WO2005062825A2 - Disposable containers coated with a latex coating - Google Patents
Disposable containers coated with a latex coating Download PDFInfo
- Publication number
- WO2005062825A2 WO2005062825A2 PCT/US2004/042703 US2004042703W WO2005062825A2 WO 2005062825 A2 WO2005062825 A2 WO 2005062825A2 US 2004042703 W US2004042703 W US 2004042703W WO 2005062825 A2 WO2005062825 A2 WO 2005062825A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- container
- latex
- latex coating
- coating
- molded thermoplastic
- Prior art date
Links
- 239000004816 latex Substances 0.000 title claims abstract description 105
- 229920000126 latex Polymers 0.000 title claims abstract description 104
- 238000000576 coating method Methods 0.000 title claims abstract description 93
- 239000011248 coating agent Substances 0.000 title claims abstract description 87
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 51
- 238000000034 method Methods 0.000 claims abstract description 49
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 49
- 239000002245 particle Substances 0.000 claims abstract description 39
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Natural products C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims abstract description 37
- 229920001577 copolymer Polymers 0.000 claims abstract description 34
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 claims abstract description 22
- 238000005507 spraying Methods 0.000 claims abstract description 20
- 229920006248 expandable polystyrene Polymers 0.000 claims abstract description 17
- 239000007788 liquid Substances 0.000 claims abstract description 17
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000000126 substance Substances 0.000 claims abstract description 16
- 235000013305 food Nutrition 0.000 claims abstract description 14
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 claims abstract description 11
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims abstract description 11
- 238000004519 manufacturing process Methods 0.000 claims abstract description 10
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 claims abstract description 9
- 230000001680 brushing effect Effects 0.000 claims abstract description 6
- 238000007598 dipping method Methods 0.000 claims abstract description 6
- 238000003860 storage Methods 0.000 claims abstract description 3
- 229920000642 polymer Polymers 0.000 claims description 23
- 239000007787 solid Substances 0.000 claims description 19
- 239000000178 monomer Substances 0.000 claims description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- HRPVXLWXLXDGHG-UHFFFAOYSA-N Acrylamide Chemical compound NC(=O)C=C HRPVXLWXLXDGHG-UHFFFAOYSA-N 0.000 claims description 4
- SOGAXMICEFXMKE-UHFFFAOYSA-N Butylmethacrylate Chemical compound CCCCOC(=O)C(C)=C SOGAXMICEFXMKE-UHFFFAOYSA-N 0.000 claims description 4
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 claims description 4
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 claims description 4
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 claims description 4
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 4
- 229920001519 homopolymer Polymers 0.000 claims description 4
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 claims description 4
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 claims description 3
- XYLMUPLGERFSHI-UHFFFAOYSA-N alpha-Methylstyrene Chemical compound CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 claims description 3
- 229920002818 (Hydroxyethyl)methacrylate Polymers 0.000 claims description 2
- JAHNSTQSQJOJLO-UHFFFAOYSA-N 2-(3-fluorophenyl)-1h-imidazole Chemical compound FC1=CC=CC(C=2NC=CN=2)=C1 JAHNSTQSQJOJLO-UHFFFAOYSA-N 0.000 claims description 2
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 claims description 2
- SJIXRGNQPBQWMK-UHFFFAOYSA-N 2-(diethylamino)ethyl 2-methylprop-2-enoate Chemical compound CCN(CC)CCOC(=O)C(C)=C SJIXRGNQPBQWMK-UHFFFAOYSA-N 0.000 claims description 2
- GOXQRTZXKQZDDN-UHFFFAOYSA-N 2-Ethylhexyl acrylate Chemical compound CCCCC(CC)COC(=O)C=C GOXQRTZXKQZDDN-UHFFFAOYSA-N 0.000 claims description 2
- OMIGHNLMNHATMP-UHFFFAOYSA-N 2-hydroxyethyl prop-2-enoate Chemical compound OCCOC(=O)C=C OMIGHNLMNHATMP-UHFFFAOYSA-N 0.000 claims description 2
- RUMACXVDVNRZJZ-UHFFFAOYSA-N 2-methylpropyl 2-methylprop-2-enoate Chemical compound CC(C)COC(=O)C(C)=C RUMACXVDVNRZJZ-UHFFFAOYSA-N 0.000 claims description 2
- CFVWNXQPGQOHRJ-UHFFFAOYSA-N 2-methylpropyl prop-2-enoate Chemical compound CC(C)COC(=O)C=C CFVWNXQPGQOHRJ-UHFFFAOYSA-N 0.000 claims description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 2
- WOBHKFSMXKNTIM-UHFFFAOYSA-N Hydroxyethyl methacrylate Chemical compound CC(=C)C(=O)OCCO WOBHKFSMXKNTIM-UHFFFAOYSA-N 0.000 claims description 2
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 claims description 2
- GYCMBHHDWRMZGG-UHFFFAOYSA-N Methylacrylonitrile Chemical compound CC(=C)C#N GYCMBHHDWRMZGG-UHFFFAOYSA-N 0.000 claims description 2
- CNCOEDDPFOAUMB-UHFFFAOYSA-N N-Methylolacrylamide Chemical compound OCNC(=O)C=C CNCOEDDPFOAUMB-UHFFFAOYSA-N 0.000 claims description 2
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 claims description 2
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 claims description 2
- 125000000118 dimethyl group Chemical group [H]C([H])([H])* 0.000 claims description 2
- YCUBDDIKWLELPD-UHFFFAOYSA-N ethenyl 2,2-dimethylpropanoate Chemical compound CC(C)(C)C(=O)OC=C YCUBDDIKWLELPD-UHFFFAOYSA-N 0.000 claims description 2
- TVFJAZCVMOXQRK-UHFFFAOYSA-N ethenyl 7,7-dimethyloctanoate Chemical compound CC(C)(C)CCCCCC(=O)OC=C TVFJAZCVMOXQRK-UHFFFAOYSA-N 0.000 claims description 2
