Three/five layer preforms and manufacture thereof and a blow moulded plastics container

Abstract: A plastic preform (24) from which a plastic container is blow molded. The preform replaces a three layer preform by providing a preform which is of a five layer construction in the base forming portion (42) thereof and wherein a secondary material (B) which forms the core layer (48) of the three layer preform construction is divided into an inner intermediate layer (56) and an outer intermediate layer (58) by a third injection of material (C). The third injected material (C) is preferably the same material as the primary material (A) which is first injected. This results in the reduction of the cost of the preform and also provides remaining in the injection nozzle (18) a quantity of the last injected material which is the same as the first injected material for the following preform in the same preform injection mold cavity (12).

Description: This invention relates to a three/five layer injection moulded plastics preform for blow moulding to form a container and to a method of forming such a preform. In particular, this invention relates in general to new and useful improvements in plastic preforms from which plastic containers are blow molded, and most particularly to a plastic preform which is of a laminated construction. Polyethylene terephthalate (PET) preforms and containers blow molded from such preforms are well known However, PET per se does not have all of the necessary characteristics desired for containers. Accordingly, there has been developed a laminated preform which is primarily of a five layer construction including PET inner and outer layers, inner and outer intermediate barrier layers and a core which may be formed of PET or some other plastic. US-A-4,609,516 (Krishnakumar et al) and US-A-4,550,043 (Beck) are typical recent patents granted with respect to laminated preforms and containers blow molded therefrom. EP-A-0161625 discloses a plastics preform having a five layer construction and a method of injection moulding such a preform. That document also discusses, as prior art thereto, a three layer preform construction in which an intermediate layer extends from the base forming portion to the body forming portion of the preform. The present invention provides an injection molded plastics preform for blow molding to form a container, said preform comprising a neck finish portion, a shoulder forming portion, a body forming portion, and a base forming portion, at least said body forming portion and said base forming portion having inner and outer layers formed of a primary material and separated by a layer of a secondary material characterised in that the preform is in part formed in three layers and in part formed in five layers, at least said body forming portion being formed of only three layers with said secondary material forming a relatively thick core layer and in a central portion of said base forming portion a central part of said secondary material being replaced by a core layer of material other than said secondary material, such that the five layer portion is the base forming portion. The present invention also provides a method of forming in an injection preform mold cavity a plastics preform, said method comprising the steps of first injecting into said mold cavity a metered quantity of a primary material (A); then injecting into the mold cavity a metered quantity of a secondary material (B) to form a core layer within said primary material (A) to form only a three layer construction; characterized by the plastics preform being in part formed in three layers and in part formed in five layers and said method including the step of finally injecting further material (C) other than said secondary material (B) for thereby filling said mold cavity and forming a further core layer within said secondary material (B) to form a five layer construction in a central portion of a preform container base forming portion with said only three layer construction extending along a substantial part of a container body forming portion of the preform above the preform container base forming portion. This invention in particular relates to a plastic preform which is primarily of a three layer construction including inner and outer PET layers and an intermediate core layer. Such preforms are also known but have the inefficiency of the core layer material being more expensive than PET and further being unnecessary in the base portion of the resultant blow molded container due to the lack of biaxial orientation of the base portion and therefore a lack of reduction of thickness of the preform portion which forms the base portion of the resultant container. This invention in particular relates to a third injection of plastic material into a preform injection mold cavity to complete the preform with this third injection of plastic material forming a core within the original core material and permitting the replacement of the more expensive core material in the base forming portion of the preform. Further, while suitable apparatus has been devised for the sequential injection of different plastic materials into a preform injection mold cavity, it is to be understood that a nozzle through which the plastic material is injected into the preform injection mold cavity will have retained therein a small portion of the last injected material. The net result is that this retained plastic material within the nozzle becomes the first injected material in the formation of a next preform in the same preform injection mold cavity. It is undesirable to have the first injected plastic material into the preform injection mold cavity that which forms the core of a three layer preform. However, by making the last injected material the same or substantially the same as the first injected material, namely PET, this deficiency of the present molding apparatus can also be overcome. Most particularly, in accordance with this invention, there is a first injection of a metered amount of a primary plastic material followed by a second injection of a metered amount of a secondary plastic