Untitled record

Preformed material and methods of manufacturing preformed material and bottle

Preform and methods of manufacturing the preform and a bottle

Full description

Background of the invention

This invention relates to products (atricles) with formable material, and more specifically to products (mono and multi-layer articles) with formable materials (atricles) and methods of manufacturing such products (atricles).

The products have generally been used to preserve beverages and food items. The use of products, such as plastic containers, as an alternative to entirely glass or metal containers in beverage packaging is becoming increasingly popular. Advantages of plastic packaging include lighter weight, less chance of breakage compared to glass, and potentially lower costs. The most common type of plastic used to make beverage containers today is polyethylene terephthalate (“PET”). PET was first approved for use by the FDA in direct contact with foodstuffs. Containers made from PET are generally transparent, thin-walled, lightweight, and have the ability to retain their shape by resisting forces exerted on the container walls by their compressed contents, such as carbonated beverages. PET resins are also fairly expensive and easy to process.

Most PET bottles are made by a process that involves blow-molding pre-formed plastic, which is made by a process that involves injection molding or an extrusion process. A PET bottle may not be a suitable thermal insulator to establish thermal contact through the walls of a PET bottle. It may be desirable to reduce heat transfer between the liquid inside the bottle and the environment surrounding the bottle to maintain the temperature of the liquid inside the bottles. Likewise, most expensive food containers do not provide an effective thermal barrier to reduce heat transfer through the container. It may be desirable to reduce heat transfer through containers or containers.

In addition, products in the form of tubes, food packaging, etc. may have inappropriate construction, insulation or other characteristics. It happens many times, or storing liquids, foods, or drinks, such as carbonated soda, in a container may affect its contents in an undesirable way. Unfortunately, when food comes into contact with the surface of certain materials of popular products, the taste of the food can be unduly altered. It may be desirable to retain the taste of foodstuffs in contact with the product.

GB1362133 discloses a method for injecting blow molded precast materials with a laminar structure having a shell of an injection moldable first synthetic resin which includes a core of a second injection moldable synthetic resin. Furthermore, the reference explains that the final product can include a foamed core layer.

US 2002/132100 A1 describes a process for preparing lightweight materials involving calendering, extrusion, blowing or injection molding of a resin of polypropylene, polystyrene, HD polyethylene, or copolymers thereof. And, mixed in, thermally expandable microspheres.

US 2001/0038074 A1 discloses a cup having a base to receive the bottom of a container body and to reduce heat gain on fluid components in the container body. The base cup is made of foam and includes a reverse coating on most of its outer surface.

U.S. Patent No. 6,276,914 discloses a method and apparatus for injection molding of thermoplastic materials using a novel valve unit to control the opening and closing of at least two edges in a single injection nozzle. Furthermore, US Patent No. 6,276,914 mentions that one of the layers of the multilayer product includes a foam material.

US Publication No. 2001/004002 discloses a method for producing a tubular preform using the injection molding method.

The present invention is intended to provide a pre-formed material for blow molding of a PET bottle with a suitable barrier for determining thermal contact through the walls of the resulting PET bottle.

Furthermore, the present invention aims to provide a method for producing a PET bottle. The present invention also aims to provide a method for producing the aforementioned preformed material, in addition to providing a method for producing a bottle from the aforementioned preformed material.

The above and other purposes are achieved by protection elements 1, 19 and 21.

Useful embodiments of independent protection elements can be derived.

General description of the invention

In a preferred embodiment, a method is provided for forming a preformed material. At least a portion of the preformed material includes an expandable material that can react to form a desired thermal insulation or finish. The preformed material is heated to the appropriate temperature for forming into a mold by blowing and at least part of the expandable material is expanded. The preformed material is blow molded into the bowl shape. In one arrangement, the preformed material is a single-layer preformed material. In another arrangement, the preformed material is a multi-layer preformed material.

In another embodiment, a process for making a foam-coated polymer product is provided including processes for supplying the preform for the foam-coated polymer and shaping the preform in a blow mold to the desired vessel shape. In one arrangement, the process involves preheating the foam-covered polymer preform before molding it into a blow mold, causing the foam covering, which includes microspheres, to begin expanding the microspheres. The microspheres can be multiplied before blow molding, during blow molding, and/or after blow molding.

In one embodiment, the foam-covered polymer product includes at least one layer of foam surrounding at least a portion of another layer that physically comprises a polyester. Foam includes a carrier material for a polymer and a foaming agent.

In another embodiment, a process for making a product including foam is provided. Foam can contain a first component and a second component. The first component can appreciate when thermally activated. Optionally, the first component includes microspheres which are generally in the first state of expansion. In one arrangement, the second component is a substance mixed with the first component. When heated, the mixture expands to generally form a closed-cell foam.

In one embodiment, the mixture is formed into a preformed material containing microspheres which expands from a first state of expansion to a second state of expansion. The preformed material is molded into a vessel containing microspheres which expand from a second state of expansion to a third state of expansion. In one arrangement, a large portion of the microspheres is unexpanded in the first position. Optionally, a large portion of the microspheres is generally partially expanded in the second position. Optionally, a large portion of the microspheres is generally expanded in the third position.

In one embodiment, the preformed material comprises a plurality of layers where one of the layers includes an expandable material. The preformed material is optionally formed into a container. In one embodiment, an inner layer of the preformed material or vessel includes material suitable for contact with the food and/or liquid and represents a holding chamber for the preformed material or vessel. In one arrangement, the inner layer includes a thermoplastic material. The second layer of the preformed material or container includes an expandable material including a polymer and microspheres. Alternatively, the expandable material can form an inner or linear layer of the preformed material or vessel.

In one embodiment, the expandable material includes a carrier material and a foaming agent. It is preferable that the carrier material be a material that can be mixed with microspheres to form an expandable material. The carrier material may be a thermoplastic or polymeric material, including, without limitation, ethylene acrylic acid (“EAA”), ethylene vinyl acetate (“EVA”), linear polyethylene Linear low density polyethylene (“LLDPE”), poly(hydroxyamino ethers) (“PHAE”), polyethylene terephtalate (“PET”), and copolymers Others include polyethylene terephthalate glycol (polyethylene terephtalate glycol (PETG), polyethylene ("PE"), polypropylene ("PP"), polystyrene ("PS"), cellulose, paste, mixtures thereof , and similar things. In one embodiment, the foaming agent includes microspheres that expand upon heating and cooperate with the carrier material to produce foam. In one arrangement, the foaming agent includes EXPANCEL microspheres.

In preferred embodiments, the expandable material has insulating qualities to prevent heat transfer through the walls of the vessel comprising the expandable material. The stretchable material can be used to maintain the temperature of food, liquids, or similar items. In one embodiment, when the liquid is in the container, the expandable material of the container reduces heat transfer between the liquid inside the container and the environment surrounding the container. In one arrangement, the vessel can hold a cooled liquid where the expandable material is a thermal insulator preventing heat transfer from the environment to the cooled liquid. Alternatively, the vessel may have a heated liquid inside, where the expandable material acts as a thermal insulator that reduces heat transfer from the liquid to the environment surrounding the vessel. Although use with food and beverages is preferred, these containers can also be used with non-food items.

In one embodiment, the foam is extruded to produce sheets that are formed into food holding containers, trays, bottles, and the like. Optionally, the plates are shaped into clam shells that are modified to hold food. Sheets may be formed into a process vessel or by more than one process, eg, heat molding or thermoforming.

In another embodiment, the product is provided comprising a foaming agent that forms a cover over the paper or wood pulp based material or container. In one arrangement, the foaming agent is mixed with the paste. Optionally, the foaming agent and paste can be mixed to form a generally homogeneous mixture which can be molded to the desired shape. The mixture may be heated before, during, and/or after forming the mixture to cause expansion of at least a portion of the foaming component of the mixture.

In another embodiment, the preformed material comprises at least a first layer comprising a material suitable for food contact and a second layer comprising a thermoplastic, such as polypropylene. Optionally, the first layer includes a thermoplastic material, such as PET, and the second layer includes a foaming material containing polypropylene and microspheres. Optionally, the first layer includes PET and the second layer consists almost or entirely of polypropylene. Optionally, the first layer includes a phenoxy type of thermoplastic and the second layer contains another material, such as polypropylene. The preformed material may be formed into a vessel by one or more processes, such as blow molding.

In one embodiment, the method of producing a bottle includes providing a preformed material containing an inner layer of PET and an outer layer comprising PP. The preformed material is then heated to a temperature typically unsuitable for processing PP. The pre-formed material is then blow molded into a bottle after heating the pre-formed material. In one arrangement, the outer layer includes a foaming material. In one arrangement, the outer layer contains mostly or entirely PP.

In another embodiment, the preformed material includes an inner layer which includes a flange defining at least part of the opening of the preformed material. An outer layer surrounds the inner layer and defines a suitable portion for a neck structure of the preformed material and also forms the outer surface of a body portion of the preformed material.

In another embodiment, there is a tube including a first layer and a second layer. In one embodiment, the first layer includes a thermoplastic material, such as PET, and the second layer includes a similar or different thermoplastic material, such as PP, and a foaming agent. Optionally, the first layer mainly includes PET and the second layer includes PP as foam material base. In one arrangement, the tube is formed by a co-extrusion process. Optionally, the tube can be blow molded into a container. Optionally, the tubing can be used as a fluid line to deliver enterable fluids.

In another embodiment, the preformed material includes an inner layer and an outer layer. The outer layer surrounds the inner layer and defines a suitable portion for a neck assembly of a preformed material. The outer layer also creates an outer surface for a body part of the preformed material.

In another embodiment, a device for molding preformed materials includes a mold core section and a mold cavity section. The mold cavity sector contains a connection system. The die core sector and the die cavity sector cooperate to define a gap when the die core sector and the die cavity sector are in a closed position. The connection system forms the bonding material inside the gap. Optionally, the device also includes an exhaust circulation (escape pipe network) in fluid communication with the gap.

In another embodiment, the method of forming the preformed material includes placing a portion of the preformed material on a rotating screw of the die. A bonding material is delivered from the output of the configured conduction system into the cavity segment defining the cavity. At least a portion of the preformed material is covered with the bonding material.

In some embodiments, the preformed material comprises a neck portion and a body portion. The body part has a parietal part and a terminal apex and includes a first layer and a second layer, the first layer comprising an expandable material. In some embodiments, the expandable material is configured to be expanded by heat treatment.

In some embodiments, the preformed material includes a grooved neck portion and a body portion. The body part includes a parietal part and a terminal crest. The body portion includes an extensible material which is less than about 40% by weight of the preformed material. In some embodiments, the expandable material comprises less than 20% by weight of preformed material. The expandable material may optionally comprise microspheres and a thermoplastic carrier material selected from the group consisting of polypropylene, PET, and combinations thereof.

In some embodiments, the method of producing the preformed material includes forming an initial layer of the preformed material. A second layer consists of the preformed material and includes an expandable and directable material. In some arrangements, the first layer is formed by injecting a starting material including polyester through a flange in an area defined by half the cavity die and half the core die to form the product. The product includes an inner surface and an outer surface. The second layer is formed by injecting an expandable material into a second area defined by the outer surface of the product consisting of the first injected material and half of the second cavity mold to form a second layer of preformed material.

In some embodiments, the method of producing a bottle includes providing a preformed material having a neck portion and a body portion. The preformed material is heated so that at least part of the preformed material expands to form the foam. The preformed material is molded by blowing into a bottle containing a foaming agent.

In some embodiments, the product includes a thread portion and a body portion. The body part includes a first layer and a second layer. The first layer has an upper end that ends below the neck grooves and contains a foaming agent. The second layer is placed inside the first layer. In some embodiments, the product is a preformed item, bottle, container, etc. The second layer includes a material suitable for food contact. For example, the second class includes a material including at least one material selected from a group consisting of phenoxy, polypropylene, polyester and combinations thereof.

In some embodiments, the bottle includes a neck portion and a body portion. The body part has an inner layer that includes polyester and an outer layer that includes foam. The foaming material includes polypropylene. The inner layer and the outer layer define at least part of the wall of the body part.

In some embodiments, the method of manufacturing a multi-layer preformed material comprises providing the underlying preformed material that has been manufactured by any of the methods known in the art. The underlying preformed material is placed in a specific cavity between the first mold part and the second mold part. The first material is injected from the outlet of the first mold part into the cavity on the underlying preformed material. Adapting the first material to form a layer on the underlying preformed material. A second material is injected from the melt portal of the first mold part onto the underlying preformed material. In some arrangements, the first material includes a binder. In some embodiments, the first material is used to encapsulate at least a portion, preferably a substantial portion of the body portion of the underlying preformed material. 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 via a drainage system. In some arrangements, the first die portion is a cavity section and the second die portion is a core section.

In some embodiments, a method of injecting material into a mold to mold a product includes providing an injection mold that is movable between an open position and a closed position. The die includes a core section and a cavity section. The material is delivered through the first gate of the cavity section. The molten material is delivered through the second gate of the cavity section. In some arrangements, the product is a preformed material or cover. Optionally, the conducting material through the first gate may include a fluid including a binder.

In some embodiments, the preformed material and container molding die includes a core segment and a cavity segment that is movable between an open position and a closed position. The core sector and the cavity sector define a cavity when the core sector and the cavity sector are in the closed position. A portal is created in the cavity section to inject the molten material into the cavity. An outlet is determined in the cavity section and prepared to inject the first material from the inlet line into the cavity. An inlet is determined in the cavity section and is prepared to pull the material into the cavity and deliver the material to the output line. In some arrangements, the gate is placed in the cavity section space to mold an end cap of the preformed material. Optionally, the gate, outlet and inlet are spaced apart and form a molding surface for the cavity section.

In some embodiments, the product molding die includes a first mold sector defining a first molding surface. A second mold sector defines a second molding surface. The first mold sector and the second mold sector cooperate to form a cavity in the shape of the product. The die delivery system includes a fluid source and a feed line. The feed line is fluidly connected to the fluid source and outlet. The port is placed parallel to the first die sector or the second die sector. The drainage system includes an inlet positioned adjacent to the first mold section or the second mold section. The drainage system includes a drainage line in preventive communication with the cavity. The melt gate is placed parallel to the second core section and is prepared to deliver the melt to the cavity. In some arrangements the delivery system includes a valve system configured to optionally control the amount of fluid delivered to the cavity. Optionally, the cavity takes the form of a preformed material or cover.

In some embodiments, the product production mold includes a core half and a cavity half configured to engage to form a cavity for molding the preformed material. One half of the cavity includes a gate. The die includes a means for delivering the packing material to the cavity and a means for removing the packing material delivered by the packing material delivery means from the cavity. Optionally, the product may be a preformed material or cover. The gate is spaced apart from the means of delivering the packing material and the means of removing the packing material.

In some preferred embodiments comprising thin sheets, preformed materials, vessels, and products comprising PETG and polypropylene, and methods for manufacturing the same, are disclosed. In one embodiment the polypropylene can be grafted or modified with maleic anhydride, glycidyl methacrylate, acryl methacrylate and/or similar compounds to improve adhesion. In another embodiment, polypropylene further comprises “micro-fine particles” or “micro-fine material”. In another embodiment the polypropylene comprises very fine particles and is grafted or modified with maleic anhydride, glycidyl methacrylate, acryl methacrylate, and/or similar compounds.

Thin sheets, preformed materials, vessels and preferred products can be manufactured using numerous techniques. For example, thin sheets, pre-formed materials, vessels and products can be formed through injection molding, up-moulding, sub-blow molding, injection-blow molding, extrusion molding, co-extrusion molding, and expansion injection molding. Blowing, and other processes disclosed herein and/or known to those skilled in the process.

In some unlimited embodiments, the products material can comprise one or more layers or portions having one or more of the following useful properties: Insulating layer, gas barrier layer, UV protective layers, protective layer (eg, vitamin protective layer, wear-resistant layer, etc.), food contact layer, non-flavoring layer, colorless layer, high durability layer, malleable layer ( compliant layer, tei layer, gas scavenging layer (e.g., oxygen, carbon dioxide, etc.), a layer or part suitable for hot filling applications, a layer with suitable melting strength For extrusion, durability, recyclability (post-consumer and/or Post-industrial), serenity, etc. In one embodiment, the single or multilayer material comprises one or more of the following: PET (including recycled and/or virgin PET), PETG, foam, polypropylene, phenoxy type of thermoplastic, poly Olefins, phenoxy-polyolefin thermoplastic blends, and/or compositions from that source.

Brief explanation of the drawings

Figure 1 is a preformed material used as an initiator for vessel formation.

Figure 2 is a cross section of the preformed material of Figure 1.

Figure 3 is a cross section of a blow molding device of the type that can be used to make a preferred vessel.

Figure 4 is a side view of the preformed vessel.

Figure 5 is a cross section of a multilayer preformed material.

Figure 6 is a cross-section of a multilayer container made of the multilayer preformed material of Figure 5.

Figure 7 is an enlarged view of the vessel of Figure 6 taken with 7.

Figure 8 is a cross section of a multilayer preformed material.

Figure 8(a) is an enlarged view of the preformed material of Figure 8 taken with 8(a).

Figure 9 is a cross section of a preformed material containing a narrow multi-layered section.

Figure 10 is a cross section of a multilayer preformed material according to another embodiment.

Figure 11 is a cross-section of a multi-layer preformed material, where the inner layer inside the preformed material is identified.

Figure 12 is a cross section of a multilayer preformed material with an inner layer and an outer layer defining the narrow portion.

Figure 12(a) is a cross-section of a multi-layer preformed material, each with an inner layer and an outer layer defining the narrow section.

Figure 12(b) is a cross section of a preformed material with an inner layer and an outer layer defining the narrow portion.

Figure 13 is a cross section of a preformed material with an inner layer that has a raised edge.

Figures 13(a) and 13(b) are enlarged cross-sections of portions of multilayer preformed materials according to some embodiments.

Figure 14 is a cross section of a multilayer preformed material with an inner layer that has a bonding structure.

Figure 14(a) is a cross-section of a vessel made of the preformed material of Figure 14, where a closure device is attached to the vessel.

Figure 14(b) is an enlarged view of a portion of the bowl and seal device of Figure 14(a) taken with 14(b).

Figure 14(c) is an enlarged view of a portion of the bowl and sealing device according to another embodiment.

Figure 15(a) is a cross section of a section of preformed material that has a narrow section without threads.

Figure 15(b) is a cross section of the preformed material of Figure 15(a).

Figure 15(c) is a cross section of a portion of a multi-part preformed material.

Figure 16 is a cross section of a preformed material according to another embodiment.

Figure 17 is a cross section of a preformed material according to another embodiment.

Figure 18 is a perspective view of the sealing device suitable for sealing the vessel.

Figure 19 is a cross section of a multilayer sealer with an interlayer.

Figure 20 is a cross-section of a multi-layer sealer with an inner layer extending along the sides of the sealer.

Figures 21(a)-21(e) are cross-sections of multi-layer fasteners.

Figures 22(a)-22(b) are cross sections of plates.

Figure 23 is a perspective view of one preferred embodiment of the preformed material.

Figure 24 is a side view of one preferred embodiment of packaging including a container with a label and a sealer.

Figure 25 is a side view of a bowl and seal according to another embodiment.

Figure 26(a) is a perspective view of the vessel.

Figure 26(b) is a perspective view of the tray.

Figure 27 is a schematic view of an embodiment of a laminar generating system with a melting stream.

Figure 27(a) is a cross section of a lamellar material made from the melt-stream lamellar generator of Figure 27.

Figure 28 is a cross-section of a type of mold that can be used to make the preformed material of shape 1.

Figure 29 is a cross-section of a type of mold that can be used to make an outer layer of the preformed material of a shape 5.

Figure 30 is a cross-section of a type of mold that can be used to make an inner layer of the preformed material of Figure 11.

Figure 31 is a cross-section of a type of mold that can be used to make an outer layer of the preformed material of Figure 11.

Figure 32 is a cross section of a type mold that can be used to make a cover.

Figure 33 is a cross-section of a type of mold that can be used to make the outer layer of the special cover of Figure 20.

Figure 34 represents a formed mold for making multi-layered pre-formed materials containing bonding layers.

Figure 35 is a cross section of a die of the die system of Figure 34.

Figure 36 is a cross-section of a 35-shaped block taken along lines 36-36.

Figure 37 is a separate enclosed view of the private space of Figure 35 taken along lines 37-37.

Figure 38 is a cross section of a modified block of Figure 35 taken along lines 36 36.

Figure 39 is a separate closed view of the private space of Figure 35 taken along lines 37-37.

Figure 40 is a cross-section view of a thin laminate material.

Detailed description

All patents and published books mentioned herein are hereby incorporated by reference in their entirety. Except as hereinafter described, certain embodiments, features, systems, devices, materials, processes and technology described herein may be similar to any one or more embodiments, feature, system, device, material, process and technology described in U.S. Patent Nos. 6109006; 6808820; 6528546; 6312641; 6391408; 6352426; 6676883;US Patent Application Numbers 745013/09 (Publication No. 2002-0100566); 168496/10 (Publication No. 2003- 0220036); 844820/09 (2003- 0031814); 090471/10 (Publication No. 2003- 0012904); 395899/10 (Publication No. 2004- 0013833) 614731/10 (Publication No. 2004- 0071885); Provisional Application 563021/60, filed April 16, 2004, Provisional Application 575231/60, filed May 28, 2004, Provisional Application 586399/60, filed July 7, 2004, and Provisional Application 620160/60, filed October 18, 2004, 621511/60, filed on October 22, 2004, Provisional Application 643008/60, filed on January 11, 2005, US Patent Application No. AP+PEP1.090A under the designation Single and Multilayer Products and Press Forming Methods for Making the Same, filed on the same day as the present application, US Patent File No. AP+ PEP1.089A under the designation single and multi-layer products and extrusion molding methods for making the same, filed on the same day as the present order, all of which are included in this description by way of reference. In addition, the embodiments, images, systems, devices, materials, processes and techniques described herein may be applied in specific embodiments, or used in combination with any one or more of the embodiments, images, systems, devices, materials, processes and techniques disclosed in said patents and applications. Up.

A- Products

Products in preferred embodiments can comprise one or more moldable materials. The products described here can be single or multilayer (i.e., two or more layers). In some embodiments, the products can be used for packaging, such as beverage articles (including preformed materials, containers, bottles, sealers, etc.), boxes, cartons and the like.

Multilayer products may include an inner layer (i.e., the layer in contact with the contents of the container) of a material approved by the regulating agency (e.g., FDA) or a material that has regulatory approval for contact with food (including beverages), drugs, cosmetics, etc. . In other embodiments, the inner layer includes material(s) that are not approved by the food contact regulatory scheme. The second layer includes a second material, which may be similar to or different from the material composing the inner layer and the products may have as many layers as may be desired. It is intended that products may comprise one or more materials that are parts but not “layers”.

1- Detailed description of the drawings

Referring to Figures 1 and 2, a preferred pre-formed material 30 shows a monolayer. Generally, the preformed material 30 has a narrow portion 32 and a body portion 34. The applied preformed material 30 can have a single layer composed of material that can be molded in a blow mold. The preformed material 30 is preferably formed in a blow mold into a container to hold liquids, such as non-carbonated liquids such as fruit juice, water, and the like. Optionally, the preformed material 30 can be formed into a holding vessel for other liquids, such as carbonated liquids. The preformed material 30 shown can be suitable for forming a 16 oz beverage bottle which would be very suitable for holding a carbonated beverage. As used here, the expression “bottle” is a comprehensive expression used in its ordinary sense and may include, a loose container (typically glass and/or plastic which has a relatively narrow neck or mouth), a bottle-shaped container for storing a liquid (preferably a liquid ),etc. The bottle may or may not have a handle.

The preformed material 30 shown has a neck portion 32 that begins at an opening 36 (Figure 2) into the interior of the preformed material 30 and extends to include the support ring 38. As used herein, the expression "narrow or neck portion" is a broad expression and is used in its ordinary sense and can include Without limitation, a portion of the preformed material attached to the cervical portion may include a narrow end, the cervical end being together with the cervical cylinder, herein referred to as the "cervical portion." The neck portion 32 of the shown embodiment is also distinguished by the presence of threads 40, which provide a method for attaching the cap or closing member to the bottle produced from the preformed material 30. Alternatively, the neck portion 32 may not be shaped to attach to the closure device or may contain means other than threads to attach to the closure device . The body part 34 is known and is a generally cylindrical structure extending from the bottom of the cervical part 32 and ending at the end cap 42. The end cap 42 shown is circular; However, the end cap can have other suitable shapes. The thickness of the preformed material 44 will depend on the total length of the preformed material 30, the desired wall thickness, and the overall volume of the resulting vessel.

Referring to Figure 3, the preformed material 30 in this blow molding process is placed in a mold whose cavity is relative to the desired vessel shape. The preformed material 30 is then heated and expanded by forcing air or other suitable fluid into the preformed material to expand the preformed material to fill the cavity, thus forming the vessel 37 (Figure 4). The blow molding method is described in detail below. An extending rod or similar device may also be used to assist in the blow molding process, as known in the method.

In some embodiments, the blow molding machine can receive warm products (e.g., preformed materials such as sleeves, preformed materials, etc.) to assist in the blow molding process, as known in the method. The mold 28 can receive pre-formed and warm materials from an injection molding machine, such as the injection molding machines described herein. Preformed materials manufactured by the injection molding machine can be quickly transferred to the mold 38 by means of a connection. Latent heat can be provided to the preformed material one or more of the following: reducing the blow molding time, reducing the energy required to heat the preformed material to a temperature suitable for blow molding, and/or the like.

Optionally, one or more delivery systems may be used to transfer preformed materials to and/or bottles away from the blow molding mold. For example, the delivery system can include a shuttle system (e.g., a linear or rotary shuttle system) for transporting preformed materials to and/or away from the mold 28. The shuttle system can supply batches of preformed materials to the mold 28 or remove preformed bottles. In a blow mold from the mold 28. Alternatively, the delivery system may include a reciprocating and/or rotary delivery system. In some embodiments, a rotary delivery system can be used to quickly deliver preformed materials into mold 28 or remove bottles from mold 28. Advantageously, rotary delivery systems can continually move products around and around mold 28 thereby increasing output.

It is expected that the connection system can be used with suitable blow molding machine for blow molding, extrusion and blow molding, extrusion, etc. In addition, the delivery system may include a combination of systems, such as a rotary delivery system and a shuttle system that cooperate to move products.