- SUPCQIBBMFXVTL-UHFFFAOYSA-N ethyl 2-methylprop-2-enoate Chemical compound CCOC(=O)C(C)=C SUPCQIBBMFXVTL-UHFFFAOYSA-N 0.000 claims description 2
- 239000001530 fumaric acid Substances 0.000 claims description 2
- VOZRXNHHFUQHIL-UHFFFAOYSA-N glycidyl methacrylate Chemical compound CC(=C)C(=O)OCC1CO1 VOZRXNHHFUQHIL-UHFFFAOYSA-N 0.000 claims description 2
- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 claims description 2
- KCTMTGOHHMRJHZ-UHFFFAOYSA-N n-(2-methylpropoxymethyl)prop-2-enamide Chemical compound CC(C)COCNC(=O)C=C KCTMTGOHHMRJHZ-UHFFFAOYSA-N 0.000 claims description 2
- DNTMQTKDNSEIFO-UHFFFAOYSA-N n-(hydroxymethyl)-2-methylprop-2-enamide Chemical compound CC(=C)C(=O)NCO DNTMQTKDNSEIFO-UHFFFAOYSA-N 0.000 claims description 2
- 229940065472 octyl acrylate Drugs 0.000 claims description 2
- ANISOHQJBAQUQP-UHFFFAOYSA-N octyl prop-2-enoate Chemical compound CCCCCCCCOC(=O)C=C ANISOHQJBAQUQP-UHFFFAOYSA-N 0.000 claims description 2
- RPQRDASANLAFCM-UHFFFAOYSA-N oxiran-2-ylmethyl prop-2-enoate Chemical compound C=CC(=O)OCC1CO1 RPQRDASANLAFCM-UHFFFAOYSA-N 0.000 claims description 2
- MNCGMVDMOKPCSQ-UHFFFAOYSA-M sodium;2-phenylethenesulfonate Chemical compound [Na+].[O-]S(=O)(=O)C=CC1=CC=CC=C1 MNCGMVDMOKPCSQ-UHFFFAOYSA-M 0.000 claims description 2
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 claims description 2
- 238000007639 printing Methods 0.000 abstract description 3
- 239000011324 bead Substances 0.000 description 19
- 239000004604 Blowing Agent Substances 0.000 description 12
- 239000004793 Polystyrene Substances 0.000 description 11
- 229920002223 polystyrene Polymers 0.000 description 11
- 238000001035 drying Methods 0.000 description 10
- 239000003921 oil Substances 0.000 description 9
- OFBQJSOFQDEBGM-UHFFFAOYSA-N Pentane Chemical compound CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 7
- -1 polypropylene Polymers 0.000 description 7
- 235000016213 coffee Nutrition 0.000 description 6
- 235000013353 coffee beverage Nutrition 0.000 description 6
- LQZZUXJYWNFBMV-UHFFFAOYSA-N dodecan-1-ol Chemical compound CCCCCCCCCCCCO LQZZUXJYWNFBMV-UHFFFAOYSA-N 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 6
- 229920005992 thermoplastic resin Polymers 0.000 description 6
- 239000006260 foam Substances 0.000 description 5
- 239000013518 molded foam Substances 0.000 description 5
- 229920003002 synthetic resin Polymers 0.000 description 5
- 229920002554 vinyl polymer Polymers 0.000 description 5
- 239000010410 layer Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical class CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 4
- 238000005070 sampling Methods 0.000 description 4
- 235000015067 sauces Nutrition 0.000 description 4
- 239000000057 synthetic resin Substances 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 150000001338 aliphatic hydrocarbons Chemical class 0.000 description 3
- 239000007900 aqueous suspension Substances 0.000 description 3
- 230000014759 maintenance of location Effects 0.000 description 3
- 239000002609 medium Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 235000012149 noodles Nutrition 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 239000012508 resin bead Substances 0.000 description 3
- 239000004094 surface-active agent Substances 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- MYRTYDVEIRVNKP-UHFFFAOYSA-N 1,2-Divinylbenzene Chemical compound C=CC1=CC=CC=C1C=C MYRTYDVEIRVNKP-UHFFFAOYSA-N 0.000 description 2
- 240000004160 Capsicum annuum Species 0.000 description 2
- 235000008534 Capsicum annuum var annuum Nutrition 0.000 description 2
- 235000007862 Capsicum baccatum Nutrition 0.000 description 2
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 2
- 229920001730 Moisture cure polyurethane Polymers 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 238000013459 approach Methods 0.000 description 2
- 239000012736 aqueous medium Substances 0.000 description 2
- 235000013844 butane Nutrition 0.000 description 2
- 239000001728 capsicum frutescens Substances 0.000 description 2
- 230000001413 cellular effect Effects 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 229920001971 elastomer Polymers 0.000 description 2
- ZINJLDJMHCUBIP-UHFFFAOYSA-N ethametsulfuron-methyl Chemical compound CCOC1=NC(NC)=NC(NC(=O)NS(=O)(=O)C=2C(=CC=CC=2)C(=O)OC)=N1 ZINJLDJMHCUBIP-UHFFFAOYSA-N 0.000 description 2
- 229910052731 fluorine Inorganic materials 0.000 description 2
- 239000011737 fluorine Substances 0.000 description 2
- 239000006261 foam material Substances 0.000 description 2
- 150000008282 halocarbons Chemical class 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- QWTDNUCVQCZILF-UHFFFAOYSA-N isopentane Chemical compound CCC(C)C QWTDNUCVQCZILF-UHFFFAOYSA-N 0.000 description 2
- 238000002372 labelling Methods 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 229920001684 low density polyethylene Polymers 0.000 description 2
- 239000004702 low-density polyethylene Substances 0.000 description 2
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical class CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 2
- 239000012071 phase Substances 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 239000005060 rubber Substances 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 235000014347 soups Nutrition 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- BEWCNXNIQCLWHP-UHFFFAOYSA-N 2-(tert-butylamino)ethyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCCNC(C)(C)C BEWCNXNIQCLWHP-UHFFFAOYSA-N 0.000 description 1
- SBYMUDUGTIKLCR-UHFFFAOYSA-N 2-chloroethenylbenzene Chemical compound ClC=CC1=CC=CC=C1 SBYMUDUGTIKLCR-UHFFFAOYSA-N 0.000 description 1
