CN1871107A - 多层熔融树脂块及从该多层熔融树脂块来压缩成形的吹塑成形用多层预成形物以及多层容器 - Google Patents

多层熔融树脂块及从该多层熔融树脂块来压缩成形的吹塑成形用多层预成形物以及多层容器 Download PDF

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CN1871107A
CN1871107A CNA2004800311236A CN200480031123A CN1871107A CN 1871107 A CN1871107 A CN 1871107A CN A2004800311236 A CNA2004800311236 A CN A2004800311236A CN 200480031123 A CN200480031123 A CN 200480031123A CN 1871107 A CN1871107 A CN 1871107A
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resin
molten resin
multilayered
intermediate layer
resin mass
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CN1871107B (zh
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渡边和伸
江藤诚
深堀穗高
广田宗久
柴田诚士
今谷恒夫
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Toyo Seikan Group Holdings Ltd
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Toyo Seikan Kaisha Ltd
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Abstract

本发明提供一种可得到多层压缩成形物的多层熔融树脂块，其中，多层压缩成形物的层分布状态为：中间树脂层完全位于内外树脂层内，且在周向上均匀分布。在用于形成多层压缩成形物的多层熔融树脂块(1)中，中间层树脂(3)在构成内外层的内外树脂(2)内，向下侧偏心而被内封，从该中间层树脂(3)的下端至多层熔融树脂块(1)的下端为止的距离(t)，小于等于多层熔融树脂块全长的10％，而且将多层熔融树脂块内的中间层树脂(3)的形状控制成凹型形状，且满足：中间层树脂伞部长度(y)≥中间层树脂中央部长度(L)、及1＞周向上的中间层树脂最大外径(d0)/周向上的多层熔融树脂块外径(D)≥0.5。