Referring to Figure 4, where the embodiment reveals the vessel 37 which can be formed from the preformed material 30. The vessel 37 includes a neck portion 32 and a body portion 34 by association of the neck and body portions of the preformed material 30. As described above with respect to the preformed material, the Modifying the neck portion 32 to attach to the locking device. The neck portion 32 shown features threads 40 which represent a method of securing the lid to the vessel. Optionally, the vessel wall 37 can prevent, preferably effectively prevent, the migration of gas (e.g., CO2) through the vessel wall 37. In some embodiments, the vessel 37 actually includes closed foam cells that prevent fluid migration through the foam.

The blow molding process is usually limited to the body portion 34 of the preformed material with the neck portion 32 including any grooves, pilfer, and/or support ring that retain their original shape as in the preformed material. However, any part(s) of the preformed material can be stretched and shaped in a blow mold. The vessel 37 may also be formed by other processes, such as extrusion or combinations of processes (e.g., injection molding on a part after extrusion). For example, vessel 37 may be formed during an extrusion molding process formed in a blow mold. Therefore, the vessels described here can be constructed from preformed materials, extruded preformed materials, etc.

Referring to Figure 5, a cross-section of one type of multilayer preformed material 50 having properties consistent with the preferred embodiment is disclosed. The preformed material 50 preferably comprises an uncoated (single-layer) primer 39 that is covered by an outer layer, 52. Preferably, the uncoated preformed material 39 comprises a polymer material, such as polypropylene, Polyester and/or other thermoplastic materials, preferably materials suitable for contact with food. In one embodiment, for example, the physically uncovered preformed material 39 comprises polypropylene. In another embodiment, the uncoated preformed material 39 actually comprises a polyester, such as PET.

The multilayer preformed material 50 includes a neck portion, 32 and a body portion 34 similar to the preformed material 30 of Figures 1 and 2. In the shown embodiment, the outer layer 52 is exposed to approximately at least a portion of the body portion 34. In one embodiment, the outer layer 52 is exposed to approximately a significant portion, preferably the entire area, of the surface of the body portion 34 of the inner layer (shown as preformed material 39 of the figure 1), ending at the base of support ring 38. The outer layer 52 in the embodiment shown does not extend to the neck portion 32, nor is it located on the inner surface of the inner layer 39 which is preferably made of a material suitable for contacting the contents of the resulting vessel. The outer layer 52 comprises either a single material or multiple layers (e.g., very fine layers) of one or more materials. Also, the outer layer 52 can be generally homogeneous, generally heterogeneous, or somewhere in between. Although not shown, the outer layer 52 can be other parts of the preformed material 50. For example, the outer layer 52 may be at least part of the inner surface of the preformed material 50 (just as the outer layer is injected onto a tube or preformed material that is open at both ends), or a portion of the neck portion 32. It may be The outer layer 52 is first suitable for contact with food materials.

The total thickness 56 of the preformed material is equal to the thickness of the initial, uncovered preformed material 39 (i.e., the inner layer 54) plus the thickness of the outer layer 52, which depends on the overall volume and desired covering thickness of the resulting vessel. However, the thickness of the preformed material 50, which may be any thickness, depends on the desired thermal, optical, insulating, and/or structural qualities of the preformed vessel 50. If a bond layer is included, the overall thickness will include any Bonding thickness. Preformed materials and vessels can contain layers of a wide variety of relative thicknesses. Given the present disclosure, the specific and total layer thickness of the preformed material or vessel can be chosen, either at a particular point or for the entire vessel, to suit the manufacturing process, or a particular end use of the vessel. In the shown embodiment, the outer layer 52 has generally equal thickness. However, the outer layer 52 and/or inner layer 54 need not be equal and can, for example, have a thickness that varies along the longitudinal axis of the preformed material 50.

Multi-layer preformed materials can be used to produce vessels. For example, the preformed material 50 may be used to form the vessel 83 (Figure 6). In one embodiment, the outer layer 52 cooperates with the inner layer 54 to form a layer or space 85 between them, as shown in Figures 6 and 7. The layer 8 can allow air to pass between the layers 52, 54 and can characteristically insulate the vessel 83 as well. Passages can be formed between the layer 52 that surrounds the inner layer 54 loosely. Alternatively, the outer layer 52 can be sized and shaped to closely adhere to the inner layer 54 such that the 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 which is similar to, or dissimilar to, one or more layers. of layers 52, 54. In another embodiment, the layer 85 may be a layer such that layer 52 is coupled to the inner layer 54. For example, layer 85 may be an adhesive or bonding layer which prevents, preferably effectively prevents, relative movement Between layers 52 and 54. For example, layer 85 may be an adhesive layer that determines relative movement between layers 52, 54. It is expected that some or none of the layers of the embodiments described herein may be bonded together by a bonding layer or the like.

In one embodiment, at least one of the layers 52, 54 can be treated to increase or decrease the adhesion between the layers 52, 54. For example, the outer surface of the inner layer 54 can be chemically treated such that the outer layer 52 adheres to the inner layer 54. For example, A binder may be used to chemically react and cure one or more of the layers 52, 54. However, it is expected that any layer (any of the layers) can be modified to achieve the desired interfacial interaction between the layers of the preformed material. Optionally, the layers 52 and 54 can be glued directly together.

In some embodiments, a vessel includes a foaming material which preferably has insulating properties to prevent heat transfer through the walls of the vessel. When liquid is in a container, such as vessel 83 of Figure 6, for example, the foaming material forming the wall 84 of vessel 83 can reduce heat transfer between the liquid contents and the environment surrounding the vessel 83. For example, vessel 83 can hold chilled ingredients, such as a carbonated beverage ( carbonated), and the foam is isolated from the vessel 83 to prevent temperature changes of the cooled fluid. Therefore, the contents can remain chilled for a desired period of time despite the surrounding outside temperature being greater than the temperature of the liquid. Alternatively, a heated substance, such as a hot beverage, may be inside the vessel 83 where the wall 84 can insulate the vessel 83 to prevent heat from being transferred from the liquid to the environment surrounding the vessel 83. Also, the foaming agent of the vessel 83 can make the surface temperature of the vessel 83 where It is within the desired temperature range such that a person can comfortably hold the vessel 83 holding a heated or cooled liquid. The thickness of the foam layer and the size and shape of the foam portion of the bowl can be varied to obtain the desired thermal qualities of the bowl.

Referring to Figure 8, a preferred embodiment of the multilayer preformed material 60 is shown in cross-sectional form. There is one difference between the preformed material 60 covered and the preformed material 50 of Figure 5, which is the relative thickness of the two layers in the tip area of the cover. In the preformed material 50, the outer layer 52 is generally thinner than the primary layer along the entire body of the preformed material. The outer layer 52 of the preformed material 60 is, however, thicker at 62 near the end of the cover 42 than at 64 in the wall part 66, and conversely, the thickness of the inner layer 54 is greater at 68 near the end of the cover 66 than at 70, in the end area of the cover 42. This premolding design is particularly useful when an external premolding material is applied in the overmolding process to make a multi-layer primer, as described below, as it has certain advantages including those of reducing the molding cycle time. Both layers may be homogeneous or may contain a collection of very fine layers. In other embodiments of the preformed material 60 not shown, the outer layer 52 is thinner at 62 near the end of the cover 42 than at 64 in the wall 66, and conversely, the thickness of the inner layer 54 is thinner at 68 in the wall portion 66 than at 70, in Cover tip area 42. At least one of the layers 52, 54 may optionally include an insulating material.

Figure 8(a) is an enlargement of a wall section of the preformed material showing the arrangement of layers in the LIM embodiment of over-injection. Layer 54 represents the inner layer of the preformed material and layer 52 is the outer layer of the preformed material. The outer layer 52 comprises an assembly of very fine layers (i.e., laminar material) of the material as would be made by using the LIM system. Of course, not all primitives of figure 8 will be of this type.

Referring to Figure 9, another embodiment of a multi-layered preform is shown in cross section and the primary difference between the overlaid preformed material 76 and the preformed materials 50 and 60 of Figures 5 and 8, respectively, is that the outer layer 52 is positioned on the neck portion 32 as well as on the body portion 34 .

Preformed materials and vessels can contain layers of a wide range of relative thicknesses. In a view of the present disclosure, a given layer thickness and the total thickness of the preformed material or vessel, either at a particular point or throughout the entire vessel, are selected to suit the coating process or a particular end use of the vessel. Furthermore, as discussed above for the layer(s) of Figure 8, layers in the preformed material and vessel embodiments shown herein may comprise one material, more than one material, or multiple materials.

The devices and methods described herein can also be used to make raw materials with three or more layers. In Figure 10, a three-layer embodiment of the preformed material 132 is shown. The material shown there has two overlay layers, a middle layer 134 and an outer layer 136. The relative thickness of the layers shown in Figure 10 may be varied to suit a particular combination of materials or to permit the manufacture of different sized bottles, and, as will be understood by one skilled in the art, a method similar to that shown here may be followed, except that the primary preformed material will have been covered. Preformed by one of the methods for making the covered preformed materials described herein, including over-forming in a die.

Figure 11 shows a cross section of a type of multilayer preformed material 160 having properties according to a preferred embodiment. The preformed material 160 preferably includes an outer layer 162 and an inner layer 164.

The multilayer preformed material 160 contains a neck portion 132 and a body portion 134 similar to the preformed material described above. Preferably, the outer layer 162 is for the outer surface 165 of the body segment 134 and the outer surface 166 of the cervical segment 132. The outer surface 166 can be shaped to attach to the locking device. Fixing the outer layer 162 around a large portion, preferably the entire portion, of the inner layer 164.

The outer layer 162 shown extends from the upper end 68 of the inner layer 164 to the opening 169 of the preformed material 160. The inner layer 164 does not extend in the embodiment shown along the length of the neck portion 132. Therefore the outer layer 162 can actually form the entire neck portion 132, as shown in Figure 11. In other embodiments, the upper end 168 of the inner layer 164 can be arranged at some point along the neck portion 132. Therefore, both the inner layer 164 and the outer layer 164 can define the neck portion. In one unspecified embodiment, the outer layer 162 comprises at least about 70% of the weight of the cervical portion (or neck end) of the cervical portion 132. In another unspecified embodiment, the outer layer 62 comprises at least about 50% of the weight of the cervical portion . In another yet unspecified embodiment, the outer layer 162 comprises approximately more than 30% of the weight of the neck portion 132.

The total thickness 171 of the preformed material 160 is equal to the thickness 172 of the outer layer 162 plus the thickness 174 of the inner layer 164, which is dependent on the total volume of the resulting vessel. In one embodiment, the thickness 172 of the outer layer 162 is actually greater than the thickness 174 of the inner layer 164. The outer layer 162 and inner layer 164, as shown, generally have a uniform thickness. However, the outer layers 162 and inner layers 164 may not have uniform thickness. For example, one or both layers 162, 164 may have thicknesses that vary along the length of the preformed material 160.

The outer layer 162 includes a primer material and the inner layer 164 preferably includes another material. For example, the outer layer 162 may include a foaming material and the inner layer 164 may include a non-foaming polymer material, such as PET (e.g., pre- or post-consumer (recycled) PET), phenoxy, etc. preferably A large part of the outer layer 162 contains a first material and a large part of the inner layer 164 contains a second material. The first and second materials may be different or similar to each other.

Figure 12 represents a cross-section view of the multi-layer preformed material 180. The preformed material 180 is generally similar to the preformed material 160, and therefore many features of the preformed material 180 will not be described in detail. The preformed material 180 includes an inner layer 184 and an outer layer 183. The inner layer 184 defines a significant portion of the inner surface 173 of the preformed material 180. The inner layer 184 contains an end 188 that is proximal to the opening 191 of the preformed material 180. In the shown embodiment, the outer layer 183 maps to the outer surface 186 of the neck portion 132, and the inner layer 184 maps to the inner surface 187 of the neck portion 132. Of course, the outer layer 183 can be operated to associate with the sealing device. In the shown embodiment, the outer surface 86 sets grooves 189 that are modified to receive a grooved cap (e.g., a screw cap).

Although not shown, the preformed materials 160 and 180 can comprise more than two layers. For example, the outer layer 162 of the preformed material 160 can comprise a plurality of layers comprising one or more of the following: laminated material, foaming material, PP, PET, and/or similar. Similarly, the inner layer 164 can include a plurality of layers. An individual of ordinary skill in the art can determine the dimensions and number of layers that make up the preformed material described here. The layers 183, 184 may be made of similar or different materials as the layers 162, 164 described above.

Optionally, a layer may cover at least part of the preformed material to prevent corrosion or wear, especially if at least part of the preformed material is a foaming material. For example, an overlay layer may surround the neck notches made of foam which may include PET, PP, compositions from that source, or other thermoplastic materials.

Figure 13 represents a cross-section view of the preformed material 190. The preformed material 190 is similar to the preformed material 180 shown in Figure 12, except as detailed below.

The preformed material 190 includes an inner layer 194 that extends downward from the opening 191 and defines the interior of the preformed material. The inner layer 194 includes an edge 193. As used herein, the expression “edge” is a broad expression and is used in its ordinary sense and can include, without limitation, one or more of the following: lip, solved portion, edge, raised edge, portion Emerging, and compositions from that source. The flange can act as a locking fitting. Additionally, the preformed material can optionally contain edge collection.

The edge 193 designates a portion of the inner surface 201 and at least a portion of the upper surface 195 of the preformed material. The flange 193 can have a fixed or variable thickness depending on the desired characteristics of the neck portion 132. In some embodiments, including the one shown, the flange 193 is positioned at the top of the fixture(s) (e.g., notches 192) to receive the locking device. In some embodiments, edge 193 means a portion of one or more grooves, ridges, recesses, and/or other assemblies for engagement with the sealing device.

With continued reference to Figure 13, the edge 193 extends at least approximately a portion of the circumference of the opening 191 and demarcates a layer of material. Preferably, the edge 193 extends approximately the entire circumference of the tool slot 191 . Therefore, edge 193 can generally be a toroidal edge. When the sealing device is attached to the neck portion 132 of the vessel of preformed material 190, the upper surface 195 of the rim 193 can be plugged with the sealing device to prevent or block food materials from escaping from the vessel. The edge 193 can block or prevent separation between the inner layer 194 and the outer layer 199.

One or more locking structures 197 of Figure 13 can prevent relative movement between the inside layer 194 and the outside layer 199. As used herein, the expression “locking structure” is a broad expression and is used in its natural sense and may include, but is not limited to: One or more of the following: ridges, surface treatments (e.g., rough surface), ridges, ridges, spines, ridges, recesses, ridges, textured pattern, or the like, preferably to prevent or reduce movement between layers 194 and 199. The locking fitting 197 can be configured by the inner layer 194 and/or the outer layer 199. In the shown embodiment, the locking fitting 197 is a protrusion extending from approximately the outer surface of the inner layer 194. In some embodiments, the lock assembly 197 is an annular protrusion extending circumferentially around the outer surface of the inner layer 194. The lock assembly 197 can be a continuous or discontinuous assembly. The inner layer 194 may contain one or more locking assemblies, such as an embodiment of a special structure (e.g., a series of grooves, cams, and the like).

In addition, the locking fitting 197 can be configured to provide an in or out taper. For example, the inner layer 194 can include a somewhat flexible material (e.g., PET) and a locking fitting that provides an outward taper during its removal from the mold. In some embodiments, the coating 199 comprises a more or less solid material (e.g., olefins) that can be provided with an outward taper during its removal from the mold. The outer layer 199 is shaped to receive the locking fitting 197. The locking fitting 197 effectively locks the outer layer 199 to the inner layer 194. Although not shown, a plurality of locking assemblies 197 may be designated by layers 194, 199 which may be arranged within the neck portion 131 and/or body portion 134 of preformed material 190. In some embodiments, the inner 194 and outer layers 199 consist of materials that They can bond or stick to each other directly. In other embodiments, the inner layer 194 is bonded to the outer layer 199, such that layers 194 and 199 can be easily separated during, for example, a recirculation process. However, the product comprising the binding layer can be recirculated in some embodiments.

The upper end of the outer layer 199 is spaced from the upper surface 195 of the preformed material. The skilled fabricator can select the thickness of the layers 194, 199 to achieve the desired compositional properties, thermal properties, strength, and/or other properties of the preformed material.

Figures 13(a) and 13(b) show modified embodiments of a portion of the preformed material 190 of Figure 13. The preformed material 190 of Figure 13(a) contains an edge 193 that extends along a portion of the upper surface 195 of the preformed material. In some unspecified embodiments, the LF length of the rim 193 is approximately less than 95% of the wall thickness T of the cervical segment 132. In one unspecified embodiment, the LF length of the rim 193 is approximately 50% to 90% of the wall thickness T of the cervical segment. In certain unspecified embodiments, the LF length of the rim 193 is approximately 60%, 70%, 75%, or 80%, or ranges including such ratios of the wall thickness T of the cervical segment. In an embodiment other than specified, the length LF of the flange 193 is approximately 40% to 60% of the wall thickness T of the neck segment. In yet another embodiment, the length LF of flange 193 is approximately less than 40% of the wall thickness T of the neck portion.

Figure 13(b) shows a portion of the preformed material having an outer layer 203 that defines an edge 223. The edge 223 extends inward and defines the upper surface 225. The edge 223 can define the inner surface of the preformed material, or a spacing between them. The length of the flange 223 may be similar to or different from the length of the flange 193. The cervical portion 132 has notches to receive the locking device. However, the neck portion may have other structures (e.g., recesses, ridges, grooves, etc.) for coupling with the sealing device. The preformed materials described above can be modified by adding one or more layers to achieve the desired properties. For example, an insulating layer can be formed on body parts of preformed materials.

Figure 14 shows a modified embodiment of the preformed material 202. The preformed material 202 includes a neck portion 132 that sets the coupling configuration 207 formed to receive the locking device. As used herein, the expression “conjugation structure” is a broad expression and is used in its ordinary sense, and may include, without limitation, a property such as a positive (e.g., ridge, cusp, etc.) or negative property (e.g., gap, cavity, etc.) . The coupling fitting can be configured to engage the locking device to hold the locking device in the desired position.

The coupling composition 207 shown is in the form of a recess modified to receive a portion of the locking device. The coupling composition 207 may extend over approximately one or more portions of the preformed material 202. In other embodiments, the coupling composition 207 extends approximately the entire circumference of the preformed material 202. The coupling composition 207 has a curve (e.g., sub-circular), V-shaped, at U-shape, or other suitable cross-section of the preformed material. Although not shown, the structure 207 can be a protrusion, such as an annular protrusion, defined by an outer layer 203. Optionally, the preformed material 202 may consist of a plurality of coupling assemblies 207 such that sealing devices of various shapes can connect to a receptacle manufactured from the preformed material. The distance between the upper surface 205 of the fittings 207 and the shape of the fitting 207 is determined by the geometry of the sealing device used to prevent leakage and seal the preformed vessel 202 .

Figure 14(a) shows the receptacle 211 resulting from the preformed material 202 of Figure 14. A closure device 213 is attached to the neck portion 132 of the receptacle 211. The closure device is composed of one piece or multiple pieces. The sealing device 213 may be attached, temporarily or permanently to the vessel 211. The sealing device 213 can be completely removed from the vessel 211 when the liquid is consumed. In other embodiments a portion of the sealing device 213 may be removed while a final portion of the sealing device 213 is still attached to the receptacle 211 during consumption. The sealing device 213 may be semi-permanently or permanently attached to the receptacle 211. If the sealing device 213 is semi-permanently attached to the receptacle, the sealing device 213 can be withdrawn from the receptacle 211. In one embodiment, if the sealing device 213 is permanently attached to the receptacle 211, the receptacle 211 and the sealing device 213 generally form one body.

As shown in Figure 14(b), the upper surface 205 of the preformed material and sealing device 213 can be sealant 231, preferably either an airtight seal or any sealant that prevents liquid from escaping between the vessel 211 and sealing device 213. Optionally , the vessel 211 can have a removable gasket or seal. For example, the vessel 211 may have a removable seal, such as a film adhered to the upper lip of the vessel, or a portion of the sealing device 213 that can be removed. Removable sealant can have a small handle or loop to make it easier to grip and remove the sealant. Alternatively, the seal 231 can be composed by a membrane or sheet which can be broken or fragmented in order to open the receptacle 211. In some embodiments, the outer layer 203 of the receptacle 211 is composed of a highly durable or generally rigid material (e.g., PP); Such that the edge 209 can be compressed between the sealing device 213 and the outer layer 203 to ensure that the integrity of the seal 231 is maintained.

As shown in Figures 14(a) and 14(b), the closure device 213 has a body 215 and a cap 218. The body 215 may be connected to the cap 218 by a hinge 221 (e.g., a die-formed material that acts like a living hinge or other fitting to permit movement). The cover 218 may be attached to the body 215 by means of a bolt or latch 217 (Figure 14(a)). The latch 217 can be moved to move the cover 218 in order to open the locking device 213. Alternatively, the cover 218 and body 215 can be hinged pieces such that cover 218 can be removed from body 215. When the locking device 213 is in the open position, the components can be released out of the receptacle 211, preferably connecting while the body 215 is still attached to the end of the neck. After removing the required amount of food from the container 211, the lid 218 can be returned to the sealing position and to reseal the container.

The body 215 of the locking device 213 may be coupled to the cervical segment. For example, the body 215 may be closed to the neck portion 132. Alternatively, the body 215 may be circularly coupled to the neck portion 132. The neck portion includes one or more clouser attaching structure 227 in the form of a passive feature, Such as a cavity or gap. The body 215 may be permanently coupled to the outer layer 203 by a bonding or melting process (e.g., induction bonding), adhesive, frictional interfacial interaction, and/or the like. The receptacle 211 can be configured to receive various types of closure devices, such as BAP closures produced by Bapco Closures Limited (England), (or similar closures), screw caps, compression closures, and/or the like. A skilled fabricator can design the neck end of the vessel 211 to receive closing devices of various shapes.

With continued reference to Figure 14(a), vessel 211 is particularly well suited for hot material filling applications. The vessel 211 generally maintains its shape during filling operations with hot material. After blow molding or hot filling, the final dimensions of the neck portion of the vessel 211 are preferred to closely match the initial dimensions of the preformed material. Additionally, this results in reduced dimensional variations of the notches on the neck end. For example, the inner layer 284 is composed of a food contact material, such as PET. The outer layer 203 includes materials that can be formed into a mold (e.g., PP, foaming material, crystalline or semi-crystalline material, lamellar material, homopolymers, copolymers, compositions from that source, and other heat-resistant materials described herein) Which is suitable for hot packing. The outer layer 203 provides the neck portion 132 with dimensional stability even during and/or after hot packing and 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 composing the neck portion 132 includes a material having high thermal stability; However, the neck can also be made of materials with low thermal stability, especially for non-hot filling applications.

Additionally, the dimensional stability of the outer layer 203 ensures that the sealing device 213 remains attached to the receptacle 211. For example, the outer layer 203 may include a highly durable material (e.g., PP) that can retain its shape thereby preventing inadvertent loosening of the coupling of the sealing device 213 from the receptacle. 211.

Referring to Figure 14(c), the necked receptacle has attached locking fittings for occlusal fit. The cervical portion in the shown embodiment includes an accessory locking fitting 227 in the form of a positive feature, such as a ridge, ridge, and the like that is suitable for engagement of the locking device 213. The accessory locking fitting 227 can form annular protrusions that extend circumferentially around the cervical portion. The locking device 213 may have a one-piece or multi-piece assembly. The vessel 211 shown has a wall that tapers upward, forming a neck end. The tapered portion of the neck end can be produced against the snap-sealing cap 213 and be leak-proof.

Figure 15(a) shows a portion of the preformed material 220 according to another embodiment. The preformed material 220 includes a support ring 222 and a body portion 224 extending downward therefrom. The first material 220 has an opening 226 at its upper end. The neck end of the preformed material may or may not contain notches. In some embodiments, the notches are attached to the neck portion 225 of the preformed material. It is expected that the preformed material 220 can be formed without a support ring. The support ring and/or notches of the preformed material 220 can optionally be formed in subsequent operations.

Figure 15(b) shows the preformed material 220 after the accessory occlusal fittings 228 have been attached to the cervical segment 225. It is expected that notches, fittings associated with an occlusal cap, or other type of retaining or connecting fitting that may be attached to the cervical segment 225 are attached before Or after the preformed material 220 is manufactured into a container. For example, closer mounting structure 228 may be attached to the preformed material 220 after the preformed material is molded, preferably blow molded into a vessel.

Preformed materials can contain other parts that are attached or attached to each other. Figure 15(c) shows the preformed material 234 in which at least a portion of the neck end 240 is coupled to the body 242 of the preformed material. The preformed material shown 234 includes a portion 238 which is coupled to the upper end 250 of the lower portion 252 of the preformed material 234. The portion 238 comprises different materials and/or microstructure than the lower portion 252. In some embodiments Part 238 comprises a crystalline substance. Therefore, Preformed Material 230 is suitable for hot material filling applications. The bottom 252 may be amorphous which facilitates blow molding. In some embodiments, the upper portion 238 comprises a different material than the lower portion 252. A skilled fabricator can select which material is the preformed material. In some embodiments, the upper end 250 is positioned under or at the support ring. The preformed materials shown in Figures 15(a) to 15(c) may have single-layer or multi-layer walls.

Preformed materials, including single-layer and multi-layer preformed materials, described above may have other shapes and compositions. Figure 16 shows a preformed material having a tapered body portion 272 and a neck end 274. The preformed material 270 can be blow molded to form a jar-like container, for example. A jar or other similar container has a mouth or opening larger than the mouth of the bottle. The material 270 has a support ring 278 and one or more accessory locking fittings 279, preferably configured to interface with a snap locking device or another type of locking device. Figure 17 shows an embodiment of a raw material having a necked end without notches. The preformed material 280 includes a body portion 281, which has a tip 283, and a neck end 282. The preformed material 280 can be suitable for being blow molded into a vessel. The preformed materials shown in Figures 16 and 17 may be single-layer or multi-layer preforms (e.g., having the layers described above). The preformed materials described above can be formed without a neck end.

Preformed materials, such as those pictured in Figures 1-18, can be subjected to a contouring and shaping process in a blow mold. The blow molding process is described primarily for single-layer preforms 30, although multi-layer preforms (e.g., preforms 50, 60, 76, 80, 132, 160, 180, 290, 216) can be processed using similar. The vessels described above can be formed by various die-casting operations (including blow-mold extrusion), for example.