- DXIJHCSGLOHNES-UHFFFAOYSA-N 3,3-dimethylbut-1-enylbenzene Chemical compound CC(C)(C)C=CC1=CC=CC=C1 DXIJHCSGLOHNES-UHFFFAOYSA-N 0.000 description 1
- CEBRPXLXYCFYGU-UHFFFAOYSA-N 3-methylbut-1-enylbenzene Chemical compound CC(C)C=CC1=CC=CC=C1 CEBRPXLXYCFYGU-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- SNRUBQQJIBEYMU-UHFFFAOYSA-N Dodecane Natural products CCCCCCCCCCCC SNRUBQQJIBEYMU-UHFFFAOYSA-N 0.000 description 1
- 240000005856 Lyophyllum decastes Species 0.000 description 1
- 235000013194 Lyophyllum decastes Nutrition 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 206010035148 Plague Diseases 0.000 description 1
- 229920002367 Polyisobutene Polymers 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- DBMJMQXJHONAFJ-UHFFFAOYSA-M Sodium laurylsulphate Chemical compound [Na+].CCCCCCCCCCCCOS([O-])(=O)=O DBMJMQXJHONAFJ-UHFFFAOYSA-M 0.000 description 1
- 241000607479 Yersinia pestis Species 0.000 description 1
- 125000005250 alkyl acrylate group Chemical group 0.000 description 1
- 239000008346 aqueous phase Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000001246 colloidal dispersion Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000007334 copolymerization reaction Methods 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- AFABGHUZZDYHJO-UHFFFAOYSA-N dimethyl butane Natural products CCCC(C)C AFABGHUZZDYHJO-UHFFFAOYSA-N 0.000 description 1
- 238000003618 dip coating Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 125000003438 dodecyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 239000003995 emulsifying agent Substances 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 229920001038 ethylene copolymer Polymers 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 235000021149 fatty food Nutrition 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 235000008446 instant noodles Nutrition 0.000 description 1
- 230000001678 irradiating effect Effects 0.000 description 1
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000008267 milk Substances 0.000 description 1
- 235000013336 milk Nutrition 0.000 description 1
- 210000004080 milk Anatomy 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 235000019198 oils Nutrition 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 229920006122 polyamide resin Polymers 0.000 description 1
- 229920001083 polybutene Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 229920006380 polyphenylene oxide Polymers 0.000 description 1
- 229920000379 polypropylene carbonate Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- QROGIFZRVHSFLM-UHFFFAOYSA-N prop-1-enylbenzene Chemical class CC=CC1=CC=CC=C1 QROGIFZRVHSFLM-UHFFFAOYSA-N 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 229960000776 sodium tetradecyl sulfate Drugs 0.000 description 1
- AIMUHNZKNFEZSN-UHFFFAOYSA-M sodium;decane-1-sulfonate Chemical compound [Na+].CCCCCCCCCCS([O-])(=O)=O AIMUHNZKNFEZSN-UHFFFAOYSA-M 0.000 description 1
- DAJSVUQLFFJUSX-UHFFFAOYSA-M sodium;dodecane-1-sulfonate Chemical compound [Na+].CCCCCCCCCCCCS([O-])(=O)=O DAJSVUQLFFJUSX-UHFFFAOYSA-M 0.000 description 1
- GGHPAKFFUZUEKL-UHFFFAOYSA-M sodium;hexadecyl sulfate Chemical compound [Na+].CCCCCCCCCCCCCCCCOS([O-])(=O)=O GGHPAKFFUZUEKL-UHFFFAOYSA-M 0.000 description 1
- HRQDCDQDOPSGBR-UHFFFAOYSA-M sodium;octane-1-sulfonate Chemical compound [Na+].CCCCCCCCS([O-])(=O)=O HRQDCDQDOPSGBR-UHFFFAOYSA-M 0.000 description 1
- UPUIQOIQVMNQAP-UHFFFAOYSA-M sodium;tetradecyl sulfate Chemical compound [Na+].CCCCCCCCCCCCCCOS([O-])(=O)=O UPUIQOIQVMNQAP-UHFFFAOYSA-M 0.000 description 1
- 235000014214 soft drink Nutrition 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 235000013547 stew Nutrition 0.000 description 1
- 229920006302 stretch film Polymers 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 238000010557 suspension polymerization reaction Methods 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 125000002348 vinylic group Chemical group 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D25/00—Details of other kinds or types of rigid or semi-rigid containers
- B65D25/34—Coverings or external coatings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/22—Boxes or like containers with side walls of substantial depth for enclosing contents
- B65D1/26—Thin-walled containers, e.g. formed by deep-drawing operations
- B65D1/28—Thin-walled containers, e.g. formed by deep-drawing operations formed of laminated material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D23/00—Details of bottles or jars not otherwise provided for
- B65D23/08—Coverings or external coatings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/0427—Coating with only one layer of a composition containing a polymer binder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/4273—Auxiliary operations after the blow-moulding operation not otherwise provided for
- B29C49/42828—Coating or painting the article
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0058—Liquid or visquous
- B29K2105/0064—Latex, emulsion or dispersion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
- B29K2105/048—Expandable particles, beads or granules
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
- C08J2325/02—Homopolymers or copolymers of hydrocarbons
- C08J2325/04—Homopolymers or copolymers of styrene
- C08J2325/06—Polystyrene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2433/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
Definitions
- the present invention relates to disposable containers. More particularly, the present invention relates to molded foam containers that are made from thermoplastic particles, e.g. expandable polystyrene particles (EPS) , and that are coated with a latex coating.