Description

多层熔融树脂块及从该多层熔融树脂块来压缩成形的 吹塑成形用多层预成形物以及多层容器
技术领域
本发明涉及一种多层熔融树脂块及从该多层熔融树脂块来压缩成形的吹塑成形用多层预成形物以及多层容器。
背景技术
以往，多层延伸吹塑成形合成树脂瓶等多层合成树脂容器得到广泛流通，通过在内部配置阻气性等优良的树脂层、或者可配置再生树脂层(参照专利文献1)等，即通过配置成多层，便可得到一种具有单层树脂容器中所不能实现的功能的容器。这种容器中，由阻气性树脂及再生树脂等构成的中间树脂层，要求不露出于容器内外面，而被内封于内外树脂层内。为满足这一要求，本发明人提出了下列方案：通过挤压成形，来制造在内外层树脂中以向下侧偏心状态来内封了中间树脂层(阻气性树脂)的多层熔融树脂块，并将该多层熔融树脂块提供给凹模，且由芯模来压缩，由此来制造作为吹塑成形用多层成形物的多层预成形物(专利文献2)。对用前述方法制造出的多层熔融树脂块而言，由于在多层熔融树脂块中，以向下侧偏心状态来含有中间层树脂，因而当用芯模来压缩时，在与芯模最初卡合的多层熔融树脂块的上部中，只存在内外层树脂，且通过基于芯模的挤压，内外层树脂沿着凹模向上方及下方流动。最后，用芯模来挤压含有中间树脂层的部分，只由内外层树脂来形成口部及颈部，而且在躯干部及底部中，在内外层之间内封了中间层树脂的预成形物，以没有浇口部的状态来形成。
对如此得到的预成形物而言，理想的是，内外层及中间树脂层在全周上具有均匀的厚度，然而可观察到还存在以下部分：中间树脂层壁厚过薄的部分、断裂部分、或者变得过厚的部分、进而中间树脂层露出于最内外层面的部分。其结果是，比如会产生下列问题：如果在中间树脂层内存在壁厚过薄的部分及断裂的部分，则不能得到适当的阻气性等，不能充分发挥中间树脂层所要求的功能。而且，还有可能产生下列等问题：当中间树脂层露出于最内层面时，内容液便会与中间树脂层直接接触，而对内容液产生不好的影响，或者中间树脂层吸收内容物的水分，而使屏障性劣化等问题。为解决前述问题点，有必要使多层预成形物的层分布成为以下状态：中间树脂层完全位于内外树脂层内，且在周向均匀分布，然而，可稳定地得到以往预成形物的这种层分布的方法还没有被确立。
专利文献1：JP特开2003-39531号公报
专利文献2：JP特开2003-33964号公报
发明内容
本发明鉴于前述事实而成，其目的在于，在将多层熔融树脂块压缩成形而得到多层压缩成形物的制造方法中，得到如下状态的多层压缩成形物，即：该多层压缩成形物的层分布状态为：中间树脂层完全位于内外树脂层内，且在周向均匀分布，更详细而言，本发明的目的在于，得到一种可得到这种多层压缩成形物的多层熔融树脂块。
为解决前述课题，本发明人进行了各种研究，结果发现：对树脂块进行压缩成形而得到的吹塑成形用多层预成形物的层分布，由多层熔融树脂块的中间层树脂的多层熔融树脂块内的形状来左右，进一步研究的结果是：找出了为得到前述层分布的中间层树脂的最佳形状，从而实现了本发明。
即，本发明的多层熔融树脂块，是一种用于通过压缩成形来得到多层压缩成形物的多层熔融树脂块，其特征在于：构成该多层熔融树脂块的中间树脂层的中间层树脂，在构成内外层的内外层树脂内，向下侧偏心而被内封，且前述中间层树脂的形状是凹型。
前述中间层树脂中，从其下端至多层熔融树脂块的下端为止的距离，最好小于等于多层熔融树脂块全长的10％。此外，更具体而言，前述中间层树脂的形状优选是：y(中间层树脂伞部长度)≥L(中间层树脂中央部长度)，而且1＞d0(周向上的中间层树脂最大外径)/D(周向上的多层熔融树脂块外径)≥0.5。通过对由这种形状构成的多层熔融树脂块进行压缩成形，可以得到周向上层分布大致均匀的多层成形物及吹塑成形用多层预成形物。通过对该吹塑成形用多层预成形物进行双轴延伸成形，可得到一种高品质的多层瓶子等吹塑成形多层容器，其中，多层压缩成形物的层分布状态为：中间树脂层完全位于内外树脂层内，且在周向几乎均匀分布，而且中间树脂层不露出于内周面。前述术语中的“下侧”及“下端”，是以将熔融树脂块置入阴模(凹模)内的场合为基准的场合的表达，在上方配置阴模、在下方配置阳模(芯模)的场合下，成为向下方的凹型而位于上侧，因此，前述术语是只出于便于使用而采用的，并非一定意味着物理意义上的下侧及下端。
根据前述本发明，可以得到一种具有大致均匀的层厚分布、且可成形确保了最内层厚度的多层成形物及吹塑成形用多层预成形物的多层熔融树脂块。因此，利用由本发明而得到的多层熔融树脂块来获得的吹塑成形用多层预成形物，在周向上层分布大致均匀，且通过对该吹塑成形用多层预成形物进行双轴延伸成形，便可得到一种高质量的多层瓶子等吹塑成形多层容器，其中，中间树脂层位于内外树脂层内，并在周向上几乎均匀分布，而且中间树脂层不露出于内周面。