2- A detailed description of the covers

As described above, lids can be used to seal containers. As used herein, the term "cap" is broad and is used in its ordinary sense and may include, but not be limited to, a cap (including a snap cap, an inverted cap, a bottle cap, a grooved bottle cap, a sealing cap), a crown (apical) cap. , cork (natural or synthetic), perforated seal, flange (e.g. lip of a cup), multi-piece lids (e.g. BAP lids produced by Bapco Closures Limited (England) or similar lid), snap lids, and/or similar .

In general, covers may contain one or more features that provide additional advantages. Some lids may contain one or more of the following: clear seal, anti-seal feature, enhanced leak sealing, storage compratment, handle fittings to facilitate lid removal/placement, spill prevention feature, and fittings from that source.

Lids may have a single-piece or multi-piece construction and are designed to attach to the vessel permanently or temporarily. For example, the lid shown in Figure 14(a) consists of a multi-piece assembly. The cover shown in Figure 18 consists of a single-layer construction. The expressions "lid" and "plug" may be used interchangeably here. It is envisaged that the lids will be used with bottles, boxes (especially boxes used to hold food items, such as juices, for example), cartons, cans and other products. As used herein, the expression “bottle cap” is a common expression used in its ordinary sense and may include, without limitation, a cap suitable for attaching to a bottle such as a glass or plastic bottle (e.g., a bottle typically shaped to hold alcoholic beverages or juices) and may include Or does not contain striations. Bottle caps can typically be removed using a bottle opener, as is known in the art. The expression “grooved bottle cap” is a broad expression used in its ordinary sense and may include, without limitation, a cap (e.g., screw cap) suitable for attaching to a bottle with notches. Given the present disclosure, embodiments of caps containing notches can be modified to form bottle caps or other types of caps for various compositions. In some embodiments, the covers can be grooved to a vessel or attached to a vessel by various methods, such as sonic welding, induction welding, a multi-step molding process, adhesives, thermoforming, and the like.

Figure 18 shows one embodiment of cap 302 that can be coupled to a product, such as the neck of a vessel. In the embodiment shown, cap 302 has internal notches 306 (Figure 19) that are shaped to engage the neck notches so that the cap 302 can be removably coupled to the vessel. Cap 302 can be attached to a container (e.g., a bottle) to close the opening or mouth of the bottle. The cap 302 includes a main body 310, and a clear seal or anti-seal fitting, such as a collar 313 (or dry) coupled to the body 310 by one or more connectors 312. The connectors 312 can be sized and adjusted such that the connectors 312 are broken when the cover 302 is removed from the receptacle, thus separating the body 310 and the collar indicating that the cover 302 has been removed from the accompanying receptacle. Although not shown, other types of clear plug fittings may be used. The surface 316 of the body 310 may have a surface treatment, such as grooves, ridges, texture treatment, and/or the like to facilitate frictional interfacial interaction with the cover 302.

In relation to Figure 19, cover 302 includes body 310 and may or may not have a liner and cover 302 shown includes an optional inner sealing layer. The inner layer 314 of the cap shown is a liner contained within the outer portion 311 of the body 310. The liner 314 may be modified to be in contact with the food substance or liquid and may be leak-proof with the lip forming the opening of the bottle. Therefore, the liner 314 is a significant portion, or a whole portion, of the contact surface of the housing 304.

The lining 314 may be an insulating lining, such as an active and passive insulating lining. Lining 314 can act as a barrier to the fluid (e.g., liquid or gas), a barrier to flavor, and compositions from that source. For example, the liner 314 can be a gas barrier that prevents or inhibits the passage of oxygen, carbon dioxide, and the like through it. In some embodiments, the liner 314 has abrasive capabilities, such as gas abrasion (e.g., oxygen abrasion).

The liner 314 can be pressed against the lip of the bottle to prevent liquid from escaping from the receptacle sealed by the cap 302. In one embodiment, the liner 314 is a gas barrier that prevents or inhibits gas from escaping from the receptacle. In another embodiment, the liner 314 is a flavor barrier that can prevent or limit the taste of the liquid inside the vessel. For example, the liner 34 can be composed of a polymer (e.g., a thermoplastic material) that acts as a flavor barrier to ensure that the food item inside the container retains the desired flavor. Therefore, the liner, 314 can help to ensure that the body 310 does not impart flavor and/or odor to the food item in the container.

Many times, some flavoring material and/or flavoring material (e.g., polyolefins such as polypropylene or polyethylene) is used to form a container, or lid, such as a bottle cap, depending on its physical properties. (e.g., durability, durability, impact resistance, and/or... strength). In certain embodiments polypropylene may exhibit one or more physical properties that are preferable to the physical properties of polymers such as PET. Unfortunately, polypropylene is required in certain circumstances to reduce or eliminate off-flavor from the contents of the bottle or remove desirable flavors or aromatic components from the contents. Therefore, a person consuming food that has previously been in contact with PP may be able to distinguish the flavor change. Distinctively, the liner 314 can include a flavor preservative so that the food substance is generally unaffected by the container when the food substance comes into contact with the liner 314. The flavor preservative should preferably be a substance approved by the FDA for contact with food materials.

In some unspecified embodiments, the flavor preservative comprises PET (such as the first PET), a phenoxy type of thermoplastic, and/or the like. Therefore the body 310 is made of a flavor abrasive material, such as polypropylene, to provide the desired physical properties and the liner 314 includes PET as an effective flavor barrier to ensure that the contents of the container retain the desired taste. The liner 314 is expected to be composed of any material suitable for contact of the food material with the container. In some embodiments, liners 314 can be of a foaming agent described herein which may or may not materially alter the taste of the contents of the vessel. Additionally, the thickness of the liner 314 may be increased to prevent gas or other fluids from passing through the liner. Optionally, the 314 liner can be of single-layer or multi-layer construction. For example, the liner 314 can include an inner layer of PET (i.e., the layer in contact with the container contents) and an outer layer of foaming material.

The liner 314 can include a layer suitable for food contact and one or more layers that act as a barrier, similar to the preformed materials described herein, and in some embodiments, for example, the liner 314 can comprise a first layer and a second layer where the first layer includes a foaming material and includes The second layer is on a barrier material. Therefore, a second layer can reduce or prevent fluid migration through the liner 314 and a first layer insulating the cover 302. In some embodiments, the liner 314 includes a PET layer and a layer including a second material. The PET layer should preferably be the lowest layer so as to form a seal with the lip of the container, the second material can be EVA or other suitable material to form part of the liner.

In some embodiments, the liner 314 of Figure 19 can be prototyped and inserted into the body 310. For example, the body 310 can be shaped like an ideal screw cap used to seal the bottle. The lining 314 can be formed by cutting out a portion of the sheet, which will be described as a bottom. The pre-cut liner 314 may then be inserted into the body 310 and positioned as shown in Figure 19. Alternatively, the liner 304 may be formed within the body 310. For example, the liner 314 may be formed during an in-die forming process, such as overmolding. At least a portion of the liner 314 may be formed by a spray coating process. For example, a single-layer liner may be sprayed and coated with a polymer (e.g., PET, phenoxy, or other materials described herein) to produce a multi-layer liner.

An additional feature can optionally be provided whereby the bushing 314 can be kept in the body 310 or attached to the receptacle and the bushing 314 can be attached to the body 310 such that the bushing remains coupled to the body 310 after the body is separated from the receptacle. Alternatively, the liner 314 can be mated to the bowl such that the body 310 and the liner are detachable. For example, the liner 314 may be transferred to the body 310 and then to the vessel opening by a welding process, such as an induction welding process.

An additional feature is provided when at least a portion of cover 302 is composed of a material to provide an ergonomic gripping surface such that the user can comfortably grip cover 302. Body 310 includes a material of sufficient stiffness, (e.g., PP), compressibility for comfortable grip (e.g., foaming material), and/or the like. In some embodiments, the outer portion 311 of the body 310 can include foam to increase the space occupied by the outer portion 311 and to provide the user with greater leverage to easily open and close the cover 302. For example, lid 302 may have an internally grooved surface that is shaped to conform grooved to the externally grooved surface of the bowl. The enlarged outer portion 311 can provide a greater lifting force so that the user can easily rotate the cap 302 to fit and remove it from the container and, appropriately, a similar or equal amount of the material composing the conventional cap can be used to form a larger diameter cap.

In some embodiments, at least a portion of parts 311 and liner 314 can be composed of a foaming material to obtain a very lightweight covering due to the low density of the foaming material. The reduced weight of cap 302 can desirablely reduce the transportation cost of cap 302. Additionally, cap foam 302 can reduce the amount of material used to create the cap, since the return foam may contain a large number of voids.

The covers described herein may be similar to or different from the cover shown in Figure 19. In relation to Figure 20, the cover 330 with body 331 includes an inner part 332 and an outer part 334. The wall 335 shown includes parts 332, 334. The inner part 332 may designate At least part of the interior of the container 330 can optionally obstruct one or more notches 336. The interior 332 is formed by an injection molding process, a spray coating process, or another process described herein to form a section of the product. In some unspecified embodiments, interior 332 includes phenoxy, polyolefin (e.g., PET), and/or other materials described herein. Figures 21(a) to 21(e) show unspecified embodiments of the covers. Figure 21(a) shows a lid 340 that has an outer portion 342 and an inner portion 344 that comprise at least part of the interior of the container 340. It is the portion designated by the outer portions 342 and the inner portion 344 (e.g., notches) of the inner surface of the lid 340. Whereas the inner portion 344 is placed within the outer portion 342, however, the inner portion 344 in other embodiments is not placed within the outer portion 342. Figure 21(b) shows a cover 350 that includes an inner portion 354 including a plurality of layers 356, 358. Figure 21(c) shows a 360 overlay including a collection of layers. The outer layer 362 is the outer surface (including the top of the wall) of the cover 360. The middle layer 364 can include one or more layers. The inner layer 366 designates a grooved contact surface 368 .

The cover may contain parts or layers of varying thickness. As shown in Figure 21(d), at least one portion or layer of covering 370 includes a thickened portion. The cover shown 370 has an internal portion 374 that has a thickened upper portion 372 that is greater in thickness than the wall portion 376.

Figure 21(e) shows a multilayer cover 380 which includes a bond 382 connected to the interior 383 of the cover 380 by one or more connectors 384. The covers shown in Figures 18 to 21(e) may have any fitting(s) or design suitable for coupling. With bowls. For example, the lids of Figures 18-21(e) may have a similar composition to the lid 213 (Figure 14(a)) and it is anticipated that the lids of Figures 18-11(e) described herein may be attached to the receptacles by a groove-bonding, welding or melting process. (e.g., induced welding), adhesive, frictional interfacial action, or similar. Covers in Figures 18-21(e) shall be fitted with ties. However, the covers may not have ties, or may contain tamper evident or other tamper evident fittings. Although the covers in Figures 18-21(e) are shown as screw caps, other types of covers (e.g. covers with a multi-piece construction, such as covers with a flange that opens and closes, a cover with a threaded connection at both ends, or the like) include Similar combinations.

Lids may have a compartment or compartments formed for storage. Compartments may contain additives that can be added to the contents of the accompanying container. Additives affect the properties of the vessel ingredients and may be in solid, gaseous, and/or liquid states. In some embodiments, additives may affect one or more of the following: odor (e.g., additives may include a lubricating gas/liquid), flavor, color (e.g., additives including dyes, dyes, etc.), nutritional content ( Example: additives including vitamins, protein, carbohydrates, etc.). Compositions from that source. Additions can be delivered from the lid to the contents of the bowl for later ingestion and preferably increase the desirability of the liquid and the consumption experience. The chamber can release toppings as you remove the lid, so the mixture is fresh. However, the compartment can be opened before or after removing the lid from the bowl. In some embodiments, the lid has a compartment that can be broken off (e.g., perforated) after the lid is separated from the receptacle. The chamber can be broken by drilling, tearing, etc. The compartment may contain a fitting to release its contents. This fitting may be a pull plug, snap cap or other fitting suitable for releasing the contents of the chamber.

Containers can also be sealed with a sealant that is separated from the lid. A sealant can be attached to the container before attaching the lid. The sealing process can be used to attach a seal to the end of the vessel neck after the vessel is filled. The seal can be similar or different from the liners attached to the lids. Leak seals may be tight (preferably capped) seals that are spill-proof, to ensure the integrity of the container contents. In some embodiments, the seal may comprise a foil (preferably including a metal, such as aluminum foil) and is applied to the vessel by a welding process, such as induction welding. However, the seal can be attached to the vessel using other suitable attachment processes, for example, an adhesive can be used.

The covers may have an internal surface suitable for attaching and fixing occlusal fittings (e.g., notches, occlusal cover fittings, and the like). The inner surface may be provided with a somewhat slippery surface to facilitate removal of the lid from the vessel. For example, the lid may contain a slippery or low-friction material (e.g., olefin polymers) to bond the vessel material. If the lid is made of PET, for example, it may stick or lock with the PET container. Therefore, the cap (including snap caps, twist caps, and the like) may be relatively difficult to remove. Favorably, a cover with a slippery or low-friction material allows for reduced clearance of the neck collar by easy removal of the cover. The slippery or low-friction material provides sufficient friction to keep the cap coupled to the accompanying container while allowing for proper removal of the cap. Therefore, the slippery or low-friction material can be selected to achieve the desired removal torque.

Referring to Figure 20, the cover 330 may include an inner portion 332 comprising a slippery or low-friction material (e.g., olefin or other material with a small coefficient of friction) and an outer portion 334 comprising a polymer, such as an olefin polymer, a foaming material , PET, and other materials described here. The covers described herein may include a slippery or low-friction material that forms an interface with the container and achieves the desired removal torque. The slippery or low-friction material of the lid can be chosen on the basis of the material of the bowl in order to produce the desired frictional interaction. The dies described herein are expected to be modified with an edge gate to form the inner most layer of the lid to interface with the vessel.

3- Detailed description of pre-formed materials and single and multi-layer sheets

Figures 22(a) and 22(b) are cross-section views of the plates. The thickness of the plates is fairly uniform or of varying thickness. The plate of Figure 22(a) is a single-layer plate 389. The plate of Figure 22 is a multi-layer plate 390 including two layers. The laminate may have any number of layers of any desired thickness depending on, for example, the laminate being used. For example, the laminates 389, 390 may be used to form the package, such as a label and at least a portion of the laminates 389, 390 include a foaming agent. For example, sheets 389, 390 include a foaming agent to provide insulation to the packaging to which the label is attached. Optionally, sheet 390 includes one or more bond layers. For example, the laminate 390 may include a bonding layer between layers 392 , 394 .

Sheets can be used in multiple applications and may be formed into multiple shapes. For example, the sheets may be cut (e.g., by thermoforming or casting) (die casting) into sheets and/or similar to the desired shape. A skilled fabricator can choose the desired shape, size, and/or composition of the sheets depending on the desired application.

Figure 23 shows a multi-layer preformed material 402. The material is preformed 402 in the form of a channel with an actual tubular shape. The shape of the preformed material 402 may generally be circular, oval, polygonal (including rounded polygon), compositions from that source, and the like. The preformed material shown 402 is generally circular in cross-section.

In some embodiments, the preformed material 402 may be a tube modified to deliver fluids, preferably modified drinking fluids. The preformed material 402 may comprise an inner layer 404 and an outer layer 406. In some embodiments, at least one of the two layers 404 , 406 may comprise a plurality of layers (e.g., thin sheet material).

The preformed material 402 may be a tube comprising a material suitable for contact with the food material and one or more additional materials having desirable physical properties (e.g., textural and thermal properties). Favorably, an interior layer 404 that is preferably in direct contact with a fluid does not significantly alter the flavor of the food item it contacts. For example, fluid conveying lines for beverage dispensing systems contain flavor-abrasive polyolefins. Favorably, the inner layer 404 does not significantly alter the flavor of the fluid passing through the cavity 408 of the preformed material 402. In another embodiment, the outer layer 406 may provide improved physical properties of the preformed material 402. In another embodiment, the outer layer 406 may provide Increased insulating and/or structural properties of the preformed material 402 For example, the outer layer 406 in one embodiment can provide increased impact resistance. In some embodiments, the coating 406 reduces heat transfer through the walls of the preformed material 402. In some embodiments, the outer layer 406 may have such a high tensile strength that a highly pressurized fluid can be passed through the preformed material 402. Therefore, the inner layer acts as a largely inert food contact surface while the outer layer(s) acts as an insulator and/or resistance External influences.

Of course, preformed material 402 can be used in many other applications. For example, the preformed material 402 may be used in hospitals (e.g., as a delivery line for medical fluids), manufacturing processes, devices, fluid systems (e.g., ingestible fluid distribution systems) and/or the like.

4- Detailed description of packing:

One or more of the described products may be used alone or in combination in numerous applications, such as packaging. Figure 24 shows a filling system 416 including a vessel 420 which can be made from the preformed materials described herein. A cap 422 may be attached to the end, 432 of the vessel 420 to seal the vessel.

Figure 24 also shows a card 440 attached to a container 420 which is in the form of a bottle. The card 440 can attach to the bottle 420 and may be single-layer or multi-layer. Card 440 optionally includes a foaming agent.

The card 440 is preferably coupled to the outer surface 442 of the receptacle 420. The card 420 can be attached to the outer surface 442 in a removable manner. The label 440 may be attached during and/or after the formation of the vessel 420. In the shown embodiment, the label 440 is generally in the form of a tubular sleeve which encloses at least a portion of the bottle. The label 440 is in any form or arrangement suitable for attaching to the bottle and displaying information. Although not shown, the label 440 may be attached to glass bottles, metal cans, or the like. Additionally, card 440 can be attached to other shapes or packaging. For example, label 440 may be attached to a box, carton, bottle (plastic bottle, glass bottle, and the like), can, and the other objects discussed herein. Additionally, printing can be done on the card 440. Optionally, the outer surface 446 of the card 440 can be treated to obtain a surface suitable for printing.

An adhesive may be used to attach tag 440 to the product. In one embodiment, after attaching the card to the product, the card foam 440 can be deployed to obtain thermal insulation, fluid barrier, protective coating, and/or desired textural qualities. The foaming material is preferably determined by heating the card 440. The card material can be foamed before and/or after placing the card 440 on the container 420. Of course, the foaming material can be adhered to the card 440 directly to the product without the use of adhesives.

Figure 25 shows another embodiment of the vessel including a moldable material. Receptacle 450 may be similar to or different from the receptacles described above. In the shown embodiment, receptacle 450 includes a lid 452, a body 454, and a handle 456 attached to the body 454. The body can be physically rigid or flexible. The handle 456 is preferably shaped and sized to be comfortably held by the user, and the body wall 454 may be single-layer or multi-layer. Container 450 may have any shape, including a shape similar to typical vessels used to hold indigestible liquids. The bowl 450 can be formed by extruding the molding process into a blow mold.

In relation to Figure 26(a), the container 460 is packaged (e.g., food packaging) which preferably includes a foaming agent. In one embodiment, a plate (e.g., plates 389 or 390) is used to form at least part of the vessel 460 by, for example, a thermoforming process. The receptacle 460 may be in the form of a flexible pod, food receptacle, or other suitable composition.

For example, sheets are formed in one arrangement into clamshell packages that are configured to hold food, such as hamburger. In another arrangement, the sheets are formed to form boxes (e.g., pizza boxes). In another embodiment, the material and dimensions of vessel 460 can be determined depending on the morphological properties, thermal properties, and/or other desired properties. For example, vessel 460 may include a foaming material for effective thermal insulation of vessel 460. In another example, vessel 460 may have thick walls such that vessel 460 is generally stiff.

Figure 26(b) shows another product that includes a moldable material. In one embodiment, product 462 is shaped like a tray that is shaped to receive the food item. Tray 462 can be formed from a sheet during thermoforming. Optionally, tray 462 can be configured to fit inside the bowl or box.

Tray 462 (or other products described herein) may be formed for heat treatment. In some embodiments the tray 462 can be used for heating and reheating and the tray can hold food items such that the food items can be heated by, for example, a heat lamp, microwave oven, oven, toaster, heated water, and the like. The exact composition of tray 462 can be configured based on the type and method of heat treatment. For example, the tray may include a crystalline material (e.g., crystalline PET) to increase thermal stability. One or more layers of the tray may be heated during the thermoforming process to a temperature higher than a predetermined temperature to cause crystallization of at least a portion of one of the layers. Therefore, at least a portion of tray 462 may be crystallized during the manufacturing process. In some embodiments, the tray 462 can comprise a single or multi-layer laminate and the tray 462 includes a first layer of thermoplastic material and a second layer (e.g., a foam layer). The first layer may include a crystalline material (e.g., amorphous, partially crystalline, or fully crystalline). Tray 462 can be used to hold food for use in a microwave oven. Of course, other products, such as a pizza box container, have a similar composition.

Products can also be in box form. The package may include polymer materials as declared herein. The enclosure may comprise a metal layer and one or more layers of another material. In some embodiments, the metal enclosure (e.g., aluminum can) may be coated with a foaming material such as a thermoplastic material. At least part of the outside and/or inside of the can is covered with foam.

B. Crystal neck ends:

The plastic bottles and containers, in some embodiments, preferably comprise one or more neck materials, the neck end and/or neck cylinder which are at least in a partially crystalline state. Such bottles and preformed materials also comprise one or more layers of material.

In some embodiments, the bottle is manufactured by a process involving blow molding of primary plastics. In some circumstances, it is preferable for the material to be in its initial plastic form in an amorphous or semi-crystalline state because the material in this state can be easily blow molded whereas fully crystalline materials generally cannot be molded. However, bottles made entirely of crystalline or semi-crystalline material may not have sufficient dimensional stability during a standard hot filling process. In these circumstances a bottle containing a crystalline material is preferred, as it will retain its shape during hot filling operations.

In some embodiments, the plastic bottle has features of both a crystalline bottle and an amorphous or semi-crystalline bottle. By blocking at least part of the upper part of the crystalline premolded material while keeping the body in the form of an amorphous or semi-crystalline premolded material (sometimes referred to here as “amorphous”), one can create a premolded material that will be easily blow molded while maintaining dimensions. Necessary in the separator neck area during the hot filling process. Some embodiments contain both crystalline and amorphous or semi-crystalline regions. This results in a starting material that is durable enough to be used in widespread commercial applications.

One or more of the embodiments described herein generally produces raw materials having a crystalline neck, which is then blow molded into typically beverage containers. Preformed materials may be single-layer; Which, include a single layer of base material, or they may be multi-layered. In the example of these layers, the material is a single material or it may be a mixture of one or more materials. In one embodiment a product is provided to comprise a neck portion and a body portion. The cervical part and the body part are one uniform layer of material. The body part is mainly amorphous or semi-crystalline, and the neck part is mainly crystalline.

Referring to Figure 1, the preferred preformed material 30 is depicted. The preformed material 30 may be made by injection molding known in the art or by methods. Announced here. The preformed material 30 contains a neck portion 32 and a body portion 34, formed uniformly (i.e., as a single, or unitary, structure). Sometimes, in some embodiments, the existing arrangement of the preformed material, when blow molded into a bottle, provides greater dimensional stability and improved physical properties compared to the preformed material composed of separate neck and body parts, which are bonded together.

By arriving as a crystalline state in the neck portion of the preformed material during the molding step, the final dimensions are substantially identical to the initial dimensions, unlike when additional heating steps are used. Therefore, dimensional differences are reduced and dimensional stability is achieved. This results in consistent performance for the caps, such as notches on the end of the neck and reduced abrasion rate of the molding process.

While a non-crystalline preformed material is preferred for blow molding, a bottle with a greater crystalline property is preferred due to its dimensional stability during the hot filling process. Accordingly, the preformed material formed according to some embodiments has a generally non-crystalline body portion and a generally crystalline neck portion. To make crystalline parts and generally non-crystalline parts in the same preformed material, one needs to achieve different levels of heating and/or cooling in the mold in the areas where the crystalline parts will be formed compared to those where the generally non-crystalline parts will be formed. Different levels of heating and/or cooling can be maintained by thermal insulation of areas with different temperatures. Thermal insulation of the grooved extrusion, core and/or cavity interface can be achieved by using a combination of high and low heat conduction materials as attached or separate materials on the meeting surfaces of these Regions.

Some of the preferred processes accomplish the manufacture of the preformed material within the preferred cycle times for uncoated precast materials of similar size by standard methods used in the production of the preformed material. Additionally, the preferred processes are enabled by the design used of the tools and process techniques to allow automatic production of crystalline and amorphous regions in special areas. On the same preformed material.

In one embodiment, a mold for making the preformed material is provided comprising a neck portion having a primary die temperature control system (e.g., cooling channels, heating), a body portion having a second temperature control system, and a core having a third temperature control system, of which the first system is To control temperature independently of the second and third temperature control systems, the cervical part is thermally insulated from the body part and the core.

Cooling of the die can be achieved in areas where the surfaces of the material are preformed and where the material is preferably generally amorphous or semi-crystalline, by means of a cooling fluid circulating through the die cavity and core. In some embodiments, a mold assembly similar to ordinary injection molding applications is used, except that there is a separate fluid circuit or electrical heating system for the areas of the mold in which the crystalline portions of the preformed material are to be formed. Thermal insulation of the die body, die end neck and core section can be achieved by using inserts that have low thermal conductivity. The neck, neck end, and/or neck cylinder of the die are preferably finished at a higher temperature to achieve slower cooling, which promotes crystallization of the material during cooling.

The above embodiments and additional embodiments and techniques relating to preformed materials with both zones and amorphous or semi-crystalline are described in US Patent No. 6,217,918 to Collette et. al.; 6,428,737 to Collette et. al; US Patent No. 2003/0031814A1 to Hutchinson et. at. and PCT Circular No. WO 46410/98 to Koch et. al..

