52 and the layer 54. In some non-limiting
embodiments, the layer 52 comprises one or more of the following:
foam material (including foamed PP, foamed PET, etc.), non-foamed
material (e.g., phenoxy-type thermoplastics, PET, PP), combinations
thereof, or other material suitable for forming the outer portion
of a preform. The layer 54 comprises one or more of the following:
PET, phenoxy, polyolefin-phenoxy blend, combinations thereof, or
other suitable materials suitable for forming a portion of the wall
of a container. In some embodiments, outer layer 52 comprises PP
(foamed or unfoamed) and the inner layer 54 comprises PET. The tie
layer 85 may comprise adhesives, phenoxy type thermoplastics,
polyolefins, or combinations thereof (e.g., polyolefin-phenoxy
blend). The tie layer 85 can advantageously adhere to both of the
layers 52, 54. Phenoxy may provide desirable adhesion between an
inner layer 54 comprising PET and an outer layer 52 comprising PP,
for example.
[0392] The multilayer articles illustrated in FIGS. 8-14B and
18-21E can have one or more tie layers, preferably one tie layer,
is between at least two of the layers of the articles. For example,
a tie layer can be interposed between the layers 52, 54 of the
preform 76 (FIG. 9). A tie layer can be interposed between the
layers 134, 136 and/or the preform 30 and the layer 134 of FIG. 10.
The preform 160 (FIG. 11) can have a tie layer interposed between
the layer 164 and the layer 162. The preform 180 (FIG. 12) can have
a tie layer interposed between the layer 184 and the layer 183. The
preform 190 (FIG. 13) can have a tie layer interposed between the
layer 194 and the layer 199. The preform 202 (FIG. 14) can have a
tie layer interposed between the layer 203 and the layer 283.
[0393] With respect to FIG. 19, the closure 302 can have a tie
layer between the layer 314 and the outer portion 311. In some
non-limiting embodiments, the outer portion 311 comprises one or
more of the following: foam material (including foamed PP, foamed
PET, etc.), non-foamed material (e.g., phenoxy type-thermoplastics,
PET, PP), combinations thereof, or other materials suitable for
forming the outer portion of a closure. The layer 314 comprises one
or more of the following: PET, phenoxy, polyolefin-phenoxy blend,
combinations thereof, or other suitable materials suitable for
forming a portion of the closure. The tie layer may comprise
adhesives, phenoxy, polyolefin, combinations thereof (e.g.,
polyolefin-phenoxy blend). Similarly, the closures illustrated in
FIGS. 21A-21E can likewise have one or more tie layers, preferably
at least one tie layer is between a pair of adjacent layers.
[0394] A further advantage is provided wherein a tie layer
comprising a phenoxy type thermoplastic, such as a phenoxy blend,
which can help compatibilization of a somewhat pure phenoxy layer
and another layer. Phenoxy can effectively compatibilize with
polypropylene, polyethylene, and the like.
[0395] In view of the present disclosure, a skilled artisan can
select various material(s) and tie layer(s) to achieve the desired
properties of an article.
5. Articles Comprising Lamellar Material
[0396] Lamellar material may form one or more portions of layers of
the articles (such as packaging including preforms, closures, and
containers). Referring to FIG. 2, the preform 30 may comprise
lamellar material. As FIG. 40 is an enlarged cross-sectional view
of the wall section 43 of the preform 30. In the illustrated
embodiment, the wall section 43 comprises lamellar material that
includes one or more layers. Preferably, the lamellar material is
made up of a plurality of microlayers. However, the layers of the
lamellar material can have any suitable size based on the desired
properties and characteristics of the preform, and the resulting
container formed from the preform. The layers of wall section 43
can comprise generally similar or different materials to one
another. One or more of the layers forming the wall section 43 can
be made from materials disclosed herein, or other materials known
in the art.
[0397] In the illustrated embodiment, the wall section 43 has an
inner layer 47, an outer layer 45, and one or more intermediate
layers 41 therebetween. In some embodiments, the inner layer 47 is
suitable for contacting foodstuffs, such as virgin polyethylene
terephthalate ("PET"), or other suitable material that can form the
inner chamber of the bottle made from the preform 30.
[0398] Optionally, the wall section 43 can have at least one layer
of a material with good gas barrier characteristics. In some
embodiments, the wall section 43 of the preform 30 has a plurality
of layers having good gas barrier characteristics. Advantageously,
one or more layers of the wall section 43 that comprise a barrier
material can inhibit or preventingress and/or egress of fluid
through the wall of a container made from the preform 30. However,
the wall section 43 can comprise a plurality of layers that do not
have good barrier characteristics.