附图说明
图1是表示本发明的多层熔融树脂块的概念的模式图。
图2是表示对多层熔融树脂块进行挤压成形的挤压装置一种实施方式的剖面模式图。
图3是表示对多层熔融树脂块进行挤压成形的挤压装置的另一种实施方式的剖面模式图。
图4(a)是本发明实施例涉及的多层熔融树脂块的剖视图，(b)是比较例的多层熔融树脂块的剖视图。
图5是吹塑成形用预成形物的正面剖视图，表示从颈下开始的尺寸位置。
图6是表示实施例及比较例中，最内层厚度的周向厚度离差的曲线图。
图7是表示实施例及比较例中，中间层厚度的周向厚度离差的曲线图。
图8是表示实施例的预成形物中轴向高度位置的各层厚度变化的曲线图。
图9是表示比较例的预成形物中轴向高度位置的各层厚度变化的曲线图。
符号说明如下：
1、30、34  多层熔融树脂块            2  内外层树脂
3、31  中间层树脂                    10、20  挤压装置
11a～11c  挤压机                     13  模具
14a、21a  内外层树脂通路             14b、21b  中间层树脂通路
14c、21c  中间层切断用树脂通路
15、22  挤压通路                     16b、16c  间歇加压机构
23b、23c  阀门机构                   33  多层熔融树脂块
具体实施方式
以下，利用图1及图2所示的实施方式，来详细说明本发明。图1是表示本发明涉及的多层熔融树脂块的基本原理的模式图，该多层熔融树脂块1，通过在内外层树脂2内埋设比如由阻气性良好的树脂构成的中间层树脂3来构成，可以利用前述专利文献1所述的熔融树脂挤压供给装置来获得。该多层熔融树脂块呈现下部稍微向外侧略圆形地膨胀的大致圆柱状外形，而且在内外层树脂内，中间层树脂以埋设状态来位于其下方部附近。内外层树脂内的中间层树脂的配置及形状，对于如后所述来控制多层压缩预成形物的层分布具有重要影响。在本实施方式中，为了多层压缩预成形物的层分布被控制成：在确保最内层厚度的同时，在周向达到均匀，因而中间层树脂3构成为：位于多层熔融树脂块内的长度方向下方，而且整体上中央部下陷，并呈现周围伞状地向上方延伸的凹形。
更详细而言，内外树脂层2内的前述中间层树脂3的配置位置及形状，有必要在图1中满足下列条件。(A)从中间层树脂3的下端至多层熔融树脂块1的下端为止的距离t，小于等于多层熔融树脂块全长Z的10％，即t/Z≤0.1，(B)中间层树脂伞部长度y，大于中央部长度L，即y≥L，(C)周向上的中间层树脂的最大外径d0，大于等于周向上的多层熔融树脂块外径D的50％，即1＞d0/D≥0.5，(D)周向上的中间层树脂的最大内径di，大于等于周向上的多层熔融树脂块外径D的50％，即1＞di/D≥0.5。
通过使由这种形状构成的多层熔融树脂块压缩成形，可以得到在躯干部及底部中在周向上层分布大致均匀的多层成形物及吹塑成形用多层预成形物。通过将该吹塑成形用多层预成形物双轴延伸成形，可以得到如下的高品质的多层瓶子等吹塑成形多层容器，其中多层压缩成形物的层分布为：中间树脂层完全位于内外树脂层内，且在周向上均匀分布，而且中间树脂层不会露出于内周面。此外，前述条件中，尽管(D)不是一个必要的条件，但希望满足该条件。前述条件中，如果t/Z＞0.1，则中间层便向上方移，而难以确保均匀的中间层，如果在1＞d0/D≥0.5及1＞di/D≥0.5这一范围外，则在压缩成形时，中间层的层厚便不稳定，而得不到层分布均匀的成形物。
比如，如图2或图3所示，可以利用挤压装置，按下列方法来形成前述多层熔融树脂块。图2所示的多层熔融树脂块的挤压装置10具有：用于对内外层树脂进行熔融混制的挤压机11a、用于对中间层树脂进行熔融混制的挤压机11b、用于对中间层切断用树脂进行熔融混制的挤压机11c。在与这些挤压机连接的模具13内设有：内外层树脂通路14a、中间层树脂通路14b、中间层切断用树脂通路14c，这些各树脂通路14a、14b、14c在挤压通路15中合流。在挤压机11b与中间层树脂通路14b之间、以及挤压机11c与中间层切断用树脂通路14c之间，分别设有间歇加压机构16b、16c，从而间歇性地挤压中间树脂层，进而计量定时，来间歇性挤压中间层切断用树脂，从而可完全切断中间层。在该场合下，作为中间层切断用树脂采用与内外层树脂同样材质的树脂，由此，可由内外树脂层来覆盖中间层树脂，并从模具口17来间歇性挤压存在中间层树脂的连续状的熔融树脂，并在不存在中间层树脂的部位将其切断，由此可形成中间层树脂被内封于内外树脂层中的多层熔融树脂块。