C- A detailed description of some preferred subjects

1- A general description of preferred subjects

Additionally, the products described here may be specifically formulated for a particular material, such as polyethylene terephthalate (PET) or polypropylene (PP), and the preferred methods may be applicable to many other thermoplastics, including those of Types of polyester and polyolefin. Other suitable materials include, but are not limited to, foaming agents, various polymers and thermosets, and thermoplastics such as polyesters, polyolefins, including polypropylene and polyethylene, poly Polycarbonates, polyamides, including nylon compounds (e.g., Nylon 6, Nylon 66, MXD6), polystyrenes, epoxies, acrylics, copolymers ,combinations, Grafted polymers, and/or modified polymers (monomers or parts thereof having another group as a side group, such as olefin-modified polyesters). These materials are used alone or together. Examples of more specific materials include, but are not limited to, ethylene vinyl alcohol copolymer ("EVOH"), ethylene vinyl acetate ("EVA"), and ethylene acrylic acid. (“EAA”), linear low density polyethylene (“LLDPE”), polyethylene 2,6- and 1,5-naphthalate (PEN). ), polyethylene terephthalate glycol (PETG), poly(cyclic hexylene poly(cyclohexylenedimethylene terephthalate), polystryrene, cycloolefin, copolymer, poly-4-methylpentene-l, poly(methyl methacrylate) ) (poly(methyl methacrylate), acrylonitrile), polyvinyl chloride, polyvinylidine chloride, styrene, acrylonitrile, acrylonitrile-butadiene- styrene), polyacetal (polyacetal), polybutylene terephthalate, ionomer, polysulfone, polytetra-fluoroethylene, polytetramethylene 1,2-dioxybenzoate Copolymers of ethylene terephthalate and ethylene isophthalate.

As used herein, the expression “polyethylene terephthalate glycol (PETG)” refers to a copolymer of PET to which an additional comonomer, cyclohexane di-methanol, is added ( CHDM, in significant amounts (e.g., approximately 40% or more by weight) of the PET mixture. In one embodiment, the preferred PETG is necessarily amorphous. We can obtain suitable PETG materials from many sources. One suitable source is Voridion, a division of Eastman Chemical Company. Other PET copolymers incorporate CHDM at lower levels so that the resulting material remains crystallizable or semi-crystalline. One example of PET copolymers containing low levels of CHDM is Voridian 9921 resin.

In some embodiments, grafted or modified polymers may be used. In one embodiment polypropylene, or other polymers may be grafted or modified with a polar group including, without limitation, maleic anhydride, glycidyl methacrylate, acryl methacrylate and/or Similar compounds to improve adhesion. In other embodiments polypropylene refers to refined polypropylene. As used herein, the term “clarified polypropylene” is broad and is used in its ordinary sense and may include, without limitation, polypropylene that includes nucleation inhibitors and/or clarification additives. Refined polypropylene is generally transparent compared to a homopolymer or agglomerated copolymer for polypropylene. The inclusion of nucleation inhibitors helps prevent and/or reduce crystallinity, which contributes to the cloudiness of the polypropylene, within the polypropylene. Refined polypropylene can be obtained from many sources such as Daw Chemical CO. On an alternative conversion, nucleation inhibitors can be added to polypropylene. One suitable source for nucleation inhibitor additives is Schulmar.

Optionally, the materials may contain microstructures such as microlayers, microspheres, and formulations from that source. In certain embodiments the preferred materials may be raw, pre-consumed, post-consumed, re-milled, re-cycled, and/or combined from that source.

As used herein, “PET” includes, but is not limited to, modified PET and also PET blended with other materials. An example of modified PET is “high IPA PET” or IPA-modified PET. Refers to PET with an IPA content of preferably greater than about 2% by weight, including about 2-10% IPA by weight, and also including about 5-10% IPA by weight. PET may be, pre- or post-consumer, recycled, re-milled PET, copolymers + PET and compositions from that source.

In embodiments of the preferred methods and processes the one or more layers may include high layers, UV protective layers, oxygen filtration layers, oxygen buffer layers, carbon dioxide filtration layers, carbon dioxide buffer layers dioxide), and other layers as may be required for the particular application. As used herein, the expressions “barrier,” “barrier resin,” and the like are broad expressions and are used in their ordinary sense and refer, without limitation, to materials that are less permeable to oxygen and dioxide. Carbon dioxide less than one or more layers, when used in preferred methods and processes as used herein. The expressions “UV protection” and the like are broad expressions used within their ordinary meaning and refer, without limitation, to materials with a UV absorption rate. Larger than one or more layers of product. As used herein, the expressions “oxygen filtering or scraping” and the like are broad expressions used in their ordinary sense and refer, but are not limited to, to materials having a higher rate of oxygen absorption than one or more layers of the product. As used herein, the terms “oxygen buffer” and the like are a broad term used within their ordinary meaning and refer, without limitation, to materials that are active or passive in nature and slow transfer of oxygen into and/or out of the product. As used herein, the expressions “carbon dioxide filtering” and the like are broad expressions used in their ordinary sense and refer, without limitation, to materials having a higher rate of absorption of carbon dioxide than one or more layers of the product. As used herein, the terms “carbon dioxide buffer material” and the like are a broad term used within their ordinary meaning and referring, without limitation, to materials that are active or passive in nature and slow transfer of carbon dioxide into and/ Or outside the product. Without wanting to be bound by any theory, students believe that in applications where a carbonated product, such as a soft drink, is contained in a product and carbonated on top, one or more layers of the product containing a Carbon dioxide allows carbonation to saturate the layer containing the carbon dioxide filter. Therefore, the carbon dioxide that escapes into the atmosphere from the product leaves the product layer first instead of the product contained inside. As used herein, the expressions “cross-linked,” “cross-linked,” and the like are broad expressions used within their ordinary meaning and refer, without limitation, to covering materials that vary progressively from a small percentage of cross-linking to including cross-linked materials. Totally transverse, such as a thermoplastic epoxy. The cross-link ratio can be adjusted to provide the appropriate amount of resistance to either chemical or mechanical use for specific conditions. As used herein, the term “binder” is a broad term used in its ordinary sense and refers, without limitation, to a gas, liquid, or suspension comprising a substance that helps bind two substances together physically and/or chemically, including but not limited to: Adhesives, surface modifying agents, active ingredient, etc.

2- Favorite subjects

In a preferred embodiment the materials include thermoplastic materials. An additional preferred embodiment includes a “phenoxy-type thermoplastic”. The phenoxy type of thermoplastic (thermoplastic), as that term is used herein, includes a wide variety of materials including those discussed in WO 20462/99. In one embodiment, the materials include thermoplastic epoxy resins ( TPEs), a phenoxy-type subgroup of thermoplastics. As an additional phenoxy subgroup for thermoplastics and thermoplastics, hydroxy-phenoxyether polymers are preferred, of which a more preferred additive is polyhydroxyaminoether copolymers (PHAE). See For example, US patent numbers: 6,455,116, 6,180,715, 6,011,111, 5,834,078; 5,814,373, 5,464,942, and 5,275,853; See also PCT Applications Nos. 48962/99 WO, 12995/99 WO; 29491/98 WO; And 14498/98 WO. In certain embodiments, the PHAEs are TPEs.

The phenoxy type of thermoplastic used in the preferred embodiments preferably includes one or more of the following types:

(1) Hydroxy-functional poly(amide ethers) having repeating units represented by any of the formulas Ia, Ib or Ic:

or

(2) poly(hydroxy amide ethers) containing repeating units represented independently by any of the formulas IIa, IIb or IIc:

or

(3) Amide- and hydroxymethyl-functionalized polyethers containing repeating units represented by formula III:

(4) Hydroxy-functional polyethers containing repeating units represented by formula IV:

(5) Hydroxy-functional poly(ether sulfonamides) containing repeating units represented by the formulas Va or Vb:

(6) Poly(hydroxy ester ethers) containing repeating units represented by the formula VI:

(7) Hydroxy-phenoxyether polymers containing repeating units represented by formula VII:

and (8) poly(hydroxyamino ethers) containing repeating units represented by formula VIII:

Wherein each Ar individually represents a divalent aromatic group, a divalent substituted aromatic group or a heteroaromatic group, or a combination of different divalent aromatic groups, aromatic groups ) Substituted or heteroaromatic groups; where R is a single hydrogen or a monovalent hydrocarbyl group; Both Ar1 are divalent aromatic groups or combinations of groups divalent aromatics bearing amide or hydroxymethyl groups; Each Ar2 is the same or different from Ar and individually represents a divalent aromatic group, a substituted aromatic group, a hetero aromatic group, or a combination of different divalent aromatic groups, aromatic groups. ) Substituted or heteroaromatic groups; R1 individually represents a dominant hydrocarbylene group, such as a group divalent aromatic, divalent substituted aromatic group, divalent hetero aromatic group, divalent alkylene group, divalent substituted alkylene group or hetero alkylene group Bivalent, or a combination of these groups; R2 is individually a monovalent hydrocarbyl group; A is an amine group or a combination of a different amine group; X is an amine, arylene arylenedioxy, arylenedisulfonamido or arylenedicarboxy group or a combination thereof; Ar3 is a cardo group represented by any of the formulas:

where Y is a zero, a covalent bond, or a bond group, where appropriate bond groups include, for example, an oxygen atom, a sulfur atom, a carbon atom, a carbonyl atom, A sulfonyl atom, methylene group or similar covalent bond, n is an integer from about 10 to about 1000; X is 0.01 to 1; And y is zero to 0.5.

The expression "predominantly hydrocarbylene" means a divalent radical that is a dominant hydrocarbon but may optionally contain a trace amount of a heteroatomic group such as oxygen, sulfur, or imino. , sulfonyl, sulfoxyl, and the like.

Preferably, the hydroxy-functional poly(amide ethers) represented by formula I are prepared by connecting N,N'-bis(hydroxyphenylamido)alkane (N,N'-bis(hydroxyphenylamido)alkane). Or arene with diglycidyl ether as described in US Patents 5,089,588 and 5,143,998.

The poly(hydroxy amide ethers) represented by formula II are prepared by connecting bis(hydroxyphenylamido)alkane or arene, or a combination of, or more These compounds, such as N,N'-bis(3-hydroxyphenyl) adipamide N,N'-bis(3-hydroxyphenyl) adipamide or N,N'-bis(3-hydroxyphenyl)glutamide N,N'-bis( 3-hydroxyphenyl) glutaramide, with epihalohydrin as described in US Patent No. 5,134,218.

The amide- and hydroxymethyl-functionalized polyethers represented by Formula III may be prepared, for example, by reacting diglycidyl ethers, such as diglycidyl ether from bis Phenol A (bisphenol A), with dihydric phenol having an amido suspension, amido substituted with N and/or hydroxyalkyl groups, such as 2,2-bis(4-hydroxyphenyl) ) Acetamide (2,2-bis(4-hydroxyphenyl)acetamide) and 3,5-dihydroxybenzamide. These polyethers and their preparation are described in US Patents Nos. 5,115,075 and 5,218,075.

Hydroxy-functional polyethers represented by Formula IV may be prepared, for example, by allowing a diglycidyl ether or a combination of diglycidyl ethers to react with dihydric phenol ) or a composition of dihydric phenols using the method described in US Patent No. 5,164,472. Alternatively, hydroxy-functionalized compounds for polyethers can be obtained by allowing dihydric phenol or a combination of dihydric phenols to react with epihalohydrin by the process described by Reinking, Barnabeo and Hale in the Journal of Applied Polymer Science, Part 7, Page 2135 (1963).

Hydroxy-functional poly(ether sulfonamides) represented by formula V are prepared by, for example, polymerizing N,N'-dialkyl. Or N,N'-diaryldisulfonamide (N,N'-diaryldisulfonamide) with diglycidyl ether as described in US Patent No. 5,149,768.

Poly(hydroxy ester ethers) represented by formula VI are prepared by reacting diglycidyl ethers from aliphatic or aromatic diacids, such as diglycidyl terephthalate. , or compounds of diglycidyl ethers from dihydric phenols with aliphatic or aromatic diacids such as adipic acid or isophthalic acid. (isophthalic acid). These polyester compounds are described in US Patent No. 5,171,820.

The hydroxy-phenoxyether polymers represented by formula VII are prepared by, for example, connecting at least one dinucleophilic monomer to at least one diglycidyl ether for a cardo bisphenol; such as 9,9-bis(4-hydroxyphenyl)fluorene, phenolphthalein, phenolphthalimidine or cardo bisphenol substituted, e.g. Bis(hydroxyphenyl)fluorine Substituted bis(hydroxyphenyl)fluorene, substituted phenolphthalein or substituted phenolphthalimidine under conditions sufficient to cause the nucleophilic groups of the dinucleophilic monomer to react with the epoxy groups to form a chain A polymer containing suspended hydroxy groups and covalent bonds to an ether, imino, amino, sulfonamido, or ester. These hydroxy-phenoxyether polymers are described in US Patent No. 5,184,373.

Poly(hydroxyamino ethers) ("PHAE" or polyetheramines represented by formula VIII) are prepared by connecting one or more diglycidyl ethers for dihydricphenol ( dihydric phenol with an amine containing two amine hydrogens under conditions sufficient to cause the amine groups to react with epoxy groups to form a covalently bonded polymer chain for the amine, covalent bonding For ether (ether) and suspended hydroxyl groups. These compounds are described in US Patent No. 5,275,853. For example, polyhydroxyaminoether copolymers can be made from resorcinol diglycidyl ether, hydroquinone diglycidyl ether, bis-phenol A Bisphenol A diglycidyl ether, or mixtures from that source.

Hydroxy-phenoxyether polymers are products of the condensation reaction of dihydric polynuclear phenol, such as bisphenol A and epihalohydrin, which has the repeating units represented by the formula IV where Ar It is an isopropylidene diphenylene group. The method for preparing these is described in US Patent No. 3,305,528, the entirety of which is incorporated by reference. One preferred non-specific hydroxyl-phenoxy ether polymer, PAPHEN 25068-38-6, is commercially available from Phenoxy Associates Inc. Other preferred phenoxy resins are available from Inchem (Rock Hill, South Carolina) and are, but are not limited to, the production step of INCHEMREZtm PKHH and PKHW.

In general, the preferred phenoxy materials are stable solutions or water-based derivatives. It is preferable that the properties of solutions/derivatives are not adversely affected when combined with water. Preferred materials range from about 10% solids to about 50% solids, and include about 15%, 20%, 25%, 30%, 35%, 40%, 45%, and ranges including such percentages. It is preferable that the material used be dissolved or dispersed in polar solvents. These polar solvents include, but are not limited to water, alcohols and glycol ethers. See, for example, US Patents Nos. 6,455,116, 6,180,715, and 5,834,078, which describe some preferred phenoxy-type solutions and/or dispersions.

One of the preferred phenoxy-type materials is polyhydroxyaminoether copolymer (PHAE), which is represented by formula VIII, as a dispersion or solution. When a dispersant or solution is placed in a container, it greatly reduces the rate of permeation of many gases through the walls of the container in a noticeable and well-known manner. The dispersion or latex it is made from contains 10-30% solids. The PHAE solution/dispersion can be prepared by shaking or stirring the PHAE in a solution of water and an organic acid, preferably acetic or phosphoric acid, but also lactic, malic, or citric. citric), glycolic acid and/or mixtures thereof. PHAE dispersions/solutions also contain salts of organic acids produced by reacting polyhydroxyaminoethers with those acids.

In some other preferred embodiments, the phenoxy-type thermoplastic is mixed or blended with other materials using methods known to those skilled in the art. In some embodiments adapters may be added to the mixture. When these adapters are used, one or more of the characteristics of the mixture are improved, including color, degree of refinement, and adhesion between the layer containing the mixture and other layers. A preferred mixture contains one or more phenoxy-type thermoplastics and one or more polyolefins. Preferred polyolefin includes polypropylene. In one embodiment the polypropylene or other polyolefins may be grafted or modified with a polar molecule or monomer, which includes, but is not limited to, maleic anhydrous, glycidyl methacrylate ), acryl methacrylate and/or similar compounds to increase compatibility.

The following PHAE solutions or dispersions are examples of stable solutions or dispersions of the phenoxy type used if one or more layers of resin are applied as a liquid material for example by dipping, flowing, or spray coating. As described in WO 04/004929 and US Patent No. 6,676,883. Experimental barrier resin BLOX is a suitable material, for example XU-19061-00 made with phosphoric acid manufactured by Dow Chemical. This particular PHAE dispersion was found to have the following typical properties: 30% solids, specific gravity 1.30, pH 4, viscosity 24 cP (Brookfield, 60 rpm, LVI, temperature 22°C) and a molecular size between 1,400 and 1,800. Angstrom. BLOX599-29 resorcinol based resins are suitable materials and have given great results as a barrier agent. This particular dispersant was found to have the following typical properties: 30% solids, specific gravity 1.2, pH 4.0, a viscosity of 20 cP (Brookfield, 60 rpm, LVI, temperature 22°C) and a molecular size between 1500 and 2000 angstroms. Other variants of polyhydroxyaminoether chemistry can be useful such as crystalline forms based on (base-based) hydroquinone diglycidylethers. Other suitable materials include polyhydroxyaminoether solutions/dispersions manufactured by Imperial Chemical Industries ("ICI", Ohio, USA) available under the name OXYBLOK. In one embodiment, the PHAE solutions or dispersions may be partially cross-linked (semi-cross-linked), fully cross-linked, or to the degree specifically required for the application by the addition of the appropriate cross-linker. Benefits of cross-linking include, but are not limited to, one or more of the following: improved chemical resistance, improved corrosion resistance, slow flare, slow surface tension. Examples of cross-linking materials include, but are not limited to, formaldehyde, acetaldehyde, or other members of the aldehyde family or materials. Suitable junctions can also be able to change to the Tg of the material, which facilitates the formation of special containers. Other materials suitable for dispersion media include BLOX5000 resin, BLOXUR588-29, BLOX0000 and BLOX4000 resin. The solvents used to dissolve these substances include polar solvents such as alcohols, water, glycol ethers, or their mixtures. Appropriate materials also include, but are not limited to, BLOXR1.

In one embodiment, the preferred phenoxy type thermoplastic is soluble in aqueous acids. A polymer dispersion/solution can be prepared by towering or stirring epoxy plastics in a solution of water and an organic acid, preferably acetic or phosphoric acid, but this acid can also be lactic. Malic, citric, or glycolic acid and/or mixtures thereof. In another preferred embodiment, the acid concentration in the polymer solution preferably ranges from about 5-20%, including about 5%-10% by weight depending on the total weight. In other embodiments, the acid concentration can be less than about 5% or greater than about 20% and can 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 polymer dissolved in a preferred embodiment of this invention ranges from 0.1% to about 40%. It is preferable to use a uniform, free-flowing polymer solution. In an embodiment of this invention a 10% polymer solution is prepared by dissolving the polymer in 10% acetic acid at 90°C. Then, while the solution is hot, it is diluted with about 20% distilled water to obtain a polymer solution with a concentration of 8%. At higher polymer concentrations, the polymer solution tends to be more viscous.

Examples of preferred copolyester materials and a method for preparing them are listed in US Patent No. 4,578,295 for Jabarin. In general, they are prepared by heating a mixture of at least one reactant chosen from isophthalic acid, terephthalic acid, and C1-C4 alkyl esters with 1,3-bis(2- Hydroxyethoxy)benzene (1,3 bis(2-hydroxyethoxy)benzene) and ethylene glycol. Optionally, this mixture may also include one or more ester-forming dihydroxy hydrocarbons and/or bis(4-b-hydroxyethoxyphenyl)sulfone. ). Preferred copolyester materials are available from Mitsui Petrochemical Co., Ltd. (Japan) as B010, B-030 and other compounds of this family.

Favorite examples of polyamide materials include MXD-6, which is made by

Mitsubishi Gas Chemical (Japan).

Other preferred polyamide materials include Nylon 6 and Nylon 66. Other preferred polyamide materials are those blends of polyamide and polyester which include those containing about 1-20% Polyester by weight, preferably more than about 1-10% polyester by weight by which the polyester is PET or modified PET. In another embodiment, the polyamide materials are a combination of polyamide and polyester, including one comprising 1-20% polyamide by weight, more preferably about 1-10% poly Polyamide by weight, whereas polyester is preferably PET or modified PET. These mixtures can be adapted using antioxidants or other substances. Examples of such materials include those listed in US Patent Application No. 2004/0013833, filed on March 21, 2003 and cited herein by reference. Other preferred polyesters include, but are not limited to, PEN and PET/PEN copolymers.

3- Preferred foam materials

As used herein, the term “foam material” is used according to its original meaning which may include, without limitation, a foam component, a mixture of a foam component and a cohesive or carrier material, an expanding cellular material, and/or Material with voids. The terms “foaming material” and “expanding material” have been used interchangeably in this invention. Preferred foam materials may achieve one or more physical properties that improve the thermal and/or structural properties of the materials (such as containers) and may enable the preferred embodiments to have the ability to withstand operating and physical stresses typically caused by containers. In one embodiment, the foam material provides structural reinforcement to the container. In another embodiment, the foam material forms an insulating layer which can reduce the crushability of the container during operation. For example, the foam material can provide abrasion resistance which can reduce the container's potential to break during transportation. In another embodiment, the foam protective layer can increase the impact resistance of the container thereby preventing or reducing the crushability of the container. Additionally, in one embodiment the foam can provide a gripping surface and/or increase the scope or appearance of the container.

In one embodiment, the foam material includes a foaming agent or blower and a carrier material. In one embodiment, the foaming agent includes expanding compositions (such as microspheres) that can expand and combine with the carrier material to produce foam. For example, the foaming agent could be thermoplastic microbeads, such as EXPANCEL microbeads sold as AKzo Nobel. In one embodiment such microspheres can be vacuum thermoplastic spheres comprising thermoplastic shells encapsulating a gas. It is preferable that when these microspheres are heated, the thermal shell flows and the gas pressure increases, causing the microspheres to expand from their original position to another expanding position. The expanded nanospheres and at least part of the carrier material can be the foam portion of the material of this invention. The foam material may be a layer comprising a single material (such as a homogeneous mixture of a foaming agent and a carrier material), a mixture or mixture of materials, a fabric consisting of two or more materials, two or more layers, a plurality of ultrafine layers (shells) which preferably contain At least on two different subjects. Alternatively, microspheres can be compositions comprising materials that can produce gas in or from the compositions. In one embodiment, these microspheres are evacuated chemical-containing structures that produce or contain a gas whose increased pressure causes the structures to expand and/or explode. In another embodiment, the ultrafine pellets are compositions made of and/or containing one or more materials that decompose or react to produce gas which expands and/or explodes the pellets. Optionally, these microspheres can have solid compositions. Optionally, these microspheres can be shells filled with solids, liquids and/or gases. Ultrafine pellets can have any shape and composition suitable for foaming. For example, those pellets could be spherical. Optionally, the microspheres can be in the shape of a rectangular or oblong spheroid. Optionally, these nanospheres may contain any gas or mixture of gases suitable for expansion of the microspheres. In one embodiment, this gas may include an inert gas such as nitrogen. In one embodiment this gas is generally nonflammable. However, in some embodiments, inert gas and/or flammable gas can fill these shells of the nanospheres. In some embodiments the foaming material may include foaming or swelling agents as known in the art. In addition, the foaming material may be entirely or largely a foaming component.

Although some preferred embodiments include nanospheres that do not break or explode, some embodiments include nanospheres that can break, explode, split, and/or the like. Optionally, part of those ultra-small pellets can break while the remaining part of those pellets remains unbroken. In some embodiments about 0.5%, 1%, 2%, 3%, 4, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% are The weight of the ultra-fine pellets breaks. In one embodiment, for example, a core portion of the nanospheres may explode and/or split as they expand. In addition, different mixtures and mixtures of ultrafine pellets can be used to form the foam.

Microspheres can be composed of any material suitable for expansion. In one embodiment such microspheres have a shell containing a polymer, resin, thermoplastic, or the like as described. The shell of an ultrafine sphere can contain a single material or a mixture of two or more materials. For example, these microspheres could have an outer shell containing ethylene vinyl acetate (“EVA”), polyethylene terephthalate (“PET”), and polyamides (such as Nylon). 6 and Nylon 66) polyethylene terephthalate glycol (PETG), PEN, PET copolymers, and compounds thereof. In one embodiment, the PET copolymer contains a CHDM comonomer at a level between PETG and PET. In another embodiment covalent monomers such as DEG and IPA are added to PET to form ultrafine spherical shells. The appropriate consistency for the type of material, size and inert gas can be chosen to obtain the desired expansion of the ultra-fine pellets. In one embodiment, the microspheres comprising the shells consist of a high temperature material (such as PETG or similar material) which has the ability to expand when exposed to high temperatures, preferably without causing the microspheres to explode. If the microbeads have a shell made of a low-temperature material (such as EVA), the pellets will break when exposed to high heat, which is suitable for operating some carrier materials (such as PET or high-boiling polypropylene). Under some conditions, for example, the microspheres of EXPANCEL can break when operated at correspondingly high temperatures. Preferably, medium-temperature microspheres are first used and vacuumed with a high-boiling carrier to produce a controlled, expandable foam without breaking the microspheres. For example, microspheres can include a mild or medium temperature material (such as PETG) or a high temperature material (such as acrylonitrile) and may be suitable for high temperature applications. Thus, the blowing agent, foam polymers, can be selected depending on the operating temperatures used.

The foam material can be an interstitial fabric containing a carrier material, preferably mixed with a blowing agent (such as microspheres) to form an expandable material. The carrier material can be a thermoplastic or polymeric material such as ethylene acrylic acid (“EAA”), ethylene vinyl acetate (“EVA”), linear low density polyethylene density polyethylene ("LLDPE"), polyethylene terephthalate glycol (PETG), poly(hydroxyamino ethers) ("PHAE"), PET, polyethylene, poly polypropylene, polystyrene ("PS"), Pulp (such as paper or wood fiber pulp, or pulp mixed with one or more polymers), mixtures thereof, or the like. However, other materials suitable for carrying the foaming agent may be used to obtain one or more of the thermal, textural, optical and/or other properties of the foam. In some embodiments, the carrier material has characteristics (such as a high boiling index) for easy and rapid expansion of the ultrafine pellets, thus reducing cycle time and resulting in increased production.

In preferred embodiments, the component material may comprise two or more elements comprising a plurality of components each having different operating windows and/or physical properties. These components can be combined so that the material formed has one or more desirable properties. The proportion of elements can be varied to produce the desired operating window and/or desired physical properties. For example, the first material could have an operating window similar to or different from the operating window of the second material. The operating window can be based, for example, on pressure, temperature, viscosity, etc. Thus, the components of the forming material can be mixed to obtain the pressure and temperature required to form the material.

In one embodiment, the combination of the first material with the second material can result in the material having an operating window that is more demanding than that of the second material. For example, the first operating material may be suitable for operation over a greater range of temperatures and the second operating material may be suitable for operation over a lower temperature range. A material that is partly composed of the first substance and partly composed of the second substance may be suitable for operation over a temperature range greater than the narrow temperature range of the second substance. In one embodiment, the operating window of the multicomponent material is analogous to the operating window of the first material. In another embodiment, the formed material comprises a multilayer sheet or tube comprising a layer consisting of PET and a layer consisting of polypropylene. The material consisting of both PET and polypropylene can be processed (eg, extruded) over a wide temperature range similar to that suitable for PET. The operating window can include several factors such as pressure, temperature, viscosity and/or the like.