material with the secondary plastic material serving to advance a first injected primary material into the preform injection mold cavity with the first injected material being wiped along the walls of the injection mold cavity and the secondary material forming a core between inner and outer layers of the primary material. By controlling the volumes of the two injected materials, particularly the secondary material, and then filling the preform injection mold cavity by way of a third injection, the quantity of the secondary material may be greatly reduced. Further, by making the third injected material the same as the primary material, there remains in the injection nozzle to be first introduced into the preform injection mold cavity in the formation of the next following preform the same material as the primary material whereby the tip end of a neck finish portion of a preform will be of the desired material. With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims, and the several views illustrated in the accompanying drawings. Figure 1 is a half sectional view taken through a conventional preform injection mold which has injected molded therein a preform of a three/five layer construction in accordance with the invention. Figure 2 is a diagram showing the injection sequence time of the three injections of plastic material into the preform mold cavity. Figure 3 is a half sectional view taken through a container blow molded from the preform of Figure 1 with intermediate parts of the container body being broken away, the different layers not being shown. Referring now to the drawings in detail, it will be seen that there is illustrated in Figure 1 a conventional preform injection mold identified by the numeral 10. The mold 10 is preferably of a multiple cavity type having a plurality of cavities 12 in which there is positioned a core 14. Each cavity 12 is provided with a base opening defining a seat 16 for an injection nozzle 18. The opening in the base of the mold 10 also includes a sprue opening 20 into the bottom of the cavity 12. The mold 10 has associated therewith an openable neck ring 22 which is separable in sequence first from the mold 10 in conjunction with the core 14 to withdraw an injected preform, such as the preform 24, from the cavity 12 and then from the core 14 to release the molded preform 24, normally after the preform 24 has been stripped from the core 14. The illustrated preform 24 includes a neck finish portion generally identified by the numeral 26 and including outer threads 28, a tamper band retaining shoulder 30 formed by a ring 32, and a support or capping flange 34. Below the neck finish forming portion 26, the preform 24 includes a shoulder forming portion 36 which is of a tapered increasing thickness and which is connected to the neck finish forming portion 26 by a short ring portion 38. Below the shoulder forming portion 36 is an elongated body forming portion 40 which is substantially cylindrical except for the slight taper of the cavity 12 and the core 14 and which is of a uniform thickness. The body forming portion 40 terminates in a base forming portion 42 which includes a cylindrical part 44 and a generally hemispherical bottom part 46. At this time it is pointed out that the cylindrical part 44 increases in thickness as compared to the body forming portion 40. The preform 24 is formed generally in accordance with the patent to Pocock et al 4,525,401 granted June 25, 1985 wherein the base forming portion is of a greater wall thickness so as to permit a reduction in thickness of the intermediate or core forming layer. As is best shown in Figure 2, the preform 24 is formed by the sequential injection of molten plastic material into the cavity 12. A preselected metered amount of a primary material A is first injected into the bottom portion of the cavity 12 through the nozzle 18. Next, a preselected metered amount of a secondary material B is injected into the cavity 12 with the material B forcing the material A into the cavity 12 with the material A adhering to the cavity walls as it passes into the cavity and the material B entering into the separated layers of the material A in the manner generally disclosed in the Krishnakumar et al and Beck patents. Previously, only the amount of the material A was metered, with the material B being injected in a quantity to completely fill the cavity 12. However, in view of the fact that the material B will normally be more expensive than the material A, it is desired to restrict the use of the material B, particularly in the base forming portion 42. In accordance with this invention, this is accomplished by a third separate injection of molten plastic material, material C, into the mold cavity 12 to complete the filling of the mold cavity 12. The material C is located substantially entirely within the base forming portion 42 as is clearly shown in Figure 1. At this time it is pointed out that the injection of the material C results in a material saving of the material B to the extent of the quantity of the material C. Further, it is to be noted from Figure 1 that the last injected material will not only fill the screw opening 20, but also the final injection passage of the nozzle 18, which final injection passage is customary and not shown. It will be thus apparent that the quantity of the material C remaining within the final nozzle passage will be that material which is first injected into the cavity 12 in the formation of the next following preform 24. In the past, it has been found undesirable to inject a limited quantity of the material B at the beginning of the injection molding cycle. In the illustrated preform 26, it will be seen that the material B extends substantially to the top of the neck finish portion 26 although it may terminate lower in the neck finish portion 26, depending upon the amount of the material A which is initially injected into the cavity 12. The material B accordingly forms a core 48 separating the material A into an inner layer 50 and an outer layer 52. Thus, the preform 24 is primarily of a three layer construction. At the present state of the plastic material