图3所示的多层熔融树脂块的挤压装置20，与图2所示的挤压装置同样具有：内外层树脂挤压机、中间层树脂挤压机、中间层切断用树脂挤压机，且在模具内设有与这些挤压机连通的内外层树脂通路21a、中间层树脂通路21b、中间层切断用树脂通路21c，这些各树脂通路在挤压通路22中合流。在该实施方式的挤压装置20中，取代图2所示实施方式的间歇加压机构，而在中间层树脂通路21b及中间层切断用树脂通路21c中设有：开闭各个出口的阀门机构23b及23c。这些阀门机构23b、23c可独立动作，图3(a)～(d)表示各个阀的开、闭的组合方式。通过用阀门机构23b来间歇性地开启中间层树脂通路21b的挤压口，来间歇性地挤压中间层树脂，进而计算定时来使阀门机构23c动作，从而间歇性挤压中间层切断用树脂，由此，可形成中间层树脂被内外树脂层覆盖、且被内封于内外层树脂中的多层熔融树脂块。
在图2及图3所示的各个挤压装置中，内外层树脂及中间层切断用树脂，由同一材质来构成，并在多层熔融树脂块的挤压工序中，调整被间歇性地挤压的中间层树脂及中间层切断用树脂的挤压定时，由此，可以控制多层熔融树脂块中的中间层树脂的形状。比如，如果同时排出中间层树脂及中间层切断用树脂，则中间层树脂便成为凸型，而如果逐次排出，则中间层树脂便成为凹型。
实施例
用图2所示的挤压装置，可得到一种如下的多层熔融树脂块30，其各层的材质由下列树脂构成，且如图4(a)所示，中间层树脂31成为凹型形状并具有下列各尺寸。使所得到的多层熔融树脂块压缩成形，而形成瓶子成形用的有底预成形物，并如图5所示，从其管口下开始，在轴向下方按10mm间隔来进行剖切，并测定其周向的最内层、中间层及最外层的厚度，调查了层分布。其结果如图6～图8所示。图6表示颈下30mm及50mm位置的周向上最内层的厚度分布，图7表示颈下30mm及50mm位置的周向的中间层的厚度分布。图8表示轴向10mm间隔的最内层、中间层、最外层的厚度变化，各位置上的层厚用该高度位置上的周向厚度平均值来表示。
多层熔融树脂块的材质
内外层树脂：聚对苯二甲酸乙二醇酯(IV＝0.82)
中间层树脂：再生聚酯树脂(PCR)(与野塑料瓶回收公司(公司名)/Yono PET Recycling CO.制造)
中间层切断用树脂：聚对苯二甲酸乙二醇酯(IV＝0.82)
树脂块的尺寸
多层熔融树脂块全长Z：66mm
中间层树脂伞部长度y：52mm
中间层树脂中央部长度L：9.4mm
从下端至中间层树脂下端为止的距离：t：2.1mm
多层熔融树脂块外径D：22.9mm
中间层树脂上端外径d0：17.7mm
比较例
以与实施例同样的树脂构成，并利用与实施例同样的挤压装置，来获得中间层树脂如图4(b)所示成为凸型的多层熔融树脂块34，由此，测定了与实施例同样位置的各层的厚度分布。将其结果与前述实施例一同，示于图6、图7及图9。
以上的结果是，对最内层的厚度分布而言，如图6所示，在实施例的场合下，可确保在颈下30mm处为大于等于0.8mm、在颈下50mm处为大于等于0.6mm的最内层厚度，而且周向离差也较小。而在比较例的场合下，在颈下30mm处只为0.55mm，在颈下50mm处只为0.45mm，从而不能确保充分的最内层厚度，而且周向离差也较大。同样，对中间层而言，如图7所示，在实施例的场合下，在颈下30mm及50mm的任意一种场合下，中间层厚度的周向离差较小，而且在整个周向上几乎达到均一厚度，而在比较例的场合下，周向上的中间层厚度的离差较大。
对预成形物的轴向颈下每隔10mm间隔的最内层、中间层及最外层的厚度分布而言，在实施例的场合下，尽管各高度均存在层分布厚度的离差，但最重要的中间层及最内层的离差较小，而且两层均可确保大于等于0.6mm的厚度，因而产生前述问题点的可能性较小。而在比较例的场合下，如图9所示，中间层及最内层的离差尤其大，而且最内层厚度尤其在下部小于等于0.6mm，从而不能确保充分的厚度。通过以上的实施例可确认：本发明的多层熔融树脂块，对于确保多层成形物的均匀的层厚及必要的层厚，是一种非常有效的方法。
这样，将本发明的多层熔融树脂块压缩成形而得到的预成形物吹塑成形，对由此而得到的瓶子等容器而言，由于没有中间层露出于容器内面之虞，因而可得到一种不会产生下列问题之虞的容器：内容液与中间层直接接触，而对内容液产生不好的影响，或者中间层吸收内容物的水分，而使屏障性劣化等问题。
工业上的可利用性
如上所述，对本发明的多层熔融树脂块而言，可得到一种具有几乎均匀的层分布、且中间树脂层不露出于外部、可确保中间层厚度的吹塑成形用多层预成形物，通过将该吹塑成形用多层预成形物双轴延伸成形，可得到一种中间树脂层位于内外树脂层内、且在周向均匀分布的多层树脂成形物，因而可有效用于瓶子等多层树脂容器、多层树脂盖罩、或者其它各种多层树脂成形物的成形。