Optionally, the amount of each component in the material can be varied to obtain the desired operating window. Optionally the materials can be combined to produce a composite material suitable for operation within a desired range of temperature, pressure, viscosity and/or the like. For example, the proportion of a material with a desired operating window can be increased and the proportion of a material with a lower, undesired operating window can be decreased so as to obtain a material with an operating window that is very similar to or substantially identical to the operating window of the first material. Of course, if the most desired operating window is between the first operating window for the first material and the second operating window for the second material, the ratio of the first material and the second material can be chosen to obtain the desired operating window for the component material.

Optionally, multiple materials with similar or different operating windows can be combined to obtain the desired operating window for the resulting material.

In one embodiment, the viscosity properties (material integrity properties) of the composition material can vary by one or more elements having different viscosity properties. For example the substrate (such as PP) can have a high boiling strength and is easy to extrude. PP can be combined with another material such as PET, which has a low boiling strength and makes it difficult to erupt, to form a material suitable for extrusion operations. For example, a layer of PP or other strong material can support a layer of PET during the assisted extrusion process (such as horizontal or vertical assisted extrusion). Thus, the material formed, which consists of PET and polypropylene, can be operated at a temperature suitable for PP but not suitable for PET.

In some embodiments, the composition of the material formed may be chosen so as to influence one or more of the material properties, for example thermal properties, textural properties, barrier properties, optical properties, viscosity properties, taste properties and/or certain other properties mentioned herein may be Obtained using the constituent materials mentioned in this invention.

4- Additions to improve materials

The advantage of the preferred methods mentioned herein is their flexibility which allows the use of multiple effective additives. These additives are known to those skilled in the art for their ability to provide CO2 protection, oxygen protection, UV protection, scaling resistance, ember resistance, shock resistance and/or chemical resistance.

Favorite toppings can be prepared using methods known to those skilled in the art. For example, these additives can be mixed directly with the substance under study, they can be dissolved/dispersed in isolation and then added to the substance under study, or they can be combined with the substance by adding the solvent that is the dispersion/solution of the substance. Additionally, in some embodiments, the preferred additives may be used individually as a single layer.

In preferred embodiments the insulating properties of the layer can be improved by adding various additives. The additives are preferably present in an amount of up to about 40% of the material, and also include 30%, 20%, 10%, 5%, 2% and 1% by weight of the material. In other embodiments, such additives are preferably present in an amount less than or equal to 1% by weight, the preferred ranges for the material including, but not specified, about 0.01% to about 1%, about 0.41% to about 0.1%, about 0.01% to about 0.1%, and about 0.1 to about 1% by weight. Also, in some embodiments, it is preferable for the additives to be stable under aqueous conditions. For example, resorcinol (m-dihydroxybenzene) derivatives can be used in combination with various preferred materials as mixtures, additives or monomers in the composition of the material. The higher the resorcinol content, the greater the insulating properties of the material. For example, diglycidyl ether can be used in PHAE, and hydroxyethyl ether resorcinol can be used in PET and some polymers and copolyesters.

“Microparticles” or “microscopic materials” may also be used. For convenience, the term microparticles used here will be used to refer to both microscopic particles and matter with microscopic particles (diameter). These microscopic particles are thin, micron-like or micron-like in size, particles of materials that increase the insulating properties of the material by creating a winding path for transporting gas molecules, for example oxygen and carbon dioxide, to penetrate the material. In separate embodiments, the microparticle material is present in an amount from 0.05% to 1% by weight, including 0.1%, 0.5% by weight and other ranges including those amounts.

The nanoparticle base product is a preferred type of microparticle material and is available through Southern Clay Products. One of the favorite products produced by Southern Clay Products is Cloisite Microparticle. In an embodiment, the microparticles comprise monmorillonite modified with a quaternary ammonium salt. In other embodiments the microparticles comprise monmorillonite modified with a tertiary ammonium salt. In other embodiments the microparticles comprise natural monmorillonite. In other embodiments the microparticles consist of organic slimes as listed in US Patent 5780376, which is incorporated herein by reference and as part of the explanation of this application. Organic and inorganic microparticles can also be used and dissolved. Manufactured and natural products are also suitable.

Another preferred type of microparticle material is a metal composite material. For example, a suitable compound in microparticle form is the aqueous dispersant aluminum oxide available from BYK Chemie (Germany). It is known that this type of microparticle material can give one or more of the following benefits: increased abrasion resistance, increased scratch resistance, increased Tg and thermal stability.

Another type of microscopic material includes particles favored on a polymer-silicate compound. In other preferred embodiments the silicate comprises monmorillonite. Suitable polymer-silicate microspheres are available from Nanocor and RTP.

In another preferred embodiment the UV protective properties of the material can be enhanced by adding various additives. In a preferred embodiment the UV protectant used gives UV protection of about 350 nm or less, more preferably about 370 nm or less and more preferably about 400 nm or less. UV protectant can be used as an additive with layers for added effectiveness or applied alone as a single layer. It is preferable for additives improving UV protection to be present in the material at a rate of about 0.05 to 20% by weight, but this percentage also includes about 0.1%, 0.5%, 1%, 2%, 3%, 5%, 10% and 15% by weight. It is preferable to add a UV protection material in a form suitable for other materials. For example, the preferred UV protection material is Milliken UV 390A Clear Shield. UV390A is an oily liquid for which mixing is carried out by first mixing the liquid with water, preferably in equal weight proportions. This mixture is then added to the substance solution, for example Blox599-29 and shaken. The resulting solution contains about 10% UV390A and gives UV protection up to about 390 nm when applied to PET. As previously described, in another embodiment the UV390A solution is used as a single layer. In another application, the preferred UV protection material contains a grafted polymer or UV absorber modifier which is added as a concentrate. Other preferred but not specified UV protectants include benzotriazoles, phenothiazines, and azaphenothiazines. UV protectants may be added during the boiling phase process before use, for example before injection molding or extrusion, or added directly to the coated material as a solution or dispersion. Suitable UV protectants are available from Milliken, Ciba and Clariant.

In other preferred embodiments CO2 scrubbing properties may be added to the material. In a preferred embodiment these properties can be achieved using an amine dopant which will react with CO2 to form a gas-rich barrier salt. This salt will act as an effective CO2 buffer. This active amine can be an addition or can be one or more moieties in a single-layer or multi-layer thermoplastic resin.

In other preferred embodiments, oxygen purification properties can be added to the preferred materials using oxygen purifiers such as anthroquinone and others known in the art. In another embodiment the appropriate oxygen clarifiers are AMOSORB oxygen clarifiers, manufactured by BP Amoco and Color-Matrix Corporation which are described in U.S. Pat. No. 6083585 for Cahill and its associates, and are incorporated herein by reference. In one embodiment, oxygen scavenging properties are added to the preferred phenoxy-type materials, or other materials, including oxygen scavengers in the phenoxy-type materials, with different activation mechanisms. O2 scavengers may operate either randomly, gradually or with delayed action until initiated by a specific firing pulse. In some embodiments, the O2 scavengers operate through exposure to UV, water (e.g., present in the contents of the container) or a combination thereof. The oxygen purifier is preferably present in an amount ranging from about 0.1 to about 20% by weight, more preferably in an amount from about 0.5 to about 10% by weight, and more preferably in an amount ranging from 1 to about 5% by weight in relation to the total weight of the coated layer. .

In another preferred embodiment, a topcoat or topcoat is applied in order to obtain stronger chemical resistance than that obtained by the overcoat. In particular embodiments, such top layers or examples are preferably water-based or non-water-based polyesters or acrylics which are optionally partially or fully cross-linked. Polyethylene terephthalate is the preferred water-based polyester, although other polyesters may be used. In some other embodiments the process of applying a topcoat or topcoat is described in US Patent Application No. 2004/0071885, entitled Dipping, Spraying, and Flow Coating Process for Forming Coated Materials, which is cited herein by reference.

Water-based polyester resin is described in US Patent No. 4,977,191 (Salsmun), which is cited here by reference. More specifically, US Patent No. 4,977,191 listed a water-based polyester resin containing a reaction product of at least 20% to 50% by weight terephthalate polymer and 10 to 40% by weight glycol. One glycol and 5-25% by weight of at least one oxyalkylated polyol.

Another preferred compound is a water-based sulfonated polyester resin listed in US Patent No. 5,281,630 (Salsman), which is cited here by reference. US Patent No. 5,281,630 specifically lists an aqueous suspension of sulfonated polyester resin, soluble or water-dispersible, which contains a reaction product of 20-50% by weight of terephthalate polymer, 10-40%. At least one glycol by weight and 5-25% by weight at least one oxyalkylated polyol to produce a prepolymer resin that has a hydroxyalkyl property. (prepolymer resin) It then reacts with about 0.10 moles to about 0.50 moles of alpha- and beta-ethylenically unsaturated dicarboxylic acid per 100 g of prepolymer resin, thus producing resin, which ends up with a prepolymer resin. Alpha- and beta-ethylenically unsaturated dicarboxylic acid reacts with about 0.5 to about 1.5 moles of sulfite per mole of alpha- and beta-ethylenically unsaturated dicarboxylic acid resin. To obtain the resin it has a sulfonated end.

Another preferred water-based polymer is the coating described in US Patent No. 5,726,277 (Salsman) and cited here by reference. In particular, US Patent No. 5,726,277 listed encapsulating compounds containing a reaction product of at least 50% by weight terephthalate polymer and a mixture of glycols comprising an oxyalkylated polyol in the presence of a glycolytic catalyst. (glycolysis) in which the reaction product also reacts with a bifunctional organic acid and the weight ratio of the acid to glycols is in the range from 6:1 to 1:2.

Whereas the foregoing examples are preferred water-based polymer compounds, there are water-based polymers suitable for use in the products and methods mentioned in this invention. By way of example, but not limited to, other suitable water-based compounds are listed in US Patent No. 4104222 (Date, et al.) and are mentioned here by reference. US Patent 4,104,222 is listed. Linear polyester resin dispersion obtained by mixing linear polyester resin with a high alcohol/ethylene oxide surfactant, melting this mixture and dispersing the product by casting it in an aqueous solution of an alkali. Under shaking conditions, Specifically, this dispersion was obtained by mixing a linear polymer resin with an additional high-alcohol/ethylene oxide surfactant, over the mixture and dispersing the resulting product by pouring it into an aqueous alkanol solution. amine) under shaking at a temperature of about 70-90 C. The aforementioned alkanol amine was chosen from a group consisting of monoethanolamine, diethanolamine, triethanolamine, and monomethyl ethanol. mono methyl ethanol amine, mono ethylethanol amine, diethylethanolamine, propanol amine, butanol amine, pentanol amine, N-phenyl Ethanolamine (N-phenylethanolamine), Alkanolamine for glycerin, the aforementioned alkanolamine, which is present in the aqueous solution in an amount ranging from 0.2 to 5% by weight, and the aforementioned surfactant is an additional product of ethylene oxide for alcohol. High has an alkyl group with at least 8 carbon atoms, phenol substituted alkyl or sorbitan monoacylate in which the surfactant has an HLB value of at least 12.

Likewise, by way of example, US Patent No. 4,528,321 (Allen) describes a dispersion in a water-miscible liquid of soluble or water-swellable polymer molecules that has been reversed-phase polymerized in a water-miscible liquid which Contains a non-ionic compound selected from C4-l2 alkylene glycol monoethers, their C1-4 alkanoates, and C6-12 polyalkylene glycol monoethers. (C6-12 polyakylene glycol monoethers) and their C1-4 alkanoates.

Materials of some embodiments can be cross-linked to increase thermal stability in various uses, for example in hot filling applications. In an embodiment the inner layers may comprise low-width cross-linked materials while the outer layers may contain high-cross-linked materials or appropriate combinations thereof. For example, the inner coating on the PET surface may contain a material with weak or no cross-linking, such as Blox588-29, and the outer coating may contain another material, such as EXP-12468-48, made by ICI, which has the ability to cross-link. To achieve maximum adhesion to PET. Suitable additives capable of cross-linking may be added to one or more layers. Cross-linkers can be selected based on the chemistry and effectiveness of the resin or material to which they are added. For example, amine cross-linkers can be useful for cross-linking resins containing an epoxide group. If cross-linking additives are present, they are preferably present in an amount of about 1% to 10% by weight of the solution/dispersion shell, preferably about 1% to 5%, and more preferably about 0.01% to 0.1% by weight, and also including 2%. , 3%, 4%, 6%, 7%, 8%, 9% by weight. Optionally a thermoplastic epoxy (TPE) can be used with one or more cross bonding agents. In some embodiments, some agent (such as carbon black) may also be coated on or combined with the TPE. TPE may represent part of the material described herein. It is noted that carbon black or other similar additives can be used in other polymers to improve the properties of the material.

Materials of some embodiments can contain an agent to accelerate ripening. As used herein, the term “accelerator” is a widely used term and is used in its original meaning herein and includes, but is not limited to, catalysts for chemical cross-linking, heat-increasing agents, and the like. As used herein, the term “thermal enhancer” is a broad term and is used in its original meaning herein and includes, without limitation, transition metals, transition metal compounds, radiation absorption additives (e.g., carbon black). Suitable transition metals include, but are not limited to, cobalt, rhadium, and copper. Transition metal compounds include, but are not limited to, metal carboxylates. Preferred carboxylates include, but are not limited to, neodecanoate, octate, and acetate. Thermal enhancers may be used alone or in combination with one or more other thermal enhancers.

Thermal enhancers may be added to the material and increase the temperature of the material during the curing process, compared to the material without the thermal enhancers. For example, in some embodiments, thermal enhancers (e.g., carbon black) can be added to a polymer such that the temperature of the polymer subjected to the curing process (e.g., IR irradiation) is higher than that of the polymer without Thermal enhancers subjected to a suitable or similar process. Increased polymer temperature due to thermal enhancers increases the curing rate and increases production rates. In some embodiments, the thermal enhancers have a higher temperature than one of the layers of material when the thermal enhancers and the material are heated by a heating device (e.g., an infrared heater).

In some embodiments, the thermal enhancers are present in an amount ranging from about 5 to 800 ppm, preferably about 20 to 150 ppm, preferably about 50 to 125 ppm, preferably about 75 to 100 ppm, including about 10, 20, 30 , 40, 50, 75, 100, 125, 150, 175, 200, 300, 400, 500, 600 and 700 ppm and ranges including these quantities. The amount of heat booster can be calculated based on the weight of the layer containing the heat booster or the total weight of all layers containing the product.

In some embodiments, the preferred thermal enhancer includes carbon black. In one embodiment, carbon black can be applied as a component of a coated material in order to accelerate the maturation of the coated material. When used as a component of a coating material, carbon black is added to one or more coating materials before, during, and/or after applying the coating material (e.g., spreading, covering, etc.) to the material being studied. It is preferable to add carbon black to the packaging material and stir it to ensure mixing. The heat increasing agent may include additional materials to obtain the desired properties of the material under study.

In another embodiment, when carbon black is used in the injection molding process, the carbon black is added to the polymer mixture in the boiling phase process.

In some embodiments, the polymer comprises from about 5 to 800 ppm, preferably from about 20 to about 150 ppm, preferably from about 50 to 125 ppm, preferably from about 75 to 100 ppm, also including about 10, 20 , 30, 40, 50, 75, 100, 125, 175, 200, 300, 400, 500, 600 and 700 ppm thermal boosters and ranges include these quantities. In a further embodiment, the packaging material is cured under radiation, such as infrared (IR) heating. In preferred embodiments, IR heating provides more effective encapsulation than curing using other methods. Other thermal and processing enhancers and methods for using them are disclosed in U.S. Patent Application No. 98315/10 filed on November 5, 2004, under the name “catalyzed process for forming coated article,” the disclosure of which is incorporated herein by reference in its entirety.

In some embodiments it is preferable to add anti-foam/bubble agents. In some preferred embodiments used for solutions or dispersing solutions or foaming the formation of dispersions and/or bubbles which can interfere with the preferred processes. One way to avoid this interference is to add anti-foam/bubble agents to the solution/dispersion. These agents include, but are not limited to, non-ionic surfactants, alkylene oxide-based materials, siloxane-based materials, and ionic surfactants. If anti-foaming agents are present, they are preferably present in an amount of about 0.01% to about 0.3% of the solution/dispersant, preferably about 0.01% to about 0.2%, but also including proportions of about 0.02%, 0.03%, 0.04%, 0.05%, 0.06. %, 0.07%, 0.08% 0.09%, 0.1%, 0.25% and other percentages include those quantities.

In another embodiment the foaming agents may be added to the coated materials such that the coated layer foams. In another embodiment the foaming agent reaction product is used. For example, but not limited to, suitable foaming agents can be azobisformamide, azobisisobutyronitrile, diazoaminobenzene, N,N-dimethyl-N,N-dinitrozoterephthalamide ( N,N-dimethyl-N,N-dinitroso terephthalamide), N,N-dinitrosopentamethylene-tetramine, benzenesulfonyl-hydrazide, benzene-3,1-di Sulfonyl hydrazide (benzene-1,3-disulfonyl hydrazide), Diphenylsulfon-3-3, disulfonyl hydrazide, 4,4'-oxybis benzene sulfonyl hydrazide, p-para-toluene 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 currently available on the market, foaming agents include, but are not limited to, EXPANCEL, CELOGEN, HYDROCEROL, MIKROFINE, CEL-SPAN and PLASTRON FOAM.

The foaming agent is preferably present in the packaging material in an amount of from about 1 to about 20% by weight, more preferably from about 1 to about 10% by weight and more preferably from about 1 to about 5% by weight. Modern foaming techniques are well known to those skilled in the art using compressed gas which can be used to create foam in place of the usual bulking agents mentioned above.

The bond layer is preferably made of a polymer with active groups, such as anhydrous and epoxies, which react with carboxyl and/or hydroxyl groups on the PET polymer chains. Bond layer materials include, but are not limited to, DU Pont BYNEL, Mitsui ADER, Eastman's EPOLINE, Arkema's LOTADER and Exxon Mobil's EVELOY.

D- Methods and systems for making laminated material

A multi-component layer can also be created from a laminar melt stream which preferably contains at least two components. A laminar melt stream, as the term used herein includes, but is not limited to, a melt stream comprising at least two layers in which the layers in the melt stream are parallel. Although a laminar melt stream can have at least two layers, a laminar melt stream can include many thin films. Since the laminar dissolution stream can be made of two materials, the dissolution stream preferably includes alternating thin films of two materials, and it is preferable for the materials used to form this stream to be polymers such as thermoplastics, which include polyester, polyolefin. (polyolefin), phenoxy-type materials and other materials as explained here. These laminated materials may include mixtures of two or more materials. Laminate materials may include additives such as microparticles, oxygen scrubbers, UV absorbers, adapters, and the like. In an embodiment, the film dissolution stream comprises a reused polyester such as PET and a barrier material.

There is some method of creating the laminar melt stream using a system similar to that described in various patents for Schrenk, US Patent Nos. 5202074, 5540878 and 5628950 which are cited here by reference. Although this method is expected to be used alongside other methods currently to obtain solute streams. Referring to Figure 27, which shows a diagram of an embodiment of a laminar melt stream synthesis system 482 the system is shown in Figure 27 an embodiment of a two-material system but it is also understood that a system comprising three or more materials will operate in the same manner. The two materials used to form the flakes are placed in or inside hoppers 484 and 485, which are fed to two separate extruders 486 and 487, respectively. In a preferred embodiment, such extruders 486 and 487 are of a threaded type that can apply both heat and pressure to bring the respective materials to the melting point. Materials are extruded at rates and thicknesses to obtain the corresponding quantities required of each material and the extruder melt stream combines to form a laminar melt stream 488 consisting of one sheet from each cylinder, preferably arranged so that each sheet lies on top of the other sheet.

The two-layer melt stream 488 exiting the cylinders is applied to a wafer enlargement system 490. In the illustrated layer amplification system 490, the two-layer melt stream 488 is enlarged to a multilayer melt stream 492 which has 10 wafers in the embodiment shown as Figure 27(a). ). Figure 27(a) shows a layout that is highly ideal in that although the layers of laminated material on average prefer to be parallel to each other, the laminated material can contain flakes that are not parallel to each other and/or flakes that are parallel in some places and not parallel in others. .

The process of doubling chips can be done in any of the ways. In one embodiment someone first divides a portion of the melt stream into two segments perpendicular to the interface of the two films. These two layers are then flattened so that each of these two pieces is equal to the length of the original piece before bisecting it in the first step, but only half of one is equal to the thickness of the first piece. The two pieces are then re-merged together to form one piece with dimensions similar to the original piece but with 4 ply, by pasting one piece on top of the other piece so that the ply parts of the two materials are parallel to each other (meaning that the adhesive is in a direction perpendicular to the layers of the melt stream). The splitting, flattening and reassembly steps can be performed several times to obtain thinner layers. The melting stream can be multiplied by performing splitting, flattening and reassembling operations multiple times to obtain a single melting stream containing many flake fractions of the element material. In this two-material embodiment, the composition of the layers will alternate between the two materials. Other methods of film formation include performing steps similar to those above but flattening the melt stream before sectioning or after reassembly. Alternatively, in any of these embodiments someone could bend the melting stream back on itself rather than break it into pieces. Combinations of splitting and bending can also be made, but it is noted that bending and splitting will achieve relatively different results because bending will cause a single sheet to double over itself. The output of the film multiplying system passes out through an orifice 494 such as a buzzer or valve and is used to form the material or a multi-component film with the material by injection or by placing a film melting stream into a mold.

In the two-material embodiment shown the composition of the films generally alternates between the two materials. However, in other embodiments any number of material may be taken into an elemental melt stream and then fed to the foil amplification system 490 which produces a foil melt stream of any desired number of repetitions and/or desired repetition size of blocks or piles of material. For example in an embodiment, the system 482 includes three extruders which connect the material to the foil augmentation system 490. The foil augmentation system 490 can be a foil stack composed of three materials.

When the foil dissolution stream contains one or more materials that have gas-trapping properties, it is preferable to use the foil dissolution stream in such a way that it is regulated so that the chips in the dissolution stream are parallel to one or more surfaces of the expanding material. For example, in a container the layers should preferably be parallel to the length of the wall or body part. Although parallelism is preferable, other directions may be used and the scope of the invention is defined. For example, one or more of the container wall portions may have chips that are parallel to each other and to the container wall surface while one or more of the other portions may have chips that are not parallel to each other. The desired winding path through the container wall is estimated by the orientation and configuration of the chips that make up the container. For example, the sheets are parallel to each other and the wall portion can substantially increase the path length through the wall that is viewed by the gas molecule. Alternatively, layers parallel to each other that generally pass into the wall lead to a short or slightly winding fluid path through the wall and thus have lower barrier material properties than a parallel solute stream.

Materials, such as the containers and pre-formed parts listed here, can be formed using the product of the foil melting stream from a system such as the one described. In some embodiments, the foil melting comprises materials having a similar melting temperature Tm to facilitate machining and molding. However, foil melting can involve materials with different TmS. For example, the foil material could include materials with a TmS in the range of about 500 F (about 260 C). Foil material materials can be selected depending on the material's thermal properties, textural properties, barrier properties, viscosity properties, operating properties and/or other properties. The foil can be formed and cooled, preferably before one or more of its components are substantially broken down. One skilled in the art can select materials to form the film material to achieve a desired material consistency suitable for the process characteristics and chosen end use.

E- Methods and devices for making preferred tools:

Single-layer and multi-layer products (including packaging products such as caps, pre-formed parts, containers, bottles) may be formed by a die-casting process (for example, injection molding including associated injection molding). One method of producing multi-layer products is generally referred to here as pan-forming, and sometimes as injection-over-injection ("IOI"). The name refers to a process that uses injection molding to inject one or more layers of material onto an existing layer, preferably made by molding. Injection. The terms "epi-injection" or "epi-molding" are used here to describe the encapsulation process by which a layer of material is injected over an existing layer or pre-formed piece(s).

One epitaxial method for manufacturing pre-formed parts on an injection machine involves union with a die containing a core mandrel or core and cavity. A first layer of precast material is formed between the preform core and a first cavity of the preform core by injecting a molten polymer (i.e., polymer melt) into the void space in the die. The first layer remains on the preform core when the preform core is pulled out of the cavity, moved, and inserted into a cavity in a second die. Then a second layer of material is injected over the existing pre-formed layer. The preform mandrel and the accompanying preformed material are then moved from the cavity, and the preformed material is moved from the preform mandrel.

In some embodiments, the top injection process is performed while the substrate has not yet completely cooled. The substrate may have retained intrinsic heat from an injection molding process then performed on the substrate. In some embodiments, the substrate may be at room temperature or at another temperature suitable for epitaxial formation. For example, overmolding of products can be done at room temperature with one or more layers of material. These products may have been stored for an extended period of time before being overmolded.

Epitaxial injection may be used to apply one or more layers of material(s) such as those including expandable/foam material (including recycled PET, PET prepared directly from the raw material), laminate material, insulating materials, combined assemblies Thereof, and/or other materials described herein over a substratum (i.e. the bottom layer). In unspecified embodiments, the substrate is in the form of a fixed-forming piece, preferably having an internal food contact surface. In some embodiments, the preformed substrate includes PET (such as PET produced directly from the feedstock), a phenoxy-type thermoplastic material, combined groups thereof, and/or the like.

Products may include one or more layers or parts having one or more of the following characteristics: insulating layer, barrier layer, food contact layer, unflavored abrasive layer, high-strength layer, ductile layer, bonding layer, gas-scavenging layer A layer or part suitable for hot filling applications, a melt-resistant layer suitable for extrusion. In some embodiments, the single-layer or multi-layer material comprises one or more of the following: PET (including recycled and/or straight-from-crude PET), foam, polypropylene, phenoxy thermoplastic ), polyolefins, mixtures of phenoxy-polyolefin thermoplastics, and/or combinations thereof. Assuming convenience, the products are mainly shown for pre-formed parts, containers and covers.