- the containers are used to retain liquids, e.g. coffee or foods containing oil and/or fatty components, e.g. precooked fat- containing foods, e.g. instant noodles, soups, fried chicken, sauces, and the like.
- the invention also relates to a method for forming a container, an article of manufacture, and an improved method for storing liquid and food substances.
- thermoplastic particles are expandable polystyrene (EPS) particles.
- EPS expandable polystyrene
- polystyrene beads are impregnated with hydrocarbon, e.g. pentane as a blowing agent that boils below the softening point of the polystyrene and causes the beads to expand when heated.
- hydrocarbon e.g. pentane
- the formation of molded containers from impregnated polystyrene beads is generally done in two steps. First, the impregnated beads are pre- expanded to a density of from about 2 to 12 pounds per cubic foot.
- the pre-expanded beads are heated in a closed mold to further expand the pre- expanded beads to form a fused article having the shape of the mold.
- the expandable polystyrene particles used to make foam containers are generally prepared by an aqueous suspension polymerization process, which results in beads that can be screened to relatively precise bead sizes.
- the raw bead diameters for making containers, such as cups range from about 0.008 to about 0.02 inch. It has been known to produce cups from beads having a diameter of about 0.03 inches.
- the containers, especially those made from EPS particles have a tendency to leak.
- liquids especially hot liquids, e.g. coffee, water, oil and/or fat
- hot liquids e.g. coffee, water, oil and/or fat
- leakage resistance is dependent on temperature. That is, hot liquid and food substances tend to penetrate around the fused beads faster than cold substances.
- Several approaches have evolved over the years in an attempt to reduce leakage in containers that retain cold and hot liquids and/or pre-cooked foods. Amberg et al . , U.S.
- Patent 4,036,675 discloses a container made from foamed plastic material, preferably foamed polystyrene, which is lined on one or both sides with unoriented polyolefin film, preferably polypropylene.
- the film is secured to the foamed plastic base material using as a heat- sensitive adhesive a vinylic polymer or polyamide resin.
- the film is coated with a wet adhesive and dried before laminating the film to the foam material. Laminating is done by heating the foam material to 250-275°F, preheating the coated film to 100-180°F, and pressing the coated film surface against the heated foam for 10 to 15 seconds by using a cold platen or roller.
- thermoplastic polymer foam cups for retaining coffee that are molded from thermoplastic polymer particles whose surfaces are coated with a fluorosurfactant before molding.
- Fanberg U.S. Patent No. 4,785,022 discloses a method for enhancing the coffee retention of molded foam cups, which involves coating the expandable polystyrene particles with various rubber polymers and copolymers .
- the rubber can be polybutene, polyisobutylene, isobutylene-butene copolymer and butene-ethylene copolymer.
- 4,798,749 approaches the problem of coffee leakage by replacing conventional blowing agents such as butanes, n-pentane, hexanes, and the halogenated hydrocarbons with isopentane in the expandable styrene polymer particles.
- Ikeda, et al . , U.S. Patent No. 4,698,367 discloses expandable thermoplastic resin particles in which the thermoplastic resin, composed of fluorinated vinyl polymer and hydrophilic vinyl polymer, covers or is included on the surface or in the surface layer of the expandable thermoplastic particle.
- the resin particles are useful for producing package containers for oily or fatty foods .
- 6,277,491 Bl is directed to preventing oil from penetrating into a molded container made from expandable thermoplastic resin beads .
- the resin beads are coated or incorporated with a fluorine-containing block copolymer comprising a fluorine-containing vinyl- type polymer segment derived from a fluorine- containing vinyl-type monomer and a lipophilic vinyl-type polymer segment derived from a lipophilic vinyl-type monomer.
- the above prior art containers are addressed to polystyrene containers, such as cups or bowls.
- the following patents pertain to paper cups that are either spray coated or that contain a thermoplastic resin film either for heat insulating purposes or for producing a high impermeability to liquids. For example, Suzuki et al .