[0399] The wall section 43 of the preform 30 can have at least one
layer formed from recycled or post-consumer PET ("RPET"). For
example, in one embodiment, the wall section 43 can have the
plurality of layers formed from RPET. In some embodiments, the
inner layer 47 can be formed from virgin PET and other layers from
the wall section 43 can be formed from virgin PET or RPET. Thus,
the preform 30 can comprise alternating thin layers of PET, RPET,
barrier material, and combinations thereof. Additionally, other
materials can be used to obtain the desired characteristics and
physical properties of the preform 30, or resulting container made
from the preform 30.
[0400] Each of the layers of the wall section 43 can have generally
the same thickness.
[0401] Alternatively, the layers of the wall section 43 can have
thicknesses that are generally different from each other. A skilled
artisan can determine the desired number of layers, thickness of
each layer, and composition of each layer of the wall section 43.
In one non-limiting embodiment, the preform 30 can have a wall
section 43 including more than two layers. In some preferred
embodiments, the wall section 43 has more than three layers.
[0402] As shown in FIG. 40, the layers of the lamellar material
forming the wall section 43 can be generally parallel to one of an
inner surface 49 and an outer surface 51 of the preform 30.
Portions of the lamellar material forming the body portion 34 can
comprise layers that are generally parallel to the longitudinal
axis of the preform 30.
[0403] The distance and/or orientation of the layers of the walls
section 45 can vary or remain generally constant along the wall
section 43. Additionally, the thicknesses of one or more layers of
the wall section 43 also may vary, or they may be substantially
constant along the preform 30. It is contemplated that one or more
of the layers may have holes, openings, or diffuse into an adjacent
layer.
[0404] Lamellar material can also form other monolayer and
multilayer articles. Referring to FIG. 5, for example, the preform
50 can comprise an outer layer 52 and an inner layer 54 defining an
interior surface of the preform 50. The outer layer 52 preferably
does not extend to the neck portion 32, nor is it present on the
interior surface of the preform 50 at least one of the outer layer
52 and the inner layer 54 can comprise lamellar material. In the
illustrated embodiment, the outer layer 52 comprises lamellar
material and the inner layer 54 comprises another material.
Preferably, the inner layer 54 comprises PET, preferably virgin
PET, so that the interior surface of the preform 50 is suitable for
contacting foodstuffs. In another embodiment not illustrated, the
inner layer 54 comprises lamellar material and the outer layer 52
comprises another material. Preferably, the inner layer 54
comprises PET that forms the interior surface. However, the inner
layer 54 can comprise other materials described herein (e.g., foam
material, PET including virgin PET and RPET, PP, etc.).
Alternatively, both the inner layer 54 and the outer layer 52 can
comprise lamellar material. Thus, various combinations of materials
can be used to form the preforms disclosed herein.
[0405] The articles illustrated in FIGS. 6-17 may comprises
multiple layers. One or more of the layers of these articles can
comprise lamellar material. For example, the preform 60 illustrated
in FIG. 8A comprises an outer layer 52 formed of lamellar material.
The outer layer 52 covers the bottom surface of the support ring 38
and extends along the body portion 34.
[0406] Referring to FIG. 10, one or more of the layers 134 and 136
may comprise lamellar material. In one embodiment, for example,
substantially the entire preform 132 is formed of different
lamellar layers 134 and 136 that are adhered together. In some
embodiments, at least one of the layers 134 and 136 comprises a
lamellar material, foam material, phenoxy type thermoplastics, PET,
PP (including foamed and non-foamed), and the like. Optionally,
only one of the layers 134 and 136 may be formed of lamellar
material.
[0407] Closures may also comprise lamellar material. The lamellar
material can form a substantial portion of the closure or only a
portion thereof. In some non-limiting embodiments, the lamellar
material comprises less than about 95% by weight, also including
less than about 5%, 15%, 25%, 35%, 45%, 55%, 65%, 75%, 85% by
weight, of the closure. In some embodiments, lamellar material
comprising ranges encompassing these percentages by weight of the
closure.
[0408] As shown in FIG. 19, at least a portion of the closure 302
comprises a lamellar material.
[0409] The layer 314 and/or the outer portion 311 may comprise
lamellar material. In one embodiment, the outer portion 311
comprises lamellar material and the layer 314 comprises lamellar
material (such as PP, PET, etc.). Additionally, the inner portion
of the closures may comprise lamellar material. In some
embodiments, the outer portions of closures may or may not comprise
lamellar material. The closures of FIGS. 21A to 21E may have
similar or different inner and outer layers (or outer
portions).