Claims (5)

1.一种多层熔融树脂块，用于通过压缩成形来得到多层压缩成形物，该多层熔融树脂块的特征在于：
构成该多层熔融树脂块的中间树脂层的中间层树脂(3)，在构成内外层的内外层树脂(2)内，向下侧偏心而被内封，且前述中间层树脂(3)的形状是凹型。
2.权利要求1所述的多层熔融树脂块，其特征在于：前述中间层树脂(3)中，从其下端至多层熔融树脂块的下端为止的距离，小于等于多层熔融树脂块全长的10％。
3.权利要求1或2所述的多层熔融树脂块，其特征在于：前述中间层树脂(3)的形状是：中间层树脂伞部长度(y)≥中间层树脂中央部长度(L)，而且1＞周向上的中间层树脂最大外径(d0)/周向上的多层熔融树脂块外径(D)≥0.5。
4.一种多层成形物及吹塑成形用多层预成形物，其特征在于：通过对权利要求1～3任意一项所述的多层熔融树脂块进行压缩成形而得到。
5.一种多层容器，其特征在于：通过对权利要求4所述的吹塑成形用多层预成形物进行双轴延伸成形而得到。
CN2004800311236A 2003-10-22 2004-10-20 多层熔融树脂块及从该多层熔融树脂块来压缩成形的吹塑成形用多层预成形物以及多层容器 Expired - Fee Related CN1871107B (zh)

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CN1871107B (zh) 2010-05-12
EP1676687A4 (en) 2006-11-15
WO2005039855A1 (ja) 2005-05-06
AU2004283959B2 (en) 2010-04-29
US20070122578A1 (en) 2007-05-31
KR101041416B1 (ko) 2011-06-15
EP1676687B1 (en) 2009-07-22
JP2005125532A (ja) 2005-05-19
CA2542906A1 (en) 2005-05-06
AU2004283959A1 (en) 2005-05-06
JP4240221B2 (ja) 2009-03-18
EP1676687A1 (en) 2006-07-05
DE602004022185D1 (de) 2009-09-03

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