- U.S. Patent No. 4,206,249 discloses a process for producing a paper container having a high impermeability to liquids which involves spray coating a polymerizable solution containing a pre-polymer onto a wall surface of the paper container and irradiating the coated wall with ultraviolet light to set the pre- polymer onto the wall surface thereof. This forms a coating that is impermeable to liquids, such as water, milk, soft drinks, oils, etc.
- This patent teaches in column 2, lines 45-62, a method in which the interior wall surface of the container is lined with a thermoplastic film. The thermoplastic film is first laminated onto a blank and the blank is formed into a container. Iioka, U.S. Patent No.
- 4,435,344 discloses a heat-insulating paper container where the outer and inner surfaces are extrusion coated or laminated with a thermoplastic synthetic resin film.
- the resin film is converted into a foamed layer on the paper substrate and the container is formed. The result is a container with good thermo-insulation properties.
- This film preferably is polyethylene and as taught in column 3, lines 50-55, this resin film can be polypropylene, polyvinyl chloride, polystyrene, polyester, nylon and the like. Iioka et al . , U.S. Patent No.
- 5,490,631 discloses a heat insulating paper container comprising a body member wherein a thick foamed heat insulating layer made of a thermoplastic synthetic resin film is formed in the printed area of the outer surface and a less thick foamed heat- insulating layer that can be made of the same thermoplastic synthetic resin film is formed in the non-printed area of the outer surface.
- the thermoplastic synthetic resin film is typically polyethylene .
- Breining, et al . U.S. Patent No. 6,416,829 B2 discloses a heat insulating paper cup where the body member is coated on its outside surface with a foamed low density polyethylene, and on its inside surface with an unfoamed modified low density polyethylene . None of these prior art containers pertain to thermoplastic containers that are coated with a latex coating and are used to retain and/or store liquid and food substances, such as coffee, soups, stews, pre-cooked foods and the like.
- thermoplastic container is molded from expandable thermoplastic particles and a latex coating is applied to a portion of at least one of the inner and outer surfaces of the container; preferably to the inner surface; and more preferably to both the inner and outer surfaces.
- the container is relatively impenetrable thereby substantially reducing or eliminating leakage, and therefore, stains from forming on the surfaces of the container.
- the latex coating if applied to the outer surface of the container can also be used for labeling and/or printing purposes.
- the latex coating may be selected from the group consisting of latex of methyl methacrylate and styrene copolymer, latex of methyl acrylate and styrene copolymer, latex of acrylic acid and styrene copolymer, and latex of butadiene and styrene copolymer .
- the thickness of the coating may range from about 0.10 mils (0.27 mg dry coating weight per square centimeter cup surface) to about 5.0 mils (13.4 mg dry coating weight per square centimeter cup surface), and preferably may be about 0.9 mils (about 0.25 mg dry coating weight per square centimeter cup surface) .
- the coating may be applied to a portion of or to the entire inner and/or outer surface of the container.
- the coating is applied substantially to the entire inner and/or outer surface of the container.
- the latex coating is applied to the containers surfaces via a brushing process, a dipping process, or a spraying process, e.g. via an airless spraying device or devices.
- the container is made from expandable thermoplastic resin beads, and in some embodiments, this expandable thermoplastic resin is expandable polystyrene (EPS) .
- EPS expandable polystyrene
- Some embodiments of the invention involve a molded thermoplastic container that exhibits improved resistance to leakage and/or stain and improved insulation properties.
- Some embodiments of the invention involve a latex coating that is applied to the inner and/or outer surface of a molded thermoplastic container.
- inventions involve a method for applying a latex coating to the surfaces of a molded thermoplastic container.
- article of manufacture comprising a molded thermoplastic container that is coated with a latex coating and that contains a liquid or food substance, and which container has improved storage longevity, improved stain resistance, and/or improved leakage resistance.
- containers e.g., cups, bowls, and the like are molded from expandable thermoplastic particles.
- the expandable thermoplastic particles are made from any suitable thermoplastic homopolymer or copolymer.
- Particularly suitable for use are homopolymers derived from vinyl aromatic monomers including styrene, isopropylstyrene, alpha-methylstyrene, nuclear methylstyrenes, chlorostyrene, tert- butylstyrene, and the like, as well as copolymers prepared by the copolymerization of at least one vinyl aromatic monomer with monomers such as divinylbenzene, butadiene, alkyl methacrylates, alkyl acrylates, acrylonitrile, and maleic anhydride, wherein the vinyl aromatic monomer is present in at least 50% by weight of the copolymer.
- Styrenic polymers are preferred, particularly polystyrene.
- the expandable thermoplastic particles are expandable polystyrene (EPS) particles .
- EPS expandable polystyrene
- the particles can be in the form of beads, granules, or other particles convenient for expansion and molding operations.
- Particles polymerized in an aqueous suspension process are essentially spherical and are preferred for molding the foam container of the invention.
- the particles are screened so that their diameter ranges from about 0.008 to about 0.02 inch.
- the expandable thermoplastic particles are impregnated with a suitable blowing agent using any conventional method.
- the impregnation can be achieved by adding the blowing agent to the aqueous suspension during the polymerization of the polymer, or alternatively by re-suspending the polymer particles in an aqueous medium and then incorporating the blowing agent as taught in U.S. Patent No. 2,983,692 to D. Alelio. Any gaseous material or material which will produce gases on heating can be used as the blowing agent.