art, virgin PET material is the preferred material for material A. On the other hand, depending upon the usage of the resultant container, the material B may be selected from a variety of materials including colored PET, recycled PET, MXD-6 nylon; copolyesters, polypropylyene (PP), PP/PET blend, polyacrylonitrile, polycarbonate, and the like. Prior to this invention, the material A would constitute 40-60% of the volume of the preform 24 while the material B would constitute the remainder of the volume of the preform 24 thus varying between 40 and 60% of the total volume. In accordance with this invention, there can be a material saving of the material B by filling the cavity 12 with the material C. The percent volume of the material B can be reduced to 30-40 while the percent volume of the material C will be between 10 and 20. Referring once again to Figure 1, it will be seen that in the base forming portion 42, the material C forms a core layer 54 within the layer 48, dividing the layer 48 into an inner intermediate layer 56 and an outer intermediate layer 58 while the inner layer 50 and the outer layer 52 remains substantially the same. Thus the base forming portion 42 is of a five layer construction. Further, as is clearly shown at the bottom of the preform 24, the last injected plastic material is the plastic material C which is in the form of a sprue 60 that extends through the outer intermediate layer 58 and the outer layer 52. As stated above, the material C is preferably the same as the material A, namely PET. Referring now to Figure 3, it will be seen that the preform 24 is blow molded to form, in a conventional manner, a container 62. The container 62 will have a neck finish portion 26 identical to that of the preform 24. It will also include an unstretched and thus unoriented ring portion corresponding to the ring portion 38. On the other hand, the shoulder forming portion 36 will be gradually stretched both axially and radially to be of a decreasing thickness and increasing biaxial orientation to define a shoulder 64. The body forming portion 40 of the preform 24 will be both axially and radially materially stretched to form a highly biaxially oriented container body 66. Finally, the base forming portion 42 of the preform 24 will become an outer generally cylindrical base portion 68, a supporting curved annulus 70 and a bottom wall 72. It will be seen that the base of the container 62 gradually increases in thickness towards the center of the base with the center of the base being substantially unstretched and of the same thickness as the extreme bottom of the preform 24. From the foregoing, it will be seen that the conventional three layer container may be modified so that the base of such a container is essentially of a five layer construction while the body portion 66 and the upper part of the container will be of a three layer construction. On the other hand, the great reduction of the secondary material in the container base in no way detracts from the appearance, strength or possible barrier characteristics of the resultant container. Thus, in accordance with this invention the container 62 may be made at a lesser material cost than a like container which is solely of a three layer construction.

Claims: An injection molded plastics preform (24) for blow molding to form a container (62), said preform (24) comprising a neck finish portion (26), a shoulder forming portion (36), a body forming portion (40), and a base forming portion (42), at least said body forming portion (40) and said base forming portion (42) having inner and outer layers (50,52) formed of a primary material (A) and separated by a layer (48) of a secondary material (B), characterised in that the preform (24) is in part formed in three layers and in part formed in five layers, at least said body forming portion (40) being formed of only three layers with said secondary material forming a relatively thick core layer (48) and in a central portion of said base forming portion (42) a central part of said secondary material (B) being replaced by a core layer (54) of material (C) other than said secondary material (B), such that the five layer portion is in the base forming portion (42). A preform according to claim 1 wherein said secondary material (B) in said central portion of said base forming portion is separated into relatively thin inner and outer intermediate layers (56,58). A preform according to claim 1 or claim 2 wherein said material (C) other than said secondary material (B) is the same as said primary material (A) whereby said preform (24) is of a two material construction. A preform according to any one of claims 1 to 3 wherein said primary material (A) and said secondary material (B) are of preselected metered quantities and said material (C) other than said second material (B) is of a quantity to complete filling of a preform injection mold cavity (12). A preform according to any foregoing claim wherein said secondary material (B) extends as a core (48) through said shoulder forming portion (36). A preform according to any foregoing claim wherein said base forming portion (42) includes a part (44) forming an extension of said body forming portion (40) and of an increased wall thickness as compared to an adjacent part of said body forming portion (40). A preform according to claim 1 wherein the primary and secondary materials (A,B) are of substantially the same plastics material. A preform according to claim 7 wherein the primary and secondary materials (A,B) are substantially polyethylene terephthalate (PET) plastics materials. A preform according to claim 8 wherein the primary material (A) is substantially virgin PET and the second material (B) is substantially recycled PET or coloured PET. A preform according to claim 1 wherein the secondary material (B) is less expensive than the primary material (A). A preform according to claim 1 wherein the primary material (A) is virgin PET and the secondary material (B) is selected from coloured PET, recycled PET, MXD-6 nylon, copolyester, copolypropylene (PP), PP/PET blend polyacrylonitrile, or polycarbonate. A preform according