[0410] FIG. 21C illustrates a closure 360 has the intermediate
layer 364 that is formed of materials that have desired structural,
thermal, optical, barrier and/or characteristics. For example, the
layer 364 can be formed of lamellar material.
[0411] The lamellar material can form at least a portion of the
layer 344 of the closure 340 (FIG. 21A), layer 356 of the closure
350 (FIG. 21B), layer 366 and/or layer 364 of the closure 360 (FIG.
21C), layer 374 of the closure 370 (FIG. 21D), layer 383 of the
closure 380 (FIG. 21E), for example. The other portions of the
closures can be formed of a similar material or different material.
In some embodiments, the majority of or the entire closure
comprises lamellar material.
6. Articles Comprising a Heat Resistance Layer
[0412] Articles described herein can comprise one or more heat
resistant materials. As used herein the phrase "heat resistant
materials" is a broad phrase and is used in its ordinary meaning
and includes, without limitation, materials that may be suitable
for hot-fill or warm-fill applications. For example, the heat
resistant material may include high heat resistant material that
has dimensional stability during a hot-fill process. The heat
resistant material may include a mid-heat resistant material that
has dimensional stability during a warm-fill process. Heat
resistant materials may include, but are not limited to,
polypropylene, crystalline material, polyester, and the like. In
some embodiments, heat resistant material has greater thermal
dimensional stability then amorphous PET. Heat resistant material
can form a portion of articles (e.g., one or more layers of a
preform, container, closure, sheet, and other articles described
herein.)
[0413] In some embodiments, a container comprises an inner layer,
comprising a thermoplastic polyester, an outer layer, comprising a
thermoplastic material (e.g., a polymer heat resistant material)
having a heat resistance greater than that of the thermoplastic
polyester of the inner layer, and an intermediate tie layer,
providing adhesion between the inner layer and the outer layer,
where the layers are co extruded prior to blow molding. Preferably,
the thermoplastic polyester of the inner layer is PET, and may
further comprise at least one of an oxygen scavenger and a passive
barrier material blended with the thermoplastic polyester.
Preferably, the passive barrier material is a polyamide, such as
MXD 6.
[0414] In view of the present disclosure, a skilled artisan can
select various types of lamellar material(s) to achieve the desired
properties of an article made therefrom. The articles disclosed
herein may be formed through any suitable means. For example, the
articles can be formed through injection molding, blow molding,
injection blow molding, extrusion, co-extrusion, and injection
stretch blow molding, and other methods disclosed herein. The
various methods and techniques described above provide a number of
ways to carry out the invention. Of course, it is to be understood
that not necessarily all objectives or advantages described may be
achieved in accordance with any particular embodiment described
herein. Thus, for example, those skilled in the art will recognize
that the methods may be performed in a manner that achieves or
optimizes one advantage or group of advantages as taught herein
without necessarily achieving other objectives or advantages as may
be taught or suggested herein.
[0415] Furthermore, the skilled artisan will recognize the
interchangeability of various features from different embodiments
disclosed herein. Similarly, the various features and steps
discussed above, as well as other known equivalents for each such
feature or step, can be mixed and matched by one of ordinary skill
in this art to perform methods in accordance with principles
described herein. Additionally, the methods which are described and
illustrated herein are not limited to the exact sequence of acts
described, nor a skilled artisan can select various types of
lamellar material(s) to achieve the desired properties of an
article made therefrom. The articles disclosed herein may be formed
through any suitable means. For example, the articles can be formed
through injection molding, blow molding, injection blow molding,
extrusion, co-extrusion, and injection stretch blow molding, and
other methods disclosed herein. The various methods and techniques
described above provide a number of ways to carry out the
invention. Of course, it is to be understood that not necessarily
all objectives or advantages described may be achieved in
accordance with any particular embodiment described herein. Thus,
for example, those skilled in the art will recognize that the
methods may be performed in a manner that achieves or optimizes one
advantage or group of advantages as taught herein without
necessarily achieving other objectives or advantages as may be
taught or suggested herein.
[0416] Although the invention has been disclosed in the context of
certain embodiments and examples, it will be understood by those
skilled in the art that the invention extends beyond the
specifically disclosed embodiments to other alternative embodiments
and/or uses and obvious modifications and equivalents thereof.
Accordingly, the invention is not intended to be limited by the
specific disclosures of preferred embodiments herein. Instead,
Applicant intends that the scope of the invention be limited solely
by reference to the attached claims, and that variations on the
methods and materials disclosed herein which are apparent to those
of skill in the art will fall within the scope of Applicant's
invention.
* * * * *