- Conventional blowing agents include aliphatic hydrocarbons containing 4 to 6 carbon atoms in the molecule, such as butanes, pentanes, hexanes, and the halogenated hydrocarbons, e.g.
- the impregnated thermoplastic particles are generally pre -expanded to a density of from about 2 to about 12 pounds per cubic foot.
- the pre- expansion step is conventionally carried out by heating the impregnated beads via any conventional heating medium, such as steam, hot air, hot water, or radiant heat.
- Any conventional heating medium such as steam, hot air, hot water, or radiant heat.
- One generally accepted method for pre-expanding impregnated thermoplastic particles is taught in U.S. Patent No. 3,023,175 to Rodman.
- the impregnated thermoplastic particles can be foamed cellular polymer particles as taught in Arch et al .
- the foamed cellular particles are preferably polystyrene that are pre-expanded to a density of from about 12.5 to about 34.3 pounds per cubic foot, and that contain a volatile blowing agent level less than 6.0 weight percent, preferably from about 2.0 wt % to about 5.0 wt %, and more preferably ranging from about 2.5 wt % to about 3.5 wt % based on the weight of the polymer.
- pre-expanded particles (“pre-puff") are heated in a closed mold to further expand the particles and to form the foam molded container of the invention.
- the latex coating suitable for use in the invention is of the type that will not be detrimental to the thermoplastic particles forming the container. That is, the latex coating of the invention will be devoid of any chemicals that tend to dissolve or react with the thermoplastic particles, particularly polystyrene particles. For example, most solvent-based polymeric coatings would not be feasible in the invention.
- "Latex" can be defined as a colloidal dispersion of polymer particles in an aqueous medium, such as water. The phase ratio (polymer phase to aqueous phase) may range from 40:60 to
- Solids content refers to the dry matter that comprises the polymer, emulsifiers, inorganic salts, etc. in the latex coating.
- a typical range for the solids content is between 40 and 60 percent weight. This measurement is derived by drying a latex coating sample to a constant mass at a temperature between 100 and 140 °C. The solids content is then expressed as the percentage ratio of the dry matter to the total mass of the sample.
- the latex used in the invention may contain surfactants and/or other minor components.
- the surfactant which generally is used for stability purposes , may be any of the commonly known surfactants used in latex coatings such as sodium octyl sulfonate, sodium decyl sulfonate, sodium dodecyl sulfonate, sodium tetradecyl sulfate, sodium hexadecyl sulfate, sodium dodecyl sulfate, branched sodium alkyl sulfate, sodium dodecyl ethoxylate (2E0) , dodecyl alcohol ethoxylate (5E0) , dodecyl alcohol ethoxylate (7E0) , dodecyl alcohol ethoxylate (8EO) , etc.
- a particularly suitable polymer of the latex coating of the invention may be a monomer selected from the group consisting of butadiene, n-butyl acrylate, i-butyl acrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, octyl acrylate, vinyl acetate, vinyl chloride, vinylidene chloride, vinyl pivalate, vinyl neo-decanoate, acrylonitrile, methyl acrylonitrile, acrylamide, styrene, ⁇ -methyl styrene, methyl methacrylate, ethyl methacrylate, n- butyl methacrylate, i-butyl methacrylate; or the polymer may be selected from the group consisting of a homopolymer or the copolymer of two or more of the above monomers or the copolymer of two or more of the above monomers with the following functional monomers including acrylic acid
- the latex coating may be comprised of a polymer selected from the group consisting of acrylate, ethyl acrylate, methyl methacrylate, methacrylate, acrylic acid, methacrylic acid, monomers or the copolymers of these monomers combined with vinyl acetate or styrene .
- Preferred latex coatings are latex of methyl methacrylate and styrene copolymer, latex of methyl acrylate and styrene copolymer, latex of acrylic acid and styrene copolymer, and latex of butadiene and styrene copolymer.
- the molecular weight for the latex coating may range from about 100 to about 1 million units (500 to about 200 million g/mol) .
- the molecular polydispersity for the latex coating may be defined as ranging from very narrow to very broad, i.e. from about 1.0 to about 20.
- the thermoplastic container may be a polystyrene cup that is fabricated by a conventional cup-forming machine that has an inner shell and an outer shell.
- a conventional cup-forming machine is Cup Production MODEL 6-VLC-125 machine, made by Autonational B.V. or is MODEL M10 cup machine, made by Master Machine & Tool Co.
- the latex coating is applied to a portion of at least one of the inner and outer surfaces, preferably, the inner surface, and more preferably, both the inner and outer surfaces.
- the latex coating is applied to substantially the entire inner and/or outer surface.
- the latex coating may be applied to the surface or surfaces of the container via any suitable process, including a dipping process, a brushing process, or a spraying process via any suitable means .
- a spraying process may be preferred from both an economic and production standpoint.
- the type of latex coating particularly suitable for the invention is comprised of polymers in solid particulate form and water.
- the initial solids content of the polymer may be about 48% to about 50% by weight, which can be adjusted to change the viscosity so that the process equipment, such as the spraying system, can adequately handle the application of the coating onto the container.
- the solids content of the latex prior to being applied to the container's surface generally will depend on the process being used to apply the latex to the container. For example, if a spraying process or a brushing process is used, preferably the solid contents will range from about 40% to about 47% by weight, based on the weight of the latex. If a dipping process is used, preferably the solid contents will range from about 8% to about 20% by weight.