In some embodiments, the products can include a foaming agent. Foaming agent can be prepared by combining a foaming agent and an inert material. In some embodiments, the carrier and foam material are extruded together, generally preferably to a homogeneous mixture of foam material. The amount of carrier and foaming agent may be varied depending on the desired amount of one or more of the following: expansion properties, structural properties, thermal properties, charge pressure, and the like. In some unlimited embodiments, the expandable/foam material comprises less than about 10% by weight, also comprising less than about 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2% , or 1% by weight, of the foaming agent. In some unlimited embodiments, the expandable/foaming material may include about 1-6% by weight of the foaming agent. In another but not particularly specific embodiment, the expandable/foaming material includes about 3-6% by weight of the foaming agent. In another unspecified embodiment, the expandable/foaming material comprises about 2-8% by weight of the foaming agent. It is envisaged that the expandable/foaming material may contain any suitable amount of foaming agent including more or less than the specific percentage mentioned above, depending on the desired properties of the foaming agent.

In some embodiments, a carrier (e.g., polypropylene pellets) and a micropellet foaming agent, preferably EXPANCEL micropellets or similar material, are charged into a hopper. The carrier and microspheres are heated to melt the carrier for efficient mixing of materials. When the mixture is heated, the microspheres may expand or become larger. Preferably, the temperature of the mixture should fall within a range of temperatures that does not cause complete expansion or dehiscence of a large portion of the microspheres. For example, if the temperature of the mixture reaches a high enough temperature, the gas inside the microspheres may expand so that the microspheres break or shatter. The melt can be co-extruded and preferably quenched quickly to determine the amount of microsphere expansion.

When the foaming material is heated for processing (e.g., extrusion, injection, etc.), the microspheres according to one embodiment may partially expand from their initially generally unexpanded position. When these microspheres are partially expanded, they may retain their ability to undergo further expansion to increase the size of the microspheres. Preferably, the pressure and temperature should be such that the microspheres are not fully expanded during extrusion for the purpose of allowing further expansion of the microspheres during blow molding, for example. Also, the foaming agent pressure can be increased to reduce, or completely prevent, the expansion of the microspheres. Hence, the pressure and temperature of the foaming material can be varied to achieve the desired amount of microsphere expansion. Partially expanded microspheres can undergo further expansion when reheated (e.g., during a blow molding cycle) as shown here.

It is envisaged that the Products may be prepared by any suitable method, including but not limited to (1) dip or flow coating, (2) spray coating, and (3) flame spraying. ), (4) fluidized bed dipping, (5) electrostatic powder spray, (6) overmolding (e.g., over-injection), and/or (7) Injection molding (including associated injection). For example, preferred methods and devices for performing forging are set forth in US Patent No. 6,352,426 and US Publication No. 2004-0071885, which are incorporated herein by reference in their entirety and form a part of this application. It is also conceivable that these methods and devices could be used to form other products described herein. The preformed parts described herein may be blow-formed using methods and devices described in references (e.g., U.S. Pat. No. 6,352,426) which are incorporated herein by reference.

1- Methods and devices for preparing a product containing foam

A product, such as preformed material 30, can be formed by injection molding by use of an injection mold. Figure 28 shows a mold 501 having a cavity 500 defined by the core 499 and the mold cavity portion 504. The mold 501 can create a product that includes an expandable/foam material. In some embodiments, including the one shown, the foaming material is passed along the line 509 and passes through a moving baffle 508 and into the cavity 500. The foaming material can fill the cavity 500 to form preformed material 30. The cavity foam 500 can be rapidly cooled or quenched to limit expansion of the foaming agent and can reduce circulation times to increase production. The mold may have a baffle or needle valve 511 to act to prevent backflow of the expanding foam.

The back pressure of the melt can be sufficient to cause the foaming material in the form of microspheres to break. However, the back pressure must act to prevent the microspheres from over-expanding in order to allow the preform to blow the preformed material to the desired shape and/or allow further expansion of the microspheres. The temperature of the melt can vary depending on the back pressure of the melt. For example, a high-temperature melt can cause the microspheres to expand. To inhibit or prevent expansion of the microspheres, the back pressure can be increased to delegate increased pressure through each of the microspheres. However, if the pressure of the melt is too great, the microspheres may break or shatter. Hence, the pressure of the melt is preferably maintained within some range such that a large portion of the microspheres does not expand completely or break. In other embodiments, however, some or all of the pellets may break upon full expansion to create foam (e.g., open-cell foam).

In some embodiments, the melt may undergo at least partial expansion before it is injected into the mold cavity 500. For example, after the melt is injected into the cavity 500, the extrusion unit screw may be contracted to serve to collect the melt for the injection next. After retrieval, the screw can be decompressed to reduce the pressure of the melt to achieve adjustable expansion of the micro-rollers in the melt. In one embodiment, the melt is not under pressure and so the microspheres can expand freely. However, pressure can be applied to the melt to selectively control the expansion of the microspheres. Accordingly, the microspheres in the melt may be partially or completely expanded before the melt is injected into the cavity 500. Preferably, the microspheres are in an expanded state such that the microspheres can undergo expansion again during, for example, Preheating process for blow molding. The melt containing the microspheres may be injected into the cavity 500 to form a preformed material with expanded microspheres. The preformed material with the expanded microspheres can then be formed in the vessel which generally contains uniformly distributed microspheres.

The cavity 500 can be heated to result in a generally uniform distribution of microspheres in the preformed material. Heat can cause a generally uniform distribution of the foaming agent. In some embodiments, the melt may include polypropylene and microspheres. It is injected into cavity 500, which can be at a temperature of about 100 F (37.8 C) to about 250 F (121.2 C). The heated cavity 500 can ensure that the microspheres are uniformly distributed throughout the preformed material. In another embodiment, the cavity 500 can be maintained at a temperature of about 150°F (65.6°C) to about 225°F (107.2°C). In another embodiment, the cavity 500 can be maintained at a temperature below about 200°F (93.3°C). The cavity 500 can be cooled at any convenient time to achieve the desired distribution of microspheres. In yet another embodiment, the melt includes polyethylene and microspheres. The cavitation 500 can be set at a temperature of about 75°F (23.9°C) to about 125°F (51.7°C) to form a preformed material, generally preferably evenly distributed microspheres. The preformed material which may have evenly distributed microspheres can then be formed by the bowl-shaped die, which, by rotating it, has evenly distributed microspheres. The above temperatures depend on the particular materials used. On the part of this invention, an expert in the art can select the material(s), processing parameters, and mold design to produce different types of products.

The speed of the melt passing through the line 509 and cavity 500 can cause frictional heat and thus cause expansion of the microspheres in addition to the heat of the melt. The mold shown in Figure 28 has a highly heat-conducting material 507 that can rapidly cool the molten material passing through the cavity 500 in order to hinder the expansion of the microspheres. The material that produces significant heat transfer 507 may form part or the entire mold cavity 504 and hence, operating parameters (e.g., flow velocity, pressure, temperature, mixture proportions, viscosity, and the like) depending on the shape, size and other properties of the template.

In some embodiments, the preformed cotton in the cavity 500 can be easily cooled rapidly or quenched to serve to retard, or even times, the expansion of the microspheres. This allows the microspheres, which may be partially expanded, to form a tight structure that can expand during blow molding. After the preformed material is cooled, it can be processed conventionally without further expansion of the microspheres. In one embodiment, the cavity 500 is maintained at an appropriate temperature to adjust the expansion rate of the microspheres during the die-forming process. In an unspecified embodiment, the cavity 500 is maintained at a temperature of about 40°F (4.4°C) to about 180°F (82.2°C) to reduce or stop expansion of the microspheres. The cavity temperature 500 may be selected depending, for example, on the forming material, size and design of the preformed material, volume of space filled by the foaming material and/or curing parameters. The material curing temperature can be chosen or set by an experienced debater after knowing the composition of the foam (carrier, foaming agent, microspheres), desired degree of expansion, and/or other parameters.

(a) Preparation of products by blow molding process

Products containing a mold can be produced by the blow molding process. A product can be formed in the form of preformed material 30 by expanding blowing to form a vessel, such as vessel 37 (Figure 4), preferably by causing expansion of the microspheres. The preformed material 30 may be subjected to a stretch blow molding process in the mold shown in Figure 3. The preformed material 30 containing expandable material is placed in the mold 28 which has a cavity corresponding to the desired vessel shape. The preformed material 30 is then heated and expanded by the expansion of the preformed material 30 to fill the cavity in the mold 28, then forming a vessel. Expansion may be accomplished by, for example, air forced into the inner part of the preformed material 30. The blow molding process is generally limited to the block part 34.

Before the preformed material 30 is expanded, it is preferable to preheat the preformed material to the blowing temperature range for the blow molding process. If the temperature of the preformed material 30 reaches the expansion temperature range, the microspheres in the preformed material 30 may expand. A range of expansion temperatures can be reached before, during, or after elongation of the preformed material 30. Preferably, the microspheres of the preformed material 30 are heated to a range of expansion temperatures to cause at least partial expansion of the microspheres before the preformed material 30 is blow molded.

After the temperature of the preformed material 30 is raised to the blowing temperature range, air is passed into the interior of the preformed material 30 to expand the preformed material into the desired shape of the container 37. It is generally preferable that the expansion temperature range be similar For a range of blowing temperatures such that the microspheres can expand during heating or reheating for blow molding. Stretchable material is stretched when air forces the preformed material to elongate and mold into the desired shape. In another embodiment, the preformed cat 30 can be molded by blowing to a desired shape and then the temperature of the vessel 37 can reach the expansion temperature range to effect expansion of the foaming material of the vessel 37. To increase the rate of expansion of the microspheres, the temperature during the cycle Blow molding can be increased and/or blown pressure can be decreased. In order to reduce the expansion rate of microspheres, the temperature during the blow molding cycle can be reduced and/or the blowing pressure can be increased. Hence, the preformed material can be heated/cooled and the pressure can be adjusted as desired.

Referring to Figure 3, the temperature of the walls 33 of the mold 28 can be adjusted for the purpose of achieving expansion of the foaming material in the preformed material 30/vessel 37. In one embodiment, the mold 28 has a temperature control system to adjust the temperature of the walls 33. The temperature control system can have heating/cooling channels or any other suitable system to effectively control the temperature of the walls 33.

In some embodiments, for example, the walls 33 are heated to cause expansion of the microspheres in the vessel 37. After the preformed material 30 is injection molded to form the vessel 37, the heated walls 33 continue to expand the microspheres in the vessel wall 37, thereby reducing Wall density. In this way, the microspheres in the walls of the vessel 37 can expand or elongate to set up a more effective thermal insulator as a result of the highly expanded microspheres.

The walls 33 of the mold 28 may be cooled for the purpose of retarding, or preventing expansion or over-expansion of the microspheres. The walls 33 may be heated during one or more parts and cooled during one or more parts of the production cycle. The walls 33 may be heated during a heating cycle to stimulate expansion of the microspheres as discussed above. After the microspheres have been expanded as desired, the mold walls 33 are preferably cooled to reduce, or preferably stop, expansion of the microspheres again. Hence, the walls 33 can be heated during a first part and cooled during a second part of the blow molding process. However, the walls 33 may be heated and/or cooled at any appropriate period of time during the blow molding process, for example, in another embodiment the walls 33 of the mold 28 are cooled during the elongation and extension of the preformed material 30 from its initial position. to the desired shape of the vessel. The preformed material 30 may be heated, inflated and expanded until the wall of the preformed material comes into contact with the cooled walls 33. Preferably, the expandable material forming the preformed material 30 can be subjected to local expansion as an elongated preformed material. When the preformed material 30 is in thermal contact with the walls 33, heat is transferred from the expanded preformed material 30 to the die 28 to serve to cool the wall 84 of the preformed material that has been formed. Once the preformed material 30 cools, expansion of the microspheres can be reduced or stopped. The pressure in the mold 28 can be increased to work to reduce the rate of expansion of the microspheres. The pressure in the mold 28 may be reduced to increase the rate of expansion of the microspheres.

The walls 33 of the mold 28 may have been surface treated or textured to achieve a desired foaming reaction during a blow molding process which may result in a roughened (ridged and ridged) surface of the vessel 37. For example, the wall surface 33 may be rough or granular so that when the outer surface of the bowl 37 comes into contact with the wall 33 during blow molding, the outer surface of the bowl 37 will have a rough foam surface. The rough surface of the wall 33 may activate additional expansion of the microspheres after at least part of the vessel comes into contact with the wall 33 of the mold 28. However, the wall surface 33 may have been subjected to any treatment to achieve a suitable structure for the outer surface of the vessel 82. In an embodiment Another, for example, the wall 33 of the mold 28 may have a low-friction finish, such as a steam polishing layer, to facilitate easy release of the bowl 37 from the mold 28. The low-friction finish can have a completely smooth surface to facilitate bowl release. The die 28 can be used to produce multilayer vessels, such as the vessel 82 of Figure 6.

2- Preferred methods and devices for preparing pre-formed pieces

Single- or multi-layer products can be formed by injection molding processes, such as co-injection, epitaxial molding, and the like. It is intended that combined combinations of injection molding can be performed to produce different shapes of products.

(a) Preferred methods and devices for associated injection molding

Figure 28 shows mold 501 that can be used for injection or co-injection to form monolayer or multilayer products, respectively. The multi-layer preformed parts may be formed by a combined injection step in which a plurality of materials are co-injected into the cavity 500 and in some embodiments, a first material and a second material are together injected into the cavity 500 to form the multi-layer preformed material. In the embodiment shown in Figure 11, a first material forming the inner layer 164 and a second material forming the outer layer 162 may be injected together through the movable barrier 508. To finish the inner layer 164 in alignment with the inner surface of the preformed material 160, the flow of the first material forming the inner layer 164 can be stopped before the stream of melt containing the first material continues through the entire cavity 500 and then one or more materials can be delivered through Moving barrier 508 at different flow rates, at the same time or at different time intervals, in varying amounts, and the like to form a desired product.

The preformed material 160 may have a thinner inner layer 164 relative to the outer layer 162. This is particularly preferable if the material forming the inner layer 164 is significantly more expensive than the material forming the outer layer 162. For example, some types of plastics Phenoxy thermoplastics may be more expensive than readily available materials, such as PET, so the amount of phenoxy thermoplastics can be used as little as possible in order to reduce the cost of the preformed part material160.

The preformed material 180 of FIG. 12 can also be formed by an associated injection molding process using the mold 501. An experienced person will readily recognize that the layers of preformed material 160, 180 can be varied to achieve the desired properties of the preformed area. Figures 12(a) and 12(b) show alternative embodiments of the multilayer preformed parts. Figure 12(b) shows a preformed material 180(b) comprising an inner layer 184(b) and/or an outer layer 182(b) having varying thickness. The layers described 182(b) and 184(b) include a mixing portion in the bulk portion of the preformed material. The inner layer 184(b) has a slightly mixed mass fraction relative to the final layer of the narrow fraction. In general, the thickness of the outer layer 182(b) is greater than the thickness of the inner layer 184(b). Although not explained, we find that the preformed material 190 in Figure 13 also has an inner layer 194 and an outer layer 199 of different thickness values.

It is conceivable that the preformed pieces of Figures 11-14 could be overly formed with a material (e.g., barrier material), preferably to form a layer that extends from a reinforcement ring in alignment with the bulk portion of the preformed material. US Patent No. 6,312,641 is incorporated herein by reference in its entirety and describes methods, systems and products formed by one or more die forming processes. In light of this disclosure, various combinations of systems can be used to produce a range of products including a wide range of products by use of associated injection processes.

(b) The first preferred method and first preferred device for epitaxial shaping

Products with multiple layers may be formed through an injection molding process, for example by an overmolding process. Figure 29 shows an example of a die 520 for superforming. The mold 520 can have a half-core 522 and a half-cavity 524 shown in the closed position prior to over-injection. The half cavity 524 includes a cavity into which the unwrapped product is placed as a substrate (e.g., aforementioned part 528). The epitaxial process can be used to deposit one or more layers onto the substrate.

The preformed material 528 can be a single-layer or multi-layer preformed material. The preformed material shown is a single-layer preformed material that may include one or more of the following: PET (e.g. PET from direct distillation of crude oil and/or recycled PET), polyester, PP, thermoplastics Phenoxy, thermoplastic and/or similar. The preformed material 528 may also be similar to the preformed parts in patent applications or patents that are incorporated by reference herein.

The support ring 538 of the preformed material 528 may rest on a protruding edge 536 and be held in place by the core half 522, which exerts pressure on the support ring 538, thus preventing the narrow portion from settling over the bulk portion of the underlying preformed material. . The core half 522 includes a die on the core 540. The core 540 selectively heats/cools the interior of the preformed material 528, while channels 544 can heat/cool the cavity half 524. For example, cooling is accomplished by circulating a fluid through channels 456 in the half-core 522 of the die 520.

Once the preformed material 528 is settled in the mold cavity, the bulk portion of the preformed material is completely centered within the cavity and preferably completely surrounded by a void space or cavity 550 and the preformed material thus placed acts as a mandrel that turns the preform by eating it in the next injection process. The overmolded material is then introduced into the mold cavity 550 from an injection unit via a movable baffle 554 and flows around the preformed material 528, preferably surrounding at least the bulk portion of the preformed material 528. After epitaxial injection the epitaxially formed layer will take on the approximate size and shape of the 550 cavity.

The packaging material may be heated to form a melt of a viscosity compatible with use in an injection molding device. The temperature for this, the injection temperature, will vary from one material to another, because the range of melting points in the polymers and the viscosity of the melts may vary as a result of the date of manufacture, chemical property, molecular weight, degree of vacuum and other properties of the material.

The mold 520 may be used to form the encapsulated preformed parts shown herein as the preformed material 50. The preformed material 50 of Figure 5 may have one or more of the layers 52, 54 also including PET, a phenoxy-type thermoplastic. (including phenoxy and polyolefin-phenoxy), polypropylene, laminate, and/or other thermoplastics. In some embodiments, the remaining layers 52, 54 may include the preformed material 50 on another material, such as foam. The expandable/foaming material may include a carrier (e.g., PP, PET, and/or ethylene acrylic acid) that is mixed with a foaming agent (e.g., microbeads, such as EXPANCEL microbeads) to produce a Foaming. For example, the inner layer 54 may include PET and the outer layer 52 may include an expandable/foam material. The preformed material may include a PET substrate. The foaming material can be delivered through the line 552 and the moving barrier 554 to the cavity 550. The injected expansion/foaming material is then cooled for subsequent removal. In light of this disclosure, an experienced person can select the material(s) based on the characteristics of the material(s) and the desired products manufactured from them.

(1) Preparation of multi-layer products by blow molding

Multi-layer products may be injection molded in a similar manner as single-layer products, except as described in more detail below. For convenience, blow molding of multi-layer products will be shown for preformed material 50. Of course, other multi-layer preformed parts can be formed in a similar manner, in particular multi-layer preformed parts containing a foaming agent.

The preformed material 50 is placed in a mold (e.g., mold 28 of Figure 3) having a cavity corresponding to the desired bowl shape. The preformed material 50 is then heated and expanded by forcing air into the inner part of the preformed material to elongate and expand the preformed material so that it fills the cavity, and then a multi-layer container is formed. Optionally the preformed material 50 can be extended by an extension leg or other means of supplying the preformed material.

In some embodiments, the preformed material 50 includes material with similar or different processing products. The preformed material may include 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 mostly or entirely of PP. Preferably, the inner layer 54 and outer layer 52 can be formed by blowing through a curing opening that is substantially wider than the curing opening of preformed pieces manufactured entirely from PP. Preferably, the width of the curing opening may be increased regardless of the thickness of the inner layer 54 and outer layer 52. Optionally, layer 85 may be used to improve adhesion between the inner layer 54 and outer layer 52. In one embodiment, a coupling agent (e.g., an adhesive) acts On the composition of layer 85 and prepare the paste between the inner layer 54 and the outer layer 52.

In some embodiments, the layer 52 can be an extensible material formed through epitaxial molding by using injection molding to inject at least one layer of an extensible material over an existing moldable item (e.g., a moldable item embedded on PET, plastics Phenoxy type thermals, etc.). The inner layer 54 and the carrier material of the foam layer 52 may have a similar Tg such that both layers 52, 54 can be cured within the preferred blowing temperature range values. As discussed previously, the expansion temperature range may be the temperature range that causes the microspheres to expand. The range of expansion temperatures can be varied by varying the pressure applied to the expandable material. Preferably, the expansion temperature range should be similar or similar to the blowing temperature range for layers 52, 54. During the blow molding process, the temperature of the preformed material can fall within the expansion temperature range to cause at least partial expansion of the microspheres. Hence, the foaming agent of the foam layer 52 can expand (1) during reheating of the preformed material for blow molding, (2) during expansion of the preformed material into the bowl shape, (3) after the bowl has generally been formed, and /or (4) combinations of (1), (2) and/or (3).

In some embodiments, the multi-layer preformed material can be blow molded into a vessel having a suitable inner layer.

(c) The second preferred method and second preferred device for superforming

The methods and apparatus shown here can be modified to make other preformed parts shown here. For example, Figure 30 shows a mold that can be used to create a liner layer of preformed underlayment material, prior to injection of the material. The material may or may not have a tight finish. For example, the material can be preformed without waisting. The die 560 has a core portion 561 and a cavity portion 566 having a cavity portion surface 568. The die 560 includes a cavity 570 defined by a core 562 of the core portion 561 and the hollow portion 566. Line 572 can charge the melt through baffle 574 and into cavity 570.

The cavity 570 has a shape corresponding to the desired shape of a portion of preformed material. In the shown embodiment, the cavity 570 is designed and sized to mold the inner layer 164 of the preformed material 160 in Figure 11. However, the cavity 570 can be sized and designed to mold any desired product. For example, cavity 570 can have a corresponding shape forming an inner layer, such as the inner layers of any of the preformed pieces described above. The melt may be injected into cavity 570 in the manner described above to form a die-formed product. The molded product can be removed from the hollow part 566 and then inserted into another cavity part (e.g., hollow part 580 in FIG. 31) for an overmolding process.

The overmolding is done by using an injection molding process using equipment similar to that used to create the inner layer 164. As shown in Figure 31, after the layer 164 is formed in the mold 560 of Figure 30, the core 562 can be inserted into the hollow portion 580. The layer 164 or hollow portion 580 defines a gap or cavity 582 corresponding to the shape of the outer layer 162 of the preformed material 160 of Figure 11. In general, the molten material is passed along the line 584 and passes through a movable barrier 586 and into the cavity 582. The molten material can fill the cavity 582 to form the outer layer 162. After the preformed material 160 has cooled in a sufficient amount, it can be removed from the mold cavity 582. After epitaxial injection the epitaxially formed outer layer 162 will take on the approximate size and shape of the cavity 582.

To perform the epitaxial forming process, it is preferable that the primary layer 164 that is to be epitomized be heated to a temperature greater than its Tg. In the case of PET, the temperature is preferably around 100 to 200°C, and most preferably around 180°C to about 225°C. If a temperature at or above the crystallization temperature for PET is used, which is approximately 120°C, care must be taken when cooling the PET in the preformed material. Cooling must be sufficient to reduce the crystallinity of the PET in the preformed material, particularly in the bulk fraction, so that the PET is in the preferred amorphous and/or semi-crystalline state. Alternatively, the primary inner layer 164 may have been injection molded very recently and not completely cooled to a high temperature as is sometimes preferred for the epitaxial molding process.

The formed material is superheated to form a melt with a viscosity compatible with use in an injection molding device. For some materials such as foam and PP, the injection temperature is preferably in the range from about 375°F to 550°F.

After the overmolding process, the multilayer preformed material should preferably cool, at least to the point where it can be dislodged from the mold or held without breaking, and removed from the mold where further cooling may occur. If the bulk portion of the preformed material has been heated to a temperature near or above the crystallization temperature of the material forming the bulk portion, cooling must be rapid and sufficient to ensure that the material is essentially in a semi-crystalline state when the preformed material is completely cooled. As a result of this process, a strong and effective bond occurs between the initial layer material 164 and the subsequent coating 162. The narrow final layer may have a greater percentage of crystalline material to provide increased dimensional stability particularly during the subsequent process (e.g., blow molding, hot filling and similar things). In light of this disclosure, a person skilled in the art may select the type and design of molds for making the single-layer and multi-layer products described herein. Molds, special processes, and other embodiments of preformed parts, including those of the foregoing, in light of this disclosure herein, and other details of molding processes (e.g., by means of an over-injection molding process) may be found in U.S. Pat. No. 6,352,426, which is incorporated herein by reference. .

3- Special methods and devices for preparing a cover (plug)

A cap, such as the caps shown in Figures 8-21(e), can be made by using an injection mold. The templates in Figures 31 and 32 are generally identical to those in Figures 28 through 31, except as also detailed here.

Figure 31 shows a die 700 that is designed to form at least a portion of the cover. The die 700 is identified by a core portion 702 having a core 704 and a cavity portion 706. In one embodiment, the material is passed (e.g., PET including straight-from-raw PET and/or recycled PET, PP, phenoxy-type thermoplastics ), expandable/foam material, PP and/or other suitable material(s) in line alignment 709 and passing through a movable baffle 708 and into the cavity 710, which is defined by the core 704 and the hollow portion 706. The material can fill cavity 710 to form at least part of the cover. The cavity 710 shown is sized and designed in the shape of the inner layer of a cap body. However, the recess 710 can be designed to form the entire cover. The cavity 710 may also optionally include a portion 711 to form a belt and connecting parts between the body and the cover belt.

The coatings shown above containing multiple layers can be formed by an epitaxial process. Figure 33 shows a die 730 for overforming. A lined layer or substrate 732 formed by the die 700 (Figure 32) may be placed in the die 730 (Figure 33). The mold 730 has a heart-shaped portion 734 and a cavity portion 736 positioned in the suspended portion prior to epitaxial injection. A slotted ring 740 may be connected to a body portion 742 and a belt 744 of the substrate 732. The cavity portion 736 includes a cavity 738 in which the uncoated substrate 732 is placed.

The substrate material 732 shown is a multilayer portion of a cover, however, the substrate 732 can be a multilayer substrate. In some non-specific embodiments, the substrate 732 may include one or more of the following: PET (e.g., PET directly from virgin and/or recycled PET), polyester, PP, phenoxy ( phenoxy), thermoplastics (including phenoxy thermoplastics), laminated materials, combinations thereof, and/or the like. The substrate 732 can also be a measuring cap used to seal bottles. A person skilled in the art may select the size and shape of the substrate 732 depending on the desired end use of the seal.