to any foregoing claim wherein the core layer (48) of material (C) extends through the other layers of secondary and primary material (B,A) to the outer surface of the preform (24) at the bottom of the preform (24). A method of forming in an injection preform mold cavity (12) a plastics preform (24), said method comprising the steps of first injecting into said mold cavity (12) a metered quantity of a primary material (A); then injecting into the mold cavity (12) a metered quantity of a secondary material (B) to form a core layer (48) within said primary material (A) to form only a three layer construction; characterized by the plastics preform (24) being in part formed in three layers and in part formed in five layers and said method including the step of finally injecting further material (C) other than said secondary material (B) for thereby filling said mold cavity (12) and forming a further core layer (54) within said secondary material (B) to form a five layer construction in a central portion of a preform container base forming portion (42) with said only three layer construction extending along a substantial part of a container body forming portion (40) of the preform (24) above the preform container base forming portion (42). A method according to claim 13 wherein said secondary material (B) in said central portion of said base forming portion (42) is separated into relatively thin inner and outer intermediate layers (56,58). A method according to claim 13 or claim 14 wherein said material (C) other than said secondary material (B) is the same as said primary material (A) whereby said preform (24) is of a two material construction. A method according to any one of claims 13 to 15 wherein said primary material (A) and said secondary material (B) are of preselected metered quantities and said material (C) other than said secondary material (B) is of a quantity to complete filling of a preform injection mold cavity. A method according to any one of claims 13 to 16 wherein said secondary material (B) extends as a core layer (48) through a container shoulder forming portion (36) of the preform. A method according to any one of claims 13 to 17 wherein said base forming portion (42) includes a part (44) forming an extension of said body-forming portion (40) and of an increased wall thickness as compared to an adjacent part of said body forming portion (40). A method according to claim 13 or 14 wherein the primary and secondary materials (A,B) are of substantially the same plastics material. A method according to claim 19 wherein the primary and secondary materials (A,B) are substantially polyethylene terephthalate (PET) plastic materials. A method according to claim 20 wherein the primary material (A) is substantially virgin PET and the secondary material (B) is substantially recycled or coloured PET. A method according to calim 13 or claim 14 wherein the secondary material (B) is less expensive than the primary material (A). A method according to claim 13 or claim 14 wherein the primary material (A) is virgin PET and the secondary material (B) is selected from coloured PET, recycled PET, MXD-6 nylon, copolyesters, polypropylene (PP), PP/PET blend, polyacrylonitrile, or polycarbonate. A method according to any one of claims 13 to 21 wherein the primary material (A) is virgin PET and is injected at a volume of from 40 to 60% of the volume of the preform (24), the secondary material is recycled PET and is injected at a volume of from 30 to 40% of the volume of the preform (24), and the further material (C) is virgin PET and comprises the remaining volume of the preform (24). A method according to claim 24 wherein the volume of the further material (C) is on the order of 10% of the volume of the preform (24). A plastics container which has been blow moulded from an injection moulded preform, the container including a neck finish, a shoulder, a body and a base, at least the body and the base having inner and outer layers formed of a primary material and separated by a layer of secondary material, at least the body being formed of only three layers with the secondary material forming a core layer between the inner and outer layers and in a central portion of the base a central part of the secondary material being replaced by a core layer of material other than the secondary material such that a five layer portion is in the base. A plastics container according to claim 26 wherein said secondary material in said central portion of said base is separated into inner and outer intermediate layers. A plastics container according to claim 27 wherein the core layer of material extends through the outer layers of secondary and primary material at the bottom of the container. A plastics container according to any one of claims 26 to 28 wherein said material other than said secondary material is the same as said primary material whereby said preform is of a two material construction. A plastics container according to any one of claims 26 to 29 wherein said secondary material extends as a core through the shoulder. A plastics container according to any one of claims 26 to 30 wherein the primary and second materials are of substantially the same plastics material. A plastics container according to claim 31 wherein the primary and second materials are substantially polyethylene terephthalate (PET) plastics materials. A plastics container according to claim 32 wherein the primary material is substantially virgin PET and the secondary material is substantially recycled PET or coloured PET. A plastics container according to any one of claims 26 to 30 wherein the primary material is virgin PET and the secondary material is selected from coloured PET, recycled PET, MXD-6 nylon, copolyester, copolypropylene (PP), PP/PET blend polyacrylonitrile or polycarbonate.

Inventors: COLLETTE WAYNE N, KRISHNAKUMAR SUPPAYAN M, NAHILL THOMAS E, SCHMIDT STEVEN LYLE, COLLETTE, WAYNE N., KRISHNAKUMAR, SUPPAYAN M., NAHILL, THOMAS E., SCHMIDT, STEVEN LYLE
Applicants: CONTINENTAL PET TECHNOLOGIES, CONTINENTAL PET TECHNOLOGIES, INC.
Application year: 1989
Main classification: B29C45
IPC codes: B29C45, B29C49