- the container may then be carried via a transport belt to a drying chamber or oven.
- the drying oven may be a conventional oven and the heating medium may be hot air, radiant heat, or heat plus vacuum. Preferably, the heating medium is hot air.
- a typical drying oven is obtained from Blue M Electric Company, Blue Island, Illinois.
- the drying time is dependent on the drying temperature, the solids content of the coating, and the coating thickness. For example if the coating is 1.5 mils, the drying temperature will be about 90 °C with a drying time of about 60 seconds.
- the drying temperature will range from about 50 °C to about 100 °C and the drying time will range from about 5 seconds to about 3000 seconds for coatings with a solids content ranging from about 8% to about 47% by weight.
- the thickness of the latex coating on the surface or surfaces of the container may range from about 0.10 mils (0.27 mg dry coating weight per square centimeter cup surface) to about 5.0 mils (13.4 mg dry coating weight per square centimeter cup surface) , and preferably may be about 0.9 mils (0.25 mg dry coating weight per square centimeter cup surface) . This coating thickness may extend on a portion of or substantially on the entire inner and/or outer surface of the container.
- the latex is applied to the container via a spraying process.
- the production rate for a single spraying device for spray coating the latex onto the inner surface of a 16-ounce cup may range from about 50 to about 600 cups per minute. It is apparent that several spraying devices can be used to accommodate the desired production rate of the cups.
- a spraying device that may be useful in the invention is an airless spraying device available from Nordson Corporation. An example of a spraying device provided by Nordson Corporation is disclosed in the aforesaid Suzuki et al . , U.S. Patent No. 4,206,249. In this instance, it is preferable that the airless spraying device applies the latex at room temperature instead of at the elevated temperatures taught in U.S. Patent No.
- the coating rate can be defined as "the dry weight of the coating sprayed onto the unit surface area of the container" . As stated herein, the coating rate may range from about 0.27 milligrams to about 13.4 milligrams dry coating weight per square centimeter cup surface.
- the latex is applied to a portion of or substantially onto at least one of the inner and outer surfaces of the container to form a coating; preferably to the inner surface; and more preferably to both inner and outer surfaces .
- the latex coating may be applied to the outer surface for leakage resistance purposes and/or for labeling and printing purposes.
- Example 1 This example illustrates the preparation of latex coated containers . Expandable polystyrene cup beads (DYLITE ® beads from NOVA Chemicals, Inc., which comprise polystyrene and pentane) were blended with zinc stearate and pre-expanded in an 11-gallon (about 1.5 cubic foot) Rodman Steam pre-expander (Artisan Industries Inc.) at atmospheric pressure. The pre-expansion was operated batch wise.
- Expandable polystyrene cup beads (DYLITE ® beads from NOVA Chemicals, Inc., which comprise polystyrene and pentane) were blended with zinc stearate and pre-expanded in an 11-gallon (about 1.5 cubic foot) Rodman Steam pre-expander (Artisan Industries Inc.) at atmospheric pressure. The pre-expansion was operated batch wise.
- the ratio of styrene to methyl acrylate may range from about 5:95 percent weight to about 95 : 5 percent weight based on the weight of the polymer segments, and the acrylic acid may range from about 0 to 10% by weight in the total polymer weight.
- the latex contained 48% by weight solids. Prior to applying the latex to the inner surface, the latex was diluted with de- ionized water to produce a latex containing 46% by weight solids.
- the coated cups were then dried in an oven using a combination of hot air circulation and radiant heat at 90°C for 1 minute.
- the coated cups were stored overnight before being tested.
- the coated cups were tested by the following method: Spicy oil at room temperature was poured into each container to fill the cup up to about 80% of its capacity. The outer surface of each container was observed for oil stains and leakage every 10 minutes for the first. 1.5 hours, every 30 minutes in the time frame from 1.5 hours to 6 hours, and, then, every hour thereafter for a total of 48 hours .
- the average time to failure (ATF) for each cup group sampling was calculated by adding the time to failure for each container, and dividing the total time to failure by the number of containers tested. Typically, ten cups in each group were tested.
- a maximum ATF value of 48 hours means that none of the cups in that group exhibited any stain or leakage.
- a minimum ATF value of 0.17 hours means that all of the cups in that group failed within the first 10 minutes .
- Table 1 The results for the oil retention (ATF) are shown in Table 1. As indicated, the cups with the latex coating had an increased ATF compared to the cups without the latex coating (control) .
- Example 2 The EPS cups were 6 ounce cups.
- the type of latex coating was the same as that used in Example 1.
- the coating was first diluted with water to produce coatings with varying solids content.
- the molded foam cups were coated via a dip coating process with the diluted latex so that both the inner and the outer surfaces of the cups were coated.
- the coated cups were dried at room temperature overnight before being tested. The results are shown in Table 2.
- the cups with the latex coating have an increased ATF compared to those cups without the latex coating (control) .
- Table 2 Table 2
- Example 3 The procedure of Example 1 was repeated except the testing method was replaced by the following method.
- Four coated cups were tested by the following method: 1) Oil fried pre-shaped cup noodles, such as those available in the market, were placed in each cup. 2) Three grams of red pepper powder were spread evenly onto the noodle surfaces. 3) Each cup was tightly sealed with an adhesive label and plastic stretch film, and placed in the oven at a temperature of 149 °F (65°C) . 4) Each sample was checked for stains first every hour during a 7 hour period and then once every 8 hours until failure for a total of 72 hours or 3 days. The average time to failure (ATF) was calculated similar to that set forth in Example 1.