When the substrate 732 settles into the mold cavity, the volume 742 of the substrate 732 is preferably centered within the cavity and completely surrounded by void space 750. The substrate 732, illustrated in this manner, serves as an internal molding mold in the next injection step. The overmolding melt is then introduced into the mold cavity of the injection unit via the movable baffle 752 and flows around the substrate 732, preferably bonding to at least the bulk portion of the substrate 732. After epitaxial injection, the epitaxial layer will take on the approximate size and shape of the 750 void space.

The mold 730 can be used to form the coated or multilayer seals described herein. In some unspecified embodiments of the invention, the plugs of Figures 18-21(e) and 24 may have one or more layers comprising essentially PET, a phenoxy thermoplastic, polypropylene, Foaming, and/or other thermoplastics. Optionally, at least one of the seal layers may include an expandable/foam material. In some embodiments, the cover 302 (Figure 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).

The method and apparatus described in the references which are incorporated by reference herein may be modified in the application to produce the covers. For example, the molding machines, apparatus and methods described in US Patent No. 6,352,426 (see Figures 10-15, 17-24) can be modified to produce covers. For example, the molds may include a material capable of highly transferring heat, cooling channels, bonded systems, gas intake systems, and/or the like.

F- Methods and devices for applying a substance to a substrate

Systems for making products can contain one or more devices or systems that deposit a range of materials. The molds shown above may have one or more delivery systems that deposit a substrate, such as a preformed product, plug, or the like. The deposited material may form at least part of a bond layer or other layer (e.g., a barrier layer). For convenience, the connection systems described here are initially discussed for molding devices, such as injection molding machines for the production of preformed parts. However, delivery systems can be used to deliver other materials (e.g., thermoplastic barrier materials, foams, etc.) to substrates in the form of seals, primers (e.g., bottles), sheets, tubes. etc.

Referring to Figure 34, the connection system 1004 of the molding device 1008 can be used in various types of molding systems, such as an injection molding system or a compression molding system, for example. The molding devices may have a delivery system 1004 to improve adhesion between air and/or material in passing the molded product.

Figure 33 shows a molding system 1000 for producing single- and/or multi-layer preformed parts. The molding system 1000 has a connecting system 1004 and a die 1002 that is similar to the die 501 shown in Figure 28, except as detailed below:

The die 1002 of Figures 34 and 35 is prepared for an overforming process. The die shown 1002 is designed to overform a plurality of preformed pieces and includes a die portion 1052 and a cavity portion 1054 that together serve to define a cavity 1008 when the die 1002 is in the closed position shown in Figure 35.

For Figures 34 and 35, the mold 1002 includes a fluid delivery system 1004 for admitting a material, preferably a binder, into the cavity 1008. The fluid delivery system 1004 has a charging line 1010 that serves to receive a fluid, preferably a pressurized fluid, from a fluid source. A drain system 1012 includes a drain line 1016 that communicates with a die cavity 1008 and a drain hole 1020 (Figure 33). The fluid delivery system 1004 injects a fluid, separating a binding fluid, through the charging line 1010 and into the cavity 1008 to encapsulate at least a portion of the substrate 1022 (Figure 35). The substrate shown 1022 is in the form of a preformed material. The preformed material is then formed on top with a layer of material. Preferably, the bonding fluid forms a bond layer that adheres to a superstructured layer with the underlying preformed material 1022.

Fluid can be removed from the cavity 1008 by passing the fluid through the drain line 1016 and out the drain hole 1020 (Figure 34). In some embodiments, a flow or pressure device, (e.g., a pump) may be positioned at the same point in alignment with the discharge line 1016 to act to create a low pressure or vacuum (e.g., suction) to improve the flow of the bonding fluid. The vacuum can be used with pressurized or non-pressurized binding fluid. The pressurized binding fluid and by the charge line 1010 and discharge can result in selectively controlled flow rates through the cavity 1008. In some embodiments, the binding fluid is delivered to the bore 1008 and then a vacuum is drawn to remove unused binding fluid. However, the drainage system 1012 may not include a suction making device. For example, drainage system 1012 may discharge directly to the atmosphere or through a purification unit to remove any environmentally harmful substances such as VOCs.

The delivery system 1004 can be used to deliver a material, preferably a packing material, to the core 1002. In some embodiments, the material is a non-binding packing material. As used herein, the term “packaging material” is a commonly used term used in its ordinary sense and may include, without limitation, a fluid or binder, polymer melt, adhesives, and similar materials which serve to form Layer with all or part of the layered product surface in the mold. The encapsulation material can give desired properties to the substrate. In some preferred embodiments, the coating material may be disposed to form a synthetic layer (e.g., bond layer, polymer layer, barrier layer) on surfaces.

As used herein, the term “tie fluid” is a commonly used term used in its ordinary sense and may include, without limitation, a fluid that may be applied to the preformed material to form a bond, adhesive, or function layer and may It improves the adhesion between materials. For example, the bonding fluid may be a chemical that may improve adhesion between thermoplastic polymers, foams, elastomers, other materials described herein, and combinations thereof. The bonding fluid may comprise one or more anhydride polymers (e.g., maleic anhydride), polymers containing an acrylate group, polymers containing an epoxy group. , acids, bases, organic solvents, etching agents (attributing the acid effect), adhesives, cross-linking agents, and/or other substances to improve adhesion, phenoxy, phenoxy/polyolefin mixtures. The binding fluid may include one or more of the following: mist, gas, plasma, particles, liquid, and/or combinations thereof. The binding fluid can be chosen depending on the materials that are in contact with the binding fluid. In some embodiments, the bonding fluid forms a bond layer prepared or designed to adhere to a foam layer on the PET substrate. In some embodiments, the binding fluid forms a bond layer that causes the PP layer to adhere more strongly to the PET layer. Additives (e.g., chemicals, fine particles, binding agents, etc.) may be added to the binding fluid to improve the adhesion properties of the binding fluid. Hence, the binding fluid can form a binder layer, such as a binder layer of vessel 83 in Figure 6. In some embodiments, the binder fluid includes one or more of the binders described above. In some cases, “binding fluid” and “binding material” are used herein interchangeably.

As shown in Figures 35 and 37, the connection system 1004 can be configured at a connection 1024 between the ribs of the die cavity surface 1018. The outlet or outlet 1028 is positioned flush with the die cavity surface 1018 and preferably spaced from a movable baffle 1040. The movable baffle can be designed 1040 is used to inject a substance (e.g., a melt, molten polymer, etc.) into the cavity 1008. The outlet 1028 shown is formed circumferentially around at least part of the cavity 1008. The outlet 1028 is small enough so that no melt material enters during Injection. Alternatively, output 1028 may include one or more individual slots or ports. Optionally, the charging line 1010 has a valve system 1030 (Figure 34) to selectively control fluid flow through the charging line 1010. The valve system 1030, if present, may be positioned at any position in the alignment of the charging line 1010. In some embodiments, including The embodiment shown in Figure 34, a valve system 1030 is positioned opposite to a plurality of cavities 1008. The valves allow or selectively prevent flow through the charge line 1010 to the cavities. The valve system 1030 is preferably buried in the material forming the hollow portion 1054. Although not shown, the valve system 1030 can be located near an outlet (e.g., outlet 1028) of the charging line 1010.

The valve system 1030 may be operated in response to a pressure, such as positive or negative pressures, and may include one or more valves, such as a lever-type brake valve. In one embodiment, the lever-type check valve is a ball-shaped check valve having a combination of a ball and a retaining portion. Pressure in the charge line 1010 may displace the ball away from the clamping line, but pressure in the opposite direction will push the ball toward the clamping portion and prevent flow in the reverse direction. Preferably there is also a spring to deflect the ball in contact with the kickstand. When the pressure in the charge line 1010 fluctuates over the deflection of the spring, the ball can be displaced from the rest allowing flow into the bore 1008 (Figure 35). In some embodiments, negative pressure can cause the fluid to flow through the valve system 1030. For example, if there is negative pressure in the bore 1008, it can cause the fluid to flow through the valve system 1030. Alternatively, the valve system 1030 can be mechanically adjusted. .Regardless of the pressure. For example, valve system 1030 may include one or more valves (e.g., movable valves, ball valves, and the like). The valve system 130 can be operated to deliver a specified amount of binding fluid to the bore 1008.

The outlet 1028 of Figure 35 can be positioned at any position aligned with the die cavity surface 1018. The position of the outlet 1028 can be measured against the desired fluid flow around the preformed material. For example, the die 1002 shown in Figure 35 has the outlet 1028 positioned near or at the portion of the die cavity 1008 corresponding to the end cap of the preformed material. The fluid being dissolved by the charge line 1010 may flow around the end crest of the preformed material and continue upward along the cavity 1008 to the drain line 1016, thereby creating a deposition of material on at least a portion of the preformed material. The mold 1002 shown is designed to deposit the binding fluid onto the bulk portion of the preformed material. As shown in Figure 37, the outlet 1028 is preferably configured by a distance 1036 between about 0.05 millimeter (0.002 inch) and about 0.127 millimeter (0.005 inch) and most preferably about 0.076 millimeter (0.003 inch) in depth. Due to its small size, the outlet 1028 generally will not be filled with melt during injection but enables fluid (binding fluid, air, materials/or other fluids) to reach outside the outlet 1028. In some embodiments, a fluid (e.g., air, binding fluid, etc.), may pass through outlet 1028 to remove any material through outlet 1028. Although shown, the outlet 1028 may be positioned at other positions in the surface alignment 1018. For example, the outlet 1028 may be at a position in the surface alignment 1018 corresponding to the body, tight end layer and/or reinforcement ring of the preformed material. . For example, the outlet 1028 may be located near the end crest region of the die, below the reinforcing ring of the preformed material, at the narrow end layer of the preformed region, or at the bulk portion of the preformed material. Also, a plurality of outlets 1028 can be positioned flush with the surface 1018. A person skilled in the art can select the size, shape, and position of the outlet 1028 to achieve the desired deposition of material onto the substrate. Outlets 1028 can be located on the same or opposite side of the preformed material as an inlet designed to receive unused binding fluid. For example, a 1028 exit could be spaced diagonally from a 1028 exit. In the shown embodiment, the inlet 1029 and outlet 1028 are positioned on the same side of the preformed material.

Referring to Figures 34 and 35, the drain line 1016 is designed to draw fluid from the bore 1008 (Figure 35). The drain line 1016 then delivers the binding fluid to the drain orifice 1020, or recirculation system so that the fluid can pass through the bore 1008 a second time. The drain line 1016 may have a valve system 1038 which may be similar to the valve system 1030 and thus will not be shown in further detail.

Upon operation, after the preformed material is placed in the die 1002, the valve system 1030 allows the fluid to flow through the charge line 1010 and into the cavity 1008. As shown in Figures 36 and 37, the bonding fluid TF can flow through the cavity 1008 and cover at least a portion of the surface The exterior of the preformed material. Preferably, the TF binding fluid encapsulates a significant portion of the preformed material forming the defined inner surface of the cavity 1008. In some embodiments, including the one shown, the binding fluid TF forms a thin layer of material over most of the bulk portion of the preformed region, or a generally organized or irregular continuous film. However, the TF bonding fluid may encapsulate any portion of the preformed material exposed to the fluid. For example, the finished threaded beam and the mass portion may be coated with the bonding fluid, if the bore 1008 is defined by both the finished threaded portion and the block portion of the preformed material.

To improve the packaging of the preformed material, the die 1002 can selectively adjust the temperature of the preformed material. In one embodiment, the special core 1040 35 heats or cools the preformed material to improve the packing of the preformed material. A person skilled in the field can choose the desired temperature for the preformed material depending on the properties of the binding fluid that coats the preformed material. Alternatively, preformed pieces can be electrostatically charged to improve the packing of the preformed material. In other embodiments, the preformed material may be physically or chemically roughened or granulated to improve the packaging of the preformed material. Optionally, the mold cavity surfaces 1018 can be thermally adjusted to optimize packing of the preformed material. For example, the surface of the die cavity 1018 may be specially cooled to ensure that the gases in the cavity 1008 generally remain in the gas phase.

Optionally, the binding material temperature can be selectively adjusted. For example, the binder may include a binder fluid that has been heated to reduce the viscosity of the binder fluid to facilitate spread of the binder fluid. Heating and/or cooling units can be used to adjust the temperature of the binder.

When the delivery system 1004 charges the binding fluid into the cavity 1008, the binding fluid encapsulates the preformed material and may flow out of the cavity 1008 and into the drainage system 1012. After the preformed material has been encapsulated, or after a previously specified period of time, The connection system 1004 can serve to reduce, and preferably stop, fluid flow in the cavity 1008. The coating on the preformed material can form a bond layer to bond the underlying preformed material 1022 to a material that is then injected through the moving barrier 1040 into the cavity 1008. If the binder is a solvent/solute, the flow can be reduced or stopped and drainage can occur from the cavity 1008. The charging line 1010 can deliver a gas or vapor (e.g., air, inert gases such as nitrogen, or other gases ) to clean the cavity 1008. The drainage system 1012 can optionally cause negative pressure to remove the gas or vapor contained in the cavity 1008. In this way, one or more solvents can be removed for the purpose of achieving the properties of the desired bond layer and/or epitaxial material.

During injection of the melt, the valve system 1030 is preferably closed. The melt through the moving baffle 1040 points upward and fills the cavity 1008. In some embodiments, the excess of binding fluid is lifted out of the mold cavity 1008 by a stream of injected melt. Then, the melt stream causes the binding fluid to be removed from the cavity 1008. For example, if the binding fluid is a gas, the gas can be forced out of the cavity 1008 by the advance of the melt stream. The binder film formed on the preformed material can be spread over the preformed material by the melt stream. As the melt stream advances along the cavity alignment 1008, the melt stream can serve to push and spread the binder around the surface of the preformed material to ensure that at least part of the bulk portion, and preferably most or all of the bulk portion, is coated with the binder. A person skilled in the art can determine the appropriate outlet location 1028 based on the characteristics of the bond layer and the melt stream to achieve the desired bond layer in the resulting vessel of preformed material.

Referring to Figure 35, during the injection of the melt stream, the valve system 1038 can open to allow the binding fluid to escape from the cavity 1008. The valve system 1038 can be enclosed after a specified amount of the melt stream has been injected to prevent or inhibit the melt from entering In the drain line 1016. Alternatively, the outlet 1029 of the drain line 1016 may be of such a small size that the filmed material will not enter to a significant extent, but will enable fluid (binding fluid, air and/or other fluids) to reach the drain line 1016. .

Optionally, when injection is complete, a pressurized fluid, preferably air, is supplied to outlet 1028 to act on the vacuum that may form between the preformed material and the cavity wall. Air is supplied to outlet 1028 at a pressure between about 27 psi (about 0.52 MPa) and 150 psi (about 1.03 MPa), most preferably 100 psi (about 0.69 MPa). In other embodiments, the preformed material is removed from the die cavity 1018 without the aid of pressurized fluid from the charging line 1010. Also, similar connection systems can be used in other parts of the die, such as the threaded area, for example without limitation.

Optionally, the core portion 1052 and the hollow portion 1054 may act together to form an infusion fluid that acts to retard or prevent binding fluid from escaping into the surrounding die medium 1002 shown in Figure 35. Hence, if the binding fluid contains volatile organic compounds (VOCs) or Other undesirable materials for tracing or the environment, the binding fluid may be present in the mold 1002. The mold 1002 can circulate and reuse the binding fluid to also reduce waste. The binding fluid may be drained via the drainage system 1012 or by another means. If the binding fluid is suitable for release to atmosphere, the binding fluid can be discharged to atmosphere. For example, the bonding fluid may escape between the preformed material and the protruding edge 1056 and may then travel between the core portion 1052 and the hollow portion 1054 and exit into the atmosphere.

The preformed material may be encased with a binder before the die 1002 is in the fully closed position. The binder may be applied to the underlying preformed material when the preformed material is inserted into the column of the hollow part 1054. The preformed material is then coated with the binder when the preformed material is nearly or at least partially in the hollow part 1054. In some embodiments , the connection system 1004 causes fluid to exit when the die 1002 is in a partially or fully open position. In one embodiment, the binding system 1004 injects the binding fluid into the cavity 1008 when the mold 1002 moves from an open position to the closed position shown in Figure 35. When the preformed material enters the hollow part 1054, the binding fluid flows upward through the cavity 1008 and encapsulates At least part of the preformed material. Before the die 1002 is in the closed position, the binding fluid can escape into the atmosphere. Hence, the mold 1002 may or may not have a drainage system 1012. For example, if the binder is placed before the die 1002 is in the closed position, the die 1002 preferably does not have a drainage system 1012. If the binder is placed after the die 1002 is in the closed position, the die 1002 preferably does not have a drainage system. 1012, particularly when the binding fluid is not suitable for discharge directly to the atmosphere.

Figure 38 shows another embodiment of the delivery system 1004. The delivery system 1004 has a plurality of inlets 1060 for injecting or delivering a fluid (e.g., binding fluid, air, etc.) into the cavity 1008. The fluid may be delivered in response to positive pressure in the charging line 1010 or drawn into Cavitation 1008 under negative pressure. In the shown embodiment the die 1002 has a charging line 1010 connected to each input. The conduction system 1004 having multiple outlets 1060 may activate a more uniform packing of the preformed material 1022.

The connection system 1004 of Figure 39 has an input 1061 defined in the terminal apex region. The inlet position 1061 results in a generally uniform, directional flow through the cavity 1008. In some embodiments, the charging line 1010 delivers the binding fluid in the form of a liquid that immerses the end crest of the preformed material. After a quantity of bonding fluid is delivered, the melt can be delivered to the cavity 1008 through the movable baffle 1040. The melt spreads the bonding material over the surface of the preformed material.

Other devices can be used here to apply bonding material to products. For example, the templates in Figures 28, 30, and 31 can be modified to be placed on the interior surface or substrate shown.

Optionally, the delivery system 1004 can be connected to a line that delivers the molten material into a cavity. For example, charging line 1010 can charge the binding fluid to a line through a moving baffle that encapsulates a substrate. After the substrate is coated, the melt can be injected through the same moving line and barrier to form an outer layer.

Additionally, the mold insertion (e.g., the mold shown in Figure 26) in US Patent 6,352,426 and the applications and patents therein may serve to inject a binding fluid to both encapsulate a preformed piece and aid in the release of the preformed material. Top-forming of the coated substrate can then be performed. The delivery system (or introduction systems) may be used to deliver other materials (e.g., one or more of the materials described herein) to the products. For the purpose of simplicity, devices are described as delivering a binding fluid. However, it is understood that in many cases other materials can be delivered by the devices described above. For example, the binding fluid or material may be replaced with a colorant, chemical, melt, polymer, powder, coating material, barrier material, and/or other material suitable for encapsulating at least a portion of the substrate.

G- Favorite products

In general, the detailed products described herein include products that contain one or more substances. The material(s) may form one or more layers of products. Product layers preferably give the same function and may be used as multiple layers, each layer having one or more functional characteristics, or as a single layer containing one or more functional components. Products may be in package form, e.g. pre-formed parts, lids, containers, etc. The materials, methods, range values and embodiments set forth herein are given by way of example only and are not intended to limit the scope of the invention in any way. The products described herein may be formed by any suitable material described herein. However, some products and materials are discussed below. In light of this disclosure, embodiments and materials may be modified by a person skilled in the art to produce other embodiments and/or alternative uses, clear modifications and equivalent versions thereof.

1- General description of the preferred materials that make up the products

(a) Unlimited products containing foaming agent

Products may contain foaming agent. In some unlimited embodiments, the foaming material can form part of a block product or the finished narrow portion of a preformed material. In some unlimited embodiments, the foaming material comprises less than about 90% by weight, further comprising less than about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80% by weight of the product (e.g. preformed material, lids, bowl, plate, etc.). In some unlimited embodiments, the foaming agent comprises about 5-30% by weight of the product. In some unlimited embodiments, the foaming agent includes approximately 20-60% by weight of the product. In some unlimited embodiments, the foaming agent includes about 10%-30% by weight of the product. In some embodiments the foaming material comprises more than about 90% by weight of the product. The foaming agent can make up most or all of the product. Foaming may result in lower weight products compared to conventional products and thus may desirablely reduce the cost of transporting the products. Also, foaming agent can reduce the amount of material used to form products, as foaming agent may have a large number of voids.

Foaming material can be applied from expandable material. For example, at least a portion of a product may include a stretchable material that has a first density that is reduced when the stretchable material expands. In some unlimited embodiments, there is a first material, preferably a stretchable material, of a first density and a second material, preferably a foaming material, made from the first material of a second density. The second density is lower at approximately 95%, 90%, 80%, 70%, 50%, 30%, 20%, 10%, 5%, 2%, 1%, and range values that include that percentage of the first density. In some unlimited embodiments, the second density is in a range from about 30% to 60% of the first density. Hence, the foaming material can be manufactured at a low density for an expandable material. It is envisaged that the Products may contain any appropriate amount of foaming agent including those above or below the special percentages noted above, depending on the desired use of the Products.

(b) Unlimited products containing a phenoxy colorant.

The products may include phenoxy thermoplastics, for example blends of phenoxy (e.g., polyolefin-phenoxy blend), PET-phenoxy, or combinations thereof. In some unlimited embodiments, the phenoxy-type thermoplastic may form a portion of the products, such as at least a portion of the inserting surface of the preformed material, lid, container, etc. In some unlimited embodiments, the phenoxy-type thermoplastic comprises less than about 30% by weight, and also includes less than about 1%, 2%, 5%, 7.5%, 10%, 12%, 15% 20%, 25%, 50% by weight, of the product. In another unlimited embodiment, the phenoxy-type thermoplastic material comprises about 1-4 wt% of the product. In another unlimited embodiment, such phenoxy-type thermoplastic material comprises about 1-15% by weight of the product. In another unspecified embodiment, comprising approximately 7-25% by weight of the product. In another unspecified embodiment, the phenoxy-type thermoplastic material comprises about 5-30% by weight of the product. In some embodiments, the phenoxy-type thermoplastic material forms an expanded layer or layer blended with another material. In some embodiments the expanded layer includes a phenoxy-type elastomer comprising approximately 0.1% to 1% by weight of the product. In some embodiments, it includes a layer expanded on a phenoxy-type thermoplastic material constituting about 0.1% to 1% by weight of the product. In some embodiments, a phenoxy-type thermoplastic material is blended with a polymer material (e.g., PET, polyolefin, combinations thereof) and may include more than about 0.5%, 1%, 2%, 5%, 7.5%, 10%, 12%, 15%, 20%, 25%, 50%, 70% by weight of the product. It is conceivable that those percentages could be of the order of magnitude in certain embodiments. The thermoplastic material may result in products having one or more of the following properties: desirable deflavor, decolorization, oxygen barrier, recyclability and/or other properties particularly suitable for contact with foodstuffs. These percentages may result in desirable effective properties while reducing the amount of phenoxy-type thermoplastic material, thus creating a cost-effective product.

Various combinations of phenoxy thermoplastic material with polyethylene, polypropylene, foam, and the like can be used to produce preformed parts, containers, and other packages of relatively larger sizes and desirable properties. Especially when a phenoxy-type thermoplastic material forms the surface of the package that comes into contact with food materials. Phenoxy thermoplastic materials can give desirable adhesion between a layer containing PCT and a layer containing PP.

It is envisaged that the Products may contain any appropriate amount of phenoxy thermoplastic material including those above or below the special percentages listed above, depending on the desired use of the Products.

2- Products in the form of pre-formed pieces/containers:

The foaming material may form part of one or more layers of products (eg packages including preformed parts and containers). The preformed material 30 of the form 31 may include a foaming material. In some embodiments, the preformed material 30 often includes a foaming agent. In some embodiments, the preformed material 30 may include a phenoxy-type thermoplastic material formed through an injection process. For example, the preformed material 30 may often include a phenoxy-type thermoplastic material. In some embodiments, the preformed material 30 may be formed by a combined injection process, wherein the inner portion and outer portions of the preformed material 30 comprise different materials. The accompanying injection material can be shaped into a desired shape. For example, the preformed material 30 may have an interior comprising one or more of the following: phenoxy thermoplastic material, PET, PETG, expandable material/foam or the like. The outer portion of the preformed material 30 may include one or more of the following: polyethylene, polypropylene (including purified polypropylene), PET, combinations thereof, and the like. Optionally, a portion of the preformed material 30 may include a foaming material.

In some embodiments, the preformed material 30 can be coated with a layer to improve its retention properties. For example, the preformed material 30 may be coated with a barrier material. For example, US Patent Application Serial No. 614731/10 (Publication No. 2004-0071885), which is incorporated herein by reference in its entirety, describes systems and methods for packing preformed parts. This system and others shown or listed herein may be used to form barrier layers as shown herein. The preformed material can then be over-formed and coated with another material to form an outer layer.

For Figure 5, the preformed material 50 may include an uncoated preformed material 39 that is then coated with a foam layer 52. The uncoated preformed material 39 may preferably include a polymer material, such as polypropylene, polyester (polyester), PET, PETG, phenoxy and/or other thermoplastic materials. In some embodiments, the preformed material 39 comprises essentially uncoated polypropylene. In other embodiments, the preformed material 39 includes a polyester base.

The foam layer 52 may comprise either a single material or multiple materials (e.g., multiple fine layers of at least two materials). In some unlimited embodiments, the foam layer 52 can include approximately 2%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and values that fall Within the range of those percentages of preformed material. In some embodiments, the foam layer 52 includes from about 2% to about 90% of the preformed material. In some unlimited embodiments, the foam layer 52 can include from about 5% to about 50% of the preformed material. In some embodiments, the foam layer 52 can include about 10% to about 30% of the preformed material. In some unspecified embodiments, the foam layer 52 can include from about 5% to about 25% of the preformed material. In some unlimited embodiments, the foam layer 52 can include less than about 20% of the preformed material. It is conceivable that those percentages can be by weight or by volume in different embodiments. The foam layer 52 may include a non-expanding foaming material. The outer layer 52 of the preformed material 50 may have a thickness preferably average wall thickness, of about 0.2 mm (0.008 in.) to about 0.5 mm (0.02 in.). In another unspecified embodiment, the outer layer 52 has a thickness of about 0.3 mm (0.012 in). In some embodiments, only the average wall thickness is taken in alignment of the block portion of the preformed material 50. In some unlimited embodiments, the outer layer 52 includes less than about 90% of the average wall thickness of the preformed material 50, also comprising less than about 80%, 70%, 60%, 50%, 40%, 30%, 20%. , 10%, 9%, 8%, 7%, 6%, 5%, of the average wall thickness of the preformed material 50.