- ATF average time to failure
- the maximum ATF value of 72 hours represents that none of the cups for the cup group sampling exhibited any stain or leakage.
- the minimum ATF value of 1 hour represents that all of the cups in the cup group sampling failed within the first 1 hour.
- the results for the stain resistance, in terms of ATF, are shown in Table 3.
- Example 4 The procedure of Example 1 was repeated except the testing method was replaced by the following method .
- the coated cups were tested by the following method: Salsa sauce, which is a spicy sauce, was poured at room temperature into each container to fill the cup up to about 90% of its capacity. The outer surface of each container was observed for stains and leakage every one hour for a total of 48 hours .
- the average time to failure (ATF) for each cup group sampling was calculated by adding the time to failure for each container, and dividing the total time to failure by the number of containers tested. Typically, five cups in each group were tested.
- a maximum ATF value of 48 hours means that none of the cups in that group exhibited any stain or leakage.
- a minimum ATF value of 1 hour means that all of the cups in that group failed within the first hour.
- the cups with the latex coating had an increased ATF for salsa sauce compared to the cups without the latex coating (control) .
- the present invention has been particularly set forth in terms of specific embodiments thereof, it will be evident to those skilled in the art that numerous variations and details of the invention may be made without departing from the instant invention as defined in the appended claims. For instance, different types of latex coatings can be applied in one or more layers to one or more surfaces of the container.
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
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JP2006547202A JP2007515355A (en) | 2003-12-22 | 2004-12-16 | Disposable container covered with latex coating |
BRPI0417963-3A BRPI0417963A (en) | 2003-12-22 | 2004-12-16 | molded thermoplastic container, method for forming a container for holding liquid and food substances, article of manufacture, and, method for storing liquid and food substances |
CA002549781A CA2549781A1 (en) | 2003-12-22 | 2004-12-16 | Disposable containers coated with a latex coating |
AU2004308334A AU2004308334A1 (en) | 2003-12-22 | 2004-12-16 | Disposable containers coated with a latex coating |
EP04814841A EP1722963A2 (en) | 2003-12-22 | 2004-12-16 | Disposable containers coated with a latex coating |
MXPA06007127A MXPA06007127A (en) | 2003-12-22 | 2004-12-16 | Disposable containers coated with a latex coating. |
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US53178503P | 2003-12-22 | 2003-12-22 | |
US60/531,785 | 2003-12-22 |
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WO2005062825A3 WO2005062825A3 (en) | 2006-09-21 |
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PCT/US2004/042703 WO2005062825A2 (en) | 2003-12-22 | 2004-12-16 | Disposable containers coated with a latex coating |
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EP (1) | EP1722963A2 (en) |
JP (1) | JP2007515355A (en) |
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CN (1) | CN1972798A (en) |
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CA (1) | CA2549781A1 (en) |
MX (1) | MXPA06007127A (en) |
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US9732474B2 (en) | 2015-05-29 | 2017-08-15 | International Paper Company | Hydrophobic coated paper substrate for polymer emulsion topcoats and method for making same |
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KR20080040723A (en) * | 2005-07-22 | 2008-05-08 | 노바 케미칼즈 인코포레이팃드 | System, apparatus and process for coating and curing disposable containers |
US8101102B2 (en) * | 2005-12-22 | 2012-01-24 | Nova Chemicals Inc. | Method for improving the resistance of fumigant sorption in an expandable polymer produce container and a related container |
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- 2004-12-16 CA CA002549781A patent/CA2549781A1/en not_active Abandoned
- 2004-12-16 RU RU2006126716/04A patent/RU2312873C1/en active
- 2004-12-16 WO PCT/US2004/042703 patent/WO2005062825A2/en active Application Filing
- 2004-12-16 BR BRPI0417963-3A patent/BRPI0417963A/en not_active IP Right Cessation
- 2004-12-16 US US11/014,648 patent/US20050153088A1/en not_active Abandoned
- 2004-12-16 MX MXPA06007127A patent/MXPA06007127A/en unknown
- 2004-12-16 AU AU2004308334A patent/AU2004308334A1/en not_active Abandoned
- 2004-12-16 JP JP2006547202A patent/JP2007515355A/en not_active Withdrawn
- 2004-12-16 EP EP04814841A patent/EP1722963A2/en not_active Withdrawn
- 2004-12-16 CN CNA2004800408674A patent/CN1972798A/en active Pending
- 2004-12-16 KR KR1020067013708A patent/KR20060126534A/en not_active Application Discontinuation
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US9732474B2 (en) | 2015-05-29 | 2017-08-15 | International Paper Company | Hydrophobic coated paper substrate for polymer emulsion topcoats and method for making same |
Also Published As
Publication number | Publication date |
---|---|
EP1722963A2 (en) | 2006-11-22 |
CA2549781A1 (en) | 2005-07-14 |
KR20060126534A (en) | 2006-12-07 |
CN1972798A (en) | 2007-05-30 |
JP2007515355A (en) | 2007-06-14 |
MXPA06007127A (en) | 2006-08-31 |
RU2312873C1 (en) | 2007-12-20 |
AU2004308334A1 (en) | 2005-07-14 |
BRPI0417963A (en) | 2007-03-27 |
US20050153088A1 (en) | 2005-07-14 |
WO2005062825A3 (en) | 2006-09-21 |
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