The foam layer 52 may include microspheres that are either unexpanded or partially expanded, for example. Also, the foam layer 52 can be generally homogeneous or generally heterogeneous. Although not shown, the foam layer 52 can form other portions of the preformed material 50. For example, the foam layer 52 can form at least part of the inner surface of the preformed material 50 or part of the civilized portion 32 .

In some embodiments, the inner layer 54 may include one or more of the following: polyethylene, PET, polypropylene (e.g., foamed polypropylene, non-foamed polypropylene, poly Purified polypropylene), combinations thereof, and the like. For example, the preformed material 50 may include an outer layer 52 of polypropylene (preferably foam) and an inner layer including PET. Optionally, a bond layer may be overlaid between the two layers 52, 54 and may include a phenoxy-type thermoplastic material.

In some embodiments, a barrier layer may be superimposed between the two layers 52, 54. The barrier layer may serve to inhibit or prevent the entry and/or exit of one or more gases, ultraviolet radiation, and the like through the walls of a vessel made of the foregoing material. Formation 50.

In some embodiments, a second layer 54 includes polypropylene. 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 also includes nanoparticles. In another embodiment, the polypropylene comprises nanoparticles grafted or modified with maleic anhydride, glycidyl methacrylate, acryl methacrylate and/or similar compounds.

Referring to Figure 6, the vessel 83 can be used as a container for soft drinks, and the thickness is 44. The wall thickness of the outer layer 52 of the vessel 83 is preferably approximately 0.76 mm (0.030 in.), 1.52 mm (0.60 in.), 2.54 mm (0.10 in.) inch), 3.81 mm (0.15 inch), 5.08 mm (0.2 inch), 6.35 mm (0.25 inch), and values within this thickness range. In some embodiments, the thickness of the coating is preferably less than about 762 mm (0.3 in), most preferably 1.27 mm (0.5 in) to 5.08 mm (0.2 in). The outer layer 52 may include a foam material having a thickness greater than about 3.81 mm (0.15 in.) In some unspecified embodiments, the outer layer 52 has a thickness in the range from about 0.127 mm (0.005 in.) to about 0.635 mm (0.025 in.).

In some unlimited embodiments, the thickness 46 of the inner layer 54 is preferably an average thickness of the inner layer 54 of 0.127 mm (0.005 in.), 0.635 mm (0.025 in.), 1.07 mm (0.04 in.), 1.52 mm (0.06 in.) , 2.03 mm (0.08 in), 2.54 mm (0.1 in), 3.05 mm (0.12 in), 3.56 mm (0.14 in), 4.07 mm (0.16 in), and values that fall within the range of these thickness values. In some embodiments, the inner layer 54 of the bowl 83 has a thickness less than about 2.54 mm (0.1 in) to give a less expensive food barrier. In some unlimited embodiments, the inner layer has a thickness in a range from about 0.127 mm (0.005 in) to about 0.635 mm (0.025 in). The vessel wall thickness 48 can be chosen to achieve the desired characteristics of the vessel 83.

To improve the detention properties of bowl 83, bowl 83 can have a barrier layer. One or more barrier layers may be configured on the inner surface of the inner layer 54, between the layers 52, 54, on the outside of the outer layer 52, and the like. For example, the outer layer 52 of the vessel (or the preformed material from which the vessel is made) may be coated with a barrier material using the methods described herein. For example, a barrier layer may be formed by the use of devices, methods and systems described in US Application No. 614731/10 (Publication No. 2004-0071885), which is incorporated herein by reference in its entirety. Also, in some embodiments, vessel 82 includes a closed-cell foam core that may serve to inhibit fluid migration through the foam. For example, the foam can be a barrier that inhibits, and preferably prevents, the migration of CO2 gas through the wall 84 of the vessel 83 consisting of the preformed material.

The preformed material in form 11 has an inner layer 164 that includes a first material and preferably an outer layer 162 that includes another material. In some unlimited embodiments, layer 162 can include about 2%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and values that fall within The range of those percentages of preformed material. In some embodiments, the foam layer 162 includes less than about 97% of the preformed material. In some embodiments layer 162 includes from about 5% to about 99% of the preformed material. In some unlimited embodiments, layer 162 can include less than about 90% of the preformed material. In some unlimited embodiments, layer 162 can include less than about 40% to about 80% of the preformed material. In some unlimited embodiments, layer 162 can include approximately 60% to 90% of the preformed material. In some unlimited embodiments, layer 162 can comprise greater than about 60% of the preformed material. These percentages are conceivable by weight or volume in different embodiments. In some embodiments, the layer 162 may include a foaming material and the inner layer 164 may include a polymeric material, such as PET (e.g., directly from the feedstock or post-consumer/recycled). The foam layer 162 may include a non-expanding foaming material. For example, foam layer 162 may include microspheres that are either unexpanded or partially unexpanded, e.g. The foam layer 162 may provide a desirable insulating layer when the preformed material 160 is shaped into a container.

It is preferable for a significant portion of the outer layer 162 to comprise a foaming material and a significant portion of the inner layer 164 to comprise PET or other food contact material. In one unlimited embodiment, the foaming material includes PP and non-expandable microspheres. In yet another embodiment, the outer layer 162 may include PP and the inner layer 164 may include PET. Preferably, a significant portion of the outer layer 162 comprises PP and a significant portion of the inner layer 164 comprises PET. In an unspecified embodiment, the entire outer layer 162 generally includes the PP. In another embodiment, large portions of the inner layer 164 and outer layer 162 can include a foaming material. The preformed materials 76 and 132 may likewise include a foaming agent and a material suitable for contact with foodstuffs.

In some embodiments, the inner layer 164 may include one or more of the following: PET, a phenoxy thermoplastic material (including blends), a foaming material (e.g., foamed PET, and/or other suitable coating/layer). For contact with food materials the coating 162 may include one or more of the following: a foaming material (including foamed PP, foamed PET, etc.), a non-foaming material (e.g., phenoxy thermoplastic, PET). , PP), or other material suitable for forming the exterior of a preformed material. In some embodiments, preformed material 160 includes a phenoxy-type thermoplastic material. In some unlimited embodiments, the phenoxy-type thermoplastic material can comprise at least about 1%, 2.5%, 5%, 10%, 20%, 30%, 50%, 60%, 70%, 80 %, 90%, and the range values included by those percentages of preformed material. In some embodiments, the phenoxy-type thermoplastic material comprises about 10% to about 30% by weight of the preformed material. In some embodiments, the phenoxy thermoplastic material comprises most or all of the preformed material. The weight is for the phenoxy thermoplastic material in a specific form or mixture. It is conceivable that those percentages can be by weight or by volume in different embodiments. For example, in some embodiments layer 164 includes a phenoxy-type thermoplastic material constituting less than 10% of the preformed material. The layer 164 can be of a thickness suitable to form a layer in contact with the food. The thickness 174 of the inner layer 164 is preferably less than 3.81 mm (0.150 in) to form an inexpensive layer in contact with the food material. The thickness of the inner layer 164 may be less than about 0.1 mm (0.004 inch), 0.02 mm (0.007 inch), 0.005 mm (0.002 inch), 0.1 mm (0.004 inch), 0.15 mm (0.006 inch), 0.2 mm (0.008 inch). ), 0.3 mm (0.01 in), 0.5 mm (0.019 in), and the range values included in that thickness. In some unlimited embodiments, the inner layer 174 includes a phenoxy-type thermoplastic material to a thickness in the range from about 0.01 mm (0.0004 in.) to about 0.05 mm (0.002 in.). In some embodiments, the preformed material 160 may be formed by a molding process, wherein the inner portion and outer portions of the preformed material comprise different materials.

In some embodiments, the outer layer 162 includes a first material and the inner layer 164 preferably includes another material. For example, the outer layer 162 may include polypropylene and the inner layer 64 may include PETG. In another embodiment, the polypropylene can be grafted or modified with maleic anhydride, glycidyl methacrylate, acryl methacrylate and/or similar compounds to improve adhesion. In one embodiment, the polypropylene also includes nanoparticles. In another embodiment, polypropylene comprises nanoparticles grafted or modified maleic anhydride, glycidyl methacrylate, acryl methacrylate and/or similar compounds.

The preformed material 180 (Figure 12) may have the inner layer 184 identical or similar to the inner layer 164 and the outer layer 182 is identical or similar to the outer layer 162. The preformed material 190 (Figure 13) may have the inner layer 194 identical or similar to the inner layer. 164 The outer layer 199 is identical or analogous to the outer layer 162. The materials forming the inner layer 194 and the outer layer 199 may be chosen so as to give the desired mutual interaction with the sealing composition 197. The preformed material 202 (Figure 14) may have layers composed of materials the same or similar to the preformed material 160.

The preformed pieces and resulting vessels may be well suited for thermal applications, for example hot filling. The vessel 211 of Figure 14(a) can generally maintain its shape during hot filling operations. After blow molding or hot filling, the final dimensions of the prepared portion 132 of the vessel 211 are identical to the initial dimensions of the preformed material. Also, this results in fewer dimensional changes of the screw parts on the finished finished part. For example, the inner layer 283 may be formed from a food contact material, such as PET. The coating 203 may include molded materials (e.g. mostly or entirely of PP, PP and foaming agent, crystalline PET, sheet material, homopolymers, copolymers, and other materials as described herein), suitable for hot filling . The coating 203 gives dimensional stability to the finished part 132 even during and after hot filling. The width of the outer layer 203 may be increased or decreased to increase or decrease, respectively, the dimensional stability of the finished civilized part 132. Preferably, one of the layers forming the finished finished part 132 includes a material with high thermal stability; However, the finished part 132 may be manufactured from materials with low thermal stability, especially for non-hot-filled applications.

Additionally, the dimensional stability of the outer layer 203 ensures that the lid 213 remains in contact with the receptacle 211 in Figure 14(a). For example, the outer layer 203 of the PP can retain its shape thereby preventing the cap 213 from unintentionally disengaging from the receptacle 211.

The preformed pieces shown above can be modified by adding one or more layers to achieve the desired properties. For example, a barrier layer can be formed on the block parts of pre-formed pieces.

3- Products in the form of covers

Covers may contain foam. In some unlimited embodiments, the foaming material comprises less than about 95% by weight, further comprising less than about 5%, 15%, 25%, 35%, 45%, 55%, 65%, 75%, 85% and values Conceivably included in those percentages of cover, those percentages may be by weight or by volume in various embodiments. In some embodiments, the foaming material includes values included in those percentages by weight of the cover. In an unlimited embodiment, the foaming material comprises approximately 45-60% by weight of the covering. In another unlimited embodiment, the foaming material includes about 15-70% by weight of the cover. In some embodiments, the cover mostly or entirely includes a foaming material. For example, a single-layer cover could be made of foam.

Referring to Figure 19, at least part of the cover 302 includes a foaming material. The layer 314 and/or outer portion 311 may include a foaming material (e.g., foamed PET, foamed PP, etc.). In one embodiment, the outer portion 311 includes a foaming material and the layer 314 includes a non-foaming material (e.g. PP, PET, etc.).

Additionally, the interior of the covers may contain a foaming material. In some embodiments, the outer portions of the covers may or may not include a foaming agent. The covers of Figures 21(a) and 22(e) may have the same or different inner layers and outer layers (parts).

Figure 21(c) shows that cover 360 may have a layer 364 composed of materials having desirable textural, thermal, optical, and barrier properties. For example, layer 364 may consist of PET, PP, PET, PETG and/or the like.

In one embodiment, a further feature is configured when the outer portion of the lid is formed from a non-confining foaming material to provide a comfortable gripping surface such that the user can comfortably slide the lid off the receptacle. The outer portion 311 of Figure 19 may be foamed to increase the space occupied by the outer portion 311 and may provide the user with a greater level of lever ability for easy opening and closing of the lid.

Lids may have an internally threaded surface that is designed to be screw-coupled with an externally threaded surface of the vessel. The enlarged outer portion 311 of the figure 19 can give increased lever capacity so that the user can easily rotate the cover 302 on or over the cover. Preferably, a similar or same amount of material that makes up a conventional cap may be used to form the larger diameter cap. Hence, the material cost of producing the 302 cover can be reduced.

The coating may include phenoxy-type thermoplastic materials. In some unlimited embodiments, the phenoxy-type thermoplastic material includes less than about 25% by weight, and also includes less than about 1%, 2%, 4%, 5%, 10%, 15%, 20 % by weight, of cap. In some embodiments, the phenoxy-type thermoplastic material has values within those weight percentages of the covering. The weight is for a phenoxy-type thermoplastic material in expanded form or a mixture. In an unspecified embodiment, the phenoxy-type thermoplastic material comprises about 0.5 to 5% by weight of the coating. In another unspecified embodiment, the phenoxy-type thermoplastic material comprises about 1 to 6 weight % of the coating.

A phenoxy-type thermoplastic material may form part of the inner surface of the cover. For example, a layer of phenoxy thermoplastic material may be applied to the inner surface 309 of layer 314 (Figure 19). Optionally, layer 37 can be made of a phenoxy-type thermoplastic material. The phenoxy-type thermoplastic material may form at least a portion of layer 344 of coating 340 (Figure 21(a)), layer 356 of coating 350 (Figure 21(b)), layer 366 and/or layer 364. of cover (360) (Figure 21(c)), layer 374 of cover 370 (Figure 21(d)), layer 383 of cover 380 (Figure 21(e)), e.g. Of course, these layers may include a material (e.g., laminate, PET, PP, and/or similar) that is coated with a phenoxy-type thermoplastic material, such as phenoxy or a phenoxy mixture. Or polyolefin-phenoxy.

The covers shown above can have one or more barrier layers to improve their retention properties. For example, an inner layer, one or more intermediate layers, and/or outer barrier layers may be formed by use of the systems and methods described in U.S. Application Serial No. 614713/10 (Publication No. 0071885/2004), which are incorporated herein in their entirety and describe Systems and methods for forming barrier layers. In some embodiments, the covering materials can be modified to improve the retention properties. For example, the foaming material may have additives (e.g., fine particles) that improve the holding properties of the foaming material. A person skilled in the art can choose to design the covers to achieve the desired retention properties.

4- Products with bond layers

Typical products can be multi-layer products. A bond layer may be applied between one or more parts or layers of products. For example, products can have a bond layer installed between layers of material. Products can have multiple bond layers, preferably with one bond layer placed between a pair of adjacent layers. In some embodiments, each plurality of adjacent layer pairs is overlapping one another in one of the bond layers.

The vessel 83 of Figure 6 has a bond layer 85 (Figure 7) between the layers 52 and the layer 54. In some unspecified embodiments, the layer includes one or more of the following: a foaming material (including foamed PP, foamed PET, etc.); Non-foaming material (e.g., phenoxy, PET, PP thermoplastic materials), combinations thereof, or other material suitable for forming the exterior of a preformed material. Layer 54 includes one or more of the following: PET, phenoxy, polyolefin-phenoxy mixture, combinations thereof, or other materials suitable for forming part of the wall of a vessel. In some embodiments, it includes an outer layer 52 on PP (foamed or non-foamed) and an inner layer 54 on PET. The bond layer 85 may include adhesives, phenoxy thermoplastics, polyolefins, or combinations thereof (e.g., a polyolefin-phenoxy blend). The bond layer 85 can preferably adhere to both layers 52, 54. The phenoxy may give desirable adhesion between an inner layer 54 containing PET and an outer layer 52 containing PP, for example.

The multilayer products shown in Figures 8-14(b) and 18-21(e) may have one or more bond layers, preferably one bond layer, between at least two layers of products. For example, a bond layer may be overlaid between layers 52, 54 of the preformed material 76 (Figure 9). A bond layer can be overlaid between layers 134, 136 and/or preformed material 30 and layer 134 of Figure 10. Preformed material 160 (Figure 11) can have a bond layer overlaid between layer 164 and layer 162. The preformed material 180 (Figure 12) can have a bond layer overlaid between layer 184 and layer 183. The preformed material 190 (Figure 13) can have a bond layer overlapped between layer 194 and layer 199. The preformed material 202 (Figure 14 ) has an overlay between layer 203 and layer 283.

For Figure 19, the cover 302 can have a bond layer between the layer 314 and the outer portion 311. In some unlimited embodiments, the outer portion 311 includes one or more of the following: a foaming material (including foamed PP, foamed PET, etc.) , non-foam material (e.g., phenoxy thermoplastics, PET, PP), combinations thereof, or other materials suitable for forming the outer part of a cover. Layer 314 includes one or more of the following: PET, phenoxy, polyolefin-phenoxy mixture, combinations thereof, or other materials suitable to form part of the covering. The binding layer may include adhesives, phenoxy, polyolefin, and combinations thereof (e.g., polyolefin-methoxy mixture). Likewise, the coatings shown in Figures 21(a)-21(e) may have one or more binders, preferably with at least one binder layer present between a pair of adjacent layers.

Another advantage is that a binder layer is prepared that includes a phenoxy-type thermoplastic material, such as a mixture of phenoxy, that can help blend a pure phenoxy layer with another layer to some extent. Phenoxy can effectively blend polypropylene, polyethylene, and the like.

In the form of this disclosure, a person skilled in the art can select the material(s) and bond layer(s) to achieve the desired properties of a product.

5- Products that include laminated material

The laminated material may form one or more parts of a layer of material (eg a package including preformed materials, seals and containers). Referring to Figure 2, the preformed material 30 may include a laminated material. Figure 40 represents an enlarged cross-sectional view of the wall section 43 of preformed material 30. In the shown embodiment, the wall section 43 includes laminated material including one or more layers. It is preferable that the laminated material consists of several small layers. However, the layers of laminated material can be of any suitable size depending on the desired properties and characteristics of the preformed material, and the resulting container formed from the preformed material. The layers of wall section 43 can generally comprise materials that are the same or different from each other. One or more of the layers forming the wall section 43 may be made of the materials shown herein, or other materials known in the art.

In the embodiment shown, the wall section 43 has an inner layer 47, an outer layer 45, and one or more intermediate layers 41 between them. In some embodiments, the inner layer 47 is suitable for food contact, such as polyethylene terephtalate (“PET”), or another suitable material that can form an inner cavity for the bottle manufactured from the preformed material 30.

The wall section 43 can optionally have at least one material layer having good gas insulating characteristics. In some embodiments, the wall section 43 of the preformed material 30 has several layers having characteristic good gas-insulating features. One or more layers of the wall section 43 comprising an insulating material preferably inhibit or prevent the entry and/or exit of fluid through the wall of a container made of the preformed material 30. However, the wall section 43 may include several layers with no distinctive features. Good dielectric.

The wall section 43 of the preformed material 30 has at least one layer composed of recycled or post-consumer PET (“RPET”). For example, in one embodiment, the wall section 43 can have multiple layers formed from RPET. In some embodiments, the inner layer 47 can be formed from raw PET and other layers of wall section 43 can be formed from raw PET or RPET. Therefore, the preformed material 30 can comprise switching thin layers of PET, RPET, insulating material and a combination thereof. Furthermore, other materials may be used to obtain the desired characteristic features and physical properties of the preformed material 30, or the resulting container manufactured from the preformed material 30.

Each of the layers of wall section 43 may generally have the same thickness. Alternatively, the layers of wall section 43 can have generally different thickness levels from each other. One skilled in the art can determine the required number of layers, the thickness of each layer, and the composition of each layer of the wall section 43. In one unrestricted embodiment, the preformed material 30 can have a wall section 43 including more than two layers. In some preferred embodiments, the wall section 43 may have more than 3 layers.

As shown in Figure 40, the layers of laminated material forming the wall section 43 can generally be aligned with one inner surface 49 and one outer surface 51 of the preformed material 30. The parts of the laminated material forming the body section 34 can include layers generally parallel to the longitudinal axis that Concerning preformed material 30.

The distance and/or orientation of the layers of the wall section 45 may vary or generally remain constant along the wall section 43. In addition, the thickness of one or more layers of the wall section 43 may also vary, or may be substantially constant along the preformed material 30. It is conceivable One or more layers must have openings, outlets, or drain into an adjacent layer.

The laminated material can also form other multi-layer or single-layer products. Referring to Figure 5, the preformed material 50 may include, for example, an outer layer 52 and an inner layer 54 defining the inner surface of the preformed material 50. The outer layer 52 preferably does not extend to the neck portion 32, and is preferably not located on the inner surface of the preformed material 50. Wherein at least one of the outer layer 52 and inner layer 54 may comprise a laminated material. In the shown embodiment, the outer layer 52 comprises a laminar material and the inner layer 54 comprises another material. The inner layer 54 preferably comprises PET, preferably virgin PET, such that the inner surface of the preformed material 50 is suitable for food contact. In another embodiment not shown, the inner layer 54 comprises a laminar material and the outer layer 52 comprises another material. The inner layer 54 preferably includes PET forming the inner surface. However, the inner layer 54 may include other materials described herein (e.g. foam material, PET including PET and RPET, PP, etc.). Alternatively, both the inner layer 54 and the outer layer 52 comprise a laminar material. Therefore, many conjugates can be used to form the preformed materials described here.

The products shown in Figures 6-17 may include multiple layers. One or more layers of these products may include a laminate material. For example, the preformed material 60 shown in Figure 8(a) includes an outer layer 52 formed from a laminated material. The outer layer 52 covers the lower surface of the support ring 38 and extends along the body portion 34.

Referring to Figure 10, one or more of the layers 134 and 136 may include laminated material. In one embodiment, the entire preformed material consists substantially of different laminated layers 134 and 136 bonded together. In some embodiments, at least one of the layers 134 and 136 comprises a laminate material, a foaming material, a phenoxy-type thermoplastic, PET, PP (including foamed and non-foamed types), etc. Only one of the layers 134 and 136 may optionally be formed from a laminated material.

Clogs may also include a laminar material. The laminate material may form a substantial part of the seal or only a part of it. In some unrestricted embodiments, the laminated material comprises less than about 95% by weight, further comprising less than about 5%, 15%, 25%, 35%, 45%, 55%, 65%, 75%, 85% of Weight of stopper. In some embodiments, the laminate material includes ranges within these percentages of the seal weight.

As shown in Figure 19, at least a portion of seal 302 includes a laminated material. Layer 314 and/or outer portion 311 may include laminated material. In one embodiment, the outer portion 311 includes a laminate material and the layer 314 includes a laminate material (e.g. PP, PET, etc.). Furthermore, the interior of the seals may include a laminar material. In some embodiments, the outer parts may first comprise a laminated material. Plugs of Figures 12(a) to 21(e) may have the same or different inner and outer layers (or outer parts).

Figure 21(c) shows seal 360 having a middle layer 364 formed of materials having structural, thermal, optical and/or insulating properties. For example, layer 364 may be formed from a laminated material.

The laminated material can constitute at least a portion of layer 344 of seal 340 (Figure 21(a)), layer 356 of seal 350 (Figure 21(b)), layer 366 and/or layer 364 of seal 360 (Figure 21(c)), Layer 374 of plug 370 (Figure 1(d)), layer 383 of plug 380 (Figure 21(e)), for example. The other parts of the plugs can be made of the same material or of a different material. In some embodiments, most of the complete seal comprises a laminar material.

6- Products containing a heat-resistant layer

The products described herein may include one or more heat-resistant materials. As used in the phrase “refractory materials” is an inclusive term used in its ordinary sense and includes, without limitation, materials which are suitable for hot casting or warm casting applications. For example, the refractory material may include a material with high heat resistance that has extended stability during the hot casting method. The refractory material may include a refractory intermediate that has dimensional stability during the warm casting process. Refractory materials may include polypropylene, crystalline material, polyester, and the like. In some embodiments, the refractory material has greater dimensional thermal stability than amorphous PET. The refractory material may form part of products (e.g., more than one layer of a profile, primer, foil, and other products described herein).

In one embodiment, an extruded and blow-molded vessel comprising an inner layer, which in turn comprises a thermoplastic polyester, an outer layer, which comprises a thermoplastic material (e.g., a heat-resistant polymer) having Thermal resistance is greater than that of the thermoplastic polymer of the inner layer and intermediate bond layer, which causes adhesion between the inner layer and the outer layer, as the layers are formed by accompanying extrusion before molding. Preferably, the inner layer thermoplastic polyester is PET, and may also include at least one oxygen scavenger and an inert carrier mixed with the thermoplastic polymer. Preferably, the inert carrier is a polyamide, such as MXD6.

In light of the present explanation, the skilled artist can select many types of laminate material(s) to achieve the desired properties of the product from which it is manufactured. The products described herein may be formed by any suitable means. Products may be formed, for example, by injection molding, blow molding, injection blow molding, extrusion, co-extrusion, injection elongation blow molding, and by other methods described herein. The several methods and techniques described above provide several ways of performing the invention. It is understood, of course, that not all of the purposes or benefits described are necessary in accordance with any particular embodiment described herein. Therefore, those skilled in the art realize e.g. The possibility of performing methods in a way that achieves or produces one of the advantages or a set of advantages in the optimal way as described herein without the need to achieve other purposes or advantages as indicated or proposed herein.

In addition to the above, the skilled artist will recognize the interchangeability of the many features of the different embodiments shown here. Likewise, one skilled in the art can perform methods according to the principles described herein by combining and matching the several features and steps described above, as well as other known equivalents for each of these features and steps. In addition, the methods described and described herein do not adhere to the exact order of the procedures described, nor can the skilled In the art of selecting several types of laminated material(s) to achieve the required properties of the product made from them. The products described herein may be formed by any suitable means. Products can, for example, be formed through injection molding, blow molding, injection blow molding, extrusion, co-extrusion, injection elongation blow molding, and by other methods described here. The several methods and techniques described above provide several ways of performing the invention. It is understood, of course, that not all of the purposes or benefits described are necessary in accordance with any particular embodiment described herein. Therefore, those skilled in the art realize e.g. The possibility of performing methods in a way that achieves or produces one of the advantages or a set of advantages in the optimal way as described herein without the need to achieve other purposes or advantages as indicated or proposed herein.

Although the invention is illustrated in the context of particular embodiments and examples, those skilled in the art understand that the invention extends beyond the specifically illustrated embodiments, that is, to other alternative embodiments and/or obvious uses, modifications, and equivalents thereof. Accordingly, the invention is not intended to be limited by the specific explanation of the embodiments preferred herein. Instead, the applicant intends that the scope of the invention be limited only by reference to the attached claims, and that modifications to the methods and materials described herein that are recognized by those skilled in the art are within the scope of the applied invention.